Among the recently discovered Fe-based superconducting compounds, the (K,Ba)Fe2As2 phase is attracting large interest within the scientific community interested in conductor developments. In fact, after some years of development, critical current densities Jc of about 105 A/cm2 at fields up to more than 10 T have been obtained in powder in tube (PIT) processed wires and tapes. Here we explore the crucial points in the wire/tape fabrication by means of the ex-situ PIT method. We focus on scaling up processes which are crucial for the industrial fabrication. We analyzed the effects on the microstructure of the different heat and mechanical treatments. By an extensive microstructural analysis correlated with the transport properties we addressed the issues concerning the phase purity, the internal porosity and crack formation in the superconducting core region. Our best conductors with a filling factor of about 30 heat treated at 800 C exhibited Tc = 38 K the highest value measured in such kind of superconducting tape. The microstructure analysis shows clean and well connected grain boundaries but rather poor density: The measured Jc of about 3 x 10^4 A/cm2 in self-field is suppressed by less than a factor 7 at 7 T. Such not yet optimized Jc values can be accounted for by the reduced density while the moderate in-field suppression and a rather high n-factor confirm the high homogeneity and uniformity of these tapes.
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