Delivering enterprise-grade security, resiliency and user experience in real-time embedded web applications designed to run under severe hardware constraints

Ruchek Shah

Lead Architect - Java Full Stack & Embedded Systems

5 mins

Published : September 23, 2025

Embedded Web Application Development systems

About the Client

The client is a global leader in energy management and industrial automation, delivering products and platforms that optimize power distribution, motor control, and digital sustainability. With strong expertise in automation, the organization sought to build a real-time embedded web application capable of running within extreme hardware constraints while ensuring enterprise-grade security.

As part of its product evolution, the client sought to build a real-time embedded web application capable of functioning under severe hardware constraints while ensuring enterprise-grade security, resiliency and user experience.

The Challenges

The client faced the challenge of building an embedded web application for monitoring, diagnostics, and control that had to perform at enterprise standards despite tight processor and memory limitations.

Key Challenges:

Processor Limitations – The TI AM4376 processor (300 MHz, single-core) provided only 30% CPU allocation for the app.
RAM Constraints – The application needed to run under 150 MB memory on a 512 MB device.
Real-Time Responsiveness – Required continuous data refreshes every second for real-time operations.
Security Requirements – Strong security was mandatory, including AES/GCM encryption, token-based authentication, and SSL certificates — all within limited hardware capacity.
Stability Under Failure – The app had to gracefully recover from firmware upgrades, network drops, and system hiccups without downtime.
Efficient Diagnostics – The system needed a user-friendly way to track multiple parameters (e.g., temperature, earth faults) with simple visual indicators.

The challenge was to balance real-time performance, security, and resiliency while keeping the application within strict hardware budgets.

The Solution

Our team redesigned the web application architecture to optimize data handling, security, and memory use. Each module was tuned to meet both performance and stability requirements.

Key Solution Elements:

Optimized Data Handling
- Implemented WebSockets for real-time data transfer instead of constant polling
- Enabled sub-second updates for monitoring and diagnostics while reducing CPU load
Memory Optimization
- Introduced on-demand module loading, ensuring memory was used only when required
- Enforced strict memory caps across modules for Monitoring, Diagnostics, Settings, etc.
Efficient Security Architecture
- Reused secure sessions and pre-calculated keys to minimize overhead
- Maintained AES/GCM encryption and SSL authentication without degrading performance
Resilient Design
- Built auto-recovery mechanisms for network drops and firmware updates
- Added robust error-handling for uninterrupted visibility
User-Friendly Diagnostics
- Designed lightweight dashboards with color-coded indicators for key parameters
- Enabled CSV exports for offline analysis and reporting
Cloud & Embedded Alignment
- Ensured the embedded app integrated seamlessly with cloud workflows, supporting long-term scalability
For another example of achieving real-time performance and usability under strict hardware and memory limits, check out our work on modernizing UI and security in the Oracle Redwood 25C release.

Tools Used

Business Impact

The application delivered enterprise-grade performance on low-power embedded hardware, exceeding expectations:

Resource Efficiency : Achieved <25% RAM usage, well under the 30% cap

Speed : Delivered <1 second refresh cycles for monitoring and diagnostics

Security : Maintained full AES/GCM encryption, SSL authentication, and token security without performance loss

Stability : Recovered seamlessly from firmware and network failures with auto-retry logic

Usability : Provided user-friendly dashboards with clear indicators and data export

Scalability : Proved that cloud-aligned apps can run efficiently on constrained devices

What the Client said......

“ With this optimized solution, our system delivers reliable real-time monitoring and diagnostics without exceeding strict hardware limits. We achieved both performance and security within embedded constraints - a true success.”

Program Manager

Ruchek Shah

Lead Architect - Java Full Stack & Embedded Systems

Ruchek has 13+ years of expertise in enterprise architecture with strong skills in Java, Spring Boot, microservices, and embedded systems. He led the design and delivery of the embedded web application, balancing security, performance, and resiliency to meet the client's stringent constraints.