The term ‘air deck’ can be defined as a tool that creates an air gap in a blasthole to reduce bulk explosive consumption and improve fragmentation in surface mine blasting operations. In addition, the primary reason for air deck application in mine blasting is to reduce bulk explosive consumption, decrease blasting costs, and also improve blasting fragmentation. In general, there are three types of air decks used in surface mine blasting: top, middle, and bottom. The most common air deck types used in blasting practices in surface mining operations in Indonesia are bottom air decks, stemming plugs, and gas bags. In addition to commercial and technical benefits, the air deck can also help reduce GHG emissions from blasting activities. However, the conventional plastic material used for the air deck still contributes to life cycle GHG emissions from its production and transportation. Plastic debris has, over time, harmed the environment; therefore, research on air deck materials with lower life cycle GHG emissions and greater biodegradability is urgent. It is proposed that biodegradable material can be used as an air-deck alternative material either in the top column of the blasthole or the bottom column of the blasthole. Further, this study evaluates a sustainable alternative: a bio-composite air deck device fabricated from Polylactic Acid (PLA) reinforced with 40 per cent soybean husk agricultural waste. By conducting a desk study of an Indonesian limestone quarry, the study compares the proposed bio-composite with industry-standard plastic devices. The results indicate that the transition to Soy-PLA achieves a 78.6 per cent reduction in device-related GHG emissions, lowering the carbon footprint from 98.8 kg to 21.1 kg CO2-eq per blast. Mechanically, despite the inclusion of waste filler, the device retains a compressive Safety Factor exceeding 1400 under static borehole loads, confirming its structural integrity during charging. Crucially, the bio-composite utilises a programmed obsolescence mechanism driven by hydrolytic degradation. Unlike conventional plastics, which persist for centuries, the proposed device degrades into harmless biomass within 12 to 24 months of burial. This transition eliminates approximately 972 kg of permanent plastic waste per site annually. This research demonstrates that valorising agricultural by-products into blasting consumables offers a viable engineering pathway toward zero waste mining without compromising operational safety or fragmentation efficiency.