Usage of crystallised pickering emulsions in biscuits as palm oil replacement

• Dough and cookie quality from particle-stabilised emulsions comparable to palm oil. • 1.0 % press cake particles yielded best processability and end product quality. • regional oil and press cake as a promising step towards more sustainable sourcing. • additionally reduced fat content by incorporation of inner water phase. The type of fat or oil used in biscuit production significantly influences dough processability during formation, rolling, laminating, shaping, and baking, as well as the final product’s firmness, crumbliness, colour, and shape. Palm fat, with its ideal melting range of 35–42 °C, is common for dough production, but sustainability concerns and the desire to avoid tropical oils have driven interest in modifying temperate-region plant oils. Research into particle-stabilised emulsions showed comparable dough and cookie quality to palm oil, significantly outperforming pure oils. Using 1.0 % press cake particles as stabilisers yielded promising results, though higher concentrations darkened biscuit colour. Minimal differences were observed between various raw materials tested. While 1.0 % press cake does not significantly improve sustainability regarding sidestreams, incorporating regional oil and press cake offers a promising step toward a more sustainable alternative. Additionally, reducing fat by incorporating an inner water phase enhances the product’s nutritional profile.