In this study the morphology of LDPE/TPS blends prepared by a one-step extrusion process is compared to that obtained by reprocessing of the original blends. The influence of composition and melt drawing is examined. A novel methodology based on the form factor of the dispersed particle was used to estimate the equivalent spherical particle size of dispersed thermoplastic starch (TPS). This approach allows for the quantitative comparison of average dispersed phase particles regardless of their shape. Blends prepared in the one-step extrusion process show increased levels of anisotropy as a consequence of a combination of coalescence and particle deformation during melt drawing. Reprocessed materials demonstrate morphologies that are highly stable to a wide range of hot stretch ratio conditions. The TPS particles of reprocessed blends show no coalescence and a low degree of deformation. This phenomenon is explained by plasticizer evaporation resulting from the second processing step. The TPS is transformed from a highly deformable phase to one resembling a partially cross-linked material. These data indicate that the one-step processing of LDPE/TPS blends can be used to generate a wide range of highly elongated morphological structures. A two-step approach, analogous to typical compounding and shaping operations and involving controlled glycerol removal in the second step can be used to prepare a wide range of highly stable, more isotropic, dispersed particle morphologies. (C) 2003 Wiley Periodicals, Inc.