The British sausage roll is about to get a health makeover – without losing the flaky texture that makes it a national obsession. Researchers at Heriot-Watt University in Edinburgh are developing a new way to make laminated pastry that could “significantly” cut the amount of saturated fat, while keeping the taste and texture people love.
An estimated 10 to 15 million sausage rolls are sold in the UK every week, but a single one can contain more than 60% of an adult’s recommended daily saturated fat intake. The puff pastry relies on solid fats for its distinctive flaky layers, making it a challenge to reformulate.
“Heriot-Watt scientists develop healthier sausage roll pastry using oleogelation to cut saturated fat.”
“The fat is not just there for flavour; it plays a crucial structural role in the pastry,” explained Professor Stephen Euston, from Heriot-Watt’s School of Engineering and Physical Sciences. “You need the fat sitting between the layers of dough so that when the pastry bakes, steam forces those layers apart and gives you that flaky texture people expect. Simply replacing the fat with a healthier oil doesn’t work, because liquid oils lack the structure needed to separate the pastry layers.”
The team is using a process called oleogelation to turn liquid oils, such as sunflower or rapeseed, into a “solid-like fat” that mimics the behaviour of traditional fats. They are focusing on oils from crops that can be grown in the UK to minimise environmental impact.
If successful, the approach could be applied to a range of popular pastries, including croissants, Danish pastries, and sweet or savoury turnovers. “Reducing the saturated fat content of these ubiquitous snacks could have a very positive impact on the nation’s health and waistlines,” Prof Euston said.
There could also be benefits for manufacturers. Traditional laminated pastry often has to be chilled repeatedly during production to prevent the fat layers from melting as the dough is folded. “We are hoping our oleogels will stay stable at higher temperatures, which means manufacturers may not have to chill the pastry as much,” Prof Euston added. “If we are lucky, they might not need to chill it at all.”
The 10-month project is ongoing, with the team working to perfect a pastry that is both healthier and just as satisfying as the original.