Global Packaging Material Manufacturer Modernizes Legacy Infrastructure to Accelerate Fan Experiences

This global packaging material manufacturer’s platform allows fans to design, customize, and print jerseys at touchscreen kiosks for football, hockey, and other sports. It manages the entire personalization and delivery process.   

However, the backend infrastructure limited the company’s ability to deliver a consistent fan experience, resulting in lost sales and diminished customer satisfaction. The legacy PHP system offered minimal reliability and maintainability, compromising order accuracy and reducing operational efficiency. Without effective logging, errors often went undetected, and incomplete orders meant missed revenue opportunities. Slow processing times exacerbated these issues, directly impacting customer experiences and sales. To address these business-critical problems, the manufacturer partnered with Wavicle to modernize its backend, driving measurable improvements in scalability, visibility, and transaction speed—all essential for unlocking business growth.   

The Challenge: Outdated architecture limiting performance and visibility  

The legacy application’s poor logging meant failures and order interruptions could not be reliably resolved, leading to untraceable canceled orders, missed revenue, and prolonged customer issues. Limited observability hindered the business’s ability to analyze trends and make informed decisions, directly slowing business growth. Slow processing times continued to frustrate customers and reduce repeat business, ultimately affecting profitability.  

The complexity of the PHP codebase increased onboarding times and operational costs, leading to a slower workforce and higher expenses. To protect revenue streams and enable future product expansion, a scalable, maintainable backend was necessary to reduce costs and accelerate innovation.   

Wavicle’s Solution: Robust C# microservices and API architecture 

Wavicle replaced PHP with modular C# APIs and microservices for better performance and integration.  

Key contributions

• Architectural migration: Rewrote and restructured legacy PHP services into modular, high-performing C# Web APIs as part of a microservices transformation.
• API development: Designed and implemented core APIs to manage jersey customization, order processing, and automated billing.
• DevOps and CI/CD enablement: Established Azure DevOps-based CI/CD pipelines to automate deployments and ensure faster delivery with reduced manual intervention.
• Cross-functional collaboration: Worked closely with frontend, printing, and infrastructure teams to integrate APIs with existing systems.
• Code quality and testing: Maintained strong coding standards by participating in regular code reviews, implementing rigorous unit tests, and optimizing service performance.

Leveraging AI for development efficiency

As part of the engagement, the manufacturer recommended using GitHub Copilot to accelerate development. The team adopted an AI-powered coding assistant to generate code from prompts, reducing development time and manual effort. Copilot helped developers complete tasks significantly faster, with an estimated 80 percent reduction in coding workload. 

The Outcome: A faster, scalable, and insight-driven platform

The project is halfway done, with core APIs complete and integration underway. Full rollout is set for next year, with early results showing clear benefits.

• The upgraded system is expected to process orders 200 percent faster than the legacy application, directly enhancing customer satisfaction and increasing throughput to drive higher sales.
• Operational burden is projected to drop by 50 percent, resulting in reduced maintenance costs, lower support staff requirements, and fewer business disruptions.
• Real-time tracking and reporting capabilities will help the client quickly address bottlenecks, improve order fulfilment, and support data-driven strategies that increase operational efficiency and profitability.
• The new architecture is designed as a reusable framework that can streamline future internal application launches, accelerating time-to-market for new revenue opportunities.

Through platform modernization, the manufacturer can deliver a more profitable, engaging fan experience, empower internal teams with actionable business data, and lay a scalable foundation for continuous innovation and revenue growth.