BEAM-PROTECT (Bacillus-Enabled Affordable Manufacturing of Pest-Control Proteins) will industrialize IBI’s lead nanobody-based bio-insecticide active ingredient, CDA-2D, through a robust, cost-effective, and transferable route based on ACIES’s secretion-based Bacillus platform. It addresses a key bottleneck in protein-based crop protection: highly selective biological actives often fail to deploy because scale-up, DSP, impurity control, residual-DNA clearance, and preserved bioactivity remain too costly for agricultural markets. BEAM-PROTECT is a manufacturing innovation project, not a discovery-stage biotechnology. It will convert a validated active ingredient into a scalable, regulation-oriented, and transfer-ready process. Over 24 months, the consortium will validate the final Bacillus production strain and baseline process at approximately 5L, optimize upstream fermentation and cost-focused DSP at 30-100L, and demonstrate the integrated process at approximately 400L, supporting regulatory-aligned production at approximately 400-1,000L. The core innovation is the co-design of upstream fermentation and DSP for secreted agricultural proteins, rather than pharmaceutical-style purification. Secretion into the broth will reduce or avoid mechanical cell disruption, lower host-derived impurity burden, simplify clarification, and support no detectable recombinant DNA in the final dry intermediate. The DSP route will prioritize clarification, impurity management, concentration, recovery, and drying/stabilization while minimizing fouling, consumables, and cost. The project will apply an analytics-driven and model-assisted development loop. ACIES will lead Bacillus fermentation, scale-up, DSP development, 400L demonstration, batch records, and transfer-ready manufacturing documentation. IBI, as coordinator and product owner, will define the target product profile, critical quality attributes, potency expectations, and agricultural cost constraints, and lead protein analytics, QC, comparability, and bio-efficacy testing. Process decisions will be guided by titer, purity, residual DNA, DSP recovery, stability, and biological performance. The work is organized through 7 WPs: governance; baseline validation; 30-100L scale-up and DSP; 400L demonstration and regulatory readiness; product analytics and comparability; bio-efficacy validation; and dissemination, exploitation, and impact. This creates a make-and-verify loop in which ACIES-generated material is tested by IBI and fed back into optimization before larger scales. Expected outputs include validated fermentation and DSP protocols, operating windows, a dry stabilized intermediate, residual-DNA and impurity-control evidence, multi-batch comparability data, and efficacy-linked quality datasets supporting future regulatory and field programs. Target KPIs include yield improvement from ~4 g/L toward 15 g/L, AI content improvement from ~10% to 20% w/w of final dry product, ≥50% target protein out of total protein, ≥70% DSP recovery, no detectable recombinant DNA in the final dry intermediate, stable dry material, 10-15% batch-to-batch variability, and reproducible bio-efficacy. By delivering a reusable manufacturing framework for secreted pest-control proteins, BEAM-PROTECT will strengthen sustainable manufacturing capacity in Europe and associated countries, reduce barriers to affordable biological crop protection, and accelerate time-to-market for safer alternatives to chemical pesticides.