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The study was designed to optimize extrusion processing conditions for production of instant grain amaranth flour for complementary feeding. Multi‐response criteria using response surface methodology and desirability function analysis were employed during the study. The central composite rotatable design (CCRD) was used to determine the level of processing variables and to generate the experimental runs. The process parameters tested included extrusion temperature (110–158°C), screw speed (40–52 Hz), and feed moisture content (11%–16%), while response variable was protein digestibility, sensory acceptability, water absorption index, water solubility index, bulk density, and viscosity. Data obtained from extrusion were analyzed using response surface methodology. Data were fitted to a second‐order polynomial model, and the dependent variables expressed as a function of the independent variables. Analysis of variance (ANOVA) revealed that extrusion parameters had significant linear, quadratic, and interactive effects on the responses. Numerical optimization indicated that the optimum extrusion parameters were extrusion temperature of 150°C, extrusion speed (screw speed) of 50 Hz, and feed moisture content of 14.41%. The responses predicted for optimization resulted in protein digestibility 81.87%, water absorption index 1.92, water solubility index 0.55, bulk density 0.59 gm/L, viscosity 174.56 cP (14.55 RVU), and sensory acceptability score of 6.69, with 71% desirability.

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