Parasite assessment test (Summy, 1993) demonstrated field production of Catolaccus grandis (Burks) in irrigated cotton. Advanced field studies planned by ARS Subtropical Agriculture Research Laboratory (SARL), Weslaco, Texas required increased parasite production to meet field release needs. The ARS Insect Rearing Research Unit (IRRU), Mississippi state, Mississippi, a unit of the ARS Southern Insect Management Laboratory (SIML), Stoneville, Mississippi was requested to develop mechanized processes to encapsulate boll weevil larvae in parafilm cells for parasitization. Mechanized boll weevil rearing processes using thermoform packing technology (Powell, 1989) is capable of providing massive quantities of third instar larvae as the preferred host food source for a large-scale parasite production program. Equipments were constructed, tested, and modified to mechanically form 2 cm diameter x 2 cm depth cavities in parafilm sheeting, semi-mechanically transfer larvae to cavities, then seal with parafilm to encapsulate larvae within the cell. Boll weevil larvae encapsulated in parafilm were shipped to SARL for parasite propagation and adult field release studies.