Predictive Fermentation Control of Lactiplantibacillus plantarum Using Deep Learning Convolutional Neural Networks

The fermentation of Lactiplantibacillus plantarum is a complex bioprocess due to the nonlinear and dynamic nature of microbial growth. Traditional monitoring methods often fail to provide early and actionable insights into fermentation outcomes. This study proposes a deep learning-based predictive system using convolutional neural networks (CNNs) to classify fermentation trajectories and anticipate final cell counts based on the first 24 h of process data. A total of 52 fermentation runs were conducted, during which real-time parameters, including pH, temperature, and dissolved oxygen, were continuously recorded and transformed into time-series feature vectors. After rigorous preprocessing and feature selection, the CNN was trained to classify fermentation outcomes into three categories: successful, semi-successful, and failed batches. The model achieved a classification accuracy of 97.87%, outperforming benchmark models such as LSTM and XGBoost. Validation experiments demonstrated the model’s practical utility: early predictions enabled timely manual interventions that effectively prevented batch failures or improved suboptimal fermentations. These findings suggest that deep learning provides a robust and scalable framework for real-time fermentation control, with significant implications for enhancing efficiency and reducing costs in industrial probiotic production.