The preparation of zein gels often leads to unstable product quality due to poor reproducibility, posing substantial challenges for the food industry and biomedical applications. Thus, it is essential to study the gelation mechanism and key factors responsible for gelation. Herein, we report four types of assembled structures from zein solutions in binary ethanol–water solvents with either a high concentration (30% w/v) and a low concentration (5% w/v), namely, spheres, spheres with tangential structures, amyloid-like fibrils, and sub-agglomerates with crystal structures. The tangential structure at the edges of the spheres was first observed by transmission electron microscopy (TEM) at the initial stage, offering a model for studying protein folding and aggregation mechanisms. By observing the gelation processes with TEM for morphology, cryo-TEM to confirm structure preservation, HR-TEM for fine details, and negatively stained TEM to reveal hidden features, along with small-angle X-ray scattering (SAXS), we identified two types of gels: one was mainly network structures formed by sphere–sphere fusion, which was thermoreversible, and the other one was irreversible gel due to the increase in the amount of amyloid-like fibrils. Results show that the existence of thermoreversible zein gels indicates potential effective regulation tools of zein gel properties. In addition, amyloid-like fibrils were first isolated from native zein. During amyloid-like fibril formation, the number of tangential structures increased considerably, which were composed of thinner fibrils. High-resolution TEM showed a substructure with a 0.35 nm interplanar spacing, providing evidence of β-sheet aggregates also as confirmed by SAXS. This unique substructure has not been reported in other edible proteins. Moreover, understanding the fibrillation mechanism of zein provides a basis for controlling and developing novel food structures for food protein function and offers insights into neurodegenerative diseases.
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