Application of Electroporation in Food

Electroporation – often implemented as pulsed electric field (PEF) processing – is an emerging non-thermal food‐processing technology that is transforming food preservation and processing. By applying short, high‐voltage pulses to foods, electroporation temporarily or permanently permeabilizes cell membranes. This non-thermal approach can inactivate microbes and enzymes while preserving nutritional and sensory quality (colors, vitamins, flavors) better than conventional heat treatments. For example, PEF can pasteurize liquid foods (e.g. fruit juices, milk, liquid egg) and tenderize solids without cooking, yielding shelf-stable yet “fresh-like” products. Beyond preservation, electroporation enhances mass transfer, significantly boosting the extraction of juices, flavors, and bioactives (such as polyphenols and antioxidants) from fruits, vegetables, and by-products.

How Electroporation Works in Food

At the cellular level, electroporation involves the application of brief, powerful electric pulses that generate a transmembrane potential exceeding a critical threshold. This induces nanoscale pores in the phospholipid bilayer. When the field strength or pulse number is high, these pores can be irreversible, causing the cell to leak and die. For microorganisms, electroporation is an effective inactivation mechanism: pulses “rupture the cell membranes of vegetative microorganisms by creating pores (electroporation)… causing leak of intracellular contents” and loss of viability. Importantly, electroporation targets cell membranes without significantly heating the food, thereby preserving proteins, vitamins, and flavors. The result is efficient microbial kill (e.g. 4–5 log reductions) with minimal impact on freshness.

In practice, pulse parameters are adjusted according to the type of food and the desired goal. Lower fields (1–5 kV/cm) on plant tissues create sub-lethal pores that soften the texture and aid in drying, whereas higher fields (20–50 kV/cm or more) are used for sterilization- or strength-pasteurization of liquids. Pulse width, frequency, and waveform also influence outcomes. For instance, long pulses can heat the product (Joule heating) to moderate temperatures, further aiding inactivation if needed. Overall, electroporation’s unique mechanism—permeabilizing membranes while avoiding extensive heat—is the basis for its multiple applications in the food industry.

Microbial Inactivation & Non-Thermal Preservation

A prime application of PEF in food is non-thermal pasteurization and preservation. By electroporating bacterial and fungal cells, PEF extends shelf life similarly to heat pasteurization, but with better retention of nutrients and sensory quality. In practice, PEF systems have been developed to process juices, smoothies, milk, and other beverages. Notably, PEF-treated organic fruit juices have been sold commercially (in Oregon, USA) since 2005pmc.ncbi.nlm.nih.govohioline.osu.edu. Pulsed fields inactivate vegetative cells (e.g., E. coli, Salmonella) while leaving color, vitamin C, flavor volatiles, and mouthfeel largely intact. For example, a PEF-treated strawberry or green smoothie maintains its bright color much better than a heat-treated one. As Campden BRI explains, “PEF provides a gentle means of pasteurisation … [with] advantages such as improved colour retention. Thermally sensitive components… can be better protected with non-thermal technologies like PEF”.

PEF is often combined with mild cooling (to avoid excessive heating) to ensure non-thermal operation. The main drawback is that PEF alone typically does not inactivate hardy spores. However, for most fresh and minimally processed foods, PEF achieves significant reductions in microbial levels. Because no chemical preservatives are needed, electroporation aligns with clean-label processing, as it achieves microbial safety through physical means, keeping ingredient lists simple. In summary, electroporation is a promising non-thermal food preservation technology that inactivates pathogens and spoilage organisms while maintaining a “fresh” quality profile.

Extraction of Compounds (Juice, Flavors, Polyphenols)

Electroporation excels at enhancing mass transfer in plant and animal tissues. In fruits and vegetables, PEF opens cell membranes, allowing water, juice, and intracellular solutes to diffuse out more easily during the pressing or extraction process. Numerous studies report higher juice yields and richer flavor/aroma extraction after PEF pretreatment. For example, treating citrus fruits (whole fruit or peel) at moderate voltages can increase juice yield by 25–59% compared to untreated controls. In berries, a PEF process boosted blueberry juice yield by 28% and raised total anthocyanin (red pigment) content by 60%. Similarly, PEF significantly improves the recovery of polyphenols, antioxidants, and other nutraceuticals from plant materials. A recent MDPI review notes that PEF “is a non-thermal technique… used for food preservation which involves short bursts of electrical power to inactivate microorganisms while minimizing [quality] impact”, and importantly, it is used “to diffuse, osmose, press and dry food… reducing the negative effects of heating”.

In practice, industrial PEF systems can be installed before a juicer or extractor. A brief PEF treatment of, say, carrot, apple or grape mash creates micro-cracks in the tissue. The result is easier pressing and higher yields with the same mechanical pressure. Importantly for quality, the juice and extracts are typically richer in bioactive compounds (polyphenols, carotenoids, flavonoids) because more cell contents have been released. This technique is now utilized in commercial settings for enhanced juice and wine production, herbal extraction, and the concentration of plant extracts. By combining electroporation with cold extraction, manufacturers achieve a greener process, characterized by lower solvent usage, reduced energy demand, and the preservation of sensitive nutrients. In fact, PEF-assisted extraction is often cited as a “clean extraction” method that aligns with modern green chemistry goals.

Structural and Textural Effects

Beyond microbiology and extraction, electroporation induces desirable textural and structural changes in many foods. In potatoes and other tubers, for example, PEF makes the flesh softer and more uniform. Potato processors worldwide utilize PEF to enhance the quality of French fries and chips. The effect of pre-treating peeled potatoes with PEF includes reduced cutting force, more uniform color after frying, and up to 50% less oil absorption during frying. Softer tissue also means shorter blanching and drying times; one report shows PEF-treated potato slices dried 57% faster in air-drying. These changes result from the controlled release of pectins and sugars, which weakens the cell wall and reduces the Maillard reaction precursors (hence, less acrylamide), producing a crisper, blanched texture.

In fruits and vegetables, electroporation can enhance processes such as osmotic dehydration, freezing, and infusion. For instance, PEF-treated spinach or broccoli freezes and thaws with less cell rupture, preserving bright color. In berries and citrus, as noted above, PEF greatly enhances firmness and juice release. The device also aids in marination or infusion of brines into meat: moderate PEF fields create microscopic channels that allow curing solutions to penetrate faster and deeper into muscle tissue. While full-scale electroporation for meat tenderization is still under study, initial findings suggest that PEF can disrupt tough muscle fibers, potentially tenderizing steaks or accelerating brine uptake. Overall, electroporation is a versatile tool for modifying structure, as it can be tuned to gently soften products for slicing or to break down tissues for rapid drying, all with less mechanical or thermal stress than conventional methods.

Applications Across Food Sectors

Fruits and Vegetables.

Perhaps the most established PEF applications are in the fruit and vegetable processing industries. Liquid foods like juice, soups and purees can be pasteurized by PEF. Solid vegetables (such as potatoes, beets, and carrots) benefit from pretreatment. French fry producers utilize PEF to reduce oil absorption and improve texture. PEF is also used before juice pressing of grapes, apples and berries to boost yield and extract polyphenols. Non-thermal cold-press juices (cold-filled, additive-free) often employ PEF to ensure safety while claiming clean-label production. Even leafy greens and soft fruits are being explored: PEF can accelerate washing and sanitation, and improve sorption of brine or treatment solutions for minimal-prep salads.

Meat and Seafood.

In meat processing, electroporation is primarily being investigated for tenderization and marination. Pulsed fields create micro-disruptions in muscle fibers, which can tenderize tough cuts with minimal aging time. Reports indicate that PEF-treated beef or chicken can absorb marinades more quickly and cook more evenly. Moreover, as with other foods, PEF can serve as a mild pasteurization step for raw meat products (e.g. meats in brine or fish-based products) since the process is effective against bacteria. PEF’s ability to speed cooling or freezing also applies to seafood: by permeabilizing tissue, freezing rates increase and thawed fillets retain texture better. While industrial meat PEF units are not yet widespread, the technology’s energy-efficient, non-thermal nature makes it attractive for high-value meats and ready-to-eat products.

Dairy.

The application of PEF in dairy is still emerging. Studies have explored the pre-treatment of milk with PEF before cheesemaking or yogurt production. Early findings suggest that moderate PEF on milk can alter protein structures to improve curd firmness, although intense PEF can stiffen cheese texture. Importantly, PEF can be used to pasteurize milk and liquid egg without heating – a boon for heat-sensitive probiotic cultures or vitamin fortification. For example, a PEF-treated fruit-yogurt beverage retained more vitamin B₂ than an equivalent heat-pasteurized product. Researchers also report that PEF can reduce whey separation and increase the yield of fermented dairy products. Overall, PEF in dairy offers potential for new “cold-filling” dairy products and more uniform cheese production without the browning or flavor changes of heat.

Other Products.

PEF is being applied in brewing (wort inactivation), egg processing (liquid egg pasteurization), and even plant-based foods (improving plant protein extraction). In each case, the appeal is the clean-label, non-thermal advantage. For instance, pasteurizing almond milk or cold-brew coffee with PEF avoids altering delicate flavors. Pulsed fields can also remove allergens or toxins from juices. In pet foods and specialty ingredients, small-scale PEF units can add value by optimizing texture and nutrition.

Advantages Over Traditional Methods

Electroporation’s benefits over conventional processing are compelling:

Non-Thermal Preservation: Unlike pasteurization or retort heating, PEF kills microbes without the use of high heat. This means vitamins (C, B-complex), natural pigments (chlorophylls, anthocyanins), and flavors are preserved. Cold-processed juices stay bright and fresh-tasting; vegetables remain crisp.
Clean Label: No added chemicals or preservatives are needed with PEF. Foods can be declared “minimally processed” or “preservative-free,” meeting growing consumer demand for clean-label products.
Improved Nutrition & Functionality: Studies show PEF-treated juices often have higher antioxidant capacity than thermally treated ones, because more bioactives (polyphenols) are recovered. Proteins and vitamins suffer minimal denaturation.
Lower Energy Use & Water Consumption: PEF systems can reduce heating energy and water usage. For example, PEF-assisted drying of fruits requires less heat and finishes more quickly. Pretreated potatoes can fry in less oil. Many processes see energy savings due to shorter times or ambient operation.
High Throughput & Integration: Modern PEF equipment can process hundreds to thousands of liters per hour and can be integrated inline. As Ohio State notes, commercial PEF systems range from hundreds to 50,000 L/h and are used for juices, milk, yogurt, and other products. PEF units are engineered for hygiene (e.g. CIP clean-in-place) and can be inserted into existing lines.
Selectivity: Processors can tune electroporation to affect only undesired components. For instance, pulses can inactivate enzymes or microbes more readily than they can affect large fruit cells, thereby preserving color. As one guide explains, lower field strengths create holes in large plant or meat cells (for drying or extraction), whereas higher strengths target small microbial cells. This selectivity is harder to achieve with blunt methods like heat or pressure.
Scalability and Research Support: A range of commercial vendors now supply industrial PEF systems (e.g., CoolWave, Elea, Energy Pulse Systems), making the technology more accessible. Academic and industry research continues to refine electrode materials and chamber designs to minimize issues (e.g. electrode corrosion) and expand applications.

In short, electroporation offers a modern alternative to traditional thermal, chemical, or high-pressure processes. It yields safer, better-quality products in a more sustainable way – a win for food scientists, processors and consumers alike.

Pars Tarava: Pioneering Electroporation in Iran’s Food Technology

Pars Tarava (Persian Bioelectromagnetics) is a leader in the development of electroporation equipment. Founded in 2018, Pars Tarava is “the first and only producer of electroporation devices in Iran”. While the company has built its reputation on medical and research-grade electroporators (up to 3,000 V and high currents), it is now expanding into the food processing sector. By leveraging its deep expertise in pulsed power systems and electrochemistry, Pars Tarava offers advanced electroporation devices for food applications. Their equipment is designed for robustness and hygiene, matching or exceeding the technical capabilities of imported systems. Pars Tarava’s entry into food technology promises to accelerate the adoption of PEF in Iran and beyond. Researchers and manufacturers working on innovative processing can benefit from Pars Tarava’s custom solutions and engineering support.

Conclusion and Call to Action

Electroporation (PEF) is rapidly maturing into a key technology for the food industry, addressing pressing needs for non-thermal preservation and efficient processing. By permeabilizing cells without heat, it inactivates microbes, boosts extraction of valuable compounds, and tailors texture – all while keeping foods “fresh”, nutritious, and free of additives. Its applications span juices, purees, raw meats, dairy products, and even waste valorization, with continuous development ensuring ever-broader use.

Discover the benefits of PEF for your products. Pars Tarava invites food researchers, manufacturers and buyers to explore custom electroporation solutions. Our team can provide technical consultation, pilot testing, and commercial-scale equipment. For inquiries or partnership opportunities, please get in touch with us via WhatsApp at +989024051862 or email info@persiantarava.me.

We look forward to helping you harness the cutting edge of non-thermal food processing to produce cleaner, higher-quality products.