A study on Dual-Layer Flavor system for Dietary Supplement: Concepts, Technologies and Applications

Abstract

Dual-layer flavor systems have emerged as a promising approach to improve the sensory appeal and functional performance of dietary supplements. Many vitamins, minerals, and probiotics exhibit bitter or undesirable tastes that can reduce consumer compliance and limit product effectiveness. By encapsulating bioactive ingredients in a core layer and applying an outer coating, dual-layer systems enable controlled flavor release, protection against environmental stressors, and enhanced stability during storage and gastrointestinal transit. This review explores the concepts, design principles, materials, and technologies used in dual-layer flavor systems, including conventional methods such as spray drying and freeze-drying, as well as advanced techniques like electrospinning, nanoemulsions, and layer-by-layer assembly. Applications in functional foods and nutraceuticals are discussed, along with the challenges of scalability, industrial feasibility, and long-term stability. The study highlights current research gaps and provides insights into future directions for the development of consumer-friendly, effective, and commercially viable dietary supplements.