For effective monitoring and control of the fermentation process, an accurate real-time measurement of important variables is necessary. These variables are very hard to measure in real-time due to constraints such as the time-varying, nonlinearity, strong coupling, and complex mechanism of the fermentation process. Constructing soft sensors with outstanding performance and robustness has become a core issue in industrial procedures. In this paper, a comprehensive review of existing data pre-processing approaches, variable selection methods, data-driven (black-box) soft-sensing modeling methods and optimization techniques was carried out. The data-driven methods used for the soft-sensing modeling such as support vector machine, multiple least square support vector machine, neural network, deep learning, fuzzy logic, probabilistic latent variable models are reviewed in detail. The optimization techniques used for the estimation of model parameters such as particle swarm optimization algorithm, ant colony optimization, artificial bee colony, cuckoo search algorithm, and genetic algorithm, are also discussed. A comprehensive analysis of various soft-sensing models is presented in tabular form which highlights the important methods used in the field of fermentation. More than 70 research publications on soft-sensing modeling methods for the estimation of variables have been examined and listed for quick reference. This review paper may be regarded as a useful source as a reference point for researchers to explore the opportunities for further enhancement in the field of soft-sensing modeling.

This work provides a novel approach to monitor the aflatoxin B₁ (AFB₁) content in maize by near-infrared (NIR) spectra-based deep learning models that integrates Markov transition field (MTF) image coding and a convolutional neural network (CNN) strategy. According to the data structure characteristics of near-infrared spectra, new structures of one-dimensional CNN (1D-CNN) and two-dimensional MTF-CNN (2D-MTF-CNN) were designed to construct a deep learning model for the monitoring of AFB₁ in maize. The results obtained showed that compared with the 1D-CNN model, the performance of the 2D-MTF-CNN model had been significantly improved, and its root mean square error of prediction, coefficient of predictive determination, and relative percent deviation were 1.3591 μg·kg⁻¹, 0.9955, and 14.9386, respectively. The results indicate that the MTF is an effective data encoding technique for converting one-dimensional spectra into two-dimensional images. It more intuitively reflects the intrinsic characteristics of the NIR spectra from a new perspective and provides richer spectral information for the construction of deep learning models, which can ensure the detection accuracy and generalization performance of deep learning quantitative detection models. This study provides a new analytical perspective for the chemometrics analysis of the NIR spectroscopy.

L-Lysine is produced by a complex non-linear fermentation process. A non-linear model predictive control (NMPC) scheme is proposed to control product concentration in real time for enhancing production. However, product concentration cannot be directly measured in real time. Least-square support vector machine (LSSVM) is used to predict product concentration in real time. Grey-Wolf Optimization (GWO) algorithm is used to optimize the key model parameters (penalty factor and kernel width) of LSSVM for increasing its prediction accuracy (GWO-LSSVM). The proposed optimal prediction model is used as a process model in the non-linear model predictive control to predict product concentration. GWO is also used to solve the non-convex optimization problem in non-linear model predictive control (GWO-NMPC) for calculating optimal future inputs. The proposed GWO-based prediction model (GWO-LSSVM) and non-linear model predictive control (GWO-NMPC) are compared with the Particle Swarm Optimization (PSO)-based prediction model (PSO-LSSVM) and non-linear model predictive control (PSO-NMPC) to validate their effectiveness. The comparative results show that the prediction accuracy, adaptability, real-time tracking ability, overall error and control precision of GWO-based predictive control is better compared to PSO-based predictive control.

The marine biological enzyme fermentation process is a time-varying, nonlinear, uncertain, and multivariable system, so high performance decoupling control is a target to seek. A decoupling control method based on a fuzzy neural-network inverse system for the marine biological enzyme fermentation process is proposed, in which the inverse system linearizing method of the nonlinear system is combined with the nonlinear identifying technology of the fuzzy neural network. First, based on the characteristics of the fermentation process, the model of a fermentation system is obtained, and the reversibility of the system is proved. Second, the ath-order inverse system of the fuzzy neural network is constructed and connected in series with the fermentation system to be a pseudo-linear compound system. Finally, closed-loop control is carried out to obtain good control performance by introducing an expert controller. The simulation experiments demonstrate that good control performance (high accuracy and good robust) can be obtained in the multivariable fermentation process based on the fuzzy neural-network inverse system.

This paper introduces a novel soft sensor modeling method based on BDA-IPSO-LSSVM designed to address the issue of model failure caused by varying fermentation data distributions resulting from different operating conditions during the fermentation of different batches of Pichia pastoris. First, the problem of significant differences in data distribution among different batches of the fermentation process is addressed by adopting the balanced distribution adaptation (BDA) method from transfer learning. This method reduces the data distribution differences among batches of the fermentation process, while the fuzzy set concept is employed to improve the BDA method by transforming the classification problem into a regression prediction problem for the fermentation process. Second, the soft sensor model for the fermentation process is developed using the least squares support vector machine (LSSVM). The model parameters are optimized by an improved particle swarm optimization (IPSO) algorithm based on individual differences. Finally, the data obtained from the Pichia pastoris fermentation experiment are used for simulation, and the developed soft sensor model is applied to predict the cell concentration and product concentration during the fermentation process of Pichia pastoris. Simulation results demonstrate that the IPSO algorithm has good convergence performance and optimization performance compared with other algorithms. The improved BDA algorithm can make the soft sensor model adapt to different operating conditions, and the proposed soft sensor method outperforms existing methods, exhibiting higher prediction accuracy and the ability to accurately predict the fermentation process of Pichia pastoris under different operating conditions.

The problems that the key biomass variables in Pichia pastoris fermentation process are difficult measure in real time; this paper mainly proposes a multi-model soft sensor modeling method based on the piecewise affine (PWA) modeling method, which is optimized by particle swarm optimization (PSO) with an improved compression factor (ICF). Firstly, the false nearest neighbor method was used to determine the order of the PWA model. Secondly, the ICF-PSO algorithm was proposed to cooperatively optimize the number of PWA models and the parameters of each local model. Finally, a least squares support vector machine was adopted to determine the scope of action of each local model. Simulation results show that the proposed ICF-PSO-PWA multi-model soft sensor modeling method accurately approximated the nonlinear features of Pichia pastoris fermentation, and the model prediction accuracy is improved by 4.4884% compared with the weighted least squares vector regression model optimized by PSO.