Reliable environmental monitoring requires more than just precise measurement technology. Continuous data availability, flexible scalability and the structured integration of new areas are equally crucial. A practical example from the biotechnology sector illustrates how a system has developed over the years from laboratory use into a site-wide, audit-ready infrastructure.
When it comes to quality assurance in regulated areas, it is the long-term availability of measurement values that counts, not only their accuracy. At the biotechnology company, Jungbunzlauer, in Ladenburg, Germany, the testo Saveris 1 environmental monitoring system has been in continuous use since 2010, an important prerequisite for seamless documentation in GxP-compliant processes. It records temperature and humidity data via networked measurement points, stores it centrally, and automatically reports deviations. The manufacturer uses it to monitor laboratories, quality control, warehouses, reference sample rooms and critical control points in production.
Jungbunzlauer Ladenburg manufactures biodegradable ingredients such as citric acid, xanthan and gellan for industries including food and beverage, nutrition and health, household products and personal care. According to Dr Jochen Jung, head of quality control, one of the key advantages is access to historical data. “I can scroll back through the system and access the original data at any time, at least for the sensors that are still in use,” he says. This allows Jung to trace the conditions under which products were manufactured, stored or tested. Comprehensive documentation forms the basis for audits and regulatory compliance. Regulatory inspections are a routine part of operations, making data integrity and continuous availability essential requirements.
From the laboratory to the infrastructure
Jungbunzlauer’s journey into digital environmental monitoring began in 2010 in the laboratory. The system was expanded step by step. Additional data loggers are now used to monitor containers, silos, retention sample rooms, as well as refrigerated storage units and drying cabinets. testo Saveris 1 now covers large parts of the site and fulfils various requirements simultaneously. In production and storage, the system triggers automatic alarms if temperature or humidity thresholds are exceeded. In the laboratory, it enables stable, reproducible conditions, for example, when temperature-controlling reagents. Materials that must be stored at a constant 25°C are placed in monitored water baths with specially adapted sensors. “This makes our work much easier,” explains Jung. “We no longer have to perform manual calculations and receive clean comparative values.”
Expansion and system architecture
The system was further expanded as part of the construction of a new bottling hall in 2025. The new area, covering around 2500 square metres, required additional measurement points as well as a review of the overall system architecture. This process was based on a detailed assessment covering the number of data loggers needed, which components could be reused, where modifications were needed to ensure GMP-compliant validation, and how the infrastructure could remain scalable in the long term. Together with Testo, Jungbunzlauer analysed how the requirements could be implemented in practice. The result is a standardised system architecture with planned redundancy. “We are now significantly more flexible, as connectivity can be provided via both Wi-Fi and radio communication,” says Jung.
Data-driven planning
The integration of the new bottling hall follows a systematic approach. Prior to the final installation, service technicians carried out a mapping exercise lasting several days to record climatic variations within the hall. To this end, they temporarily installed 26 sensors, which recorded temperature and humidity data over a ten-day period. On this basis, the optimal positions for the permanent sensor system could be defined, supplemented by additional measurement points on the individual filling lines. The result is a needs-based sensor layout rather than a one-size-fits-all approach to sensor deployment, a major advantage in large-scale production environments.
Operation and further development
In addition to the technical infrastructure, day-to-day operations are also crucial. Testo’s service engineers regularly calibrate the sensors in use to ensure long-term measurement accuracy. The system also demonstrates flexibility in day-to-day operation. “We find creative solutions, for example, when a sensor is installed high up in a high-bay warehouse and the reference sensor needs to be positioned using a forklift,” explains Jung.
With the expansion of the filling hall, the development of the monitoring system at the site is not yet complete. Further areas, new laboratory sections or additional production lines can be integrated at any time. “I‘ve learned that it pays to ask,” concludes Jung. “For many requirements, suitable solutions already exist and can be implemented immediately.”
For more information contact Testo Saveris,
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