Bio-inspired shellac gel/chitosan gas permeation controlled edible coating for efficient preservation of fresh-cut lotus root

• A bio-inspired SG/CS edible coating with gas permeation control was developed. • Shellac self-assembled into nanoporous gel enhancing coating gas permeability. • SG/CS coating suppressed respiration, ethylene release, and enzymatic browning of lotus root. • 0.1% SG/CS coating preserved quality and extended fresh-cut lotus root freshness for 8 days. • The coating is safe (LD₅₀ > 15,000 mg kg -1 ) and offers a natural preservation strategy. The rapid deterioration of fresh-cut fruits and vegetables remains a critical challenge to food safety and sustainability, highlighting the need for natural preservation strategies. Herein, we presented a bio-inspired shellac gel/chitosan (SG/CS) edible coating with gas-permeation control to extend the shelf life of fresh-cut lotus root. Molecular dynamics simulations revealed that shellac, as an atypical amphiphile, self-assembled under glucono delta-lactone induction through hydrophilic and hydrophobic interactions into transient vesicles or micelles, which aggregated into a porous gel network. Shellac gel particles incorporated into chitosan coatings retained abundant nanoporous structure upon drying on fresh-cut lotus root, modulating gas permeability and enabling a gas-permeation controlled edible coating. Acute oral toxicity tests in mice (LD₅₀ > 15,000 mg kg⁻¹) confirmed the coating to be practically non-toxic. Functionally, SG/CS coatings suppressed respiration rate, ethylene release, moisture loss, and enzymatic browning, maintaining color, texture, and nutritional quality of lotus root by modulating the surrounding gas microenvironment. Notably, the 0.1% SG/CS coating achieved superior preservation effects, extending freshness of fresh-cut lotus root to 8 days. This study introduces a safe and efficient preservation strategy and provides a promising alternative to conventional antibacterial or antioxidant coatings in the development of edible coatings for fresh-cut produce.