<p>Wadi, a traditional Indian pulse-based nugget made from black gram (<i>Vigna mungo</i>) and green gram (<i>Vigna radiata</i>), is culturally and nutritionally significant. However, traditional preparation methods are labour-intensive, time-consuming and often unhygienic, with inconsistent product quality. This study presents the design, development and optimization of a hand-operated wadi-making machine to address these issues. The machine consists of a hopper for uniform batter flow, grooved cylindrical rollers, a spur gear-driven rotation mechanism and a manual cutting unit for consistent nugget formation. Key process parameters namely hopper angle, roller speed, batter moisture content and cutting speed were optimized using Central Composite Design (CCD) and Response Surface Methodology (RSM). Their optimal settings (66.11° hopper angle, 22.82 rpm roller speed, 66.15% moisture content and 24.80 strokes/min cutting speed) resulted in a maximum throughput of 10.223 kg/h and a Wadi uniformity index of 9.6, with a desirability value of 0.961. Experimental validation confirmed consistent performance with wadis of 22 mm diameter, 4.2 g weight and 15 mm height. Nutritional evaluation indicated acceptable levels of moisture, protein, fat, ash and carbohydrates. The compact, power-free design makes the machine a cost-effective and hygienic option for small-scale processors, rural entrepreneurs and traditional food industries aiming to improve efficiency and product standardization.</p>