The effect of spray dryer processing parameters on the product yield and insecticidal activity of baculovirus was evaluated. Spray-dried samples of a granulovirus (GV) from Pieris rapae (L.) and a multiple nucleopolyhedrovirus (MNPV) from Anagrapha falcifera (Kirby) were prepared using two dryer-atomiser configurations (rotary atomiser and two-fluid spray atomiser), four drying temperatures (50–100°C outlet temperatures) and two encapsulating formulations (lignin and methacrylic acid polymer). The samples were evaluated based on yield and insecticidal activity under laboratory conditions. The two atomising configurations produced similar outlet temperatures for dryer stock feed rates of 4.12 and 20 ml/min when processed using increasing inlet temperatures. The atomiser selection significantly affected the physical properties like the product yield; the microparticles produced with a two-fluid spray atomiser had lower product yields (57.8 ± 18.80% – 74.6 ± 4.26%) when compared with paired samples produced with a rotary-disc atomiser (58.1 ± 7.13% – 82.6 ± 3.12%). Spray drying reduced insecticidal activity of the GV but did not significantly reduce insecticidal activity of the MNPV when compared with samples that were not dried. Among dried samples, the spray dryer processing parameters (atomiser, drying temperatures and formulation) had minimal effect on the insecticidal activity of either baculovirus. The versatility of spray drying for processing baculoviruses was demonstrated by identifying parameters that improve process yield while having minimal impact on insecticidal activity.