In this work, the re-use of aluminum AA6061 chips and fly ash particles by solid-state processes (cryomilling, cold compaction and hot extrusion) is presented. The process was performed in following steps: comminuting of chips, cryomilling of comminuted chips, aluminum powders and fly ash particles, cold pressing-hot extrusion approach without sintering step. Comparative analysis of the recycled composites with fine and coarse granulated chips was focused on mechanical properties and correlated to microstructural features. The density and electrical conductivity of the recycled composites are lower than those of the unreinforced aluminum alloy due to the presence of fly ash particles. Regarding mechanical properties, the recycled composites with coarse granulated chips showed higher hardness and compressive strength than the recycled composites with fine granulated chips, but the compressive strength of the recycled composites with coarse granulated chips decreased with the increase of fly ash content.