The aim of present study is to develop a new process chain for the manufacturing of uni-directional (UD) tape structure based on recycled carbon and thermoplastic fibers. For this purpose, a process chain consist of carding, drawing and tape development processes was designed. Initially, technical and kinematical parameters of carding and drawing machines were optimized for the gentle processing of recycled carbon fiber. Furthermore, auto leveling unit of the drawing machine was also modified for uniform production of drawn sliver with minimum fiber damage. Finally, uniform sliver were processed on a prototype process to develop UD tapes for fiber reinforced plastics.