Palm kernel shell biochars (PKSB) ejected as residues from a gasifier have been used for solid fuel briquette production. With this approach, palm kernel shells can be used for energy production twice: first, by producing rich syngas during gasification; second, by compacting the leftover residues from gasification into high calorific value briquettes. Herein, the process parameters for the manufacture of PKSB biomass briquettes via compaction are optimized. Two possible optimum process scenarios are considered. In the first, the compaction speed is increased from 0.5 to 10 mm/s, the compaction pressure is decreased from 80 Pa to 40 MPa, the retention time is reduced from 10 s to zero, and the starch binder content of the briquette is halved from 0.1 to 0.05 kg/kg. With these adjustments, the briquette production rate increases by more than 20-fold; hence capital and operational costs can be reduced and the service life of compaction equipment can be increased. The resulting product satisfactorily passes tensile (compressive) crushing strength and impact resistance tests. The second scenario involves reducing the starch weight content to 0.03 kg/kg, while reducing the compaction pressure to a value no lower than 60 MPa. Overall, in both cases, the PKSB biomass briquettes show excellent potential as a solid fuel with calorific values on par with good-quality coal.CHNS: carbon, hydrogen, nitrogen, sulfur; FFB: fresh fruit bunch(es); HHV: higher heating value [J/kg]; LHV: lower heating value [J/kg]; PKS: palm kernel shell(s); PKSB: palm kernel shell biochar(s); POME: palm oil mill effluent; RDF: refuse-derived fuel; TGA: thermogravimetric analysis.