Application of a barrier between edible layers

A layer inside a product which is in contact with another layer sometimes contain a component which may migrate and affect the product quality. To a certain degree, this migration can be prevented. The choice of a barrier ingredient and the application method are critical.

Updated Jul 31, 2021 - 10 min Read


Core products

This product can be :
A wafer on which a light aerated cream is applied
A biscuit on which an ice cream is applied …
In most cases the component whose migration must be prevented is water. Its ability to migrate is measured by water activity. Alternatively, the component is fat e.g. butter.



The ingredient used to form a barrier can be :
Fat, generally a saturated fat which is solid at ambient temperature
Chocolate is such a fat, especially if it is partly made of vegetable cocoa equivalent
Protein-based ingredient: zeine, gluten
Proteins or other hydrocolloids have a limited barrier effect against moisture and are rather used as a barrier against fat migration


How does it work?

The coating operation consists in applying the required quantity in an homogeneous way.
It is usually a continuous or semi-continuous operation in the industry.
After coating, the applied ingredient must be stabilised by cooling or drying depending on its nature.


Fat or hydrocolloid preparation



Application by enrobing or spraying



Stabilisation by drying or cooling


Coating system

The application system may consist in an enrobing machine or better a spaying machine if only a topical application is desired.


Coating system

Application spray system


How do you measure your success?

Key quality features

The coating must meet precise requirements


Even thickness


The choice of the ingredient should not affect the overall taste of the product


The coating must retain its efficiency. It is a challenge as heating in a further step reduces the barrier effect by melting or swelling and moisture migration.

Key quality parameters

The process is driven by critical factors


In case of fat, the fat must be applied fluid and set rapidly

Dosage control

The dosage must be precise in surface, quantity and homogeneity

Ingredient choice

It depends on the lower and upper layer to separate