MONITORING THE FERMENTATION PROCESS

The fermentation process is basically a very complex process. The complexity arises from the interactions of the various components in the fermentation process such as:
1 Microbial component
2 Substrate or feed component
3 Product components

All the components above occurring within the fermentation environment of the fermentor.

The main objectives in any industrial fermentation is to produce the microbial fermentation products in the most optimum quantity and quality within the shortest time possible and in the most economical way.

NARROW BAND OF FERMENTATION OPTIMIZATION RANGE
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This is difficult to achieve or require skill operations. The optimum fermentation conditions that can produce the fermentation products efficiently and economically usually occur within a very narrow band of operating parameters or conditions. If the fermentation conditions deviate slightly then the fermentation conditions will never be considered as optimal. The consequences of this deviations from the optimal operating conditions will often result in:

1 Decline in the volume of fermentation products produced
2 Decline in the quality of the fermentation products

Both these factors will affect not only the productivity of the fermentation process but also in the economics of the fermentation process.

MONITORING OF FERMENTATION
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In order to ensure that the fermentation conditions in the fermentor are always operating under the narrow range of optimal fermentation conditions, the fermentor and the fermentation process must be closely monitored. Monitoring of the fermentation process will include:

1 Visual monitoring
2 Microbiological monitoring
3 Physical monitoring
4 Biochemical monitoring

Of all aspects of the fermentation process especially with regard to substrate input, product monitoring, microbial performance and fermentation operating among others. If deviations from the various parameters occurred, steps must be taken to return it back to the optimum conditions by rectifying the problems. We can therefore say "monitoring" is putting the eyes on the whole fermentation process

TYPE OF SAMPLINGS
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In monitoring the performance of the fermentor and the fermentation process we have to depend on getting information from the fermentation process. These information can be obtained by analyzing or measuring the samples from the fermentation process. The samplings or analysis may be done as:
1 Off line analyses
2 On line analyses
3 In line analyses

These analysis may be carried out by analysing the samples chemically, micro biologically or biochemically. In certain instances the analytical readings may only require simple sensors and electrodes which do not really require removing the samples from the fermentation broth. Modern fermentation industries depends more and more upon electrochemical analyses which not only gives a rapid real time reading but do not intrude or are invasive of the fermentation process. A good example is in the use of off gas analyses using mass spectrophotometers.

Rapid real time analyses are accurate and reflect the real situations in the fermentor at the exact time and place. This will allow immediate remedial actions to be taken compared to previous biochemical analyses in which data may be obtained hours or days after the fermentation process. By then it is already too late to rectify the problems

ADVANTAGES OF MONITORING
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Depending on the speed of the fermentation and frequency of analyses, these measurements can:
1 Improving the process control
2 improving the process yield
3 speeding up fermentation process by controlling rate of nutrients, identifying the important reactions and verifying presence of undesired compounds
4 trouble shooting for the cause of fermentation failures

There are other other parameters which can be monitored to provide clues to the state of fermentation besides the routine parameters commonly used in monitoring fermentation process