This research explores the potential of combining dissimilar materials and substrates using needle punching to create composite nonwoven fabrics with superior properties. The study focuses on the effect of different fiber denier and structures on the performance of grey composite needle-punched nonwoven fabrics. Recycled polyester staple fiber and virgin polyester staple fiber are used with three levels of fiber blend composition and two levels of woven fabric as reinforcement for needle punched composite nonwoven. The six samples are analyzed for properties like air permeability, pore size, thickness, bursting strength, tensile strength, and elongation, shrinkage. The study concludes that a tailored approach can be employed to select blend ratios and scrim fabric to achieve the desired properties for required applications. The anti-static property can be used to control the electrostatic charge accumulation in the filter media. The findings suggest that the combination of different technologies can create multi-functional and economical composite nonwoven products.