This research investigated the impact of grind size in wheat and sorghum-based floating feeds for Nile tilapia. The study looked at expansion metrics, pellet durability, water stability, and animal performance. Diets were ground through either a 0.61, 1.02, or a 1.27 mm hammermill screen before being extruded through a Wenger X20 single screw extruder. Processing conditions were kept similar for all treatments. As particle size decreased, mechanical energy inputs increased (267 to 359 kJ/kg), and pellet expansion increased resulting in lower bulk densities (453 to 367 g/L). Specific expansion was significantly affected by grind size in sorghum-based diets, with expansion ratios increasing as grind size decreased (1.45 to 2.15). Specific length (mm/g) followed similar trends in both grains; as grind size decreased, values increased for both wheat and sorghum-based feeds (327-361 mm/g and 335 to 371 mm/g respectively). Water stability results indicated that all diets were similarly stable in water (~80% by dried pellet weight). Sorghum-based diets led to better growth performance, with all sorghum-based diets resulting in larger tilapia than wheat-based diets. Tilapia fed the medium grind sorghum diet had the most efficient feed conversion ration (FCR) of 1.03, while fish fed the wheat-based fine grind diet had the largest (1.13). These results indicate that grain sorghum can be successfully incorporated into diets for Nile tilapia with positive impacts on both physical feed qualities and growth rates of the fish. While grind size may impact processing parameters and feed qualities, there were limited impacts on digestibility and growth rates, with indications that grinding energy consumption can be minimized while still obtaining better feed conversion. Overall, sorghum demonstrated strong potential as a viable, sustainable alternative to wheat in tilapia feeds.