Increase in usage plastic substance has dominated the effects of global warming by directly burn and dump those PET (Polyethylene terephthalate) like plastic substance in the open atmosphere. This study investigates the mechanical, thermal, and flammability properties of vinyl ester composites reinforced with 30 vol% Areca fruit fiber, cellulose, and a recycled PET bottle waste foam core, with a focus on the effects of silane coupling agents on these properties. The recycled PET bottle waste foam and Areca fruit fiber were surface-modified using a 3-Aminopropyltrimethoxysilane (APTMS) coupling agent to enhance interfacial bonding and improve the composites’ resistance to thermal and water-induced degradation. Post-fabrication, the composites underwent aging under various conditions, including exposure to borewell water, reverse osmosis water (RO), and elevated temperatures of 40 °C and 50 °C for200 hrs. The results demonstrated that silane-treated composites with 30 vol% Areca fibers provided significantly better shear, thermal conductivity, and flammability, drilling properties than their untreated counterparts, even after extensive aging. Silane-treated composites, including B2, C2, D2, and E2, showed significant improvements in mechanical, thermal, and flammability properties under various aging conditions. For composite B2, aged in borewell water for 200 h, rail shear strength increased from 17.18 MPa to 19.2 MPa, lap shear strength from 17.33 MPa to 20.3 MPa, and thermal conductivity from 0.14 W/mK to 0.17 W/mK. Moreover, composite D2, aged at 40 °C, showed improvements in rail shear strength from 16.34 MPa to 18.3 MPa, lap shear strength from 16.2 MPa to 19.2 MPa, and thermal conductivity from 0.12 W/mK to 0.15 W/mK. Furthermore, the SEM analysis of silane-treated vinyl ester composites reveals that the application of silane coupling agents and the inclusion of cellulose significantly enhance interfacial bonding and microstructural integrity. Drilling tests on silane-treated composites with 60 vol% PET foam core, 30 vol% areca fiber, and 3 vol% cellulose filler using 4 mm and 8 mm top drill diameters show reduced kerf widths compared to untreated composites. These findings confirm that the application of silane coupling agents significantly enhances the thermal stability, water resistance, and overall durability of the composites, making them suitable for demanding applications requiring high mechanical strength, effective thermal management, and robust fire resistance, particularly under challenging environmental conditions.