The term “shortening” describes how saturated fats function. They shorten gluten development, leading to a more tender texture in the final product. 

“Flour, primarily composed of carbohydrates and a small percentage of protein, forms a protein matrix when mixed with water,” said Roger Daniels, vice president, research, development and innovation, Stratas Food. “This matrix… creates elasticity but can also result in a tough texture. Shortenings contain both solid fats and liquid oils. The proportion of these components determines the final texture and consistency of the baked product, as the saturated fats in the shortening coat the protein strand, limiting their interaction and preventing excessive gluten formation. This results in a more tender and palatable dough.”

Stratas Foods often recommends soy-based solutions to assist with reducing saturated fat content. Sometimes these oils become more solid through the rearrangement of the three fatty acids, which is known as interesterification. 

“Shortenings with the right levels of saturated and unsaturated fatty acids can be produced by interesterifying a hard fat such as fully hydrogenated soybean oil with a liquid oil such as high-oleic soybean oil,” explained Frank Flider, fats and oils consultant, United Soybean Board. “The process allows for precise control over the fat’s properties — such as texture, melting point and performance — by adjusting the ratio of solid to liquid fats.”

Through careful blending of fats and oils, total saturated fat content can be reduced, but this is not a one-size-fits-all science.

“While there are options to provide functionality, they are not always drop-in replacements,” said April Parker, principal product developer for bakery, Cargill. “Depending on a baker’s process, the application and other ingredients in the formula, some additional modifications may be needed. These might include changes to processing procedures.”

Cargill offers an all-purpose shortening with 23% saturated fat, which is a big reduction from palm oil, which typically has 50% saturated fat. It is made from high-oleic canola and hydrogenated cottonseed oils.

“The resulting shortening system still provides the functionality bakers need, including plasticity, sensory attributes and ease of use in operations,” Parker said. 

Patco Products’ Trancendim specialty diglyceride product line creates lower fat shortenings and puff pastry margarines while maintaining their spreading and workability.   

“Our newest distilled monoglycerides, Alphadim 90 HO-V and Alphadim 90 MAK, are great for creating low-fat spreads, where a portion of the fat phase is replaced by water,” said Margaret Walsh, senior scientist at Patco Products.

Toppings and more

Many bakers rely on saturated fats to produce frostings, fillings and icings. They require a different approach to reformulating.

“Cookie and wafer fillings are generally a blend of sugar, fat, salt and other minor ingredients,” Parker said. “The type of fat used drives the consistency and eating characteristics of these fillings. Saturated fat helps provide the necessary structure for aeration, oxidative stability and the texture needed for depositing operations.”

Saturated fat also contributes to the durability of these toppings and fillings during manufacturing, distribution and consumption. 

“Blends can help customers reduce saturated fat in icings, too,” Parker said. “We offer an icing shortening that cuts saturated fat levels in half, compared to palm oil-based products.

The newest addition to Cargill’s shortening lineup brings together soybean oil and emulsifiers as a way to reduce saturated fat and still get top performance. It contains around 28% saturated fat.

Another newer option in the market comes from Epogee. EPG reduces total calories by as much as 45%. 

“This alternative fat can help bakers reduce the level of saturated fats in their formulas by up to 80%,” said Jayme Caruso, chief commercial officer, Epogee.

Yet another approach is to explore ingredients outside the fats and oils toolbox.

“Fat reduction in baked goods requires a multi-targeted approach,” said Ashley Beech, bakery applications development manager, Corbion. “Because saturated fats lend to not just processing but finished product quality as well, manufacturers should identify the key functionality of the fat being replaced.”

Corbion, for example, offers enzyme solutions to reduce the need for fats and oils without sacrificing texture or taste, Beech said. There’s one for reducing the fat in sweet, chemically leavened goods and another that can reduce fat in breads, buns and tortillas as well as replace monoglycerides in breads and buns.

The time is now for bakers to reevaluate the fats and oils used in their products. They can reformulate to meet shelf life needs as well as consumers’ sensory expectations and health-conscious demands. 

This article is an excerpt from the April 2025 issue of Baking & Snack. To read the entire feature on Fats & Oils, click here.