Mechanically Recycled PLA Films Reinforced with Rice Husk and Carbonized Rice Husk Particles

This study investigates the development of mechanically reprocessed poly(lactic acid) (rPLA) films reinforced with rice husk (RH) and rice husk biochar (RHB) to evaluate their processing behavior, key functional properties, and disintegration under composting conditions. rPLA was produced from PLA through an additional processing cycle to simulate the valorization of industrial PLA waste, while composites containing 1 and 3 wt.% RH or RHB 500 µm sized particles were manufactured by melt extrusion followed by a compression molding process. Reprocessing increased the melt flow index and decreased intrinsic viscosity and viscosimetric molecular weight, evidencing the occurrence of chain scission during mechanical reprocessing. The addition of RH slightly restricted melt flow and promoted higher surface hydrophilicity, whereas RHB showed a filler-loading-dependent effect on melt flow and increased surface hydrophobicity at low content, consistent with its carbonized and less polar nature. Both RH and RHB promote a nucleating effect, with increased crystallinity in RHB-containing films, and tensile tests showing that filler incorporation mainly reduced ductility compared with unfilled rPLA, while stiffness and strength was maintained or exhibited more moderate variations. Despite these contrasting trends in surface properties and thermo-mechanical performance, all formulations achieved complete disintegration within 21 days under composting conditions at laboratory scale level. Overall, RH and RHB provide a viable route to valorize agro-industrial residues in rPLA films and to tune structure–property relationships within the circular economy framework.