Waste management of the nonwoven polypropylene (PP) fabric has become an emerging issue due to its increased usage. This study presents the upscale recycling of PP nonwoven fabric scrap generated during medical‐grade disposable gown manufacturing. To prepare PP and carbon black (CB) nanocomposite, a two‐step novel melt blending process is used. A maximum density of 937 kg/m3, shore D hardness of 74.45, and highest improvement in UV degradation resistance with a carbonyl index of 0.40 is recorded at 2 wt% of the CB while melt flow index is the lowest at 0.5 wt% of the CB. The results of this study revealed the peak melting point (161.81°C), thermal degradation temperature (421°C), highest flexural strength (49.16 MPa), and Izod impact strength (6.76 kJ/m2) are at 0.50 wt% of CB loading. A morphological study indicated that the highest agglomeration of CB particles was found at 2 wt% CB. The results showed that the optimum value of CB in PP nanocomposite is 0.5 wt%, at which the majority of the properties are maximized. This research might pave the way for the recycling of nonwoven PP waste fabric and provide an alternative to the exciting virgin raw materials.