Microbiological safety of dehydrated foods: risk analysis, technology evaluation, and synergistic strategies for next-generation processing

Drawing on nearly two decades of systematic research in food dehydration and recent reports of microbial contamination in dehydrated food systems, this review highlights the urgent need for interdisciplinary collaboration to ensure microbiological safety in emerging dehydrated food matrices. We deconstruct the microbial hazards inherent to these products while challenging the long-held assumption of their intrinsic safety. The review proceeds through four key dimensions: (i) taxonomic profiling of pathogenic microorganisms associated with dehydrated foods, supported by outbreak reports and regulatory recalls; (ii) mechanistic evaluation of physicochemical intervention strategies for microbial inactivation, including efficacy comparisons and operational limitations; (iii) critical appraisal of advanced dehydration technologies—such as electromagnetic field-assisted drying, thermal gradient drying, and modified atmosphere drying—for real-time microbial control; and (iv) synergistic protocols integrating pretreatment sterilization with optimized drying parameters. Notably, electromagnetic technologies (microwave, radiofrequency, infrared) offer dual benefits, achieving log10-scale pathogen reductions while improving dehydration efficiency through volumetric heating. Evidence shows that hybrid approaches coupling physical sterilization with precision drying can achieve 2.3–4.7 log CFU/g microbial reduction without compromising product quality. These insights not only provide a framework for developing next-generation dehydration processes but also emphasize their public health significance, industrial applicability, and contribution to consumer protection.