The production of energy pellets from biomass sources holds immense potential for sustainable renewable energy generation. This study investigates the influence of key process parameters on the moisture content of energy pellets derived from Khaya senegalensis, a promising biomass feedstock in Malaysia. With a focus on unlocking the relationship between process variables and pellet moisture, a systematic experimental approach was adopted. The objective of this study is to investigate the effects of raw material moisture, feedstock particle size, compression pressure, and pelletization temperature on the manufactured biomass energy pellet's moisture content. By employing a comprehensive design of experiments and statistical analysis, the nuanced effects of these parameters are revealed on the moisture content of Khaya senegalensis energy pellets. The results illuminate the complex interplay between these process variables and the final moisture characteristics of the pellets. Understanding how these parameters impact moisture content is crucial for optimizing pellet quality, combustion efficiency, and storage stability. The study found a quadratic relationship between particle size, compression pressure, and pelletization temperature, indicating that larger particle sizes correlate with higher moisture content. Excessive pressure led to elevated levels while increasing temperature showed a decreasing trend. This research contributes valuable insights that advance the knowledge frontier of biomass pelletization, paving the way for enhanced utilization of Khaya senegalensis as a renewable energy resource.