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Extensive studies have been conducted on the impacts of plastic film residue on crop productivity in dryland agriculture. However, the relevant results were inconsistent or even opposite, which was most probably affected by both the size and concentration of residual films. To clarify this issue, a three-year (2019–2021) field experiment was conducted to examine plastic residue landfill effects on maize productivity using three sizes (0.4 × 0.4 cm2 (small), 4 × 4 cm2 (medium), and 10 × 10 cm2 (large)) under the low and high addition concentrations in an irrigated maize field. The data indicated that medium-sized residues significantly reduced maize yield by 7.3% and 13.8% in low and high addition levels respectively, relative to non-landfill group (CK) (p < 0.05). Large and small-sized residues under low level had no significant impact on yield (p > 0.05), while high amounts of small residues turned to positively influence yield. This trend was closely correlated with soil temperature, soil moisture, key enzyme activities, macroaggregate proportion, soil organic carbon and total nitrogen contents. Structural equation modelling and relative importance analyses demonstrated soil hydrothermal (27.4%), soil nitrogen (22.0%), and physical properties (21.1%) as primary drivers. A general trend was that the sizes of residues showed evidently greater impacts than their addition levels. Moreover, medium residues showed negative effects, while large and small ones had neutral or positive effects. For the first time, our findings confirmed the size- and concentration-dependent effects of plastic residues on crop productivity and provided a novel insight into plastic film pollution assessment & management in agricultural ecosystems. • Medium plastic residues evidently reduced maize yield across the concentrations. • Large and small plastic ones turned to neutrally and positively affect maize yield. • Soil hydrothermal and nutrient status were affected by residue size & concentration. • Residue size showed greater impacts on maize productivity than its concentration. • This study filled knowledge gap in understanding plastic residue production effect. [ABSTRACT FROM AUTHOR]