In-pack sonication of chicken breast: effects of ultrasound conditions on physicochemical and microbiological properties, and shelf-life of optimally processed meat during frozen storage

Conventional ultrasound (US) has been used to incorporate active components into packaging material, but in-pack sonication and its effect on food quality and shelf-life need further exploration. This study aims to examine how US treatment conditions and packaging materials affect aged chicken breast’s shelf-life, microbiological, sensory, and physicochemical characteristics, including peroxide value (PV), free fatty acids (FFA), cooking loss (CL), and muscle fiber index (MFI). Samples were sonicated either without packaging (WP) or packed inside low-density polyethylene (LDPE). The results were then compared with untreated and conventionally treated samples. Response surface methodology (RSM) optimized the specific energy consumption (SEC), acoustic power, and product characteristics based on sonication power (4.4, 35.5, and 66.0 W) and time (10, 20, and 30 min). The quality attributes of optimally processed samples were then assessed during 60 days of -18 °C frozen storage. The optimal sonication conditions were identified as 15.46 min of 66 W, corresponding to 5.16 kJ/kg SEC and 17.03 W acoustic power. In-pack sonication was superior to conventional sonication in terms of product quality attributes. Optimized in-pack sonication reduced PV, FFA, and total bacteria count by 15.0, 17.6, and 37.4% but increased CL, MFI, and shelf-life by 4.1, 107.8, and 64.2%, respectively. The proposed in-pack ultrasonics approach could contribute to achieving sustainable development goals (SDGs) and sustainable food production, considering the low energy consumption and food waste reduction through delaying food spoilage. Graphical Abstract