Traditional and Emerging Physical Processing Technologies: Applications and Challenges in Allergen Control of Animal and Plant Proteins

ABSTRACT Under global food shortages and environmental challenges, the food industry is shifting from animal to plant proteins, coinciding with a rising prevalence of food allergies. Structural and functional differences between animal and plant proteins significantly influence their allergenic potential. Traditional and emerging physical processing technologies can modify protein structures and reduce immunoreactivity without chemical additives, preserving food quality. These technologies are categorized into thermal, radiation, light, high‐pressure, transient pressure, mechanical wave, plasma, and electric field effects. Cold plasma is particularly effective in modifying protein structures by generating reactive species. High hydrostatic pressure also demonstrates significant potential, particularly when combined with heat treatment. Ultrasound, especially when integrated with other methods (e.g., enzymatic hydrolysis or glycosylation), offers versatile and cost‐effective solutions. Microwave heating remains a practical option due to its efficiency and scalability, while gamma irradiation remains an effective tool for allergen reduction despite its regulatory and consumer acceptance challenges. Low‐allergenic processed foods can induce oral tolerance in allergic individuals, necessitating comprehensive safety evaluations covering allergenicity, toxicity, and nutrition. Unintentional allergens in food processing pose risks, and current regulations are insufficient. International organizations have proposed precautionary allergen labeling to protect consumers. While processing technologies cannot fully eliminate allergenicity, optimized selection can mitigate risks. Future research should focus on their impact on functional properties, nutritional value, safety, cost, and production efficiency to ensure safe and effective application in the food industry.