Python Application Modernization

“With bespinian, we secured and stabilised our legacy MES system, ensuring operational continuity and clearer governance. Their work not only strengthened release and monitoring processes but also enhanced our understanding of the production processes supported by the application. A reliable and results-oriented partner.”

Martina Catozzo, Group IT Coordination

Customer

AFV Beltrame Group, operating through Stahl Gerlafingen AG in Switzerland, specializes in manufacturing long steel products—primarily reinforcing steel for concrete and structural steel profiles. With a workforce of approximately 2,900 employees, the Group maintains an annual production capacity of around 3 million tonnes, serving both domestic and broader European markets.

The Group distinguishes itself through an industrial model centered on ferrous scrap recycling and advanced steelmaking processes, establishing its position as Switzerland’s largest producer of recycled steel. Its products serve critical applications across civil construction, infrastructure development, mechanical engineering, automotive manufacturing, energy sectors, oil & gas industries, and diverse industrial applications.

Initial Situation

About 15 years ago, there was a need to collect data from multiple industrial control systems in a central location and combine it with additional operational data, such as production orders from ERP systems. For this purpose, a Python-based web application was developed to manage devices and peripheral systems and make data available to users. Later, the software was extended to support the production process. In 2023, bespinian was engaged to modernize the application, provide operational support, and implement robust monitoring.

Project Goals

The goal was to place the software on a sustainable and maintainable foundation and ensure reliable operations. Key activities included migrating to the latest Python version, introducing dependency management, implementing an automated deployment process, and setting up monitoring. Additionally, unit tests were to be written to improve reliability.

bespinian’s Role

Operational Support

bespinian supports the IT department in operating the application and acts as a troubleshooter when issues arise. Several change requests have also been implemented.

Application Modernization

After introducing Git for version control, we wrote over 800 unit tests to reduce the risk of code changes. These tests are now automatically executed in a GitLab pipeline before each deployment. This has drastically reduced the number of incidents after a deployment. After that, we were able to migrate Python to the latest supported version and split individual Python files, some with over 6,000 lines of code, into manageable modules.

Monitoring

For proactive monitoring of the application and its environment, we use the open source products Prometheus, Grafana, and Loki. Instead of reacting to user reports, IT and we can now respond proactively and investigate problems using clear dashboards and centralized logging. Additionally, we wrote an OPC XML exporter for Prometheus that allows us to monitor PLCs (machine controllers).

Technologies

• Version Control: GitLab
• Back End: Python
• Monitoring: Prometheus & Grafana
• Logging: Loki
• Database: Microsoft SQL Server
• Integration System: ERP
• Industrial Communication:OPC XML