Despite the large potential of the BCZT system and the frequent reports of secondary phases, a detailed analysis of the formation mechanisms of this solid solution and possible secondary phases is still missing. To close this knowledge gap, we used thermal analysis and in-situ X-ray diffraction (XRD) to investigate the solid-state synthesis of the Ba0.82Ca0.18Zr0.08Ti0.92O3 composition. This approach has been applied to different material systems with great success in the past . Based on the identified formation conditions of secondary phases, we applied adaptations to sample processing and tested their efficacy using microstructure analysis and electromechanical measurements.