Data-Augmented Deep Learning Algorithm for Accurate Control of Bioethanol Fermentation Using an Online Raman Analyzer

Abstract

Fed-batch fermentation has become the preferred strategy in many industrial biomanufacturing processes. However, a key challenge remains in optimizing the feeding strategy to achieve stable maximum yields. In this study, we present an online Raman spectroscopy-based monitoring and control system, using bioethanol production by Saccharomyces cerevisiae as a case study. To address the issue of limited labeled data, a pseudo-labeling approach based on semi-supervised learning was employed, expanding the available training data set by 100-fold compared to conventional labeling methods. In addition, we developed a spectral-temporal concatenation convolutional neural network (STC-CNN) that incorporates sequential spectral features. Comparative evaluations with multiple machine learning algorithms demonstrated the superior performance of STC-CNN, achieving a root mean square error (RMSE) of 3.63 g/L for glucose prediction. The system enabled rapid and automated glucose feeding to maintain various target concentrations. Notably, a glucose setpoint of 30 g/L yielded the highest ethanol concentration of 140.68 g/L—an increase of 3.85% over traditional Fed-batch fermentation—while reducing glycerol by 6.67%. These results highlight the significant potential of Raman spectroscopy combined with deep learning for automated bioprocess optimization and discovery of optimal operating strategies.