This study investigates the effect of Halloysite nanotube (HNT) reinforcement on the mechanical, thermal, and structural properties of recycled polylactic acid (rPLA) composites. Composites were prepared with 1-5 wt.% HNTs and characterised using tensile, flexural, compressive testing, thermogravimetric analysis (TGA), and X-ray diffraction (XRD). Tensile strength increased from 42.98 MPa for neat rPLA to a maximum of 49.39 MPa at 2 wt.% HNT, while tensile modulus improved steadily from 2423.13 MPa to 2971.26 MPa at 5 wt.%. Flexural strength peaked at 78.54 MPa (22 % improvement compared to neat rPLA) at 3 wt.%, and the highest flexural modulus of 2292.30 MPa was achieved at 4 wt.% HNT. Under compressive loading, strength and modulus increased from 100.94 MPa and 2361.52 MPa for neat rPLA to 108.69 MPa and 2479.87 MPa, respectively, at 5 wt.% HNT, showing improved resistance to deformation. Thermal degradation temperatures rose from 452.12 °C for rPLA to 465.58 °C at 5 wt.% HNT, with char residue at 600 °C increasing from 4.23 % to 9.96 %, confirming the thermal barrier effect of Halloysite. XRD analysis showed enhanced crystallinity, increasing from 57.49 % (neat rPLA) to 59.22 % at 5 wt.% HNT, indicating effective nucleation and structural ordering induced by the nanotubes. Overall, the incorporation of 2-4 wt.% Halloysite offered the most balanced improvement in strength, stiffness, and thermal stability. These results demonstrate that rPLA-Halloysite composites can be suitable for sustainable, high-performance applications in packaging, automotive interiors, and structural bioplastics.