Optimizing extrusion parameters is crucial for reducing energy consumption, enhancing product quality, and extending tool life: all of which lower operational costs and increase efficiency. It also helps to minimize material waste and tailor product’s mechanical properties, ensuring a more sustainable and productive extrusion process. In the present study, the influence of various process parameters on extrusion load has been investigated for Al-6061, a widely utilized alloy in the forming industry. Key extrusion parameters, including extrusion ratio, operating temperature, friction conditions, ram velocity, and die length, have been selected as input variables for this investigation to assess their individual and combined effects on the extrusion process outcomes. A Taguchi-based gray relational analysis was performed using an L25 orthogonal array, assessing five factors at five levels each. Simulations were performed using the Deform-3D package to determine the maximum load requirements, as well as strain distributions across the billet profile. Analysis of Variance (ANOVA) determined the significance of each parameter. In descending order of influence operating temperature, extrusion ratio, shear friction factor, ram velocity, and die length influence the extrusion process. The results were compared with simulations conducted using a linear converging die and were found to be highly favorable in terms of energy efficiency.