Data-driven soft sensors can estimate fermentation product concentrations from routinely recorded process variables, but strong performance during normal operation does not establish reliability during process deviations. This study evaluated current-time penicillin-concentration estimation using 100 simulated IndPenSim batches comprising 90 normal-operation batches and ten documented deviation batches, with 113,935 observations in total. Initial normal-trained models and five follow-up experiments examined complete-batch validation, dependence on batch-progress features, phase-specific error, model-family comparisons, early out-of-distribution warnings and empirical prediction ranges. These analyses motivated a matched comparison between normal-only and fault-inclusive HistGradientBoosting regressors using 36 current and causal history-based inputs. Normal performance was evaluated in five regime-balanced complete-batch folds, and deviation performance by leave-one-fault-batch-out evaluation; every tested deviation batch was excluded from its own model fit. Batch-balanced sample weights were used, with a factor of three assigned to permitted deviation batches in fault-inclusive fitting. On held-out deviation batches, pooled RMSE decreased from 3.195 to 2.564 g/L, a reduction of 19.73%, while MAE decreased from 2.076 to 1.441 g/L and R2 increased from 0.8580 to 0.9085. Normal-operation RMSE was nearly unchanged at 1.981 and 1.983 g/L. Eight of ten deviation batches improved. The mean paired fault-batch RMSE difference was -0.7063 g/L, with a descriptive 95% batch-bootstrap interval of -1.2844 to -0.2194 g/L. Improvement was largest within the first-to-last recorded fault-reference window, but late-stage errors persisted. Batch 100 remained poorly predicted, with fault-inclusive RMSE of 6.631 g/L and R2 of -2.4837. A fault-risk classifier, Isolation Forest OOD detector and empirical error ranges offered incomplete reliability information. Fault-inclusive training therefore improved this benchmark on average, but did not establish generalization to unseen fault mechanisms, calibrated safety warnings or deployment in physical fermentation.
Behlim, A. B., Tilewale, A., Patel, D.
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