<p>Due to the increasing global demand for eco-friendly alternatives to conventional packaging materials, interest in the development of bio-based materials has grown. A considerable amount of sugarcane bagasse waste is available after sugar mill utilization. Therefore, the present study is focused on the development of blending these sugarcane bagasse powders (SBP) with polypropylene and exploring its suitability for packaging application with a specific reduction of environmental impacts. The SBP in dry powder form is used as reinforcement with varying weight propositions of 10%, 15%, 20% and 25% of the total material weight. The PP-SBP blended material was utilized to make various test samples. A total of twenty-four samples (three in each category) were prepared and tested as per ASTM standards. From the tests, an increase in the %weight of SBP resulted in a reduction in tensile strength and an increase in modulus. Also, upon adding the SBP, the flexural rigidity and strength of the material were improved. Further, TGA, FTIR and SEM analyses were conducted to identify the material’s thermal stability and the presence of functional groups. TGA exhibited a minimum loss with the increased thermal stability of PP upon reinforcing with SBP. No new functional groups were identified after adding SBP with PP in FTIR, and only mechanical bonding was observed between PP and SBP in SEM analyses. In conclusion, PP with SBP can be considered as an alternate material for packaging applications due to its increased flexural behaviour.</p>