Here's my first stab at guidelines on converting individual low level monsters to swarm units for facing high level PCs:
Unit Swarms: Conversion
Converting Individual Soldiers to Unit Swarms.
Troop density is x2 by area, eg 8 medium-sized men fit in a 10'x10' 2 square x 2 square area.
8 man Unit (squad): Medium figure 1x1 goes to Large 2x2 (4), Large 2x2 goes to Gargantuan 4x4 (16), Huge 3x3 (9) goes to Gargantuan 6x6 (36).
16 man Unit (squad): Medium figure 1x1 goes to Huge 3x3 (9 squares), Large 2x2 (4) goes to Gargantuan 6x6 (36)
32 man Unit (platoon): Medium figure 1x1 goes to Gargantuan 4x4 (16 squares)
64 man Unit (platoon): Medium figure 1x1 goes to Gargantuan 6x6 (36 squares)
128 man Unit (company): Medium figure 1x1 goes to Gargantuan 8x8 (64 squares)
8 man Squad: Minion converts to Swarm standard monster of 4 levels higher. Standard monster converts to Swarm elite monster 8 levels higher.
16 man squadron: Minion converts to Swarm standard monster of 8 levels higher. Standard > elite Swarm 12 levels higher.
32 man platoon: Minion converts to Swarm standard monster of 12 levels higher. Standard > elite Swarm 16 levels higher.
64 man platoon: Minion > Swarm 16 levels higher. Standard > elite Swarm 20 levels higher.
128 man Company: Minion > Swarm 20 levels higher. Standard > elite Swarm 24 levels higher.
Examples:
Savage Orc brute minion-4
In an 8 man squad they become an 8th level Swarm standard monster, size 2x2.
In a 128 man company they become a 24th level standard monster, size 8x8.
Human Town Guard soldier standard-3
In an 8 man squad they become an 11th level Swarm elite monster, size 2x2.
In a 128 man company they become a 27th level Swarm elite monster, size 8x8.
Swarm size should be tailored to PC level. Eg 27th level PCs should face a 27th level, 128 man Guards unit statted as a single swarm, whereas 23rd level PCs should face the same soldiers as 2 23rd level, 64 man platoons. 19th level PCs should face the same soldiers as 4 19th level, 32 man platoons, and 15th level PCs should face them as 8 15th level, 16 man squads. 11th level PCs could face them as 16 11th level, 8 man squads, but at that level individual guards can also threaten as 11th level minions.
Unit Swarms: Conversion
Converting Individual Soldiers to Unit Swarms.
Troop density is x2 by area, eg 8 medium-sized men fit in a 10'x10' 2 square x 2 square area.
8 man Unit (squad): Medium figure 1x1 goes to Large 2x2 (4), Large 2x2 goes to Gargantuan 4x4 (16), Huge 3x3 (9) goes to Gargantuan 6x6 (36).
16 man Unit (squad): Medium figure 1x1 goes to Huge 3x3 (9 squares), Large 2x2 (4) goes to Gargantuan 6x6 (36)
32 man Unit (platoon): Medium figure 1x1 goes to Gargantuan 4x4 (16 squares)
64 man Unit (platoon): Medium figure 1x1 goes to Gargantuan 6x6 (36 squares)
128 man Unit (company): Medium figure 1x1 goes to Gargantuan 8x8 (64 squares)
8 man Squad: Minion converts to Swarm standard monster of 4 levels higher. Standard monster converts to Swarm elite monster 8 levels higher.
16 man squadron: Minion converts to Swarm standard monster of 8 levels higher. Standard > elite Swarm 12 levels higher.
32 man platoon: Minion converts to Swarm standard monster of 12 levels higher. Standard > elite Swarm 16 levels higher.
64 man platoon: Minion > Swarm 16 levels higher. Standard > elite Swarm 20 levels higher.
128 man Company: Minion > Swarm 20 levels higher. Standard > elite Swarm 24 levels higher.
Examples:
Savage Orc brute minion-4
In an 8 man squad they become an 8th level Swarm standard monster, size 2x2.
In a 128 man company they become a 24th level standard monster, size 8x8.
Human Town Guard soldier standard-3
In an 8 man squad they become an 11th level Swarm elite monster, size 2x2.
In a 128 man company they become a 27th level Swarm elite monster, size 8x8.
Swarm size should be tailored to PC level. Eg 27th level PCs should face a 27th level, 128 man Guards unit statted as a single swarm, whereas 23rd level PCs should face the same soldiers as 2 23rd level, 64 man platoons. 19th level PCs should face the same soldiers as 4 19th level, 32 man platoons, and 15th level PCs should face them as 8 15th level, 16 man squads. 11th level PCs could face them as 16 11th level, 8 man squads, but at that level individual guards can also threaten as 11th level minions.