Repulpable and recyclable composite packaging articles and related methods

A method of manufacturing a heat sealable and recyclable packaging structure, the method comprising:

• extrusion coating of a plurality of released fibers with a plurality of polymer/particle fragments that during recycling comprise a thermoplastic resin and a plurality of mineral particles;
• wherein said plurality of polymer/particle fragments have a mean surface area in the range of 0.0005 mm2 to 2 mm2 and a density in the range of 1.01 g/cm3 to 4.75 g/cm3;
• wherein said plurality of mineral particles comprise (i) a plurality of mineral nano-particles that are 100 nanometers or less in size and (ii) a plurality of ultrafine mineral nano-particles ranging from 0.06 microns to 0.10 microns in size;
• wherein said extrusion coating process is carried out under the following conditions:
• said thermoplastic resin having a melt flow index in the range of 4.0 g/10 min to 16 g/10 min;
• a melt temperature of 590° F.±20%;
• an extruder screw or tube barrel pressure in the range of 1,200 psi to 2,500 psi;
• an extruder screw or tube barrel air gap in the range of 4 inches to 16 inches;
• extruder screw or tube barrel die gap in the range of 0.020 inches to 0.050 inches;
• a barrel temperature in the range of 400° F. to 640° F.;
• and
• an extrusion lamination line speed from 100 PPM to 3,500 PPM.