Technical Abstract: Prior work demonstrated the economic feasibility of gin waste based pellet fuel operations. The goal of this project was expand the original economic model to include a multi-scenario manufacturing approach to improve the economics of the process. The objectives required a complete and comprehensive analysis of three different machine configurations for manufacturing of pellet fuel from cotton byproducts. The results concluded, within the parameters of the analysis, a scenario which excluded the use of extruders in the manufacturing process was the most economically feasible for producing pellet fuels from cotton byproducts. It was projected that the break-even production point for the selected scenario was 5,435 metric tons of finished product with a pay back period of 1.97 years. This equates to a return on investment of 49.51%.