Impact of a novel partial defatting technology on oxidative stability and sensory properties of peanut kernels

•Novel and healthy peanuts’ defatting process by mechanical extraction was developed.•Major effect of pressure and water content on low-fat peanuts’ oxidative stability.•Lipid oxidation and flavor fade were linked to higher defatting ratios in peanuts.•Physical damage facilitated oxidation of the remaining oil in defatted peanuts.•Peanuts hydrated to 12%d.b. and defatted at 6 MPa had the best flavor and stability. A novel process, ‘mechanical expression preserving shape integrity’, was conceived to prepare low-fat peanuts in response to health-conscious consumer demands. The main purpose of this study was to preserve the taste, aroma, and oxidative stability of the defatted product. Results generated from a central composite rotatable design showed that highest consumer sensory scores were reached at low pressures (4–6 MPa). Free fatty acid, peroxide, p-anisidine, and total oxidation values were mostly affected by water content [W] and pressure [P] with high correlation coefficients (82%