Manufacturing highly-filled polymeric systems produces feedstock for the powder injection molding industry and creates color concentrates, but these systems have not been fully explored as feedstock for sheet extrusion. With higher filler loading, the melt viscosity increases and the melt strength decreases. The changes in melt properties are not a problem in the powder injection molding industry, where the filler loading can approach 90%v, because injection pressures are high and the melt is supported by the mold. In sheet extrusion, however, melt strength is required to support the polymer melt flow from the die, through the air gap, and into chill rolls. In this work, the continuous compounding and sheet extrusion of highly-filled polymer systems was investigated to identify the limitations of generic polymer and standard processing equipment in this highly filled sheet extrusion process. The consistency of the filler loading, the filler dispersion, the stability of both processes, and the issues arising during continuous compounding and sheet extrusion are discussed.