A laboratory twin-gear reactor (TGR) was investigated as a new means for the pretreatment of high solid lignocelluloses. Response surface methodology based on Box Behnken Design was used to optimize the enzymatic digestibility with respect to the pretreatment process variables: temperature of 50-90 degrees C, NaOH concentration of 2-6% and no. of cycles of 30-60. The results revealed that the TGR-based pretreatment led to the significant structural alterations through increases in pore size, pore volume, cellulose crystallinity and surface area. SEM images also confirmed the surface modifications in the pretreated rice straw. A response surface quadratic model predicted 90% of the enzymatic digestibility, and it was confirmed experimentally and through the analysis of variance (ANOVA) as well. The TGR extrusion proved to be an effective means for exceedingly high solids lignocellulose. (C) 2016 Elsevier Ltd. All rights reserved.