With the introduction of Industry 4.0, and smart factories accordingly, there are new opportunities to implement elements of industry 4.0 in nonthermal processing. Moreover, with application of Internet of things (IoT), smart control of the process, big data optimization, as well as sustainable production and monitoring, there is a new era of Internet of nonthermal food processing technologies (IoNTP). Nonthermal technologies include high power ultrasound, pulsed electric fields, high voltage electrical discharge, high pressure processing, UV-LED, pulsed light, e-beam, and advanced thermal food processing techniques include microwave processing, ohmic heating and high-pressure homogenization. The aim of this review was to bring in front necessity to evaluate possibilities of implementing smart sensors, artificial intelligence (AI), big data, additive technologies with nonthermal technologies, with the possibility to create smart factories together with strong emphasis on sustainability. This paper brings an overview on digitalization, IoT, additive technologies (3D printing), cloud data storage and smart sensors including two SWOT analysis associated with IoNTPs and sustainability. It is of high importance to perform life cycle assessment (LCA), to quantify (En)—environmental dimension; (So)—social dimension and (Ec)—economic dimension. SWOT analysis showed: potential for energy saving during food processing; optimized overall environmental performance; lower manufacturing cost; development of eco-friendly products; higher level of health and safety during food processing and better work condition for workers. Nonthermal and advanced thermal technologies can be applied also as sustainable techniques working in line with the sustainable development goals (SDGs) and Agenda 2030 issued by United Nations (UN).

Background: The aim of this study was to evaluate high voltage electrical discharges (HVED) as a green technology, in order to establish the effectiveness of phenolic extraction from olive leaves against conventional extraction (CE). HVED parameters included different green solvents (water, ethanol), treatment times (3 and 9 min), gases (nitrogen, argon), and voltages (15, 20, 25 kV). Methods: Phenolic compounds were characterized by ultra-performance liquid chromatography-tandem mass spectrometer (UPLC-MS/MS), while antioxidant potency (total phenolic content and antioxidant capacity) were monitored spectrophotometrically. Data for Near infrared spectroscopy (NIR) spectroscopy, colorimetry, zeta potential, particle size, and conductivity were also reported. Results: The highest yield of phenolic compounds was obtained for the sample treated with argon/9 min/20 kV/50% (3.2 times higher as compared to CE). Obtained results suggested the usage of HVED technology in simultaneous extraction and nanoformulation, and production of stable emulsion systems. Antioxidant capacity (AOC) of obtained extracts showed no significant difference upon the HVED treatment. Conclusions: Ethanol with HVED destroys the linkage between phenolic compounds and components of the plant material to which they are bound. All extracts were compliant with legal requirements regarding content of contaminants, pesticide residues and toxic metals. In conclusion, HVED presents an excellent potential for phenolic compounds extraction for further use in functional food manufacturing.

Food loss and waste constitute a substantial threat to global food system sustainability, representing 38% of energy consumption in the supply chain. The 2030 Agenda for Sustainable Development highlights a vision integrating social, economic, and environmental pillars. Addressing environmental impact requires recycling (destruction for new creations) and upcycling (converting waste into valuable products). This review highlights nonthermal green extractions and sustainable techniques in upcycling raw materials such as olives, red beetroot, sugar beet, and coffee, which are widely used in the food industry. Nonthermal processing efficiently extracts bioactive compounds and utilizes waste. Key approaches for its valorization include life cycle assessment, environmental footprint analysis, energy efficiency strategies, digitalization, and sustainability considerations. However, challenges remain in calculating their environmental impact. Waste and by-product valorization from raw materials address disposal issues, offering economic and environmental benefits. Nonthermal techniques show optimistic opportunities in green extraction and sustainable upcycling. The focus is on raw materials including olives, red beetroot, sugar beet, and coffee byproducts, and possible product development. There are powerful connections offering industry tools for impactful sustainability management and guiding decisions on waste-to-value or ‘upcycling’ products. The review contributes to filling the gap in usage of nonthermal processing in upcycling of waste and by-products.

The objective of this study was to evaluate the potential of green solvents for extractions of bioactive compounds (BACs) and essential oils from wild thyme (Thymus serpyllum L.) using theoretical and experimental procedures. Theoretical prediction was assessed by Hansen solubility parameters (HSPs) and conductor-like screening model for realistic solvents (COSMO-RS), to predict the most suitable solvents for extraction of BACs. An experimental procedure was performed by nonthermal technology high voltage electrical discharge (HVED) and it was compared with modified conventional extraction (CE). Obtained extracts were analyzed for chemical and physical changes during the treatment. Theoretical results for solution of BACs in ethanol and water, as green solvents, were confirmed by experimental results, while more accurate data was given by COSMO-RS assessment than HSPs. Results confirmed high potential of HVED for extraction of BACs and volatile compounds from wild thyme, in average, 2.03 times higher yield of extraction in terms of total phenolic content was found compared to CE. The main phenolic compound found in wild thyme extracts was rosmarinic acid, while the predominant volatile compound was carvacrol. Obtained extracts are considered safe and high-quality source reach in BACs that could be further used in functional food production.

Rosemary (Rosmarinus officinalis L.) is a Mediterranean medicinal and aromatic plant widely used due to valuable bioactive compounds (BACs) and aromas. The aim of the study was to evaluate the extraction of intracellular compounds from rosemary combining experimental procedure by means of high voltage electrical discharge (HVED), with a theoretical approach using two computational simulation methods: conductor-like screening model for real solvents and Hansen solubility parameters. The optimal HVED parameters were as follows: frequency 100 Hz, pulse width 400 ns, gap between electrodes 15 mm, liquid to solid ratio 50 mL/g, voltage 15 and 20 kV for argon, and 20 and 25 kV for nitrogen gas. Green solvents were used, water and ethanol (25% and 50%). The comparison was done with modified conventional extraction (CE) extracted by magnetic stirring and physicochemical analyses of obtained extracts were done. Results showed that HVED extracts in average 2.13-times higher total phenol content compared to CE. Furthermore, nitrogen, longer treatment time and higher voltage enhanced higher yields in HVED extraction. HVED was confirmed to have a high potential for extraction of BACs from rosemary. The computational stimulation methods were confirmed by experimental study, ethanol had higher potential of solubility of BACs and aromas from rosemary compared to water.