Off-gas analyzers and bioprocess software for CO2, O2 and CH4 – made in Germany, no sampling required

BlueSens gas sensor GmbH

Herten, Germany · Wood Dale (Chicago), USANew on Amplifa

2001Founded

2Locations (Herten, Wood Dale/USA)

Market leader in off-gas analysisMarket position (self-reported)

Shake flask to manufacturing scaleComponent size/application range

ISO 9001:2015 (DEKRA)Certification

About BlueSens

BlueSens gas sensor GmbH, based in Herten, Germany, is a specialist in gas analysis in bioprocesses. The company develops and manufactures off-gas analyzers for the gases oxygen (O2), carbon dioxide (CO2) and methane (CH4) – from simple single-gas analyzers of the BCP series to combination devices of the BlueInOne series and the maintenance-free variable off-gas sensor BlueVary. The analyzers deliver PAT-compliant online measurements in real time, work without sampling and without gas conditioning even in fully saturated gas streams; minimum or maximum flow rates are not required. The sensors can be used with fermenters from all manufacturers, from shake flask to manufacturing scale, and are suitable for cell culture, microbial fermentation as well as single-use and stainless-steel bioreactors. The portfolio is complemented by gas volume measurement (BlueVCount, YeastForce), the bioprocess software BlueVIS with offline data import (BODI), the Yieldmaster system for automated BMP determination and the modular retrofit system Use What You Have. A US subsidiary in Wood Dale near Chicago serves the American market. In business since 2001, the company describes itself as the market leader in the off-gas analysis sector.

Site: Herten
Processes: Off-gas analysis (CO2/O2 in parallel in real time), Off-gas analysis (CH4/CO2 combination), In-situ single-gas analysis (BCP series)
Materials: Oxygen, Carbon dioxide, Methane, Off-gas analysis (online, in situ), BMP determination (Yieldmaster)
Certificates: ISO 9001:2015 (DEKRA, Reg. 51019754/2)
Founded: 2001
Industries: Microbiology, Alternative proteins, Yeast, Renewable energies, Cell culture

01
Development
02
Production
03
Calibration with certified test gases
04
Sales
05
Service & Maintenance
06
Software & Process Integration

Measured Gases & Analysis Methods

Oxygen

Single-gas and combined measurement of O2 in off-gas analysis of fermentation processes.

CO2

Carbon dioxide

Central measurement gas for respiratory activity and process monitoring in bioreactors.

CH4

Methane

Measurement of methane/biogas, among other things for biogas processes and renewable energies.

Off-gas analysis (online, in situ)

PAT-compliant real-time measurement without sampling and without gas conditioning.

BMP

BMP determination (Yieldmaster)

Fully automatic determination of the biogas potential (biomethane potential).

Locations

Herten

Headquarter: development, production, sales, service

Materials: O2, CO2, CH4

BCP series in-situ gas analyzers
BlueInOne series off-gas sensors
BlueVary off-gas sensors
BlueVCount gas volume meters
Yieldmaster BMP determination system
YeastForce gas meter system
BlueVIS bioprocess software

Wood Dale (Chicago)

US subsidiary: sales and market coverage for North America

Products & Analysis Systems

**BlueInOne combination analyzer CO2/O2 or CH4/CO2**Off-gas analysis · Bioprocess technology

**BlueVary variable off-gas sensor**Off-gas analysis · Fermentation

**BCP series in-situ gas analyzer**Single-gas analysis · Microbiology

**BlueVCount gas volume meter**Gas volume measurement · Process industry

**BlueVIS bioprocess software**Process control · Biotechnology

**Use What You Have (UWYH) modular system**Retrofit · Bioreactor technology

Inside the production

BlueSens – off-gas analysis for every bioprocess

BlueVary – maintenance-free off-gas sensor

Industries

MicrobiologyAlternative proteinsYeastRenewable energiesCell culture

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
Off-gas analysis (CO2/O2 in parallel in real time)Testing	–	–	–	–	CO2, O2
Off-gas analysis (CH4/CO2 combination)Testing	–	–	–	–	CH4, CO2
In-situ single-gas analysis (BCP series)Testing	–	–	–	–	O2, CO2, CH4

8 Anlagen & Maschinen

Machine	Manufacturer / model	Quantity	Working area	Year built	Site
Off-gas sensor	BlueSens BlueVary	–	CO2/O2 & CH4/CO2, maintenance-free, cartridges	–	Herten, Germany
Off-gas sensor	BlueSens BlueInOne series	–	parallel real-time measurement of CO2 and O2	–	Herten, Germany
In-situ gas analyzer	BlueSens BCP series	–	CO2, O2, CH4 individually	–	Herten, Germany
Gas volume meter	BlueSens BlueVCount	–	high and low gas flows	–	Herten, Germany
Bioprocess software	BlueSens BlueVIS	–	automatic calculations, process control	–	Herten, Germany
Gas meter system	BlueSens YeastForce	–	gas volume determination (e.g. leavening power in doughs)	–	Herten, Germany
BMP determination system	BlueSens Yieldmaster	–	fully automatic BMP determination	–	Herten, Germany
Modular bioreactor solution	BlueSens Use What You Have (UWYH)	–	revamp/retrofit of existing bioreactors	–	Herten, Germany

Quality

All products are manufactured in Germany; high-quality components, consistent product controls and calibration exclusively with certified test gases ensure quality and reliability. Development and production work closely together, so improvements can be implemented quickly.

Evidence	Herten
ISO 9001:2015 (DEKRA, Reg. 51019754/2)

History

2001
Foundation of BlueSens as a specialist in gas analysis in bioprocesses.
ca. 2011
Ten years after its founding, BlueSens achieved, according to its own statements, market leadership in the off-gas analysis sector.
2025
Recertification according to ISO 9001:2015 by DEKRA (Reg. 51019754/2, valid until 2028-10-21).