Abstract Background The cryptic nature of pink bollworm Pectinophora gossypiella (Saunders) larvae enables its reduced vulnerability to insecticidal control. Further, the development of resistance against Bacillus thuringiensis (Bt) toxins posed a serious threat to transgenic cotton cultivation. This necessitated determining the critical timing of spray applications on the control effectiveness. This study assessed the influence of egg age (freshly laid vs . three-day-old) and the location of larvae (directly exposed to the insecticide residues on the boll rind vs . burrowed inside the bolls) on insecticide control efficacy. Results The results revealed a significant decrease in the ovicidal activity of tested insecticides with an increase in the age of eggs from one day old to three days old (paired t -test, P  < 0.05). The larvae directly exposed to the insecticide residues on the boll rind were more susceptible (> 80% mortality) than the larvae exposed after they had burrowed inside the bolls (< 49% mortality). The inhibitory effects of tested insecticides on developmental biology were more pronounced in the experiment on pre-larval release insecticide treatment compared with insecticide treatment given post-larval release and entry inside the bolls. Conclusion Egg age influences the insecticide susceptibility, as does the larval location, directly exposed vs burrowed inside the bolls. Older eggs and the larvae that had burrowed inside the green bolls of cotton were relatively less susceptible to the insecticide treatments. The toxic effects of insecticides on egg and larval stages were primarily ephemeral. These findings are significant for devising a comprehensive strategy for pink bollworm management on a sustainable basis.