Adjusting the roller settings on a dry roller mill based on barley kernel size improved starch digestibility compared to a single roller setting. Barley samples processed with multiple roller settings (MRS), tailored to large, medium, and small kernels, had greater in situ starch digestibility at early incubation times (0-12 hours) compared to a single roller setting (SRS). While final (48 hour) starch digestibility was unaffected, the rate of digestion was 18.6% per hour for MRS versus 11.9% for SRS. Processing barley with roller settings adjusted for varying kernel sizes may improve efficiency and animal performance by reducing unprocessed grains and increasing surface area for microbial attachment in the rumen.