Abstract Optimization of machine parameters using response surface methodology (RSM) greatly overcomes the numbers of experimental trials generally undertaken for milling study of pigeon pea apart from maximizing the output of the system. The independent milling parameters for Central Institute of Agricultural Engineering dal mill viz., roller speed, emery grit size, and feed rates were optimized for pigeon pea dehulling using RSM. The roller peripheral speed of 9.6 m/s, emery grit size 1 mm, and feed rate 111 kg/h were found optimal. The dal recovery and milling efficiency at optimized independent parameters were 75% and 80%, respectively.