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NexGen Logistics·Logistics & Supply Chain

Migrated 200+ bare-metal servers to Kubernetes in 6 weeks with zero downtime.

Manual deployments, hardware-bound scaling, and a fragile monitoring stack — transformed into a containerised, orchestrated platform with automated CI/CD.

NexGen Logistics — Migrated 200+ bare-metal servers to Kubernetes in 6 weeks with zero downtime.

Starting Point

Where it began

200+ bare-metal servers across three data centers, manual deployments, and a monitoring stack built on SSH alerts forwarded to email.

The Challenge

What was in the way

A single server failure during peak season caused a 14-hour outage. Infrastructure teams spent 70% of their time on maintenance instead of new features, and scaling required hardware orders weeks in advance.

Our Approach

The strategy

  • Map workloads and dependencies across the fleet.
  • Containerise services in dependency order.
  • Stand up Kubernetes with staging parallel runs.
  • Add CI/CD with automated rollback gates.
  • Deploy Prometheus, Grafana, and OpenTelemetry observability.
  • Cut over incrementally with zero unplanned downtime.

The Solution

What we built

We containerised workloads with Docker, orchestrated them on Kubernetes, and built CI/CD pipelines with automated rollback gates. The migration ran incrementally with parallel runs proving stability before cutover.

Technology

The stack

DockerKubernetesTerraformCI/CDPrometheusGrafana

Customer Experience

What changed for the customer

Customers experienced no downtime during the migration. Post-migration, deployments became routine and the platform stopped failing at the worst possible moments.

The Journey

How the transformation unfolded

  1. 01

    Bare-Metal Servers

  2. 02

    Containerisation

  3. 03

    Kubernetes Orchestration

  4. 04

    Automated CI/CD

  5. 05

    Full Observability

  6. 06

    Resilient Platform

Outcomes

Where it landed

6 weeks

Migration window

0 min

Downtime during migration

1/mo → 50/day

Deployment frequency

70% → 15%

Infra maintenance time

$1.1M

Annual infra cost saved

-82%

On-call incidents

Services Involved

DevOps & Cloud AutomationKubernetes Migration

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