With fermHUB and ‘Golden Batch Fermentation’, I no longer find any surprises in the bioreactor

Oct 7

2 min read

Every fermentation is unique—yet in production, one thing matters above all: reproducibility. Anyone running biological processes knows the challenge: slight deviations in pH, dissolved oxygen (DO), or off-gas parameters during the early hours can ultimately determine whether you achieve maximum yield or end up with a failed batch.

Nick Harbring, BSc, at Westfälische Hochschule in Recklinghausen, using fermHUB-SCADA for fermentation control — Nick Harbring using fermHUB-SCADA for fermentation control at the Westphalian University of Applied Sciences in Recklinghausen

With the Golden Batch feature in fermHUB, you turn historical successes into a clear navigation compass for every new process run.

1. What is "Golden Batch Fermentation" in fermHUB?

The Golden Batch describes the ideal process profile of a fermentation. Instead of manually sketching theoretical setpoint curves, fermHUB leverages your real historical data:

Data Selection: You select datasets from past runs that have proven to deliver the best results (e.g., highest biomass, maximum product yield, or optimal enzyme activity).
Defining the Framework: From these selected sensor profiles, fermHUB automatically calculates an elastic corridor profile (confidence interval / tolerance band). This framework establishes the "green zone" for all future fermentations of the same type.

2. Dual Value in Ongoing Processes

As soon as a new run is started, fermHUB compares incoming live data in real time against the defined Golden Batch corridor. This offers two decisive advantages:

a) Immediate Status Analysis (Real-Time Monitoring)

You can see at a single glance on the dashboard whether your current parameters (such as pO2, temperature, pH, or VOC off-gas values) are moving within the target corridor.

The Result: Time-consuming manual data comparisons become obsolete. Deviations are detected immediately, long before critical thresholds are breached.

b) Prediction & Action Recommendations (Predictive Analytics)

fermHUB does not just analyze the present; it looks into the future of your running fermentation:

Trend Forecasting: Is a sensor trajectory following a trend that will cause it to leave the Golden Batch corridor in a few hours? fermHUB identifies this trend early on.
Recommended Actions: Rather than simply triggering an alarm, the system provides concrete recommendations—such as adjusting the feed rate, fine-tuning agitation speed, or lowering the temperature—to bring the process back into the optimal corridor in time.

Display of a ‘Golden Batch Fermentation’ in fermHUB — Display of a Golden Batch Fermentation in fermHUB: Golden batch (gold); VOC-measurement (blue); Prediction (green)

Conclusion: Moving from Reaction to Action

The Golden Batch Fermentation in fermHUB shifts your operation from reactive correction to proactive control. Instead of waiting for offline lab sample analytics to learn that a batch went off track, you intervene dynamically while the process is running. This saves raw materials, secures product quality, and maximizes overall yield.

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