Composite nonwovens, characterized by their versatility and multifunctional capabilities, are produced by combining disparate components using various technologies and substrates, making them cost-effective materials for a wide range of applications. This study aimed to investigate the impact of different levels of fiber blend percentage and processing methods on the properties of needle-punched composite nonwoven fabrics with normal scrim. To achieve this objective, we introduced a 1000 denier polyester multifilament high-strength, low-shrinkage scrim between the top and bottom layers of needle-punched nonwoven fabric during the manufacturing process. Twelve samples were meticulously prepared using the needle-punched nonwoven machine line, with machine parameters being held constant. The key variables manipulated were the fiber blend composition and finishing process methods; fiber blend compositions include three distinct ratios: 50:50%, 65:35%, and 80:20% of 3 denier recycled:1.4 denier virgin. These samples underwent three different processing methods: singeing, calendering, and a combination of calendering and singeing (Finish). Subsequently, these samples were tested and evaluated for filtration efficiency, air permeability, mean pore size, filtration quality coefficient (Q factor), bursting strength, thickness, tensile strength, elongation, shrinkage, and stiffness. Based on statistical analysis, specifically using two-way ANOVA without replication, the effects of blend ratio and processed fabric types along with gray fabric were analyzed for each fabric property. The results revealed significant influences of both fiber blend composition and processing method on filtration efficiency, air permeability, pore size, and Q factor. Notably, a 50:50 blend finished (calender + singe) fabric has high filtration efficiency with high Q-factor value and lowest air permeability and mean pore size compared to other blends that helped in better filtration efficiency, low pressure drop, and improved Q factor. Use of recycled polyester also enhances the sustainability of the product. In conclusion, this research underscores the critical importance of a customized approach in selecting the right fiber blend ratios and processing techniques to tailor needle-punched composite nonwoven fabrics to meet specific application requirements.