Combined with real-time monitoring of density and temperature, the control of the redox potential provides a new approach to influencing cell metabolism during growth, cell viability and non-growing yeast activity in wine fermentations. Prior research indicates that the problem of sluggish and incomplete fermentation can be alleviated by maintaining a constant redox potential during the ethanol fermentation. A secondary trait of hydrogen sulfide formation from elemental sulfur also seems to be associated with the development of low redox potentials during fermentation and this might be prevented by the deliberate control of redox potentials in a certain range. While the control of the redox potential during wine fermentations has been demonstrated previously at the research scale (100 L), the ability to control it in larger volumes typically seen in commercial conditions remained unanswered. Wine fermentations from the same load of Cabernet Sauvignon grapes from the 2021 harvest were conducted at three volumes: 100 L and 1500 L in a research winery and 10,000 L in a commercial winery. Using only pulses of air delivery, the redox potential was successfully controlled to −40 mV referenced to a silver/silver chloride electrode throughout the fermentations, at all scales. This appears to be the first published result of a controlled fermentation trial that includes the commercial scale and demonstrates the scalability of control of redox potential in wine fermentations.

The ability to model the kinetics of wine fermentation enables the early detection of abnormal, sluggish or stuck fermentations, and the prediction of present and future rates of energy, CO₂ and ethanol vapor release. While several wine fermentation models have been published, there are only a few that have been successfully adopted for commercial practice. In this work, the mathematical descriptions of wine fermentation are reviewed and compared. The common features of these include descriptions for the kinetics of yeast growth; substrate and nutrient consumption; product formation; and total and viable cell mass. Additional features include the inhibition of growth by ethanol; competitive inhibition of glucose and fructose uptake; glycerol formation; and the calculation of density from solution composition and solute properties. Three models were selected to compare their ability to describe the sugar, ethanol, biomass and nitrogen of benchtop fermentations at four temperatures, previously published. The models are assessed for their goodness of fit to the data in synthetic-medium fermentations and their suitability for analyzing and predicting commercial wine fermentations.

Redox potential is a solution property that influences specific yeast and bacterial activities and the rate of fermentation completion. There is a need to control it if reproducible fermentation outcomes are to be achieved and reliable conclusions are drawn at both the research and commercial scale of wine fermentation. Desirable outcomes that have been observed so far in wine fermentation include the prevention of sluggish and incomplete fermentations, an enhancement in cell viability, increases in the maintenance rate of non-growing cells, and the avoidance of hydrogen sulfide formation when elemental sulfur is present. Other expected fermentation outcomes include changes in the ratios of glycerol and succinate to ethanol, certain aroma and flavor components, and sulfite formation from sulfate in the juice. The juice composition determines the redox potential’s initial value, and the yeast strain’s interaction with the changing juice composition determines the pattern of the potential during fermentation. This interaction also establishes the dynamic response of the prevailing redox buffer to disturbances and the ability to control the potential during fermentation. The chemical reaction sequence, entities, and speciation thought to be responsible for establishing the redox potential in juices and wine are described. A quantitative model for control purposes remains elusive. Examples of the role of added iron in juice, different yeast strains, ambient light, and the addition of external hydrogen peroxide on the response of the potential are presented. Recent examples of controlling the redox potential during white wine and red wine fermentation at a commercial scale are presented, and areas for future research are identified.

Real-time process metrics are standard for the majority of fermentation-based industries but have not been widely adopted by the wine industry. In this study, replicate fermentations were conducted with temperature as the main process parameter and assessed via in-line Oxidation Reduction Potential (ORP) probes and at-line profiling of phenolics compounds by UV-Vis spectroscopy. The California and Oregon vineyards used in this study displayed consistent vinification outcomes over five vintages and are representative of sites producing faster- and slower-fermenting musts. The selected sites have been previously characterized by fermentation kinetics, elemental profile, phenolics, and sensory analysis. ORP probes were integrated into individual fermentors to record how ORP changed throughout the fermentation process. The ORP profiles generally followed expected trends with deviations revealing previously undetectable process differences between sites and replicates. Site-specific differences were also observed in phenolic and anthocyanin extraction. Elemental composition was also analyzed for each vineyard, revealing distinctive profiles that correlated with the fermentation kinetics and may influence the redox status of these wines. The rapid ORP responses observed related to winemaking decisions and yeast activity suggest ORP is a useful process parameter that should be tracked in addition to Brix, temperature, and phenolics extraction for monitoring fermentations.

Wine fermentation is traditionally monitored through manual measurements of density; however, such measurements become labor-intensive as the number of fermentations increases. Various in situ density measurement techniques are currently used in the wine industry; however, they have not been widely studied nor widely adopted. In this work, we combine in situ measurements of density based on differential pressure measurements with a wine kinetic model and parameter estimation routine to predict the progression of a 1500-L wine fermentation. Pressure transducers were mounted at three vertical positions, and the influence of sensor precision and vertical separation of the transducers was investigated. The transducer measurements were in agreement with the density of samples from a hand-held densitometer. The density measurements from the start of fermentation to 75, 100, 125, and 150 h were used to predict future fermentation behavior. The results show that the automated measurement methodology, combined with a wine kinetic model, can be used in commercial wineries to monitor and predict ongoing fermentations.

Large-scale commercial wine fermentation requires the monitoring and control of multiple variables to achieve optimal results. Challenges in measurement arise from turbidity, stratification in large unmixed volumes, the presence of grape skins and solids during red wine fermentations, the small changes in variables that necessitate precise sensors, and the unique composition of each juice, which makes every fermentation distinct. These complications contribute to nonlinear and time-variant characteristics for most control variables. This paper reviews sensors, particularly online ones, utilized in commercial winemaking. It examines the measurement of solution properties (density, weight, volume, osmotic pressure, dielectric constant, and refractive index), sugar consumption, ethanol and glycerol production, redox potential, cell mass, and cell viability during wine fermentation and their relevance as variables that could enhance the estimation of parameters in diagnostic and predictive wine fermentation models. Various methods are compared based on sensitivity, availability of sensor systems, and their appropriateness for measuring properties in large commercial wine fermentations. Additionally, factors influencing the adoption of control strategies are discussed. Finally, potential opportunities for control strategies and challenges for future sensor developments are outlined.