Process Deviations Causes Consequence Solution

Parameters

FLOW No 1. Pump failure 1. Fermentation process 1. Inspect pump

cannot occur

Low 1. Line blockage 2. Longer filling time 2.

2.

High 1. Turbulences within 1. Foaming 1. Install a detecting

the fermenter electrode positioned at a
predetermined level in
the fermentation vessel
2. Supply a controlled
amount of an anti-foam
substance into the
fermentation vessel
whenever foam causes a
change in potential at the
detecting electrode.
3. Install online brix
meter

Level No 1. Pump is not 1. Product losses 1. Inspect pump if it is

working working properly
2. Valve closed 2. Check valve
3. Drainage is open

Low 1. Line P-40 blocked 1. Longer time needed to 1.

fill up the tank

High 1. Valve fails to close 1. Liquid overflow 1. Install Emergency

Shut off
2. Pump is left running
2. Always supervise
filling

Temperature Low 1. Cold weather 1. Slow metabolism 1. Install Temperature

Alarm on Cooling Water
2. Longer fermentation In/Out
time
3. Higher cost

High 1. Hot weather 1. Reactor failure due to 1. Install Temperature

yeast death Alarm on Cooling Water
In/Out
Yeast count No 1. Yeast source valve 1. It causes stuck
not opened fermentation which leads
to plant shutdown for
cleaning.
2. It affects the efficiency
of the fermentation.
1. Sterile grade filtering
of gas flows and all the
liquid feeds to the
reactor.
2. Install steaming ports
before and after each
feed or sampling event.
3. Maintaining a positive
pressure (usually by inert
gas like nitrogen) in the
reactor.

Low 2. High temperature 3.

High

Ethanol No

Low 1. Acetic acid is

formed
2. Competitors (wild
yeast) present
High

pH Low all fermentation stops

after the pH drops
below about 4.2
High Increasing acidity will
kill the yeast