I’m currently developing an Asian-style chili crisp and ran into an issue with texture and flavor distribution.

My Goal & Constraints

• Low Water Activity (aw): Using 100% dried ingredients to keep aw low, prevent microbial growth, and achieve a minimum 1-year shelf life.
• Flavor Profile: Balanced savory, sweet, and tangy profile using salt, sugar, and apple cider vinegar powder.

Current Formulation & Process

1. Base dry blend: All solid ingredients (chili flakes, aromatics, spices, salt, sugar, apple cider vinegar powder).
2. Oil infusion/fry: Pour 80–90°C oil over the dry blend, then raise the temperature to 110–120°C and hold for 3–5 minutes until the solids absorb oil and the mix thickens.
3. Hot fill: Fill glass jars while hot, cap immediately, and allow to rest for 24 hours before opening.

The Problem

Because salt, sugar, and organic acid salts/powders are insoluble in oil, they clump together during the heating phase rather than distributing evenly. Whether I use standard granular sizes or grind them into a fine powder beforehand, I end up with gritty, concentrated "pockets" or hard clumps in the final product.

Questions for the Community

Has anyone successfully dispersed crystalline/dry water-soluble solids in oil without clumping? Does ultra-fine micronizing (e.g., using a colloid mill or high-shear blender after oil addition) help, or does fine powder make agglomeration worse due to surface tension?