Unexpectedly unique and environmentally friendly composite material structures, storage articles fabricated therefrom, and related methods. The composite structure includes at least one or more fiber-containing layers, such as fiberboard or other layers having fibers from natural and/or synthetic sources, and one or more mineral-containing layers. The mineral-containing layer(s) comprises a thermoplastic bonding agent fixing the mineral particles in place. The fiber-containing layer(s) and mineral-containing layer(s) can be shaped, sized, and manufactured such that the composite structure formed therefrom is capable of being machined to form the storage article. The composite structure can be repulped and recycled without the use of dispersions, emulsions, or aqueous solutions. Further, the composite reduces layer mass requirements for heat seal, barrier, and fiber adhesion compared to polymer layers. The composite structure further has tensile strength and other structural characteristics that allow it to be readily machined into desired storage article forms.

An advanced manufacturing plant and process to efficiently deconstruct and recycle post-consumer carpet primarily in an aqueous environment. The water-based technology substantially eliminates airborne particulate emissions into the workplace and the environment. It also significantly increases the quality and quantity of the resources recovered from the carpet. In addition to recycling residential carpet, it also reclaims and recycles material from commercial broadloom carpet.

Unexpectedly unique and environmentally friendly composite material structures, storage articles fabricated therefrom, and related methods. The composite structure includes at least one or more fiber-containing layers, such as fiberboard or other layers having fibers from natural and/or synthetic sources, and one or more mineral-containing layers. The mineral-containing layer(s) comprises a thermoplastic bonding agent fixing the mineral particles in place. The fiber-containing layer(s) and mineral-containing layer(s) can be shaped, sized, and manufactured such that the composite structure formed therefrom is capable of being machined to form the storage article. The composite structure can be repulped and recycled without the use of dispersions, emulsions, or aqueous solutions. Further, the composite reduces layer mass requirements for heat seal, barrier, and fiber adhesion compared to polymer layers. The composite structure further has tensile strength and other structural characteristics that allow it to be readily machined into desired storage article forms.

A reusable, fiber containing pulp product is described that is highly suited for use in the manufacture of paper products. The reusable, fiber containing pulp product provides a mixture of fibers and small, dense polymer/particle fragments. The polymer/particle fragments within the reusable, fiber containing pulp product have a size range and density that facilitates efficient removal of the polymer/particle fragments using pressure screens.