Lead-free piezoelectric ceramics with nominal composition at morphotropic phase boundary Ba0.85Ca0.15Ti0.9Zr0.1O3 (BCTZ) prepared by different processing routes and sintered either by conventional solid-state reaction or by spark plasma sintering (SPS) techniques were comparatively investigated to observe the role of structural modifications and of microstructures on the dielectric, ferroelectric, piezoelectric and electrocaloric responses. The ceramics presented relative densities from 75% to 97% and showed variations in their phase composition as a result of variable mixing and different synthesis and sintering parameters providing local compositional heterogeneity. As result, all of the ceramics showed diffuse phase transition and ferroelectric switching responses, with parameters affected mostly by density (Pr between 3.6 to 10.1 μC/cm2). High values for the electrocaloric response in the Curie range were found for the ceramics with predominantly orthorhombic character. Field-induced structural modifications were probed by tunability anomalies and by XRD experiments in remanence conditions. Piezoelectric effects with notably high figure of merit values were assigned to the better densification and poling efficiency of BCTZ ceramics.