The steady increase in corn based ethanol production has resulted in a dramatic rise in the supply of its co-product known as distillers’ dried grain with solubles (DDGS). Currently, the main outlet for DDGS is the animal feed industry, but the presence of fibers makes them indigestible by non-ruminants such as swine and poultry. Separation of fiber from DDGS would increase the nutritional value of DDGS with higher protein and fat contents and reduced fiber content. The fiber from DDGS can be separated through a physical separation process known as elusieve. The DDGS fiber has the potential to be used as a fiber filler in thermoplastic composites. This research project evaluates DDGS fiber as a filler in thermoplastic composites. The fibers from corn hull and DDGS have been used as fillers at 30% and 50% fiber loading in high density polyethylene (HDPE) composites and compared against a standard oak fiber filler composites at a lab scale. DDGS and corn fiber composites showed comparable mechanical properties as the oak wood fiber HDPE composites. Further evaluation was completed on the performance of composite samples at commercial scale with six combinations of oak fiber, corn hull fiber and DDGS fiber with fiber loading maintained at 50%, and then samples were exposed to UV accelerated weathering for 2000 h. The UV weathering decreased the mechanical properties of all the exposed samples compared to the unexposed samples. Also, UV weathering resulted in a severe chain scission of the HDPE polymer, increasing their crystallinity. The performance of mercerized or sodium hydroxide (NaOH) treated DDGS fiber as filler was investigated by characterizing the effects of treated and untreated DDGS fibers on physical, mechanical, and thermal properties of HDPE composites. The NaOH treated DDGS fiber at 25% loading showed consistent improvement in flexural and tensile modulus of elasticities of the composites compared to the neat HDPE.