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Accelerated bioprocess development with Kuhner TOM and fermSYS – VOC sensors

  • Jul 9
  • 2 min read

Updated: Jul 22

The search for the optimal medium and suitable process conditions is the key step in biotechnological process development. In practice, however, this is time-consuming and resource-intensive: many variants are tested in parallel, real-time data is limited, and decisions are often based on endpoint analyses such as biomass or product titre.


Shaking incubators, such as the Kuhner TOM system, enable reproducible cultivation with a high degree of parallelisation. Through the continuous monitoring of Oâ‚‚ and COâ‚‚ data, they already provide valuable information on growth and metabolic activity. However, important questions remain unanswered for a comprehensive understanding of the process:

  • When do by-products form?

  • When does metabolic stress occur?



Additional metabolic insights through VOC analysis


Here, the fermSENSE – MULTI FLOW system from fermSYS broadens our understanding of the process. Online analysis of volatile organic compounds (VOCs) reveals metabolic changes in real time. VOCs serve as:

  • metabolic fingerprints,

  • early indicators of changes in processes,

  • signals of by-product formation and cellular stress.

 

Whilst the Kuhner TOM system measures key physico-chemical process dynamics, the fermSENSE – MULTI FLOW system provides additional metabolic information. The combination of both systems enables data-driven screening with significantly greater insight and transforms a conventional shaker into a mini-bioreactor system.


fermSENSE – MULTI FLOW in the Kuhner TOM system
fermSENSE – MULTI FLOW in the Kuhner TOM system

Use Case: New Level Media Screening

In a typical experiment, up to eight shake flasks are cultured in parallel. The aim is to identify a medium that:

  • enables high biomass production,

  • supports a high product yield,

  • and at the same time minimises the formation of undesirable by-products.

Trend in VOC readings over the fermentation period (fermSENSE - MULTIFLOW)
Trend in VOC readings over the fermentation period (fermSENSE - MULTIFLOW)
Trend in OTR/CTR values over the fermentation period (Kuhner TOM)
Trend in OTR/CTR values (for B1) over the fermentation period (Kuhner TOM)

Observations

The data show that VOC signals increase significantly even during the phase of maximum oxygen uptake. The onset of exponential VOC production almost coincides with the OTR maximum. VOCs could therefore serve as an early metabolic indicator for detecting changes in metabolic state even during the active growth phase.


More than just measurement

The combination of Kuhner process data and fermSENSE metabolite profiles makes screening experiments more meaningful. It lays the foundation for data-driven decisions and, in the long term, paves the way for automated process optimisation and closed-loop fermentation.

 

Conclusion: A powerful duo for modern process development

In practical terms, this means the following for laboratory screening:


=> More data => Better decisions => Faster development.


The combination of the Kuhner TOM System and fermSYS demonstrates how existing laboratory infrastructure can be specifically enhanced to achieve genuine process intelligence.

 


Call-to-Action

Are you interested in how real-time monitoring can be integrated into existing shaker set-ups?

Find out more about the possibilities offered by fermSYS in combination with Kuhner systems – and how you can optimise your fermentation process using data.


Literature (german only):

Brandstetter, J. (Kühner Shaker GmbH, Herzogenrath, Deutschland); Janetzy, R. (Westfälische Hochschule, Recklinghausen, Deutschland); Schulte, A. (Kühner Shaker GmbH, Herzogenrath, Deutschland); Eiden, F. (Westfälische Hochschule, Recklinghausen, Deutschland): Optimierte Fermentation durch smarte Online-Messmethoden. GIT (18 März 2025).



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