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World J Microbiol Biotechnol (2015) 31:1845–1852

DOI 10.1007/s11274-015-1940-0

REVIEW

Recent advances in electronic nose techniques for monitoring


of fermentation process
Hui Jiang1 • Hang Zhang1 • Quansheng Chen2 • Congli Mei1 • Guohai Liu1

Received: 21 July 2015 / Accepted: 31 August 2015 / Published online: 4 September 2015
Ó Springer Science+Business Media Dordrecht 2015

Abstract Microbial fermentation process is often sensi- also propose the technical challenges and future outlook for
tive to even slight changes of conditions that may result in the electronic nose techniques.
unacceptable end-product quality. Thus, the monitoring of
the process is critical for discovering unfavorable devia- Keywords Electronic nose  Sensor array 
tions as early as possible and taking the appropriate mea- Fermentation  Odor  Process monitoring
sures. However, the use of traditional analytical techniques
is often time-consuming and labor-intensive. In this sense, Abbreviations
the most effective way of developing rapid, accurate and 2NM 2-Norm method
relatively economical method for quality assurance in ANN Artificial neural network
microbial fermentation process is the use of novel chemical ANOVA Analysis of variance
sensor systems. Electronic nose techniques have particular BPNN Back propagation neural networks
advantages in non-invasive monitoring of microbial fer- CA Cluster analysis
mentation process. Therefore, in this review, we present an DFA Discriminant factorial analysis
overview of the most important contributions dealing with GC Gas chromatography
the quality control in microbial fermentation process using GP Gaussian process
the electronic nose techniques. After a brief description of HCA Hierarchical cluster analysis
the fundamentals of the sensor techniques, some examples HPLC High-performance liquid chromatography
of potential applications of electronic nose techniques ICA Independent component analysis
monitoring are provided, including the implementation of IDCs Interdigitated chemocapacitors
control strategies and the combination with other moni- KNN K-Nearest neighbors
toring tools (i.e. sensor fusion). Finally, on the basis of the LDA Linear discriminant analysis
review, the electronic nose techniques are critically com- LSD Fisher’s least significant difference
mented, and its strengths and weaknesses being high- MDM Mahalanobis distance method
lighted. In addition, on the basis of the observed trends, we MIRS Mid infrared spectroscopy
MLR Multiple linear regression
MOS Semiconducting metal-oxide sensors
MLR Multiple linear regressions
& Hui Jiang MOSFET Metal-oxide semiconductor field-effect
h.v.jiang@hotmail.com; h.v.jiang@ujs.edu.cn
transistors
& Quansheng Chen NIRS Near-infrared spectroscopy
q.s.chen@hotmail.com
OCP Organic conducting polymer
1
School of Electrical and Information Engineering, Jiangsu PCA Principal component analysis
University, Zhenjiang 212013, People’s Republic of China PCR Principal component regression
2
School of Food and Biological Engineering, Jiangsu PCs Principal components
University, Zhenjiang 212013, People’s Republic of China PLS Partial least squares

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QCM Quartz crystal microbalance qualitative identification of a gas and cheap chemical
QMBs Quartz microbalances sensors which can be easily integrated in current produc-
SAW Surface acoustic wave tion processes, thus becoming particularly suitable for the
SmF Submerged fermentation continuous monitoring of microbial fermentation process.
SOM Self-organizing map In our work, major contributions of electronic nose appli-
SSF Solid state fermentation cations in the monitoring of microbial fermentation pro-
SVM Support vector machine cesses will be commented.
TDNNs Time-delay neural networks Previous research reviews, complementary to the scope
VOCs Volatile organic compounds of this review, have been conducted related comments in
some specific field of fermentation. Rudnitskaya and Legin
(2008) summarized recent achievements in the research,
development and applications of electronic tongues and
noses to the monitoring of biofuel production processes.
Introduction Peris and Escuder-Gilabert (2013) reviewed two new
analytical techniques, including electronic nose technique
Microbial fermentation is a biomolecule manufacturing and their applications for monitoring of food fermentation
process which is widely used in the food, pharmaceutical, processes. Herein, we review in detail the trends in the
fuel and textile industries. These biomolecules are mostly application of electronic nose techniques for monitoring of
metabolites generated by the bulk growth of microorgan- microbial fermentation processes, covering SmF and SSF.
isms on a growth medium, often with the goal of producing We also present the technical challenges and future outlook
a specific chemical product useful to humans. In order to for the electronic nose techniques.
reduce stuck and sluggish fermentation, as well as to ensure
the quality and productivity of fermentation products at all
stages of the microbial fermentation process, effective Electronic nose techniques
process monitoring, which can rapidly provide real time
information, is important due to the rapid pace of devel- The term ‘‘electronic nose’’ refers to the capability of
opment in the fermentation industry (Wang et al. 2014). reproducing human senses using sensor arrays and pattern
However, only several process parameters (pH, tem- recognition systems. That is, an electronic nose is a device
perature, dissolved oxygen, etc.) can be easily measured which is often associated with the detection of odors or
in situ during submerged fermentation (SmF) (Peris and flavors. During 1980s, research has been conducted to
Escuder-Gilabert 2013). In the process of solid state fer- develop electronic nose equipment, which could ‘‘smell’’
mentation (SSF), only the temperature can be real-time odors and flavors of organic material. The recognition
detected and controlled due to the lack of free water (Jiang process is similar to human olfaction and is performed for
et al. 2012a). Thus, more information (biomass concen- identification, comparison and quantification, including
tration, substrate concentration, etc.) required for the pro- data storage and retrieval (Persaud and Dodd 1982). Over
cess control and decision of fermentation is often based on the last decade, the electronic nose techniques have
data produced by offline sampling analysis. Usually, the undergone important developments from a technical and
analysis of these parameters by use of traditional methods commercial point of view and are now used to fulfill
requires sample preparation and specific analytical equip- industrial needs.
ment (such as high-performance liquid chromatography, The electronic nose device was developed in order to
HPLC; and gas chromatography, GC.) and is time-con- crudely mimic human olfaction that functions as an inter-
suming and labor-intensive (Cozzolino and Curtin 2012). active mechanism (Baldwin et al. 2011). Generally, the
Therefore, the real-time monitoring and control approaches electronic nose systems include three major parts: a sample
or techniques of microbial fermentation processes are delivery system, a detection system and a computing sys-
essentially required to assure the quality and consistency of tem. The sample delivery system enables the generation of
the target product. the headspace (volatile organic compounds, VOCs) of a
In recent years, electronic nose techniques have become sample. The system then injects this headspace into the
valuable tools in all major areas of application, particularly detection system of the electronic nose. The sample
due to recent technological developments in sensor tech- delivery system is essential to guarantee constant operating
nology and the computing power of computer hardware. conditions. The detection system, which consists of a
Generally, the electronic nose system is attractive for a sensor array, is the ‘‘reactive’’ part of the instrument. When
number of significant features, such as the relatively fast in contact with VOCs, the sensors react, which means they
assessment of headspace, a quantitative representation or experience a change of electrical properties. The

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computing system is used for data recording, then to gen- relevant applications involve laboratory and industrial field
erate signal pattern that are used for characterizing odors research, with some other non-invasive tool coupled to
based on chemometrics methods. Figure 1 shows a sche- electronic nose techniques for monitoring of microbial
matic diagram of measurements and gas flow of the elec- fermentation processes, as discussed in the following sec-
tronic nose system. tions. The major contributions of electronic nose tech-
In most electronic nose, the sensor array often consists niques relevant to the most research works in the
of non-selective sensors that interact with volatile mole- fermentation monitoring fields are summarized in Table 1.
cules, that is to say, each sensor of the sensor array is For each reference, we listed the fermentation product and
sensitive to all volatile molecules but each in their specific the main study purposes that are presented in the Table 1.
way. In sensor array react to volatile molecules, the
adsorption of volatile compounds on the sensor surface Submerged fermentation
causes a physical change of the sensor. The non-selectivity
of the sensors results in many possibilities for unique signal Submerged fermentation (SmF) has been defined as fer-
combinations, patterns or fingerprints. The more commonly mentation in the presence of excess water. In the modem
used sensors for electronic nose system include metal-ox- industrial manufacturing, almost all the large-scale enzyme
ide semiconductor (MOS), metal-oxide semiconductor producing facilities are using the proven technology of
field-effect transistors (MOSFET), organic conducting SmF due to better monitoring and ease of handling
polymer (OCP), quartz crystal microbalance (QCM), (Singhania et al. 2010). Since 2000, electronic nose tech-
quartz microbalances (QMBs), surface acoustic wave niques as a promising tool have been applied to on-line
(SAW), interdigitated chemocapacitors (IDCs), etc. (Roeck and/or off-line monitoring of SmF processes. The main
et al. 2008; Oh et al. 2011). Today, several commercial application of electronic nose with respect of SmF is
electronic nose devices have emerged in the market. These qualitative and quantitative analysis by using fingerprints
instruments are often promoted as generic devices and obtained of odor, such as parameters detection and state
suitable for a range of applications. monitoring.
Bachinger et al. (2001) evaluated the use of a chemical
gas sensor array for monitoring the metabolic burden. The
Fermentation monitoring authors found that selected gas sensors responded in a
substantially different way to microbial cells which are
In recent years, some successful applications of electronic subjected to a high metabolic burden, and cells which are
nose techniques to monitoring of microbial fermentation not. The study indicated that the gas sensors technique
processes have been published. Generally speaking, the could be further developed and provides a promising tool
applications of electronic nose techniques in fermentation for monitoring bioprocesses and improving recombinant
monitoring found in literature can be classified into two expression control.
main categories: SmF (Sect. ‘‘Submerged fermentation’’) Pinheiro et al. (2002) investigated the monitoring of the
and SSF (Sect. ‘‘Solid state fermentation’’). All the evolution of the muscatel wine-must fermentation using the

Fig. 1 The schematic diagram


of measurements and gas flow
of electronic nose system Personal computer

Sensor array

Solenoid
valve-3 (V3)

Ambient air
Solenoid Solenoid
valve-1 (V1) valve-2 (V2)

Vacuum pump

Tail-gas
Sample vessel treatment unit

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Table 1 Summary of the applications of electronic nose techniques in monitoring of fermentation process
Fermentation Application Type of study Sensors Data Off- On- References
processing line line
algorithm

Submerged Heterologous Detection of the metabolic burden on 10 MOSFET, Corrcoef H Bachinger et al.
fermentation protein recombinant microorganisms 19 MOS (2001)
fermentation
Wine-must Monitoring of muscatel aroma profile 32 OCP (A32S PCA H H Pinheiro et al.
fermentation during the wine-must fermentation AromaScan)a (2002)
Wine-must Detect the evolution of aroma profile 10 MOS PCA H Buratti et al.
fermentation (PEN2)d (2011)
Red wine Prediction of alcohol concentration 12 MOS PCR, PLS H Zhang et al.
fermentation (FOX-3000)b (2012)
Yoghurt Prediction of galactose, lactose, lactate, 10 MOSFET, PCA, ANN H Cimander et al.
fermentation pH and the process state of the yoghurt 19 MOS (2002)
culture
Yogurt and filmjölk Visualizing the fermentation state by 10 MOSFET, PCA, PLS H Navrátil et al.
fermentation generating process trajectory 19 MOS (2004)
Tokaj wine Wine fermentation control by gas sensor 6 MOS PCA, MLR H Maciejewska
fermentation array et al. (2006)
Milk fermentation Classify different strains 12 MOS ANOVA, PCA H Gutiérrez-
(FOX-3000)b Méndez et al.
(2008)
Alcoholic Identify differences between the two 18 MOS (FOX PCA, DFA, H Calderon-
fermentation strains 4000)c LDA Santoyo et al.
(2010)
Lactic fermentation Monitor some parameters (FOX 4000)c PCA H Calderon-
Santoyo et al.
(2013)
Partially Discrimination between fermented and 8 QMBs PCA H Garcı́a-Martı́nez
fermentation of unfermented musts et al. (2011)
sweet wines
Vinegar Differentiate different vinegar samples 1 SAW PCA H Lee et al. (2012)
fermentation (zNose)e
Acidithiobacillus Identify each day of reactor evolution 11 MOS PCA, CA H Rosi et al. (2012)
thiooxidans
fermentation
Alcoholic Discriminate between a normal and a 8 IDCs PCA H Oikonomou et al.
fermentation potential spoiled fermentation process (2014)
Solid state Black tea Detection of optimum fermentation time 8 MOS PCA, 2NM, H Bhattacharyya
fermentation MDM, et al. (2007b, a,
TDNN, SOM 2008)
Black tea Detection of optimum fermentation time 8 QCM PCA H Sharma et al.
(2015)
Anaerobic digestion Detection of organic overload in 6 MOS ANOVA, LSD, H Adam et al.
anaerobic digestion domain PCA (2013)
Protein feed Identification of fermentation state 11 MOS PCA, LDA, H Jiang et al. (2014)
KNN, SVM
Protein feed Identification of fermentation state 11 MOS PCA, GP, SVM, H Mei et al. (2014,
BPNN 2015)
Protein feed Monitor the critical time of fermentation 11 MOS PCA, ICA, H Jiang and Chen
process BP_AdaBoost (2014)

For details see the abbreviations section


a
A32S AromaScan is an organic conducting polymer (OCP) commercially available electronic nose from Osmetech plc, UK
b
FOX 3000 is a metal oxide semiconductor (MOS) commercially available electronic nose from AlphaMOS, France
c
FOX 4000 is a metal oxide semiconductor (MOS) commercially available electronic nose from AlphaMOS, France
d
PEN2 is a metal oxide semiconductor (MOS) commercially portable electronic nose from WMA, Germany
e
zNose is a surface acoustic wave (SAW) commercially available electronic nose from Electronic Sensor Technology, USA

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electronic nose. In this work, a commercially available control variable. The multiple linear regression models
electronic nose was used to collect data. Data analysis was were developed using the PC1 extracted for prediction of
carried out by principal component analysis (PCA). The the alcohol content, organic acids and ethyl acetate con-
results achieved of the study demonstrated that the elec- centration in fermenting medium. However, these param-
tronic nose could only perceive the evolution of the ethanol eters indicated the progress of fermentation process as well
during the fermentation without any sample pretreatment. as the sensory quality of final wine, and the PC1 very well
In 2011, Buratti et al. (2011) applied NIRS and mid correlated with human sensory assessment of the intensity
infrared spectroscopy (MIRS), electronic nose and elec- of odour and flavour of fermenting medium. The results
tronic tongue to monitor wine-must fermentation. In their obtained of the work indicated the potential of gas sensor
work, the electronic nose was particularly used to follow array to provide an alternative to human operator control of
the evolution of the aroma profile during the fermentation wine fermentation control.
process. The work demonstrated the possibility to employ Gutiérrez-Méndez et al. (2008) presented a study to
the electronic nose was shown in order to describe the capture the aroma generation of Lactococcus lactis strains
evolution of aroma profile during must-wine fermentation. isolated from different sources by an electronic nose and
Moreover, the kinetic modeling of different techniques data sensory evaluation for their potential use in starter cheese
shows that these non-destructive approaches were suitable cultures. Twenty-three strains of L. lactis were isolated
to follow the fermentation process giving crucial infor- from dairy sources, and all the strains were assessed for
mation about the quality of the final product. Thus, these their ability to produce aromas by the electronic nose and
devices were able to provide real time information for sensory analysis after their incubation in milk. The elec-
monitoring of the fermentation process from a chemical tronic nose data were processed by using PCA, and a clear
and sensorial point of view. Besides, in red wine fermen- difference of four sample groups based on their odor
tation, Zhang et al. (2012) predicted the alcohol content intensity scores (yogurt-like and Fresco cheese-like).
during the red wine alcoholic fermentation by near-infrared Calderon-Santoyo et al. (2010) investigated the no-line
spectroscopy (NIRS) and electronic nose techniques. The monitoring of alcoholic fermentation with an electronic
results demonstrated that both NIRS and electronic nose nose coupled to gas chromatography. The alcoholic fer-
could predict the alcohol concentration during the alcoholic mentations were conducted by Saccharomyces cerevisiae
fermentation of red wine, and the combination of two ICV-K1 and S. cerevisiae T306, and the two strains were
instruments could improve the analysis precision. widely applied in oenology. The differences between the
Cimander et al. (2002) verified the use of sensor fusion two strains were identified using discriminant factorial
(including standard bioreactor probes; NIRS and electronic analysis (DFA) with PCA based on the electronic nose
nose) techniques to efficiently monitor the lab-scale responses. The work showed that the electronic nose was
yoghurt fermentation. The signals obtained were fused by a both a descriptive and predictive tool for the fermentation
cascade neural network. Although the accuracy of the monitoring. Afterwards, the research group used the same
neural network prediction was acceptable and comparable system to monitor some parameters during the lactic fer-
with the off-line reference assay, its stability and perfor- mentation process as ethanol, lactate and biomass con-
mance were significantly improved by correction of faulty centration (Calderon-Santoyo et al. 2013).
data. The results demonstrated that the sensor fusion could Garcı́a-Martı́nez et al. (2011) employed an electronic
improve monitoring and quality control of yoghurt fer- nose in combination with GC, to capture changes in fer-
mentation with implications to other fermentation pro- mentation processes effected by osmo-ethanol-tolerant
cesses. In a similar study, Navrátil et al. (2004) applied the S. cerevisiae strains (strains X4 and X5) added to musts
multi-sensor system to real-time production monitoring in from off-vine dried Pedro Ximenez grapes. The fermented
a dairy under industrial conditions. The features of NIRS and unfermented musts could be classified using the elec-
and electronic nose signals were extracted by using PCA. tronic nose data with the help of a PCA.
The results of the study showed that the first principal Lee et al. (2012) investigated the effects of different
components (PCs) of the multi-sensor data could be used nuruk contents and fermentation methods on organic acids
for on-line generation of a process trajectory plot visual- and volatile compounds in brown rice vinegars. The elec-
izing the actual state of fermentation, and the fusion of the tronic nose was applied to identify the samples obtained
multi-sensor signals had a potential for rapid monitoring from different fermentation conditions. The results of the
and assessment of process quality of yogurt fermentation. study showed the electronic nose analysis had its potential
Maciejewska et al. (2006) studied the process control of superiority to effective differentiate different samples.
Tokaj wine fermentation by using an array of partially Rosi et al. (2012) designed a special electronic nose for on-
selective gas sensor. The gas sensor responses were pro- line monitoring of released vapors during Acidithiobacillus
cessed by PCA, and the first PC1 was extracted as a process thiooxidans grown under aerobic conditions. The sensor array,

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which was made of eleven MOS gas sensors, was placed at the methodology to detect the optimum fermentation time of
top of the bioreactor sensing the headspace in equilibrium with black tea using an electronic nose consisting of eight QCM
the evolving liquor at any time without the need of aspiration sensors. The results showed good agreement with the
and pumping of gases into a separated sensor chamber. The estimations of the ultra-violet-visible (UV) spectropho-
results showed that the specially designed electronic nose was tometer based reference method. Though their research, it
capable to differentiate each day of reactor evolution since could be concluded that the electronic nose technique could
inoculation within periods marked off culture medium be used to monitor the volatile emission pattern for black
replacements using multivariate data analysis. tea fermentation process with a very high degree of accu-
Oikonomou et al. (2014) presented a study on moni- racy, reliability and repeatability. Such objective method-
toring and evaluation of alcoholic fermentation of Sava- ology might be instrumental in manufacturing consistent
tiano must with the use of a gas sensor array composed by quality of black tea.
eight IDCs under laboratory conditions. Two batches of Adam et al. (2013) investigated the utilization of an
fermentation must were tested and also subjected to cor- electronic nose to monitor anaerobic digestion process,
responding standard chemical analysis. According to the especially for detecting organic overload of the reactors.
chemical analysis, two musts with distinctly different fer- An array of non-specific MOS gas sensors were used for
menting characteristics were monitored using the gas sen- process fault diagnosis due to organic overload events
sor array. Sensor array responses to the fermentation must existing in several anaerobic semi-continuous reactors.
samples were compared with those obtained either for pure Two monitoring campaigns were conducted according to
or contaminated samples with controlled concentrations of three different load strategies, and the two groups of data
standard ethanol solutions of impurities. The results indi- were recorded. Then, Hotelling’s T2 value and upper con-
cated that the sensor system could classify between a trol limit to a reference set of digesters fed with a cautious
normal and a potential spoiled grape must fermentation organic loading rate was used as indirect state variable of
process. Therefore, the gas sensor system could be used for the reactors. Overload situations could be identified by the
control and evaluation of the wine fermentation procedure. electronic nose with Hotelling’s T2 values at least four
times higher in magnitude than the upper control limit of
Solid state fermentation 23.7. The results of the study demonstrated that the elec-
tronic nose was a promising tool for on-line monitoring of
Solid state fermentation (SSF) is defined as the fermenta- process imbalances in the domain of anaerobic digestion.
tion in absence or near absence of free water; in such Jiang et al. (2014) evaluated the use of electronic nose
systems, water is present in a solid substrate whose technique for monitoring of the fermentation process of
capacity for liquid retention varies with the type of material SSF of feed protein. Different linear and nonlinear methods
(Jiang et al. 2012a, b). However, with the lack of biological (i.e. linear discriminant analysis, LDA; K-nearest neigh-
sensors, there are no effective measurement methods for bors, KNN; and support vector machine, SVM.) were
key parameter (such as biomass) in SSF. The off-line respectively used to calibrate identification models for
measurements are usually time-consuming and labor-in- monitoring of varying stages of fermentation. The results
tensive, and this strategy is not effective for real-time of the paper showed that the electronic nose technique
monitoring and control of SSF. In recent years, with the combined with an appropriate chemometric approach could
development of chemical sensor technology, although be successfully used in monitoring of SSF process.
electronic nose techniques have also been applied in SSF Recently, two similar researches were reported by Mei
domain, studies found in literature only focused on quali- et al. (2014, 2015), which form the same research team.
tative analysis. The results obtained of the research revealed that the GP is
Bhattacharyya et al. (2007a, b, 2008) presented a a promising method for identify fermentation state of SSF
research on aroma monitoring of black tea during the fer- of protein feed. Additionally, in their further study (Jiang
mentation processes by use of an electronic nose system as and Chen 2014), electronic nose coupled to NIRS tech-
well as determination of the correct fermentation time. In niques were employed to monitor the critical moment in
the work, five different time-delay neural networks the SSF process of protein feed. The results of the work
(TDNN) and self-organizing map (SOM) algorithms were demonstrated a good ability of electronic nose and NIRS
used to develop models for identification of different smell techniques to follow the fermentation process giving cru-
stages during the fermentation runs of black tea processing. cial information about the state of the SSF process of feed
The results demonstrated that most of the electronic nose protein. Compared with the single technology model, the
readings accurately matched with the colorimetric as well modeling of fusion data showed that the combination of
as human panel data. Additionally, in monitoring of black these non-destructive tools could significantly improve
tea fermentation, Sharma et al. (2015) presented a identification performance of the process state of SSF of

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feed protein. Therefore, it could be concluded that these selecting and designing an efficient, practical machine
devices can be regarded as valid and simple instruments, learning algorithm is a precondition for successful appli-
able to provide real-time signals during SSF in order to cation of the electronic nose systems in on-line monitoring
monitor the development of the process from different of microbial fermentation processes, and can also accel-
perspectives. erate processing speed to meet modern manufacturing
requirements. In brief, developing high-performance, low-
cost electronic nose equipment will be a trend to its future
Conclusions and future trends practical application for on-line monitoring of microbial
fermentation process in industrial production field.
In this paper, applications of electronic nose techniques to
the monitoring of microbial fermentation processes are Acknowledgments The authors gratefully acknowledge the finan-
cial support provided by the Natural Science Foundation of Jiangsu
reviewed. The technology has great potential for detection Province (Youth) (Grant No. BK20140538), the China Postdoctoral
of complex mixtures of liquid, gas and solid, due to its Science Foundation (Grant No. 2014M550273), and the Advanced
some particular advantages over conventional analytical Talents Science Foundation of Jiangsu University (Grant No.
techniques such as rapidity, simplicity and relatively 13JDG094). We also wish to thank many of our colleagues for many
stimulating discussions in this field.
inexpensive, and the fact of being non-invasive analytical
techniques thus can efficiently and continuously control at Compliance with ethics standards
all stage of a fermentation process. The general trend
seems to point toward the use of the electronic nose tech- Conflict of interest All authors declare that they have no conflict of
interest.
niques to optimize production cost-effectiveness and pro-
duct quality in fermentation industries.
As can be seen from Table 1, firstly, the electronic nose
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