Revolutionizing Processed Meat Industry: The Power of High-Pressure Processing (HPP)

???Imagine a world where our favorite meat products are not only safe and fresh but also boast longer shelf lives without the need for additives. Welcome to the realm of High-Pressure Processing (HPP), a nonthermal technology that has taken the food industry by storm for over a decade. With meat manufacturing industries capturing a staggering 25 to 30% of the HPP-treated food market share, this technology has emerged as a game-changer [1].

???In 2019 alone, the United States processed 881 million pounds of meat products using HPP in 50 dedicated facilities [2]. The secret behind its success lies in the ability of HPP-treated products to meet consumer expectations for additive-free, fresh, and longer-lasting commodities [3–5]. Unlike thermal processing, which can lead to off-flavors, texture changes, and alterations in color and nutritional quality, HPP targets weak hydrophobic and non-covalent bonds while preserving nutrients and flavor compounds, ensuring both food safety and quality [6–8].

????HPP employs isostatic pressure ranging from 200 to 700 millipascals (MPa), along with variable holding times and treatment temperatures tailored to specific foods and pathogens [8,9]. Interestingly, the United States Department of Agriculture (USDA) allows the use of HPP as an antimicrobial treatment on meat and poultry products without prior approval from USDA-FSIS, demonstrating its recognized effectiveness [10].

???HPP has found popularity as a post-process intervention for ready-to-eat (RTE) poultry and meat products, successfully reducing pathogens such as?Salmonella,?Shiga toxin-producing Escherichia coli (STEC), and?Listeria monocytogenes?[11–15]. By meeting the strict Salmonella performance standards and Listeria control regulations set by the USDA-FSIS, HPP ensures both safety and minimal alteration of organoleptic and nutritional characteristics [3,11,14,15].

???But how does HPP achieve this remarkable microbial cell death? By targeting multiple sites on bacterial cells, HPP induces alterations in cell membrane integrity, protein denaturation, ribosome dissociation, and structural changes within the cell [6,17–21]. The pressure deactivates enzymes responsible for ATP synthesis, disrupts the membrane potential, and ultimately leads to cell death [22,23]. Although some speculation exists regarding the development of pressure resistance in bacteria, the mechanisms of pressure-mediated microbial cell death and resistance are still not fully understood [6,25,26].

???The range of HPP-treated meat and poultry products available in the market is impressive. While most are ready-to-eat (RTE) products, some fresh options, such as minced beef, undergo further processing before consumption. Major meat producers have introduced HPP-treated hamburgers, poultry strips, oven-roasted chicken, deli meat, fermented meats, and more. The global market offers a variety of options, including fermented sausages, steak tartar, carpaccio, deli meats infused with extra virgin oil, meat and cheese snack products, thick-sliced ham, chicken and turkey products, cooked and serrano ham, chrizo, sliced dry-cured meat, and cooked meat [1].

???One notable example is Cargill's HPP-treated beef patties, which undergo an extra decontamination step, ensuring further food safety while retaining their color and taste. HPP treatment has been explored extensively for various meat products, including fresh and processed meat, such as chicken breast fillet, turkey breast, pre-rigor pork, beef, cooked ham, dry-cured ham, marinated beef, fermented sausages, and pork sausage with carrot fiber, highlighting the versatility and potential of this nonthermal technology. Furthermore, HPP can even help reduce sodium and phosphate content in processed meat, enhancing protein functionality [1].

???Ongoing research continues to explore the capabilities of HPP in the meat industry. For example, studies have revealed that HPP can improve the tenderness and quality of pre-rigor and hot-boned beef. However, challenges such as cooked appearance changes and increased lipid oxidation rates in HPP-treated raw meat have prompted investigations into combining HPP with essential oils and antimicrobials to prevent such defects [37–42]. Additionally, efforts are underway to reduce sodium content in processed meat by leveraging HPP to improve protein functionality, achieving promising results [45–47].

???While HPP does require a higher initial investment and operational costs, it is proving to be a cost-effective and sustainable alternative compared to other technologies. Recent studies using Life Cycle Costing (LCC) and Life Cycle Assessment (LCA) methodologies have shown that HPP is cheaper and has a lower environmental impact than modified atmosphere packaging (MAP) and thermal processing, making it an attractive choice for the meat industry [51,52]. Moreover, HPP-treated food aligns with the growing consumer demand for green technologies and is perceived as more natural, tastier, and nutritionally superior [2,53].

???Leveraging the unique advantages of HPP, we recommend its use in low-salt sausage production. By improving protein solubilization, gelation, and meat binding, HPP can facilitate the reduction of salt content in sausages without compromising texture or taste. Combining HPP with plant-based functional ingredients, such as carrot fiber or potato starch, holds tremendous potential to meet the demands for healthier, low-salt meat products while enhancing their overall quality [54–56].

??In conclusion, HPP has emerged as a revolutionary cold pasteurization method for the meat industry, ensuring food safety, extending shelf life, and paving the way for cleaner label processed meats. This innovative technology empowers the meat industry to explore new possibilities across the entire supply chain, enabling the development of safer, more sustainable, and nutrient-rich meat products. Embracing HPP signifies a step forward in achieving enhanced food security, superior quality, and greater sustainability in the meat industry. Together, let's shape a future where safety and excellence are synonymous with our food choices.

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