The optimisation of DC plasma process towards maximising the fabric's hydrophilicity using Design-Expert 7.0.0 software has been reported in this paper. Out of various designs available, the Box-Behnken design was adopted for this purpose. The process parameters considered for optimisation were pressure of the gas (commercial grade air) used to produce plasma, DC current and the time for which the fabric was exposed to the plasma. These were keyed in as the three input parameters and the corresponding measure of hydrophilicity was fed as the response. Analysis of Variance (ANOVA) of the model and an associated discussion on the basis of Langmuir probe analysis, Physical analysis and ATR-FTIR analysis has been reported. The response predicted by the model was in good agreement with that obtained through experiment.