Described are methods of making a thermoplastic core paint roller using a composite cover material having a backing made from a compound comprising a polypropylene-based elastomer and calcium carbonate having between 5% and 50% calcium carbonate by weight. One or various compounds of polypropylene and calcium carbonate having between 5% and 66% calcium carbonate by weight may be used to form portions of one or multiple components that make up the paint roller, including, for example, the thermoplastic strips and/or the adhesives. The materials can be assembled in a continuous manufacturing process.