In this study, pre-compaction was evaluated as a method to enhance stable reed canary grass pellet production. An experimental design of the factors raw material moisture content, steam addition, raw material bulk density, and die temperature was used to find production conditions for high quality pellets by multiple linear regression modelling of responses. Response variables being modelled were variability of pelletizer current (as a measurement of uneven production), pellet bulk density, and pellet durability. By pre-compacting the raw material from a bulk density of 150 kg/m(3) to 270 kg/m(3), continuous production could be obtained at minimum raw material moisture content of 13.8%. Bulk density and durability were both highly correlated to raw material moisture content, but showed different optima. Multiple response optimization was used to target process settings for production of high quality reed canary grass pellets with bulk density >650 kg/m(3) and durability >97.5%. (C) 2007 Elsevier Ltd. All rights reserved.