The impact of independent variables of extrusion on dependent variables of pre-milled Douglas-fir forest residuals was studied to enhance the enzymatic hydrolysis for production of fermentable sugar without catalysts. Co-rotating twin screw extruder was operated with three different feedstock moisture contents (30, 40, and 50%) at four different barrel temperatures (25, 50, 100, and 150 degrees C) as a pretreatment. The specific mechanical energy input ranged from 0.07 and 0.30 kWh/kg and had a very strong positive correlation with torque (r = 0.96, p < 0.01), glucose (r = 0.92, p < 0.01) and xylose/mannose yields with (r = 0.84, p < 0.01). Douglas-fir residuals extruded at lowest moisture content (30%) and temperature (25 degrees C) had the highest sugar yield, requiring the highest SME. Higher barrel temperature increased the median particle size and had lower glucose and xylose/mannose yields. Recrystallization and agglomeration were observed under higher temperature conditions.