Highly filled polymeric pellets, methods, and systems for converting filler powders and fiber fillers into the same

A highly filled polymeric concentrate comprising:

• at least one filler;
• and
• at least one polymer matrix including the at least one filler disposed therein;
• wherein the at least one filler is substantially free of chemical wood pulp;
• wherein the at least one polymer is substantially free of a liquid carrier;
• and
• wherein the at least one filler forms about 70 weight percent or more of the highly filled polymeric concentrate.

A system to convert filler powder or fiber filler into a highly filled polymeric concentrate, the system comprising:

• an extruder including a barrel having a proximal end and a distal end downstream from the proximal end, the barrier defining a chamber and an outlet at or near the distal end;
• at least one polymer source configured to hold at least one polymer and dispense the at least one polymer into the chamber at a first location;
• at least one filler source configured to hold at least one filler and dispense the at least one filler into the chamber at a second location that is downstream from the first location;
• at least one heater configured to heat the barrel at least between the first location and the second location;
• and
• a pellet mill configured to receive a mixture dispensed from the outlet of the extruder.