A screening design is used to establish the contribution of various parameters to the roughness of cylindrical extrudates. A dimensionless response variable is proposed to characterize the extrudate roughness, and the effects of ten parameters on this roughness response were examined. Two polyethylenes (one high density and one linear low density) were investigated using a 45 mm single screw extruder. The results show that the main parameters affecting the extrudate roughness are, in order of importance, apparent shear stress at the die wall, die diameter, ratio of die length to diameter, and type of polymer. The other six parameters (the use of an additive, recycling, type of entrance adapter, die material, die. temperature, melt temperature) were found to have a non-significant contribution to roughness.