Emerging applications of non-thermal ultrasound technology in functional beverages processing, a comprehensive review

Non-thermal ultrasonication (US) is emerging as a promising process-intensification technology for producing functional beverages (FB) as the conventional thermal processing and additive-reliant preservation methods often compromise thermolabile nutrients, sensory profile, and clean-label appeal of FB. However, evidence regarding the application of US to the processing and preservation of FB matrices remains limited and fragmented, and clear, reproducible guidelines for process optimization and commercial translation are still lacking. This review critically summarizes recent research on the application of non-thermal US across key FB unit operations, including extraction, fermentation, preservation, and physicochemical structuring, and examines how cavitation-driven mechanisms influence nutritional, functional, sensory, and stability outcomes. A structured literature review was conducted, with studies organized by processing functions and beverage matrix characteristics to identify consistent trends and matrix-dependent variations (including occasional reversals in effects). Overall, US frequently enhances mass transfer and dispersion, improves the recovery and retention of selected bioactive compounds, supports textural and physical stability (e.g., reduced sedimentation or creaming), and aids microbial and enzymatic control, especially when integrated into hurdle strategies (e.g., US combined with mild heating, clean-label antimicrobials, or other non-thermal technologies). Nevertheless, broader translation remains constrained by inconsistent reporting of delivered acoustic energy and temperature profiles, strong dependence on formulation factors (e.g., viscosity, total soluble solids, particulates, and protein-polysaccharide interactions), and a lack of pilot-scale or continuous-flow validation supported by techno-economic assessment. Critically, claims of health relevance of FB are weakly supported because bioaccessibility and bioavailability testing, in vivo animal studies, and human clinical evidence remain largely missing. Collectively, this review provides a function-based framework together with practical research priorities to enable reproducible optimization, scalable processing, and more robust claims regarding the quality and functionality of US-processed FB.