In this study, highly porous ZrMo@KIT-6 heterogeneous catalyst was developed using Aloevera gel along with Pluronic as a mixed template. The catalytic activity was executed in biodiesel production from low valued deep fried oil to develop a sustainable energy approach. The physiochemical properties of the developed catalyst were assessed in depth using different analytical techniques including, TGA, XRD, BET, TPD-NH3, FESEM- EDX and XRD analyses. It was noted that the catalyst synthesized with Aloevera gel and Pluronic mixed template possessed improved texture, morphological properties and evenly distributed active centers with total acidity of 0.95 mmol/g and surface area of 741.46 m2/g. These experimental results were further endorsed by DFT analysis. Moreover, the designed catalystexhibited paramounted catalytic efficacy in transesterification reaction of deep fried oil into biodiesel, providing a phenomenal 97.7 % biodiesel yield under optimal reaction conditions. Apart from this, the designed catalyst sustained catalytic activity up to five times with biodiesel yield 87 %. Thus, the designed catalyst presents a novel fuel strategy which will bring both financial and environmental sustainability in the future.