Hybrid thermal–nonthermal processing approaches for sustainable dairy production: Synergistic effects on safety and quality

Background, Context, or Rationale Dairy products are widely consumed across the world and are considered essential components of a healthy diet. Pasteurisation and ultra‐high‐temperature processing are the main techniques used in the dairy industry to inactivate pathogenic microorganisms and reduce microbial load. However, exposure to high temperatures during conventional thermal processing can lead to losses in nutritional and sensory quality. Novel thermal and nonthermal processing technologies have been used as alternatives to reduce energy consumption and processing time, and to better preserve the nutritional and sensory properties of dairy products. However, these technologies may present limitations, including insufficient microbial and enzymatic inactivation. Therefore, recent research has focused on hybrid systems that combine thermal and nonthermal processing to provide synergistic effects. Hybrid processing approaches aim to enhance microbial safety while minimising quality deterioration and improving process sustainability. Aim(s) This review aimed to evaluate new thermal, nonthermal and hybrid processing technologies applied to dairy products, discussing their effects on microbial safety, quality, functional properties, protein structure, and shelf life. Additionally, sustainability, current limitations, and research gaps in hybrid dairy processing were addressed. Methods Literature on thermal, nonthermal, and combined processing methods applied to dairy systems was critically evaluated using Scopus, Web of Science and PubMed. Sources were selected from recent peer‐reviewed studies, emphasising microbial inactivation outcomes, quality parameters, structural analyses, and technological feasibility. Major Findings Although both emerging thermal and nonthermal processes have various advantages, there are limitations to their application in dairy products. Therefore, thermal and nonthermal technologies can be combined to minimise the limitations of these techniques. Remaining challenges include cost, process optimisation, and regulatory limitations. Scientific or Industrial Implications Hybrid processing enables more energy‐efficient dairy processing while maintaining higher product quality and lowering environmental impact. Addressing technical and regulatory gaps will support industrial adoption and advance sustainable dairy technologies.