A new mark‐capture technique involving field applications of Bacillus thuringiensis Berliner (Bt) to study the dispersal of potato tuber moth, Phthorimaea operculella (Zeller) (Lepidoptera: Gelechiidae), was investigated as a tool to improve information on the potential impact of insect pest dispersal on crop infestation and insecticide resistance. The acquisition and persistence of Bt on moths were characterized and potential contamination of moths from naturally occurring Bts was examined. This mark‐capture technique was developed to mark larger numbers of moths than had been previously achieved with laboratory marking using fluorescent dyes in mark‐release‐recapture experiments. Applications of commercial preparations of Bt to 0.3 and 1.0 ha potato fields were estimated to have marked ca. 50 000 moths in each experiment. Pheromone trap catches of potato tuber moths in the Bt‐sprayed fields and in potato fields at distances of ca. 80, 200, 350, and 750 m were assayed for the Bt marker using selective microbiological media and identification of characteristic Bt crystal inclusions. Marking rates of moths were 78–100% in the sprayed fields and, compared with our previous mark‐release‐recapture studies, marking at ca. 200 m was increased by 15–18‐fold to >3.0 moths per trap. This capture rate allowed the calculation of a dispersal curve that improved the reliability of estimates of movement at farm‐scale distances. These estimates indicated that 10% of the population dispersed to 240 m in 3 days, and suggested that moths can potentially disperse throughout a typical potato‐growing area in one growing season. This level of dispersal has implications for the spread and management of potato tuber moth populations, especially if insecticide resistance is present.