Cereal grains vary in terms of cost and nutrient content but also in terms of processing characteristics. Likewise, energy cost for grinding is directly proportional to how fine the grind size, directly impacting energy cost and processing characteristics of the feed. Consequently, the type of processing and cereal grain can have a major impact on processing, final feed cost as well as performance of the culture species. Yet, there is little work relating various carbohydrate sources or the effects of grind size. This research focused on grain sorghum as an ingredient in floating tilapia feed and studied the impacts of particle sizes on final product qualities and fish performance. As particle size of the diets decreased, extruded floating feed expansion increased and bulk density decreased off the extruder (452.5 to 367 g/L) demonstrating an effect of grind on expansion. Grain source also impacted pellet durability, with sorghum-based diets having a statistically significant higher pellet durability index (PDI) than wheat diets on average (98.76% vs 98.39%). With regards to biological response, Tilapia fed the sorghum-based diet were larger than those fed the wheat-based diets. In terms of feed utilization, fish fed feeds using the sorghum-based medium grind had the lowest feed conversion ratio (1.03), while fish fed the wheat-based fine grind diet had the highest (1.13). These results indicate that grain sorghum can successfully be incorporated into Nile tilapia diets with positive effects on both physical feed qualities, as well as growth rates of the fish. This work also demonstrates although grind size may affect processing parameters, there was limited effects on digestibility or growth of the fish. Overall, sorghum is a suitable cereal grain for tilapia feeds.