Complete data since 2010:
Biotechnology manufacturer Jungbunzlauer boasts a reliable monitoring system
Jungbunzlauer is one of the leading producers of high-quality, sustainable ingredients from natural sources. The company supplies a wide range of industries – including food and beverages, nutrition and health, and household and personal care. Since late 2010, the biotech company has relied on the testo Saveris 1 environmental monitoring system.
Laboratories, quality control, storage areas, retention sample rooms and critical control points in production are all monitored. Data recording has been continuous from the outset – and this level of reliable documentation is essential for GxP-compliant processes. When a new 2,500 m² filling facility was commissioned in 2025, the system was expanded and modernized. We discussed the company’s 15 years of experience with environmental monitoring with Dr Jochen Jung, Head of Quality Control.
Wide range of applications
From tablet coatings to plasticizers in flooring: Jungbunzlauer’s ingredients are used in such a variety of products that virtually all of us have come into contact with them. Their core products include citric acid and various mineral salts – such as potassium, magnesium and calcium compounds. As the range of applications increases, so do the demands on quality assurance and process monitoring. Seamless documentation of environmental conditions is particularly essential in the pharmaceutical sector.
System update with inventory check
“During the planning phase for the new filling facility, we did the calculations: How many loggers do we need? What must be updated to ensure GMP-compliant validation?Together with us, Mr Geipert from Testo conducted an inventory of the existing testo Saveris 1 system and determined the best way to implement our requirements in practice,” recalls Jochen Jung. Jungbunzlauer wanted to implement the technical advancements company-wide and chose to modernize the trusted system. “Now everything is standardized again, with planned redundancy in case of failure. This has given us a lot of flexibility because the connection runs either via WLAN or radio – Testo offers many options here, so we can always choose the best solution for a stable connection.”
Expansion in the new filling facility
The new 2,500 m² filling facility will be integrated into the monitoring system in 2025. “Two Testo service technicians are conducting comprehensive on-site mapping to identify hot and cold spots, as well as humid and dry zones. To accomplish this, they have installed 26 probes that will collect measurement data for ten days. Based on this data, five probes will then be permanently installed, along with an additional logger for each filling line,” Jung explains.
Complete data since 2010
The testo Saveris 1 system at Jungbunzlauer has been running without interruption since 6 December 2010. “I can scroll back in the system and access the original data at any time, at least from the probes that are still in use,” says Jochen Jung. This enables Jungbunzlauer to provide complete documentation of the conditions under which production, storage or testing took place at any time. The documentation is fully traceable and audit-ready. The company is regularly audited by the FDA and the Tübingen Regional Council, and can always provide the required documentation.
From the lab to the field
The environmental monitoring system was first implemented in the laboratory in late 2010 – the very first digital monitoring system at Jungbunzlauer in Ladenburg. Additional loggers were gradually added for containers, silos, drying cabinets, refrigerators and retention sample rooms. In production and storage, the loggers now trigger automatic alerts if temperature or humidity readings move outside the specified tolerance range. A uniform temperature standard was also introduced in the laboratory. Reagents that require storage at 25 °C are kept in temperature-controlled water baths – monitored by custom-made probes that are immersed directly in the liquid. “This makes our work much easier. If everything is kept at 25 degrees, we don’t need to recalculate anything and can rely on consistent reference values,” says Jochen Jung.
Why Testo?
“One thing that certainly spoke in Testo’s favour was that they offer durable probes that are ideal for use with chemicals,” says Jung. He was also impressed by the system because it features a base station and suitable software that allows all data to be centrally recorded and accessed. The alarm function is also a plus. “Some of the instruments have been in continuous use since 2010. Of course, there have been occasional updates for both the firmware and the software.”
Well-coordinated cooperation
These days, the system at Jungbunzlauer in Ladenburg is calibrated annually. “Over the years, we’ve gotten to know quite a few Testo technicians, and no matter who shows up, the quality is always excellent,” says Jung. “Occasionally, creative solutions have also been necessary. If the probe is mounted high up in the high-bay warehouse, for example, the reference probe is simply lifted up using a forklift.”
Jochen Jung was already familiar with Testo from his previous work in a service laboratory: “When I joined Jungbunzlauer and heard that a Testo system was going to be introduced, I thought: Excellent choice – Testo always delivers. It gave me a very positive first impression.”
Looking ahead
Jungbunzlauer plans to continue expanding its use of the testo Saveris system in the future – for example, in new laboratory areas and on additional production lines. Over the past 15 years, Testo has developed an impressive range of applications.
“That’s one of the things this project has shown me,” says Jochen Jung: “If you have an idea, just get in touch with Testo and ask: What’s the latest technology? What solutions are out there? What can you offer us?”
Now everything is standardized again, with planned redundancy in case of failure. This has given us a lot of flexibility because the connection runs either via WLAN or radio – Testo offers many options here, so we can always choose the best solution for a stable connection.
Dr. Jochen Jung
Head of Quality Control
