Upcycled Silica-Rich Rice Husk Ash Reinforced Cellulose Acetate Composite Films for Light-Shielding Sustainable Packaging

Silica-rich rice husk ash (RHA) was upcycled as an inorganic filler to engineer cellulose acetate (CA) films with tunable properties for higher-value sustainable packaging. Composite films were produced by solvent casting, varying RHA loading with and without glycerol plasticization. FTIRconfirmed the chemical integrity of CA and indicated an increase in hydroxyl interactions in glycerol-plasticized films. Optical microscopy showed that RHA progressively induces particle domains and aggregation, while glycerol improves dispersion and surface uniformity. These microstructural effects translated into controllable optical–mechanical trade-offs: neat CA remained highly transparent, whereas RHA reduced transmittance. Glycerol had a minor effect effect on transmittance, indicating that shielding is primarily governed by the ash-derived inorganic domains and tensile testing highlighted an optimal low-filler regime. A small RHA addition maximized strength and stiffness in non-plasticized films. Contact-angle measurements in neutral and alkaline media indicated pH-sensitive wetting, with faster deterioration under alkaline conditions. Thermogravimetric analysis confirmed increased char residue with RHA addition and that glycerol introduces an early mass-loss stage. Overall, the CA/RHA platform offers a simple and potentially scalable route to upcycled, silica-reinforced films, and the formulation of CA and 1.33 wt% RHA (without glycerol) stands out as a robust secondary layer with low transmittance in the UV-Vis range, making it suitable for high-value light-sensitive flexible healthcare packaging, such as protective overwraps or translucent pouches.