Secretly collect! 10 fermentation big data that will surprise your jaw!
10 jaw dropping fermentation data reveal the core pain points in process control, equipment management, and technological innovation in the industrial fermentation field.
Regarding parameter control
The fermentation process requires monitoring over 20 core parameters (temperature, pH, dissolved oxygen, stirring power, etc.), among which temperature fluctuations exceeding ± 0.5 ℃ can cause 50% of batches to produce abnormal metabolites.
Animal cell culture - parameter control (speed, temperature, pH, DO)
Regarding bacterial contamination
Industry statistics show that bacterial contamination accidents caused by incomplete sterilization account for 65% of fermentation failure cases, with Bacillus contamination accounting for over 40% of bacterial contamination incidents.
Possible causes and prevention methods of bacterial contamination in fermentation tanks (6 major reasons and their solutions)
Regarding dissolved oxygen fluctuations
When the fluctuation amplitude of dissolved oxygen (DO) exceeds the set value by 30%, more than 30% of batches show bacterial growth stagnation or metabolic pathway deviation, and urgent feeding adjustment is required.
What are the abnormal phenomena in fermentation production? (Poor cell growth, abnormal pH value, abnormal dissolved oxygen level, abnormal foam, etc.)
Regarding pH control
If the pH of the fermentation broth deviates from the optimal range by 0.3 units for more than 2 hours, it will result in a 25% loss of enzyme activity, directly affecting the efficiency of product synthesis.
Regarding energy consumption and cost
Insufficient optimization of stirring power parameters has resulted in energy consumption exceeding the budget by more than 20% for 15% of fermentation batches, directly affecting the company's profit margin.
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About sterilization system
Improper sterilization operation of the jacket resulted in a decrease in heat transfer efficiency of 15% of the equipment and an extension of sterilization time by 30% -50%.
Sorting out industrial fermentation sterilization methods: heat sterilization, radiation sterilization, chemical sterilization, filtration sterilization
About data-driven approach
Only 35% of enterprises achieve real-time data modeling and analysis, while the remaining 65% rely on manual experience judgment, resulting in a 35 fold extension of process optimization cycles.
Intelligent fermentation factory design: large-scale IoT perception, multi-source big data analysis
Regarding humidity control
When the humidity deviation of the material in solid fermentation exceeds ± 5%, the fungal spore production decreases by 40% and the product extraction rate decreases by 18%.
Regarding process amplification
During the process of laboratory to industrial scaling up, over 30% of the processes were unable to achieve the expected production capacity due to calculation errors in mass and heat transfer parameters.
Amplification of fermentation process
Regarding Intelligence
The application of AI models has improved the accuracy of dissolved oxygen control by 40%, but only 12% of enterprises have completed the deployment of intelligent control systems, and the technology conversion rate needs to be improved.
