Rearing, sterilization, and packaging operations for the boll weevil were carried out successfully for the 1987 Alabama Sterile Release Program. A total of 11.2 million weevils were released over the nine weeks of June and July, averaging 1.25 + 0.15 (SD) million weevils/week. Mean weight (± SE) per weevil increased significantly (P < 0.05) from 13.1 + 0.2 mg before feed-out to 17.4 + 0.1 mg after feed-out. Required numbers of high quality weevils were produced on schedule using tray-form-seal equipment. Several technological advances were implemented during the 1987 program, resulting in improved production capabilities. These included 1) adding beta-carotene to the diet, 2) collecting and holding adult weevils from emergence cages in a chilled environment (12-15 C), 3) using large cages for feed-out (0.4 cu m), 4) using a diflubenzuron water dip treatment, and 5) restricting release of packaged weevils to morning periods.