design and fabrication of a new image processing-based sensor for continuous non-invasive monitoring of cell density

A new image-processing-based turbidity sensor has been designed, built, and evaluated for non-invasive, real-time cell growth monitoring. the sensor employs advanced turbidimetric measurement methods without traditional optical sensors and achieves greater measurement precision. the major steps in its development included sensor design, optimization of light transmittance, image processing software development, and sensor calibration. the sensor was validated using real-time monitoring of recombinant e. coli in high-cell-density culture (hcdc) within a bioreactor. calibration involved correcting light intensity for accurate culture monitoring and cross-referencing with offline biomass measurements. capable of measuring up to 52 g/l (od620=116) of cell concentration without any sample pretreatment, the system is ideally suited for industrial bioreactors. this technology enhances bioprocess automation by providing accurate, real-time biomass measurements without dilution, offering a low-cost and scalable industrial solution.