Abstract: Olestra, a low-calorie natural fat and oil substitute, that is normally a viscous semi-solid at ambient temperatures is rendered substantially permanently liquid and pumpable by application of shear mixing from the semi-solid state, slow cooling from the melted state, or shear mixing and slow cooling from the melted state. Slow cooling inhibits the formation of the crystalline network that is characteristic of the viscous semi-solid form, and shear mixing further inhibits such formation. Olestra processed according to the invention advantageously returns to the semi-solid form after use in snack food manufacturing, thus providing the desired passive oil loss control. The invention greatly improves the practical handling of Olestra in fried food manufacturing processes.