Scientists are working to develop healthier sausage rolls by reducing their saturated fat content without compromising the pastry’s characteristic flakiness. Currently, a single sausage roll can contain more than 60% of the recommended daily intake of saturated fat for an adult. With up to 15 million sausage rolls sold weekly in the UK, the initiative aims to improve public health by offering a lower-fat alternative.

The research is being led by Professor Stephen Euston of Heriot-Watt University in Edinburgh. His team is investigating ways to replace the solid fats traditionally used in puff pastry with healthier liquid oils, such as sunflower or rapeseed oil. The challenge lies in maintaining the flaky texture, as the solid fats help separate layers of dough during baking by creating steam pockets.

“To achieve a flaky pastry, the fat needs to sit between the dough layers, allowing steam to separate them as the pastry cooks,” Professor Euston explained. “Simply substituting solid fat with liquid oils is unsuccessful because liquid oils do not provide the necessary structure to keep the layers apart.”

The researchers are employing a method known as oleogelation, which involves transforming liquid oils into a gel-like, solid form. This technique could potentially mimic the structural properties of solid fats while offering a healthier fat profile.

The project is expected to last approximately 10 months and focuses primarily on sausage rolls. However, the findings may have broader applications for other baked goods that rely on flaky pastry textures, including croissants, Danish pastries, and various sweet or savory turnovers.

By addressing the technical challenges associated with fat replacement in puff pastry, the team hopes to contribute to healthier snack options without sacrificing the taste and texture that consumers expect.