An improved method for maintaining a designed functional shape in fabricated,
expanded snack products by utilizing discrete, solid lipid particles. These lipids
must be solid at room temperature with a melting point above 100 F. such
that they remain discrete and solid when mixed with the dough and are subsequently
sheeted or extruded. During the toasting, frying, or baking step, the solid lipid
particles melt and soften and disrupt the starch matrix, thus allowing steam to
escape and preventing undesirable defects such as excessive blistering, pillowing,
and other shape defects that prevent the intended functionality. The addition of
solid lipid particles, however, prevents steam accumulation only in the localized
area where a solid lipid particle exists. Thus, by changing the level of solid
lipid particles in the dough, the degree of shape deformities can be controlled.