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MasterControl: Enterprise MES Transformation

Success Story

Next-Gen Manufacturing Execution System

From monolith to cloud-native microservices with modern UX and enterprise-grade reliability.

Cloud-native scalability

with architecture ready to handle enterprise-level workloads.

Improved user experience

thanks to redesigned UI/UX tailored for diverse life sciences clients.

Technologies

Java

Spring Boot

React

JavaScript

AWS

Kubernetes

Postgres

Expertise

Microservices

Cloud

Legacy modernization

Back-end engineering

Front-end engineering

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Monolithic bottlenecks

A tightly coupled architecture limited scalability and slowed performance under heavy workloads.

Outdated user experience

The UI/UX was nearly nine years old, making workflows cumbersome for diverse end-users.

Compliance-driven complexity

As an FDA-certified application, every enhancement had to balance speed with regulatory rigor.

Limited flexibility

The existing system couldn’t adapt easily to new manufacturing workflows or client-specific requirements.

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Let’s modernize a legacy system into a cloud-native platform.

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Enterprise modernization

Expertise in transforming monolithic applications into distributed, cloud-native microservices without sacrificing reliability.

Domain alignment

Deep knowledge in manufacturing and regulated industries ensured compliance remained at the core of delivery.

Zoolatech is a senior-heavy engineering firm with Silicon Valley roots and a Miami HQ, specializing in legacy modernization, system re-architecture, and AI deployment to drive long-term, compounding value.

2017

Year Founded

600+

Employees

96%

Client Satisfaction

Phase 1

System and UX design

Redesign of system architecture, database models, and UX/UI to address legacy pain points.

Phase 2

Architecture transition

Shifted from monolithic services to microservices, enabling flexibility and resilience.

Phase 3

Implementation and testing

Developed core MES modules using Java and React, with developers also owning testing responsibilities.

Phase 4

Data migration

Migrated historical records and production data from legacy CMX system to the new platform.

Phase 5

Hardening and QA

Intensive stabilization phase focused on bug fixing, performance improvements, and compliance readiness.

Phase 6

Future roadmap

Expansion of AI-assisted modules (e.g., intelligent template builder, automated reporting) is underway but not yet public.

A cloud-native MES platform replaced a legacy monolith, delivering scalable performance, modern UX, and compliance-ready manufacturing operations.

Advanced production records

Enhanced execution workflows with robust product recordkeeping, new reporting tools, and compliance-grade audit logs.

Template builder and workflow automation

No-code builder for flexible data capture and routing rules tailored to diverse manufacturing processes.

Extended logging and monitoring

Expanded activity logging and event tracking to meet stringent life sciences regulatory requirements.

Option	Risk	Mitigation
Expanding scope under pressure	Scope growth stretched delivery timelines and risked quality trade-offs.	Adjusted schedules but maintained quality benchmarks through rigorous testing and phased releases.
Compliance without compromise	Regulatory requirements limited flexibility in cutting corners.	Developers owned both implementation and testing, ensuring compliance at every stage.
Hardening fatigue	Extended bug-fixing cycles tested team morale and efficiency.	Structured hardening phases with clear goals and rotation of tasks to reduce burnout.