Kernel processing and theoretical length of cut (TLOC) of whole-plant corn silage (WPCS) can affect feed intake, digestibility, and performance of dairy cows. The objective of this study was to evaluate for lactating dairy cows the effects of kernel processing and TLOC of WPCS with vitreous endosperm. The treatments were a pull-type forage harvester without kernel processor set for a 6-mm TLOC (PT6) and a self-propelled forage harvester with kernel processor set for a 6-mm TLOC (SP6), 12-mm TLOC (SP12), and 18-mm TLOC (SP18). Processing scores of the WPCS were 32.1% (PT6), 53.9% (SP6), 49.0% (SP12), and 40.1% (SP18). Twenty-four Holstein cows (139 ± 63 d in milk) were blocked and assigned to six 4 × 4 Latin squares with 24-d periods (18 d of adaptation). Diets were formulated to contain 48.5% WPCS, 15.5% citrus pulp, 15.0% dry ground corn, 9.5% soybean meal, 6.8% low rumen degradability soybean meal, 1.8% calcium soap of palm fatty acids (FA), 1.7% mineral and vitamin mix, and 1% urea (dry matter basis). Nutrient composition of the diets (% of dry matter) was 16.5% crude protein, 28.9% neutral detergent fiber, and 25.4% starch. Three orthogonal contrasts were used to compare treatments: effect of kernel processing (PT6 vs. SP6) and effect of TLOC (particle size; SP6 vs. SP12 and SP12 vs. SP18). Cows fed SP6 produced 1.2 kg/d greater milk yield with no changes in dry matter intake, resulting in greater feed efficiency compared with PT6. Cows fed SP6 also produced more milk protein (+36 g/d), lactose (+61 g/d), and total solids (+94 g/d) than cows fed PT6. The mechanism for increased yield of milk and milk components involved greater kernel fragmentation, starch digestibility, and glucose availability for lactose synthesis by the mammary gland. However, cows fed SP6 had lower chewing time and tended to have greater levels of serum amyloid A compared with PT6. Milk yield was similar for SP6 and SP12, but SP12 cows tended to have less serum amyloid A with greater chewing time. Cows fed SP18 had lower total-tract starch digestibility and tended to have lower plasma glucose and produce less milk compared with cows fed SP12. Compared with PT6, feeding SP6 raised linear odd-chain FA concentration in milk. Similarly, a reduction of these same FA occurred for SP12 compared with SP6. Cows fed SP6 had greater proportion of milk C14:1 and C16:1 compared with PT6 and SP12. Lesser trans C18:1 followed by greater C18:0 concentrations were observed for SP12 and PT6 compared with SP6, which is an indication of more complete biohydrogenation in the rumen. Under the conditions of this study, the use of a self-propelled forage harvester with kernel processing set for a 12-mm TLOC is recommended for WPCS from hybrids with vitreous endosperm.