Scientists at Heriot-Watt University in Edinburgh are developing a new method to reduce saturated fat content in sausage roll pastry without compromising its characteristic flaky texture. The initiative aims to address health concerns linked to one of Britain’s most popular snacks, with weekly sales estimated between 10 and 15 million sausage rolls nationwide.

Currently, a single sausage roll may contain more than 60 percent of an adult’s recommended daily intake of saturated fat, a nutrient associated with increased risk of cardiovascular disease. Researchers at Heriot-Watt’s School of Engineering and Physical Sciences are exploring innovative techniques to produce layered pastry with significantly lower saturated fat levels.

The team, led by Professor Stephen Euston, is investigating the replacement of traditional solid fats with healthier liquid oils, such as sunflower oil, which naturally contain less saturated fat. To maintain the desirable pastry texture, the researchers are employing a process known as oleogelation. This technique transforms liquid oils into a semi-solid state that behaves similarly to conventional solid fats, allowing for the creation of laminate layers essential to flaky pastry.

Professor Euston emphasized the broader implications of the research, noting that while the current focus is on sausage rolls, the approach could extend to other baked goods that rely on laminated pastry. These include croissants, Danish pastries, and various sweet and savory turnovers.

If successful, this innovation could offer consumers healthier options without sacrificing the taste and mouthfeel that have made such pastries staples in the UK diet. The researchers are continuing to refine the process and assess its potential for commercial application across bakery products.