In a biofermentation workshop, you may see this problem. The last batch gets a yield of 100, and this batch only gets 80. The strain is the same. The fermenter is the same. The process parameters are the same as in the manual. This typical phenomenon is Fermentation Yield Fluctuation.
This is not about luck.
Fermentation works with tiny living things. It is not a simple rule, and input A cannot always give fixed output B. This special feature of biology easily causes Fermentation Yield Fluctuation.
The Invisible Butterfly Effect
The first factor leading to Fermentation Yield Fluctuation is the strain seed. You may think one strain tube from the fridge can produce the same clone group. But this is not true.
Microbes change on their own while they grow. Some good strains in a high-yield group may have random changes, and they become better. Some bad strains may also appear. They stop making the target product, and they use all energy for fast growth. This internal difference of strains directly brings Fermentation Yield Fluctuation.
Bad strains in a big fermenter can take resources from other cells fast, and the yield goes down. The strain source stays the same, but each new batch forms a cell group with a different structure. It finally leads to Fermentation Yield Fluctuation.
The Microenvironment Inside the Fermenter: Uniformity Is Only on the Outside
The large steel fermenter looks firm and stable. The inside micro space has uneven flow and different local environments, and this hidden difference also causes Fermentation Yield Fluctuation.
1、Oxygen Is Not Spread Evenly
Oxygen supply relies on stirring and air input. The area close to the stirrer gets more oxygen. The dead corners inside the tank get less oxygen. Cells in different positions stay in different growth states. A slight change of stirring speed can break this balance and trigger Fermentation Yield Fluctuation.
2、Nutrients Change in Time and Space
Added nutrients cannot spread evenly at once. Cells near the feeding point take in rich nutrients in a short stirring period. Cells far from the feeding point get fewer nutrients. The nutrient difference directly affects cell metabolic activity and results in Fermentation Yield Fluctuation.
3、Small Details in Operation
Many minor operation steps can affect the final result and bring obvious Fermentation Yield Fluctuation.
4、Sterilization Strength
Culture medium heating is similar to food cooking. Too much heat will destroy nutrients, and it will produce unwanted byproducts. Small changes of steam pressure can greatly affect medium quality and further cause Fermentation Yield Fluctuation.
5、Inoculation Time
There is a proper time to transfer seed liquid from small tanks to large fermenters. The final yield will fall if the cells are too young or too old. Unreasonable time control is another key reason for Fermentation Yield Fluctuation. Staff experience and judgment decide the best inoculation time to avoid Fermentation Yield Fluctuation.
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Bailun upgrades the intelligent level of bioreactors. The company sets up large bioreaction models and one-stop platforms for synthetic biology business. The platform covers strain research and industrial mass production. It effectively controls and reduces Fermentation Yield Fluctuation.
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