The key to a flaky samosa crust is using cold ingredients, especially cold fat (ghee or oil), and avoiding overmixing the dough to prevent gluten development.
Achieving a perfectly flaky samosa crust relies on a few crucial techniques. First, use ice-cold water when mixing the dough. Cold water helps to keep the fat solid, which is essential for creating layers of fat and dough that separate during baking or frying, resulting in flakiness. Second, the fat, whether ghee or oil, must also be very cold. Cut the cold fat into the flour using a pastry blender or your fingertips until the mixture resembles coarse crumbs. This ensures that the fat remains distributed in small pieces throughout the flour. Finally, avoid overmixing the dough. Overmixing develops the gluten in the flour, leading to a tough crust instead of a flaky one. Mix just until the dough comes together, then wrap it and chill it in the refrigerator for at least 30 minutes before rolling it out. This chilling period allows the gluten to relax and the fat to solidify further, contributing to a flakier final product.
When rolling out the dough, avoid rerolling scraps too many times. Rerolled dough tends to be tougher. Instead, try to use the dough efficiently the first time around, or combine scraps with freshly made dough for a slightly less uniform, but still delicious, result.