Virus-based biopesticides are effective biocontrol agents of crop insect pests. Development of suitable formulations and production processes are necessary to obtain high-quality products easily adopted by farmers. A detailed unit operation study was carried out for the production process of a Phthorimaea operculella granulovirus-based biopesticide to control the tomato leafminer, Tuta absoluta, one of the most important pests affecting this crop. Physicochemical, microbiological, and insecticidal parameters were implemented in the process and applied to the finished product, and a scaling strategy was developed. A Quantitative Polymerase Chain Reaction (Q-PCR) technique was implemented to quantify viral concentrations in the active ingredient (5.34 ± 1.44 x10 9 Occlusion Bodies mL -1 ) and in the finished product (>1.6x10 9 OB mL -1 ), without contaminant interferences. The Q-PCR methodology was also useful to select the appropriate solid mixing time following Lacey´s mixing index (8 min). Factors and similarity principles influencing the liquid mixing process were identified in the scaling evaluation. Furthermore, the drying kinetics analysis enabled identifying a drying temperature of 35 °C, with an efficacy under controlled conditions higher HIGHLIGHTS• Technological analysis of the production for a virus-based biopesticide.• Selection of technological conditions considered to have a significant influence.• Scale-up strategy based on geometric and the dynamic similarities.• Reproducibility and repeatability assessment of the formulation process.

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Aims The leaf‐feeding pest Cerotoma arcuata tingomariana (Bechyné) (Coleoptera: Chrysomelidae) produces huge economic losses in different crops. This study aimed to produce conidia by semisolid‐state fermentation and to establish the insecticidal activity of two formulation prototypes based on a native Beauveria bassiana isolate for controlling this pest. Methods and results A novel fabric‐based semisolid‐state fermentation strategy for quick and large‐scale conidia production was performed and characterized. Conidia were formulated as an emulsifiable concentrate (EC) and a water‐dispersible granulate (WG). Afterwards, the mortality of C. a. tingomariana adults was assessed. A conidia concentration of 2.9 × 109 conidia cm−2 was obtained after 9 days‐course fermentation and a yield of 33.4 g kg−1 dry‐substrate. Conclusions The polyester fabric‐based fermentation is an efficient technique for producing and collecting B. bassiana spores. Regarding LC90, the potency analysis showed that the EC was 21‐fold more potent than the non‐formulated conidia, and ~ 2.6‐fold more potent than the WG. Significance and impact of study A high throughput fermentation based on polyester fabric as support for B. bassiana conidia production and subsequent formulation as an EC comprises a promising strategy for obtaining a bioproduct to control adults of C. a. tingomariana and other Chrysomelidae pests.