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%