This study aimed to quantify the effects of roll gap (RP) and theoretical length of cut (TLOC) settings, and storage length on fermentation profile, and berry processing score (BPS) of whole plant sorghum silage. Sorghum plants from 4 replicated plots were harvested and processed to achieve 1 of 4 treatments which were a combination of 2 RP settings (1 or 3 mm) and 2 TLOC (15 or 22 mm). Plants were handfed into the chopping cylinder of a self-propelled forage harvester and 800 g samples were sealed in vacuum bags in quadruplicate. Mini silos were allowed to ferment for 0, 30, or 90 d. Measurements of BPS were performed to determine the percentage of starch passing through a 1.7-mm sieve. Data were analyzed as a complete randomized design with a 2 × 2 × 3 factorial arrangement of treatments using PROC GLIMMIX. The model included TLOC, RP, storage length and their interactions as fixed effects. A 3-way interaction occurred for lactic (P < 0.01) and acetic (P < 0.01) acids, and mold count (cfu/g; P < 0.04). Lactic acid concentrations increased with storage length and at 90 d the concentrations were greatest with the combination of a 1-mm RP and a 22-mm TLOC. Likewise, acetic acid increased until 30 d with the greatest concentrations observed for 3 mm RP coupled with a 22-mm TLOC. Mold counts were reduced within all treatments as storage length progressed. A RP by storage length interaction was observed for pH (P < 0.01). The pH with a 1-mm RP was greater at 0 d but lower at 30 d compared with the pH with a 3-mm RP. An interaction between TLOC and RP was observed for BPS (P < 0.02). The combination of a 1-mm RP with 15-mm TLOC provided the greatest BPS (25.69% vs. 21.50%). These results demonstrate that reduced RP and TLOC settings, in conjunction with extended storage length, improves the fermentation profile of whole plant sorghum silage. Additionally, the utilization of reduced RP and TLOC settings increase BPS in whole plant sorghum silage.