The use of near infrared spectroscopy (NIRS) was investigated in the context of an efficient high cell density fed-batch industrial Pichia pastoris bioprocess for the production of a therapeutic mammalian protein. This process represented a considerable challenge from the viewpoint of using NIRS to model key analytes because it involved two carbon sources (glycerol and methanol) added at differing rates and times, used a chemically complex medium, and showed a change in liquid phase behaviour due to cell growth. Models for biomass, glycerol, methanol and product were constructed. Different methods of spectral collection and mathematical procedures were used relative to which analyte in the fermentation matrix was being modelled and the rationale behind the model building is clearly described. Regardless of the mode of spectral collection it was essential to consider the changes in modelled analyte concentration relative to changes in other spectral contributors (analytes). The study considerably extends the use of NIRS in fermentation processes to high cell density complex industrial production processes, and comments on how this further developments the technology towards routine in situ NIRS monitoring of bioprocesses. (c) 2005 Elsevier Inc. All rights reserved.