•Does rearing scale impact black soldier fly (BSF) farming on different substrates?•Can wheat starch processing by-products be used as rearing substrates for BSF?•Medium (M)- and large (L)-scale rearing are preferable to test novel feeds for BSF.•Wheat starch processing by-products are suboptimal rearing substrates for BSF.•The best by-product-based diets can mainly be identified at M and L scales. Rearing scale may influence black soldier fly (BSF) larvae traits when they are fed on a single diet, but different feeding substrates have not been tested yet. This study evaluated the effects of wheat starch processing by-products-based diets on growth performance, bioconversion efficiency, and nutritional profile of BSF larvae reared in different scales. Four diets (D1 and D2 isonitrogenous, isolipidic and isoenergetic; D3 and D4 displaying 1:1 and 1:2 as protein to carbohydrate ratios, respectively) were tested at 3 rearing scales (4 replicate boxes/diet, with a constant volume 0.84 cm3/larva and feed 0.7 g/larva): 1) small (S; 12 × 12 cm, substrate height: 4 cm, 686 6-day-old larvae (6-DOL)/box), 2) medium (M, 32 × 21 cm, substrate height: 7 cm, 5 600 6-DOL/box), and 3) large (L, 60 × 40 cm, substrate height: 7 cm, 20 000 6-DOL/box). Larval weight was recorded at the beginning of trial and every 4 days, and growth rate (GR), specific growth rate (SGR), feed conversion ratio (FCR), survival, bioconversion efficiency corrected for residue (BER), reduction rate (RR), and waste reduction index (WRI) calculated at the end of larval growth (frass DM ≥ 55%). Substrate pH, T and height were measured at the beginning, every 4 days, and end of trial. Larval proximate composition was analysed at the end of trial. Data were analysed by generalised linear mixed model (SPSS software, P < 0.05). The D1 larvae showed higher weight, GR, SGR and WRI (along with higher substrate T) than D2 at M scale, while increased SGR and FCR – as well as decreased survival, RR and WRI – were observed in D2 larvae at S scale (P < 0.05). Larval CP and ether extract (EE) contents were influenced by M and L scales only, being higher in D2 group than in D1 (P < 0.001). Differently, decreased ash was recorded in D2 larvae when reared at S and M scales, while L scale revealed higher ash in D2 group than D1 (P < 0.001). The D3 larvae displayed greater weight, SGR, survival, RR and WRI (along with greater substrate T) than D4 at M scale, with increased survival and substrate T being also highlighted in L scale (P < 0.05). The D3 larvae also showed lower DM and EE – as well as higher CP – than D4 at all the rearing scales (P < 0.001). In conclusion, D1 and D3 led to better BSF larval growth performance, bioconversion efficiency and nutritional profile mainly at M and L scales, as a consequence of their ability to facilitate larval aggregation and, in turn, allow achieving a higher substrate T.