Sonication in food packaging: Mechanisms, applications, and advancements toward sustainable and functional materials

The growing demand for sustainable, safe, and high-efficiency food packaging has accelerated the shift toward non-thermal green processing technologies. Among these methods, ultrasound (US) has gained attention for its physical and chemical effects, which are mediated by acoustic cavitation. This review provides a focused and systematic examination of US technology specifically applied to food packaging materials and processes, which is distinct from its conventional role in direct food processing. The results show that acoustic cavitation achieves surface decontamination by disrupting microbial cells on packaging materials. In biopolymer-based film fabrication, US modulates the microstructure of film-forming solutions, producing packaging films with improved mechanical strength and reduced water vapor permeability (WVP). For active packaging, US enables efficient incorporation, homogeneous dispersion, and controlled release of antimicrobial and antioxidant compounds, which extends the shelf life of packaged foods. In smart packaging, US-assisted assembly facilitates the activation of embedded sensors for real-time monitoring of food freshness, temperature, and gas composition, contributing to supply chain transparency. Industrial applications in dairy, meat, fresh produce, and beverage packaging are analyzed alongside technical, equipment, and regulatory challenges that limit commercialization. This review establishes a dedicated framework for understanding how US technology enhances the properties of food packaging materials and processes beyond its general application in food processing, contributing directly to the development of functional, safe, and sustainable food packaging systems.