Researchers at Heriot-Watt University in Edinburgh are developing a new method to make sausage roll pastry healthier by significantly reducing saturated fat while preserving its flaky texture. The project, funded by UKRI EPSRC, aims to replace solid fats with healthier liquid oils using a process called oleogelation.
Health impact of sausage rolls
An estimated 10-15 million sausage rolls are sold weekly in the UK, with a single roll containing over 60% of an adult's recommended daily saturated fat intake. Newcastle-based Greggs is a major retailer, but the snack is popular nationwide. The new technique could cut saturated fat levels without compromising taste or texture.
Oleogelation: a solid-like fat from liquid oils
Professor Stephen Euston from Heriot-Watt’s School of Engineering and Physical Sciences explained: “We want to lower the level of saturated fat while keeping the taste and texture that people love. We’re focused on sausage rolls, but this also applies to other baked goods that contain laminated pastry such as croissants, Danish pastries and sweet or savoury turnovers.” The team uses oleogelation to turn liquid oils like sunflower or rapeseed into a solid-like fat, mimicking the structural role of traditional fats in separating pastry layers during baking.
Challenges and benefits for bakers
Traditional puff pastry requires repeated chilling to prevent fat layers from melting. Professor Euston noted: “We are hoping our oleogels will stay stable at higher temperatures, which means manufacturers may not have to chill the pastry as much. If we are lucky, they might not need to chill it at all.” The team focuses on UK-grown crops to minimise environmental impact. The 10-month project involves industry collaborators New Food Innovation and AB Mauri.
Funding and future testing
Dr Andrew Bourne, UKRI EPSRC’s executive director for innovation and partnerships, said: “UKRI EPSRC’s Impact Acceleration Awards use public funding to turn promising research into practical solutions, and this project does exactly that. By taking innovative food science out of the lab into the kitchen and testing it with everyday consumers, it has the potential to make the nation’s favourite snacks healthier and make a genuine difference to our health and wellbeing.” The modified pastry will be taste-tested with real consumers.
