This study explores the production of bio-composites from barley, wheat, and cassava flours, reinforced with varying ratios of oil palm residues. The research emphasizes principles of circular economy and sustainability. Both flours and reinforcements underwent characterization to elucidate how their physicochemical properties affect the mechanical behavior of the bio-composites. Barley flour exhibited significantly higher levels of protein (11.11 %), crude fiber (5.64 %), and ash (2.80 %) compared to wheat and cassava flours. Conversely, cassava flour stood out for its high carbohydrate concentration (approximately 97.8 % on a dry weight basis). Characterization highlighted enhanced adhesion between reinforcements in bio-composites with cassava flour, alongside morphological distinctions on fractured surfaces. Fourier-transform infrared (FTIR) analysis unveiled several functional groups in the bio-composites, while thermogravimetric analysis delineated five stages of thermal degradation. In terms of mechanical properties, bio-composites with barley flour showed higher elastic modulus values (970.5 MPa), while those with 12 % OPKS exhibited tensile strengths of 1.7–2.1 MPa. The interaction among components emerged as a fundamental factor influencing the mechanical properties of bio-composites, underscoring the necessity of considering reinforcement composition and distribution during fabrication.