Minimizing process variations by early identification of deviations is one approach to make industrial production processes robust. Cell morphology is a direct representation of the physiological state and an important factor for the cell’s survival in harsh environments as encountered during industrial processing. The adverse effects of fluctuating process parameters on cells were studied using flow cytometry and imaging. Results showed that altered pH caused a shift in cell size distribution from a heterogeneous mix of elongated and short cells to a homogenous population of short cells. Staining based on membrane integrity revealed a dynamics in the pattern of cluster formation during fermentation. Contradictory findings from forward scatter and imaging highlight the need for use of complementary techniques that provide visual confirmation to interpret changes. An atline flow cytometry or imaging capable of identifying subtle population deviations serves as a powerful monitoring tool for industrial biotechnology.