This study explores the development of long fiber-reinforced thermoplastic (LFT) composites based on blends of poly(lactic acid) (PLA) and polyhydroxyalkanoate (PHA), reinforced with sisal fibers. A novel lab-scale LFT line was employed to fabricate the long fiber composites, effectively addressing the challenges associated with dispersing and processing high-aspect-ratio natural fibers. The rheological, mechanical, thermal, and morphological properties of the resulting bio-LFT composites were systematically characterized using FTIR, SEM, rotational rheology, mechanical testing, DSC, and TGA. The results demonstrated generally homogeneous fiber dispersion, although limited interfacial adhesion between the fibers and polymer matrix was observed. Mechanical tests revealed that sisal fiber incorporation significantly enhanced tensile strength and stiffness, while impact toughness decreased. Thermal analyses showed improved crystallinity and thermal stability with increasing PHA content and fiber reinforcement. Overall, this work highlights the potential of natural fibers to create high-performance, sustainable biocomposites and lays a solid foundation for future advancements in developing eco-friendly structural materials.