An attempt was made to introduce CL‐20 in a TNT/energetic thermoplastic elastomer (ETPE)‐based melt cast formulation, to obtain an insensitive composition with reduced adverse environmental properties. A loading limit of 42% w/w of CL‐20 in melted TNT was observed, while it should have been around 70%. This paper describes the investigation that was undertaken to understand the observed phenomena. It was demonstrated that CL‐20 undergoes structural alterations in melted TNT. The relative solubility of CL‐20, RDX and HMX in melted TNT was determined and the α‐, β‐, γ‐ and ε‐CL‐20 were prepared and characterized using Raman spectroscopy and DTA. CL‐20 was mixed in melted TNT, as much as 4.2 g of CL‐20 dissolved in 100 g of TNT. This allowed a transformation from ε to β‐CL‐20 and a modification of CL‐20 particle size and distribution. The later modification induced a raise in CL‐20 specific surface and was responsible for the loading limit, while the transformation to β‐CL‐20 caused an increase in sensitivity and a decrease in density. This indicates that the use of CL‐20 in TNT melt cast is not promising. Our study also showed that CL‐20 is sensitive to morphological transformations, which should be taken into consideration in future processing using this compound.