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This paper explores the effects of various parameters on the triticale straw cutting process and the subsequent biomass yield. The impact of blade angle (α), rake angle (β), and the distance between the blade and counter-blade (g) were examined in relation to the shaft torque (T d) on the cutting knife drum, the energy consumption (E c), and the required power (P) for processing straw. Heterogeneity among straw samples was taken into account to ensure accurate calibration of responses. An analysis of variance (ANOVA) was employed to investigate the interactions between input variables and recorded responses, leading to the identification of optimal cutting parameters (α = 35° and β = 0°) that minimise T d , E c , and P. Additionally, the components of the recorded torque T d , including cutting torque (T c) and friction torque (T f), were analysed. Parameter f was used to ascertain the percentage of T f in T d , enabling an optimisation process that confirmed the experimental results and pinpointed the parameter values that resulted in the least energy-intensive process. • ANOVA analysis of influence of process settings on the cutting process results. • The knife blade angle has the most significant influence on energy consumption. • The distance between blade and counter-blade has less influence on energy consumption. • The share of friction torque in the cutting torque facilitated numerical optimisation. • Lower energy consumption of cutting improves energy balance of biofuel production. [ABSTRACT FROM AUTHOR]