In this work, a new physical method was used to process agro-waste pineapple leaf bres (PALF) instead of any chemical treatment for fabricating polypropylene (PP) matrix composites. Carding process was used for individualization and partial brillation of PALF as well as for removal of dust and sticky bres.The high melt viscosity of PP hinders its penetration into the composite reinforcement. To overcome this di culty, the separated and brillated PALF and PP bres of different neness were blended (50%/50% by weight) in the carding process to ensure homogeneous distribution of reinforcement and matrix phases within composites. The blended carded silver was further parallelized through a gill-drawing process, and subsequently, unidirectional composites were fabricated using compression moulding technique. A homogeneous bre-matrix distribution was achieved in case of longer PALF and ner PP bres, leading to the best mechanical properties of fabricated composites. The used carding process with optimum number of passages did not reduce the bre length or deteriorate the mechanical properties of bres and also found effective in improving bre surface roughness, leading to an improved bre-matrix interface. This study is the rst to demonstrate the use of carding for processing of PALF and how PALF length and carding process in uence different properties of fabricated composites.