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, the fat used in the dough, whether ghee or oil, must be very cold. Cold fat remains in small, solid pieces within the dough. During baking or frying, this fat melts, creating steam that separates the layers of dough, resulting in flakiness.
Second, avoid overmixing the dough. Overmixing develops gluten, which makes the crust tough and chewy instead of flaky. Mix the ingredients just until they come together, and then gently knead the dough a few times to form a cohesive ball.
Finally, resting the dough in the refrigerator for at least 30 minutes allows the gluten to relax, further contributing to a tender and flaky crust. This resting period also helps the fat to solidify again if it warmed up during mixing.
Use a food processor to pulse the flour and cold fat together. This helps to distribute the fat evenly and quickly, minimizing gluten development and keeping the fat cold.