To obtain an in-depth physical knowledge of the protective barrier stability and uniformity under fire conditions, we prepared highly filled polyamide 6/organoclay nanocomposites and characterized their thermal and flammability properties. The objectives were to identify a critical composition that is needed to form a stable char with no apertures or cracks and to gain a thorough understanding of the mechanisms of flame retardancy. It was shown that there is no need for higher percentages of clay and even smaller amounts of clay (<10 wt%) should be enough to achieve good fire performance. Factors such as incoherency, poor stability and non-uniformity of the char or the presence of large cracks and formation of island-like structures were insignificant in slowing down the heat release and mass loss rates. Nevertheless, there was no stage during the flammability test where the fire completely extinguished even when the protective layer was stable and free from major cracks/apertures. Based on these results, new insights and approaches to process better flame retardant polymer nanocomposites are discussed.