Ingredient blends containing 28% protein with distillers dried grains with solubles, soy flour, corn flour, fish meal, mineral mix and vitamin mix was extruded in a C.W. Brabender single screw laboratory extruder using 7 different die nozzles. The die nozzle diameter (D), length (L) and L/D ratio of the dies were in the range of 2.0 mm to 6.0 mm, 10.0 mm to 30.0 mm and 3.33 to 10.00, respectively. The moisture content of the ingredient mix was varied from 15% to 25% and the temperature of the transition zone and die section were varied from 100° C to 140°C. The response variables studied in the experiments include extrudate properties viz. unit density, bulk density, pellet durability, water absorption index, water solubility index, sinking velocity , color and extruder processing variables viz. mass flow rate, dough temperature, absolute pressure inside the die, torque and apparent viscosity of the ingredient melt. The effect of die nozzle dimensions, moisture content of the ingredient mix and temperature profile in the barrel was analyzed statistically with linear quadratic model. The R 2 values of the model with die dimensions, moisture content of the ingredient mix and temperature profile in the barrel for many of the response variables was found to be over 0.6. Increasing the moisture content of the ingredient mix from 15% to 25% had resulted in 2.0%, 16.0%, 13.2%, 3.2%, 63.7% decrease in bulk density, water solubility index, sinking velocity, mass flow rate and absolute pressure respectively and 11.6%, 16.2% increase in pellet durability and water absorption index respectively. Increasing the cooking temperature had resulted in 17.0%, 5.9%, 35.4%, 50.6%, 28.8%, 33.9%, 33.9% decrease in unit density, pellet durability, sinking velocity, absolute pressure, specific mechanical energy, torque and apparent viscosity of the dough respectively, and 23.6 to 49.1% and 16.9% increase in dough temperature and water absorption index, respectively.