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Silver (Ag) micro-nano structure array is widely adopted in surface-enhanced Raman scattering (SERS) substrate for biological detection applications. The high-precision and high-efficiency construction of an ordered Ag micro-nano structure array becomes a crucial problem to be solved. In this study, the roll-to-plate (R2P) process was adopted for high-resolution and high-throughput fabrication of an ordered micro-pyramid array on the silver sheet, which could have a larger surface area to adsorb more probe molecules and possess potential to further expand the arrangement of hotspots in SERS application. The effects of main process parameters were analyzed through both single-factor and Box–Behnken design (BBD) experiments, including roller gap, temperature and speed. Based on single-factor experiments, it was found that the effect of roller speed was relatively small while the roller gap and temperature could cause significant effects on forming results. According to BBD experiments, it was known that the roller gap was the most important process parameter. A better process window for R2P embossing of the micro-pyramid array could be obtained, that was the temperature between 85 °C and 100 °C, the speed between 200 and 300 r min−1, and the gap between 0.10 and 0.12 mm. This research could provide beneficial guidance for high-precision and high-efficiency fabrication of ordered micro-nano structure arrays. [ABSTRACT FROM AUTHOR]