The effects of processing and solution parameters on the morphology of food grade electrospun fibers were investigated. The relationship of entanglement concentration (C-e) of zein solution and its electrospinnability was inspected to determine the correlation of fiber morphology with the theology of solutions. Bead-free and uniform zein electrospun fibers were successfully constructed. Response surface methodology (RSM) was utilized to facilitate a more systematic understanding of the electrospinning parameters of zein solutions. The electrospinning parameters studied were concentration of zein solution, solution feed rate, applied voltage and distance between needle tip and collector. The individual and interaction effects between the parameters on average diameter of the electrospun fibers were determined using Box and Behnken factorial design. The interaction effect between feed rate and voltage, the quadratic coefficients of the applied voltage as well as linear coefficients of the solution concentration, voltage and feed rate were found statistically significant in the fabrication of sub-micron fibers. Hence, this work provides an overview on the impact of solution and processing parameters to the fabrication of zein electrospun fibers which may find uses as nanostructured materials in food industry. (C) 2011 Elsevier Ltd. All rights reserved.