A Colombian Spodoptera frugiperda nucleopolyhedrovirus NPV003 with high potential for the development of an efficient biopesticide was microencapsulated by spray drying with a pH dependent polymer (Eudragit® S100

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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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