Successful preparation of polymer nanocomposites, exploiting graphene-related materials, via melt mixing technology requires precise design, optimization and control of processing. In the present work, the effect of different processing parameters during the preparation of poly (butylene terephthalate) nanocomposites, through ring-opening polymerization of cyclic butylene terephthalate in presence of graphite nanoplatelets (GNP), was thoroughly addressed. Processing temperature (240°C or 260°C), extrusion time (5 or 10 minutes) and shear rate (50 or 100 rpm) were varied by means of a full factorial design of experiment approach, leading to the preparation of polybutylene terephthalate/GNP nanocomposite in 8 different processing conditions. Morphology and quality of GNP were investigated by means of electron microscopy, X-ray photoelectron spectroscopy, thermogravimetry and Raman spectroscopy. Molecular weight of the polymer matrix in nanocomposites and nanoflake dispersion were experimentally determined as a function of the different processing conditions. The effect of transformation parameters on electrical and thermal properties was studied by means of electrical and thermal conductivity measurement. Heat and charge transport performance evidenced a clear correlation with the dispersion and fragmentation of the GNP nanoflakes; in particular, gentle processing conditions (low shear rate, short mixing time) turned out to be the most favourable condition to obtain high conductivity values. . This manuscript version is made available under the CC-BY-NC-ND 4.0 license http://creativecommons.org/licenses/by-nc-nd/4.0/ ©2017. This manuscript version is made available under the CC-BY-NC-ND 4.0 license http://creativecommons.org/licenses/by-nc-nd/4.0/ higher thermal conductivity [28,29]. In a recent paper, we demonstrated that the addition of hightemperature-annealed rGO in a polymer matrix leads to a thermal conductivity which is about 2-fold those of poly (butylene terephthalate) containing pristine rGO (higher defectiveness) or GNP [30], further confirming the need of high quality nanoflakes for the preparation of highly thermally conductive polymer nanocomposites. On the other hand, the control of GRM organization into a polymer matrix remains crucial in terms of nanoparticle distribution and quality of contacts between particles. Attempts in precisely controlling orientation and contacts between nanoparticles indeed resulted in an improvement of thermal transfer [31-33] but the methods adopted for the preparation of these nanocomposites are hardly up-scalable or requires very high filler concentrations. Finally, the reduction of interfacial thermal resistance was also pursued by nanoparticle functionalization [34][35][36], despite the effectiveness of this strategy may be also related to the lateral size of the nanoflakes [37]. Recently, the preparation of polymer nanocomposites was obtained by in-situ ring-opening polymerization of cyclic butylene terephthalate (CBT) oligomers into poly (butylene terephthalate), ...