The challenge
Bioferm required a web platform to monitor fermentation processes in real time, manage batch production, and provide detailed analytics for quality control teams.
What we delivered
We built an industrial web application with real-time sensor visualisation, automated alerting, batch management workflows, and exportable compliance reports.
Real-time data with real consequences
Fermentation is unforgiving. A temperature or pH excursion that goes unnoticed for an hour can compromise an entire batch, and the cost of a lost batch is measured in five figures. The existing process relied on operators checking gauges on a walking round.
The engineering requirement was therefore reliability rather than sophistication. A monitoring system that is occasionally wrong is worse than no system, because operators stop trusting it and revert to the manual round while still paying for the software.
What we built
A React application backed by a time-series data pipeline ingesting sensor readings continuously, with alerting that fires on trend rather than only on threshold breach — catching excursions while they are still correctable.
Batch management ties every reading to a specific production run, which turned compliance reporting from a manual reconstruction exercise into an export. That single change accounted for much of the measured time saving.
- Real-time sensor visualisation with sub-minute refresh
- Trend-based alerting that predicts excursions before threshold breach
- Batch-linked data model tying every reading to a production run
- One-click compliance report export
- Redundant ingestion path so sensor data is never silently lost
Outcome
Quality checks run roughly 60% faster, waste dropped around 30%, and the platform has held 99.9% uptime. The compliance export alone removed several hours of manual work per production cycle.
Technology used
“The platform Zeebrix built completely transformed how we monitor our fermentation processes. Real-time data visibility has improved our product quality significantly.”
Services used on this project
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