First-principles modeling and optimization of the dip-coating process for starch-glycerol edible films using viscosity measurements

Abstract

This current study presents a first-principles approach for modeling and optimizing the dip-coating of starch–glycerol edible films via simple viscosity measurements. Eleven formulations were prepared and characterized at 40°C using a Brookfield viscometer to capture their shear-thinning and yield-stress behavior. The Herschel–Bulkley and Cross models were then used to predict key coating parameters, including film thickness, shrinkage, and adhesion. Strong agreement between theoretical predictions and experimental data (R² > 0.94) confirmed the models’ reliability. Wet film thickness ranged from 0.78 mm to 1.95 mm, dry thickness from 0.12 mm to 0.55 mm, shrinkage from 70.9 % to 88.2 %, and adhesion from 0.0195 N to 3.25 N. These results reveal the interplay of starch content (enhancing structural stability) and glycerol concentration (improving flexibility), enabling the design of films with tailored mechanical and barrier properties. Overall, this streamlined, mechanistic framework significantly reduces the need for extensive empirical trials and offers a scalable route to developing high-performance, biodegradable packaging.