Low Fat Products Applications

Low Fat Fork



Fried foods are popular due to their taste, distinctive flavour, aroma and crunchy texture, which results from an important and versatile cooking process that has been around since antiquity. Modern manufacturing also likes the Deep Fat Frying (DFF), since not only does it make a unique contribution to the smell and taste of the food, but the relatively low cost of large-scale frying, has made fried foods the staple of the ever growing late 20th-century fast food industry. The downside, however, is that the high content of saturated fats associated with DFF is considered a major factor in increasing health risks such as coronary heart disease, cancer, diabetes and hypertension. A large proportion of the total fat consumed in modern society is through fried foods.

Scientists and Food Technologists have worked hard to understand the principles of DFF in order to reduce the uptake of fat which occurs within the process. Currently, there are two processes that have achieved commercial results, the first is the application of a Barrier Emulsion which blocks the take-up of fat during the frying process; the second creates a product with the appearance of a DFF product but achieves this by using oven baking, resulting in all the enjoyment of fried food without the guilt.

Saturn has worked closely with Food Scientists from some of the top European Food Technology Centres to support the development of these processes. We were approached because Saturn’s Spinning Disc Technology demonstrably met the demanding criteria necessary for the successful application. Saturn’s DiscMaster™ and DiscMatic™ products have shown that precision all over spraying with controlled deposition is crucial to achieving consistently high-quality low-fat products.

Barrier Emulsions

By applying a barrier emulsion to the food product prior to the deep fat frying process, the emulsion blocks the rapid take-up of oil during the initial phases of the cooking process. Careful control of the application process can ensure the finished product will be classified as low fat. Recent formulations make it impossible to discern a difference in the presentation and taste of the finished product. Control of the barrier application is a key part in the successful outcome of the process.

Oven Cooking

By applying a preparation of specialist oils to the food product, which is then oven baked, the results are outstanding and in all represent the look, feel and taste of a deep fat fried product. The control is to know exactly how much oil is applied by the weight of the uncooked product. Precision spraying methods are vital in maintaining low-fat results.

The Low Fat Chip and Roast Potatoes

The humble potato is sometimes considered as the mainstay of western cuisine. Served roasted, chipped, sautéed, scalloped or just plain mashed, the versatile potato has always been popular. However, in the last few decades, it is perhaps fitting that the two more unhealthy versions the potato, the ‘chip’ and the ‘roasted’ potato have undergone a healthy makeover. Modern production techniques have been applied to provide us with the oven cooked low-fat chip and the low-fat roasted potato, all the flavour with only a little of the guilt.

Without completely demystifying an elaborate and carefully controlled production process, the essential aim of the ‘low-fat’ potato product, is to carefully control the type and amount of oil take-up in the cooking process. By pre-covering the potato with exactly the correct amount of oil coverage by weight, the final oven cooked product will be perfect every time.

By applying a ‘3D all over spray’ of oil to a mono-layer of the potato product, Saturn Spraying’s DiscMaster™ and DiscMatic™ are up to the task of applying the precision control to the spray process. Without this control, it would be impossible to claim the ‘low-fat’ accolade so necessary for this process.

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