Safety software development case study
Rebuilding a mission-critical safety platform for the modern world
ESG had spent years helping global manufacturers communicate chemical hazards safely and clearly. However, its WASPS platform was decades old – and it showed. We rebuilt the system from the ground up for longevity, flexibility and growth.
Quick look
✅ Complete rebuild of legacy Visual Basic software
✅ Cross-platform support for Windows, Mac and Linux
✅ Custom licensing infrastructure and subscription management
✅ Reverse-engineered with no access to source code
Project profile
The client
Environmental Science Group
Founded in 1994, Environmental Science Group (ESG) soon established a reputation for innovation in delivering industrial environmental solutions. Its flagship WASPS software generates visual safety data sheets harnessing universally recognisable pictographs, helping overcome language barriers and improve workplace safety.
- Used by major industrial organisations
- Complex scientific decision-making engine
- Safety-critical outputs
The problem
A valuable tool trapped on an obsolete platform
WASPS had been helping organisations communicate chemical hazards since the late 1990s.
The original software was built in Visual Basic. And while it continued to deliver valuable functionality for major manufacturers and industrial businesses, the technology underpinning it was becoming harder to maintain.
Key challenges included:
- Legacy software no longer compatible with modern operating systems
- Manual software distribution and licence management
- Regulatory and environmental guidance that had evolved significantly over time
- No source code available for the original platform
With major industrial organisations relying on the software to support safe chemical handling procedures, standing still wasn't an option.
Our solution
A modern, cross-platform architecture built for longevity
Legacy Visual Basic application no longer compatible with modern operating systems
Full rebuild using modern technologies, including:
- Cross-platform architecture built with Node.js
- Native support for Windows, MacOS and Linux
- Modern user interface and improved usability
- Foundations for future browser-based development
Original application had no accessible source code
Complete reverse-engineering exercise, involving:
- Behavioural analysis of the original software
- Recreation of business logic and calculation workflows
- Validation of outputs against the legacy platform
- Modernisation of historical compliance rules and datasets
Software licensing and updates relied on manual processes
Fully automated licensing ecosystem, featuring:
- Custom Wix integration for software purchases
- Bespoke licence generation infrastructure
- Secure activation and verification services
- Automatic update delivery for active subscribers
Platform relied on sensitive proprietary scientific data
Security-first software engineering, using:
- Encrypted local databases
- Obfuscated application source code
- Digitally signed installers
- Protected intellectual property and data assets
Project timeline
Discovery and technical assessment
Reverse engineering of legacy software
Rebuild of scientific rules engine and matrix logic
Development of cross-platform application
Licensing infrastructure and deployment systems
Testing, validation and release
Roadblock…
There was one big elephant in the room from the start: the original software had no usable source code.
Rebuilding the application wasn't simply a migration exercise. It meant recreating years of accumulated logic, workflows and decision-making processes using only the finished software as a reference.
…Averted
By carefully analysing the behaviour of the legacy application, we were able to reverse-engineer its functionality – window by window, feature by feature and output by output.
The result was a modern platform that preserved the integrity of the original scientific model while unlocking entirely new capabilities for future development.
This was no mere software update. It was a complete technological rebirth designed to support another generation of growth.
Cross-platform development
across Windows, Mac and Linux
Automated licensing
with subscription management built in
Modern architecture
ready for future web deployment
Long-term maintainability
with specific support for compliance changes
Get in touch
Need to modernise niche software?
Some systems are too important to replace and too valuable to abandon.
We helped ESG preserve decades of specialised expertise while creating a platform capable of supporting future growth, changing regulations and new ways of working.
We can do the same for you. Whether you're replacing unsupported systems or bringing an ambitious new idea to life, get in touch with our experts today. We'll help you find the shortest route between technical complexity and commercial success.
