High-density polyethylene nanocomposites with different expanded graphite (EG) contents (0.34-1.80 wt %) were prepared by polymerization-filling technique using an industrial heterogeneous catalyst (cat K), and characterized using a range techniques: melting flow index (MFI), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), and transmission electron microscopy (TEM). The MFI data showed that EG acts as a plasticizer decreasing melt viscosity in comparison to neat HDPE produced exclusively by cat K. DSC results showed that EG nucleated the HDPE crystallization as established by the increased crystallization temperature, and the degree of crystallinity. HDPE/EG nanocomposites displayed a significant improvement in the flexural (increased from 1458 to 1831 MPa), and storage modulus (increased from 122 to 1627 MPa) at only 1.80 wt % EG content. TEM images confirmed a homogeneous distribution of EG into the polymer matrix with the presence of dispersed, intercalated and aggregated EG nanofillers.