Exploring the future of precision fermentation: PPTI webinar highlights the transformative role of Process Analytical Technology

In last week's webinar hosted by Protein Production Technology International, industry experts and innovators explored how Process Analytical Technology (PAT) is reshaping the future of precision fermentation. In partnership with Hamilton Process Analytics, the discussion brought together a diverse panel of leaders, each providing insights into PAT’s applications, challenges, and potential for optimizing product quality in precision fermentation.

PAT isn’t new, but its role in precision fermentation is groundbreaking. Previously established in pharmaceuticals, PAT enables continuous monitoring of critical process parameters. In the context of precision fermentation, PAT provides real-time data that manufacturers can use to adjust conditions, ensuring quality and efficiency at every production stage. This technology is critical as companies seek to scale up from lab environments to commercial production while meeting stringent quality and safety standards.

Charlotte Hughes, Scientific Content Writer at Hamilton Process Analytics, kicked off the session with a presentation outlining PAT's impact on the fermentation process. Hughes highlighted how PAT tools, such as inline sensors, allow real-time adjustments, ultimately reducing waste, lowering costs, and ensuring consistent quality. "PAT is a gateway to a quality-by-design approach, aiming for continuous improvement of both product and process," she explained. She also noted that PAT enables companies to "make data-driven decisions in the moment", allowing manufacturers to catch issues early, rather than troubleshooting after production.

The session highlighted PAT’s role in addressing common challenges in scaling up precision fermentation processes. Precision fermentation—where microbes are engineered to produce specific molecules like proteins or fats—requires high precision in controlling environmental conditions. Hughes underscored the importance of continuously monitoring parameters such as dissolved oxygen and cell density to maintain process stability and consistency across different production scales.

Klaus Kienle, Co-founder of Food Brewer, elaborated on the role of PAT in his work developing sustainable cacao and coffee alternatives. He emphasized the value of real-time monitoring to foresee potential issues as processes scale up. For Food Brewer, PAT technology is crucial in managing the challenges of larger production volumes, including controlling cooling systems and maintaining consistency. “The right PAT strategy,” Kienle said, “allows us to understand the intricacies of our process at the R&D scale and helps ensure a seamless transition to larger production volumes.”

As production scales up, understanding and controlling process variability is vital. The panel agreed that PAT’s real-time data capabilities are pivotal for precision fermentation’s success. “We’re looking to make fermentation processes leaner and more efficient,” said Adam Leman, Principal Scientist of Fermentation at The Good Food Institute. He pointed out that PAT can help companies analyze data to refine their operations continuously. By doing so, companies can improve product yields, reduce costs, and ultimately provide affordable, high-quality alternatives to traditional animal-based products.

Anastasia Krivoruchko, CEO & Co-founder of Melt&Marble, explained how her team leverages PAT to optimize the development of precision-fermented fats. By adjusting factors such as dissolved oxygen and pH in real-time, Melt&Marble can influence the sensory properties of its fats, ensuring they meet desired qualities in terms of mouthfeel and flavor. “Precision fermentation is like alchemy,” Krivoruchko remarked. “You take a basic feedstock and transform it into exactly what you want, creating a universe of possibilities for sustainable, healthier, and more delicious foods.”

The panel also discussed the value of machine learning (ML) and artificial intelligence (AI) in fermentation. DairyX founder Arik Ryvkin shared how his team uses ML to analyze data collected by PAT sensors. “Sensors in the fermenter are like our eyes,” he said, noting that ML models help predict and mitigate issues before they arise. With these insights, DairyX can fine-tune the fermentation process to achieve the specific quality and functionality required for casein proteins, used as a foundation for animal-free dairy products like cheese and yogurt.

PAT’s potential for continuous improvement also extends to ingredient sourcing and cost management. Leman pointed out that real-time process data could influence decisions on feedstock, cooling, and energy use, making production both cost-effective and sustainable. As precision fermentation evolves, the panel agreed that industry-wide data standards would be essential. Standardized data could allow companies to “plug and play” various control mechanisms, fostering collaboration across the industry and accelerating progress.

Despite the challenges, the panelists emphasized that PAT’s integration into precision fermentation represents a major step forward in creating sustainable food systems. “Precision fermentation is the next evolution of food systems,” Ryvkin said, highlighting that the efficiency of microorganisms could eventually make these products more affordable and accessible.

In closing, Hughes summed up the session’s tone: “This is an exciting venture that opens up new opportunities for producing complementary foods for a growing world.” As companies scale up precision fermentation, PAT is poised to play an essential role in making these products reliable, affordable, and, ultimately, transformative for the future of food.

If you missed the webinar, you can watch the whole 60 minutes right now on-demand! Click here