In this paper the influence of melt-processing on the final polymer/layered silicate nanocomposite morphology is discussed. In particular the role of shear forces on the transformation of the original large clay agglomerates is of interest. Several polymer nanocomposites were prepared by melt-extrusion, involving polycaprolactone, poly(ethylene oxide), polyamide-12 or polyamide-6 as the matrix polymer. The nanocomposite morphology was characterised by X-ray diffraction and transmission electron microscopy and the clay tactoid morphology with polarised optical microscopy and scanning electron microscopy. The development of the tactoid and nanocomposite morphology during melt-mixing under shear was studied time-resolved by optical microscopy in conjunction with a rheometer and synchrotron X-ray scattering together with a Couette type flow cell. The shear forces in the melt-preparation of polymer layered mineral nanocomposites facilitate the break-up of large-sized agglomerates, whereas the extent of further exfoliation of the mineral layers is determined by the compatibility between the polymer matrix and the mineral layers rather than by shear forces. (c) 2005 Elsevier Ltd. All rights reserved.