A Kaolin-filled, high-density polyethylene (HDPE) system was used to illustrate the influence of particulates on modulus and toughness of the bulk material. A variation of filler content, particulate size and coupling quality for two HDPE-matrix systems with different viscosity led to a strong dependency of elastic modulus and fracture toughness under various testing conditions, e.g. static loading, fatigue and impact. A stiffness improvement with increasing filler content was achieved by all coupling qualities. The developed Kaolin reinforcement of HDPE with optimised coupling offers an improvement of the stiffness and toughness under all investigated loading conditions. The degree of improvement depends on the particulate size and matrix viscosity. The energy dissipation mechanisms were investigated by fractographic analysis.