This study presents experimental study on a novel methane fuel processing system for hydrogen (H-2) production. The unit includes into a single package the autothermal reformer, the CO shift converter, the preferential oxidation reactor and the internal heat exchangers. Effects of operative conditions, related to the H-2 productivity, on the performances, were investigated experimentally, in order to evaluate the integration of the fuel processor with a Polymer Electrolyte Fuel Cell (PEFC) system for residential applications. The sensitivity analysis showed that the overall performance is strongly dependent upon the operative conditions considered. Copyright (C) 2012, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.