Fiber-enriched food has numerous health benefits. This study develops ‎functional fiberenriched pasta (FEP) by partially substituting wheat flour ‎for alcohol-insoluble residue prepared from potato processing byproducts ‎‎(AIR-PPB) at various particle sizes (PS). The independent variables’ ‎effects, AIR-PPB at 2–15% substitution levels, and PS 40–250 μm were ‎investigated in terms of chemical, cooking, thermal, and sensory properties. ‎AIR-PPB is rich in total dietary fibers (TDF) (83%), exhibiting high water-‎holding capacity (WHC) and vibrant colors. Different concentrations of ‎AIR-PPB increase TDF content in FEPs by 7–21 times compared to the ‎control pasta (CP). Although the optimal cooking time (OCT) decreases by ‎‎15–18% compared to CP, where a lower OCT should reduce cooking time ‎and save energy, cooking loss (Cl) increases slightly but remains within an ‎acceptable range of 8%. Additionally, AIR-PPB altered the texture ‎properties of FEP, with a moderate decrease in mass increase index (MII), firmness, and stickiness. AIR-PPB impairs the ‎gluten network’s structure in pasta due to AIR-PPB’s WHC, which ‎competes with starch for water binding, increasing the starch gelatinization ‎temperature. FEPs show an increased lightness and yellowness and ‎improved sensory properties. Highly acceptable FEPs were obtained for the ‎following substitution levels: FEP11 (AIR-PPB at 2% and PS of 145 μm), ‎FEP9 (AIR-PPB 4% level with PS of 70 μm), FEP6 (AIR-PPB of 4% level ‎with 219 μm PS), and FEP1 (AIR-PPB = 8.5% with 40 μm PS), as ‎compared to other FEPs.‎