Pitching & Inoculum — Mathematical Formulations Science · v5.0
Viability — applied only at the commercial purchase point
Viability is a specification of commercial yeast (ADY or CmY): the fraction of total cells/g that are metabolically active. Dead cells don't multiply during propagation and don't ferment. Viability therefore affects one thing only — how much commercial yeast must be purchased to deliver the required number of viable cells to the stage that receives it.
Fermenter cell concentration is determined by inoculum target Xi and working volume V alone, not by the commercial viability spec.
Direct pitch (Ferm is the purchase point):
mcommercial (g) = (Xi · Vw,mL) / (ncells/g · vviability)
Staged (propagation or HDYC chain):
mFerm pitch, viable (g) = (Xi · Vw,mL) / ncells/g ← no viability
The biomass arriving at Ferm is fresh propagate from the upstream stage — assumed essentially 100% viable. Viability of commercial yeast enters only at the most upstream stage (the starter that IS purchased).
mcommercial starter (g) = mstage initial, viable / vviability
Three kinetic models per stage
Propagation, Pre-Fermentation, HDYC, and the Fermentation Growth Window each independently select from Logistic, Gompertz, or Exponential (full parity across all stages). Each has a forward (Xi → Xf) and inverse (Xf → Xi) formulation used by Design back-calc, Target back-calc, and the forward/performance modes.
Model-aware specific growth rate (µ)
µ is not the same quantity in every model, so the calculator labels it accordingly:
- µi (Logistic) — intrinsic/initial rate; the maximum the culture achieves, at low density.
- µmax (Gompertz) — maximum specific growth rate, the tangent slope at the inflection point (Zwietering form).
- µavg (Exponential) — time-averaged rate over the full window, µavg = ln(Xf/Xi)/t.
Exponential (no ceiling — average µ)
Xf = Xi · exp(µavg · t) ⟺ Xi = Xf / exp(µavg · t)
A no-ceiling comparison case. It is only honest when µ is the average rate over the full growth time (µavg = ln(Xf/Xi)/t) — feeding it a peak/intrinsic rate over the full window overshoots reality. It does not apply to the HDYC Performance or Bioreactor Design modes, which require a finite ceiling.
Logistic (default)
Sigmoidal growth toward an empirical ceiling Xmax that lumps ethanol inhibition, substrate depletion, oxygen limitation, and nutrient exhaustion:
dX/dt = µi · X · (1 − X / Xmax)
Closed-form forward and inverse solutions:
X(t) = X0 · Xmax / [ X0 + (Xmax − X0) · exp(−µ·t) ]
X0 = Xf / [ exp(µ·t) − (Xf/Xmax)·(exp(µ·t) − 1) ]
Gompertz (Zwietering modified)
Adds an explicit lag phase λ before exponential entry — captures rehydration, anaerobic adaptation, or stress recovery. µ here is the inflection-point maximum µmax:
X(t) = X0 · (Xmax/X0)G(t), G(t) = exp(−exp(µmax·e · (λ − t)/A + 1)), A = ln(Xmax/X0)
The forward function is monotone in X0; the inverse is solved by bisection on X0 ∈ (0, Xf] to machine precision (no closed form exists).
Generation count Z
Z = log2(Xf / Xi)
Valid across all three kinetic models. For Exponential reduces to Z = µavg·t / ln(2).
Fermentation Growth Window
The active growth window is the first 18–22 h of fermentation when cells divide; after this the culture is stationary-phase and ethanol production continues without further division for another 30–50 h. The calculator forward-models (Diagnostic) or back-calculates (Target) this window only.
Mass ⇄ cell-density conversion
Mkg = Xcells/mL · VL / ncells/g ⟺ Xcells/mL = Mkg · ncells/g / VL
For the seed-train stages, biomass is tracked in the format-consistent product-mass basis (kg ADY or kg CmY) and ncells/g is format-aware via the Yeast Format selector. For the Fermentation Growth Window, biomass is tracked in dry-cell-weight (DCW) using the fixed dry-cell reference, so the in-fermenter growth result is the same regardless of which product is purchased.
Diagnostic mode (forward)
Given end-of-fill Xi, forward-model to end-of-growth density Xf,growth. Verdict compares Xf,growth against the healthy industrial range 1–3×10⁸ cells/mL.
Target mode (back-calc)
User specifies Target Xf (desired end-of-growth density); inverse kinetic solves for required Xi, which then drives upstream seed-train sizing. Infeasibility is flagged when Target Xf ≥ Xmax,ferm.
HDYC Forward chain (HDYC topology)
Given commercial starter mass and HDYC/Pre-Ferm/Ferm volumes + kinetics, forward-compute through the chain:
X0,HDYC = mcomm · vviab
Xend,HDYC = forward(X0,HDYC, µHDYC, tHDYC, Xmax,HDYC, λHDYC)
X0,PF = Xend,HDYC · ηHDYC
Xend,PF = forward(X0,PF, µPF, tPF, Xmax,PF, λPF)
mpitch,ferm = Xend,PF · ηPF
Xi,ferm = mpitch,ferm · ncells/g / Vferm,L
Infeasibility at any stage (X0 ≥ Xmax) halts the chain with a descriptive error. Saturation (Xend > 0.98·Xmax) triggers a soft warning — the stage has no headroom and more time won't yield more biomass.
Transfer efficiency
ηk captures physical losses (residual in lines, transfer pumps, etc.) at stage boundary k. In back-calc direction, upstream viable biomass demand scales by 1/η. In forward direction, transferred mass scales by η directly.
Capacity mode (reverse direction)
Given available yeast mass mavailable and target Xi:
Vw,max (mL) = (mavailable (g) · ncells/g · vviab,eff) / Xi
vviab,eff is commercial viability in direct-pitch mode, 1 in staged modes (where the available mass represents propagated biomass).
Fill-cycle geometry (Semi-Batch only)
Fermenter fills linearly from Vheel to Vworking over tfill hours. Yeast is pulsed in over txfer starting at txferStart. Peak cell density occurs at transfer-complete (all cells in, minimum volume):
Vfill-frac(t) = Vheel + (1 − Vheel) · t / tfill
V@xferEnd = Vworking · Vfill-frac(txferStart + txfer)
Peak Xi = (Xi,target · Vworking) / V@xferEnd
Dilution factor = Vworking / V@xferEnd = Peak Xi / Xi,target
At Batch strategy the fill cycle is instantaneous; this section is hidden and values display em-dashes. Current model treats growth during fill as negligible — realistic for short transfers and dilute early-fill conditions; a µfill overlay could be added in a future build.
Fed-batch feed profile (staged modes)
For biomass balance dX/dt = µ·X at constant µ:
F(t) = µ · V · Xviable(t) / (Yx/s · Sfeed)
Peak feed rate is at t = tend. Total sugar delivered:
Stotal = Xi,viable · V · (eµt − 1) / Yx/s
Process Type and Process Strategy (all stages user-controlled)
Each upstream stage (Propagation, Pre-Fermentation, HDYC) exposes a user-selected Process Type (oxygen regime: aerobic / Fermento-Respiratory / fermentation) and Process Strategy (Batch / Semi-Batch / Fed-Batch). The Process Type sets the carrying-capacity default for that stage's oxygen regime; the Process Strategy controls the fed-batch feed-profile panel. None of these is auto-classified from µ — they are physically determined by operator choice, so the calculator leaves them under user control.
For reference, the respirofermentative transition for S. cerevisiae sits near a critical specific growth rate µcrit ≈ 0.27 hr⁻¹ (Crabtree-on above, substrate-limited respiratory below) — useful when choosing an aerobic fed-batch feed rate, but applied as guidance, not an automatic switch.
Ethanol yield vs biomass yield — metabolic mode and feeding strategy
Ethanol and biomass compete for the same carbon, so the useful design ratio is ethanol produced per unit biomass formed, Yp/x = Yp/s ÷ Yx/s. Which metabolic mode dominates — and therefore where Yp/x lands — is set by the residual glucose concentration the cells experience, with oxygen as a permissive (not forcing) factor. The feeding strategy is simply the lever that controls glucose.
Yield ranges by metabolic mode
- Fully fermentative (anaerobic) — Yx/s ≈ 0.08–0.12 g DCW/g glucose (little carbon to cells); Yp/s ≈ 0.42–0.48 g EtOH/g glucose (90–95% of the 0.511 theoretical max). Ethanol per biomass ≈ 4–6 g EtOH/g DCW (higher in optimized VHG systems where biomass is deliberately minimized).
- Fermento-respiratory (micro-aerobic, mixed) — Yx/s ≈ 0.15–0.30 g DCW/g glucose (more carbon to cells); Yp/s ≈ 0.25–0.40 g EtOH/g glucose (some carbon fully oxidized to CO₂). Ethanol per biomass ≈ 1–2.5 g EtOH/g DCW.
In round terms, fully fermentative metabolism yields roughly 2–4× more ethanol per unit biomass than fermento-respiratory — the reason production fermenters run anaerobically while oxygen is confined to the propagation / seed train, where biomass is the goal.
Critical concentration parameters
- Glucose — Crabtree threshold ≈ 0.1–0.15 g/L (~0.5–1 mM). Above this residual glucose, S. cerevisiae ferments to ethanol even under full aeration (overflow metabolism — respiratory capacity is saturated and excess flux spills to ethanol). Below it, the cell respires fully and makes biomass. Aerobic fed-batch biomass production is fundamentally an exercise in feeding glucose to keep residual concentration under this threshold; the associated critical rate is µcrit ≈ 0.25–0.28 hr⁻¹.
- Oxygen — dissolved O₂ and transfer rate. Respiratory (biomass) metabolism needs DO above ~5–20% of saturation and an oxygen transfer rate (OTR / kLa) high enough to meet the cells' uptake at the target density — high-density culture is usually OTR-limited. Critically, oxygen alone does not force respiration: high glucose overrides high oxygen via the Crabtree effect, so you need both low glucose and adequate O₂. For ethanol production O₂ is kept near zero, though trace micro-aeration is sometimes supplied because the yeast needs a little O₂ to synthesize sterols and unsaturated fatty acids for membrane integrity and ethanol tolerance — exactly the fermento-respiratory niche, trading a little ethanol yield for more robust cells.
Summary — feeding system, metabolic mode, and ethanol/biomass
| System | Glucose regime | O₂ regime | Dominant metabolism | EtOH/biomass (g/g) |
| Batch | High throughout | Low (anaerobic) | Fermentative | ~4–6 |
| Semi-Batch | Varies with fill | Low–micro | Mostly fermentative | ~3–6 |
| Fed-Batch | Held below ~0.1 g/L | Aerated (high OTR) | Respiratory | Low; ~1–2 |
| Fed-Batch, micro-aerated | Low–moderate | Trace / micro | Fermento-respiratory | ~1.5–2.5 |
Unifying principle: glucose concentration sets the metabolic mode via the Crabtree threshold; oxygen enables (but does not force) respiration; the feeding system is the lever for controlling glucose. Ethanol-per-biomass is maximized by keeping glucose high and oxygen low (batch / anaerobic); biomass is maximized by keeping glucose low and oxygen high (aerobic fed-batch). Values are literature-typical ranges for S. cerevisiae — they shift with strain, temperature, gravity, and nutrient status, so calibrate against plant-specific data for design.
Batch vs Semi-Batch strategy (Fermentation)
- Semi-Batch — fermenter fills over tfill while yeast is pulsed in. Fill Cycle section active.
- Batch — full charge at t=0, instantaneous pitch. Fill Cycle section hidden; Xi represents pitch density at t=0 (equivalent to end-of-fill density in Semi-Batch since fill is instant).
Growth Window math is identical in both strategies — the distinction affects fill dynamics, not post-fill growth.
Carrying capacity Xmax — cells/mL primary, regime-dependent
Each stage's carrying capacity is entered as a viable cell density (cells/mL) and is the ceiling the Logistic/Gompertz models approach. The g/L product-mass equivalent is derived and shown read-only:
g/L (product) = Xmax,cells/mL · 1000 / ncells/g
Because ncells/g is format-aware, the displayed g/L changes with ADY/CmY (≈1:5.5) while the cells/mL value — a physical density — stays fixed. The default carrying capacity adapts to the stage's oxygen regime (Process Type):
- Aerobic ≈ 1.2×10⁹ cells/mL · Fermento-Respiratory ≈ 1.0–0.8×10⁹ · Fermentation ≈ 0.5×10⁹
Custom values are preserved when the regime changes (only recognized regime defaults auto-swap).
Fermenter carrying capacity in dry-cell-weight (DCW)
The Fermentation Growth Window carrying capacity is internally a dry-cell-weight density (g DCW/L) using the fixed dry-cell reference (≈2×10¹⁰ cells/g dry), so the in-fermenter growth model is independent of whether ADY or CmY is purchased — a fermenter's living-biomass ceiling is a physical quantity, not a product-mass quantity. The cells/mL ⇄ g DCW/L conversion uses that fixed reference, not the format-aware product cells/g.
HDYC Performance and Bioreactor Design (drive-to-maximum modes)
Both modes drive each stage to a high fraction (99%) of its carrying capacity and chain forward to the fermenter, reporting the maximum achievable Xi and the commercial HDYC inoculum required. They require a finite ceiling (Logistic or Gompertz) — Exponential is rejected.
Bioreactor Design adds Pre-Ferm conditioning and viability balance:
viabilityPF = v0 · (1 − K · util²), util = Xend/Xmax (K ≈ 0.12)
C = conditioning factor ∈ [0,1] (computed from Pre-Ferm regime × residence-time, or user override)
λferm = λbase · (1 − C)
µferm = µbase · (1 + 0.20 · C)
Conditioning models fermentative adaptation: a well-conditioned pitch (C→1) enters the fermenter with reduced lag and a higher early rate. These relationships are gentle, monotonic engineering correlations — tunable in one constants block — not a mechanistic metabolic model.
Sig-fig display
Outputs use 3 significant figures: formatSigFigs(1556.73, 3) = "1560", formatSigFigs(0.00423, 3) = "0.00423". Avoids misleading 2-decimal precision across 6 orders of magnitude.
Tolerant number parser
The inoculum input accepts: 10E6, 1e7, 10M, 10,000,000, 10 000 000, 1.0e+07. Internal canonical: scientific notation with uppercase E.
Sensitivity analysis
Per-stage sensitivity tables vary ±10% and ±20% on one parameter (µ or t) holding all else fixed, reporting the corresponding change in Xi mass in the display convention for that stage (commercial purchase for the upstream-most stage, viable biomass for intermediate). Intended as quick-and-dirty "how sensitive am I to this choice?" not a full Monte-Carlo.
Scope and caveats
- Kinetic models are lumped — Xmax absorbs ethanol inhibition, substrate depletion, O2 limitation, and nutrient exhaustion empirically without modeling them separately. For full mechanistic modeling (Monod, Levenspiel product inhibition, Yx/s-vs-µ Crabtree coupling), use the FermAxiom Ethanol Time-Course Simulator.
- Growth Window assumes cells stop dividing at tgrowth (default 20 h) — consistent with industrial observation that ethanol accumulation halts division by hour 18–22. The rest of the ferm run is stationary-phase and not modeled here.
- Fill cycle treats biomass as purely volumetric (no growth during fill). Realistic for short transfers; a µfill kinetic overlay would refine this if needed.
- Fed-batch feed profile assumes constant µ throughout the stage — in reality, µ may drift.
- Strain comparison is mass/cost only; physiological differences (stress tolerance, flocculation, byproduct profile) are not modeled.
- Fresh propagate is assumed ~100% viable; real propagated biomass typically has 95%+ viability but the commercial-viability specification does not apply to it.