Ammonium perchlorate (AP) based propellants are the most widely used type of composite solid propellant. The high oxygen content in AP and its thermal decomposition without any solid residue determines its application as an exceptional and irreplaceable oxidizer in composite rocket propellants. Re-crystallization of Ammonium perchlorate was carried out by varying cooling patterns and agitator rpms. Several kinds of macro and micro size AP crystals with different morphology were obtained including needle like, rod like, dendritic type etc. The product crystallites were characterized by sieve analysis, Moisture content, Bulk density, Image analysis, Thermal analysis and Scanning Electron Microscope (SEM) for particle size distribution, shape and surface roughness. The effect of crystallization parameters on crystal size and shape are investigated.