Hydrogen peroxide is widely used as a sterilizing agent in food processing due to its strong oxidative properties, which effectively eliminate bacteria, viruses, and fungi. It is particularly valued for surface decontamination of fruits, vegetables, and packaging materials, where maintaining food safety without compromising quality is critical. The compound decomposes into water and oxygen, leaving minimal residues, which makes it an environmentally friendly alternative to traditional chemical sterilants. Regulatory bodies such as the U.S. Food and Drug Administration (FDA) and the European Food Safety Authority (EFSA) have approved its use within specific concentration thresholds, ensuring both efficacy and consumer safety.

In food processing, hydrogen peroxide is applied in liquid or vapor form. Liquid applications typically involve spraying or dipping produce in solutions with concentrations ranging from 1% to 5%. These concentrations are sufficient to reduce microbial loads on surfaces without damaging the texture or nutritional quality of the food. For packaging materials, higher concentrations up to 35% may be used, particularly for aseptic packaging systems where sterility is essential to prevent post-processing contamination. The FDA permits hydrogen peroxide use in sterilizing food-contact surfaces and packaging, provided that residues do not exceed 0.5 ppm on treated surfaces. The EFSA similarly regulates its use, requiring that residual levels pose no risk to consumers.

Vapor-phase hydrogen peroxide (VPHP) is an emerging technique that offers advantages over liquid applications. VPHP systems generate a fine mist of hydrogen peroxide, which disperses uniformly over surfaces, including hard-to-reach areas. This method is highly effective for decontaminating processing equipment and packaging materials, as it achieves a higher penetration efficiency than liquid sprays. VPHP is particularly useful for heat-sensitive materials where traditional thermal sterilization is impractical. Studies have demonstrated that VPHP can achieve a 6-log reduction in microbial populations, meeting sterility assurance levels required for high-risk food products.

Residual safety is a key consideration in hydrogen peroxide applications. While the compound breaks down rapidly into water and oxygen, excessive residues can affect food taste and safety. Regulatory limits ensure that residual hydrogen peroxide does not accumulate to harmful levels. For example, the FDA mandates that residues on food surfaces must not exceed 1 ppm, a threshold deemed safe for consumption. Monitoring systems, such as peroxide-specific test strips or spectrophotometric methods, are employed to verify compliance with these limits.

Chlorine-based sterilants, such as sodium hypochlorite, have traditionally dominated food sanitation due to their low cost and broad-spectrum efficacy. However, hydrogen peroxide offers several advantages over chlorine-based methods. Unlike chlorine, hydrogen peroxide does not produce harmful byproducts such as trihalomethanes or chloramines, which are associated with health risks. Additionally, hydrogen peroxide is less corrosive to processing equipment and does not impart undesirable odors or flavors to treated foods. While chlorine remains effective for certain applications, hydrogen peroxide is increasingly preferred in operations where residue-free sterilization is a priority.

Emerging techniques are expanding the utility of hydrogen peroxide in food processing. Advanced oxidation processes (AOPs), which combine hydrogen peroxide with ultraviolet light or ozone, enhance its antimicrobial activity, enabling lower concentrations to achieve the same decontamination results. Electrochemically activated hydrogen peroxide solutions are also gaining attention for their stability and on-demand production capabilities, reducing the need for chemical storage and transportation. These innovations align with industry trends toward sustainable and efficient sterilization methods.

The selection of hydrogen peroxide as a sterilizing agent depends on the specific requirements of the food product and processing environment. For delicate produce such as leafy greens or berries, mild concentrations and short contact times prevent tissue damage while ensuring microbial safety. For durable surfaces like metal equipment or plastic packaging, higher concentrations and extended exposure times may be applied without adverse effects. Process validation is essential to confirm that the chosen method achieves the desired log reduction in pathogens without compromising product integrity.

In summary, hydrogen peroxide serves as a versatile and effective sterilizing agent in food processing, with applications ranging from fresh produce decontamination to packaging sterilization. Regulatory approvals from the FDA and EFSA provide clear guidelines for its safe use, while emerging technologies like VPHP and AOPs enhance its efficiency and applicability. Compared to chlorine-based alternatives, hydrogen peroxide offers superior environmental and residue profiles, making it a preferred choice for modern food safety protocols. Continued advancements in application methods and monitoring systems will further solidify its role in ensuring the microbiological safety of food products.