A two‐level factorial experimental design was used to examine the combined effects of o‐MMT gallery polarity, surface modification of MDH, MA‐g‐PP and antioxidant addition, together with processing variables, on the burning behaviour and thermal stability of ternary composites based on PP, MDH and o‐MMT. Regression equations highlighted the detrimental effect of o‐MMT intercalants and possible improvement in the dispersion of o‐MMT at higher MDH levels. A polar gallery environment (providing quat OH groups) led to increased char formation, and MA‐g‐PP combined with o‐MMT led to a higher oxidation onset temperature. Addition of o‐MMT to PP/MDH composites can lead to a reduction in the level of MDH required for effective flame retardation.magnified image