Scientists Develop Healthier Pastry Techniques

Scientists at Heriot-Watt University in Edinburgh are developing innovative methods to create healthier versions of popular baked goods, focusing initially on the ubiquitous sausage roll. The research aims to significantly reduce saturated fat content while maintaining the taste and flaky texture that consumers expect.

Up to 15 million sausage rolls are sold weekly in the UK, with each often containing over 60% of an adult's recommended daily saturated fat intake. The research team is working on replacing traditional solid fats used in puff pastry with healthier liquid oils, such as sunflower or rapeseed oil. These oils are lower in saturated fat but lack the necessary structure to create the characteristic flaky layers.

To overcome this, the scientists are employing a process called oleogelation, which transforms liquid oils into a solid-like fat. This technique aims to mimic the functional properties of traditional fats, enabling the separation of dough layers that expands during baking to create the desired flakiness. Professor Stephen Euston, from the university's School of Engineering and Physical Sciences, explained that fat plays a crucial structural role beyond just flavor, and simply substituting liquid oils would not yield the expected texture.

The project also prioritizes using oils from crops that can be grown within the UK, aiming to minimize environmental impact. An additional potential benefit is the possibility of reducing or eliminating the chilling process required for traditional laminated pastry. The researchers hope their oleogels will remain stable at higher temperatures, which could streamline manufacturing.

This 10-month project involves collaboration with industry partners New Food Innovation and AB Mauri. It is funded by the UK Research and Innovation Engineering and Physical Sciences Research Council (UKRI EPSRC). The initiative plans to move the modified pastry from laboratory development to kitchen testing with consumers.

Dr. Andrew Bourne, UKRI EPSRC’s executive director for innovation and partnerships, stated that taking innovative food science from the lab to the kitchen and testing it with consumers has the potential to make popular snacks healthier and positively impact public health and well-being. Beyond pastries, the researchers are also investigating the application of this technology to reduce saturated fat in vegan cheese alternatives.