Plant-Based Biofillers for Polymer Composites: Characterization, Surface Modification, and Application Potential
Mateusz Pęśko, Anna Masek
Abstract
The mounting global concern regarding the accumulation of plastic waste underscores the necessity for the development of innovative solutions, with particular emphasis on the incorporation of plant-based biofillers into polymer composites as a sustainable alternative to conventional materials. This review provides a comprehensive and structured overview of the recent progress (2020-2025) in the integration of plant-based biofillers into both thermoplastic and thermosetting polymer matrices, with a focus on surface modification techniques, physicochemical characterization, and emerging industrial applications. Unlike the prior literature, this work highlights the dual environmental and material benefits of using plant-derived fillers, particularly in the context of waste valorization and circular material design. By clearly identifying a current research gap-the limited scalability and processing efficiency of biofillers-this review proposes a strategy in which plant-derived materials function as key enablers for sustainable composite development. Special attention is given to extraction methods of lignocellulosic fillers from renewable agricultural waste streams and their subsequent functionalization to improve matrix compatibility. Additionally, it delineates the principal approaches for biofiller modification, demonstrating how their properties can be tailored to meet specific needs in biocomposite production. This critical synthesis of the state-of-the-art literature not only reinforces the role of biofillers in reducing dependence on non-renewable fillers but also outlines future directions in scaling up their use, improving durability, and expanding performance capabilities of sustainable composites. Overall, the presented analysis contributes novel insights into the material design, processing strategies, and potential of plant biofillers as central elements in next-generation green composites.