The effect of ultrasound-assisted hydration (UAH) was investigated as a non-thermal processing approach to enhance the nutritional and functional properties of pearl millet (Pennisetum glaucum (L.) R.Br.). A Box–Behnken design (BBD) was employed to study the combined effects of ultrasound amplitude (30–70 %), treatment time (10–30 min) and grain-to-water ratio (1 : 1–1 : 5) using a 20 kHz probe-type ultrasonic processor. Key response parameters included moisture content, anti-nutrients (phytate, tannin, raffinose-family oligosaccharides), starch functionality, B-vitamins and minerals (Ca, P, Fe, Zn, Na, Mg). The UAH significantly reduced anti-nutritional factors: phytate decreased from approximately 594 to 270 mg/100 g with similar reductions in tannins and raffinose family oligosaccharides (RFOs) while improving starch properties as reflected by higher degree of gelatinisation and increased content of resistant starch. B-vitamin retention remained above 80 %, indicating limited degradation. A gradual decline in total mineral content was observed with increasing ultrasonic amplitude and duration, primarily due to cavitation-induced leaching and enhanced mass transfer. Response surface models showed strong predictive accuracy (R² > 0.90), identifying amplitude and time as major influencing parameters. The process parameters were optimised in the range of 30–70 % (ultrasound amplitude), 10–30 min (treatment time) and 1 : 1 to 1 : 6 (grain-to-water ratio). The optimised values of these process parameters were reported to be 68 %, 27.69 min and 2.60 : 1 respectively. Model validation confirmed the reliability of optimisation. The UAH offers a rapid and efficient approach to improve the nutritional and functional quality of pearl millet.