Summary Pigeonpea grain (c.v. C11) was used for optimization of dehulling pretreatments. Treatments applied for dehulling were soaking in urea solution and hot milling. Second order polynomial equations were developed to describe a dehulling index and dehulling time. Response surface methodology was also used. Treatment with urea solution was applied to both nonscarified and scarified grain. Different concentrations, solution‐to‐grain ratios and duration of treatments were tested in five levels as independent factors in the first set of experiments. In the second set, hot milling, heating time and heating temperature were factors in five levels. Hot milling was followed by optimized treatment with urea solution. The levels of these factors were optimized to give a maximum dehulling index and minimum dehulling time, this would yield the maximum product recovery and reduce grain scouring. The results revealed that hot milling after urea treatment of scarified grain increased the dehulling index by about 11% and, consequently, reduced dehulling time by approximately 65% when compared with the treatment followed in commercial mills. This subsequently increased the product recovery and intact pearled grain by about 19 and 23%, respectively.