All projects

Rebuilding a testing lab's platform without losing a single record 2025 – ongoing

Business platform rebuild for a packaging testing laboratory

Rebuilding the platform an accredited packaging testing laboratory runs on, from specifications and scheduled testing to certificates, quality issues, and invoicing, on current .NET and Angular. The main dashboard now loads in seconds instead of minutes.

Client
Under NDA
Industry
Packaging testing and quality
Scope
UX and UI design, client reporting portal, legacy platform rewrite, performance optimization, data continuity, ticketing integration
Period
2025 – ongoing
The reality

Every Package Has to Pass a Test First

Almost everything on a shelf, or on a doorstep, arrived in packaging that someone had to test. Cups, films, pouches, mailers, and corrugated boxes all have to meet a specification before a brand or retailer signs off on them, with tensile strength, fiber tear, thickness, and weight each measured and recorded.

A packaging lab runs on a monthly rhythm. Testing notices go out to suppliers at the start of the month, certificates go to clients later on, and invoices follow right behind. When the software behind that cycle slows down, the whole lab slows with it.

The challenge

A Platform That Had Grown Slow

Our client is an ISO 17025 accredited packaging testing laboratory that brands, retailers, and manufacturers rely on to confirm their packaging does what it should. We can't name them, but the shape of their work will be familiar to anyone in quality: specifications, recurring tests, certificates, and the occasional failure that needs chasing down.

Their whole operation runs on a web platform that had grown with them over the years. It had aged, the technology underneath had fallen behind, and the main dashboard took several minutes to load.

Replacing a system this central is one of the riskiest things a business can do. Rewrites are where companies lose features they didn't know they relied on, or data they can't get back. The new platform had to match everything the old one did, keep every record intact, and be much faster, without the lab ever pausing its monthly cycle.

What we built

Phase 1: A Portal Built Beside the Old System

We didn't start with a big-bang rewrite. We began with a new .NET and Angular application running beside the existing one, on the same database and the same user accounts, so nothing in the live system had to change.

Our design team took it from UX wireframes of every user flow to a full UI design in Figma. The result is a portal where administrators build a tree of report pages, decide which roles see each one, and embed a Power BI report per page, filtered so every client and supplier sees only their own data. Certificates of Analysis, non-conformances, corrective actions, testing notices, and invoices each got their own views, with PDF and CSV export.

Clients got a modern window into their data. We got a detailed map of the lab's business logic, which shaped everything that followed.

Phase 2: The Full Rebuild, With Parity as a Goal

The second phase rebuilds the platform itself on the latest .NET and Angular, with MS SQL Server behind it and an architecture brought up to current standards. The goals were written down from the start: a modern stack, no bottlenecks, better performance, full functional parity, and all existing data available and working. Parity and data are where rewrites usually fail, so they're requirements, not hopes.

The easiest way to see what the rebuild covers is to follow a single product through the lab.

It starts with a specification. The lab defines what to test, how many samples to take, and what counts as a pass, building it from reusable pieces so the same product can be held to different standards depending on where it's made. Every change is versioned and can be rolled back, because a result is only as trustworthy as the specification behind it.

From there, the platform schedules the testing. Recurring testing requests go out to suppliers automatically, the system tracks who received and read them, and it chases the ones that go quiet. In the lab, technicians record every step and every measurement against a full audit trail, so anyone can see who did what, and when.

When a result comes back out of bounds, nobody has to spot it by hand. A rule engine raises a quality issue on its own, with the right severity and the failing values attached, and opens a ticket in Freshdesk, where the support team handles the conversation. Status updates flow back into the platform automatically, so the issue and the ticket never drift apart. When everything passes, a certificate is generated for the client to review and publish.

Finally, the work turns into money. Completed tests generate their own invoices, scheduled billing runs retry if anything fails, and payments are matched back to the invoice they settle. Throughout it all, every client, supplier, and facility sees exactly what their role allows and nothing more.

From Several Minutes to Several Seconds

Performance was a priority from the start, not something saved for the end. By finding and removing the bottlenecks behind it, we brought loading of the main dashboard down from several minutes to several seconds.

That's a change users feel on the first day. The screen people open most often stops being a coffee break, and the time saved adds up across every user, every day.

The outcome

Live, Fast, and Nearly There

Phase 1 is live, with clients and suppliers using the reporting portal. Phase 2 is in final user acceptance testing, with delivery expected by the end of 2026.

When it lands, the lab keeps the system its people and clients already know, with every feature and every record in place and far more automation on top. That's the point of a rewrite done carefully: users get a better product, and the business never has to take a leap of faith to get it.

What we built

Delivered for this project

A reporting portal for clients and suppliers

A designed-from-scratch portal where administrators, clients, and suppliers get their own Power BI reports on live data, each page visible only to the right roles.

From minutes to seconds

The main dashboard went from several minutes to load to several seconds, by finding and removing the bottlenecks behind it.

The whole lab, on a modern stack

A rewrite of every module the lab runs on, with full feature parity and all existing data kept available and working.

How it is put together

System architecture

Client
AngularTypeScript
API
.NETREST
Data
MS SQL Server
Integration
Power BIFreshdesk

More work

Have something similar?

Get a realistic estimate

The more we know about your project, the better we can fit the solution to match your needs. So - let's talk!

Get a realistic estimate