Poly(ethylene terephthalate)/clay nanocomposite multifilament yarn was manufactured by conventional masterbatch approach. Poly(butylene terephthalate) was used as a carrier polymer in masterbatch steps. The masterbatches were diluted into pilot melt spinning machine and subsequently drawn with 2.65 ratios to prepare fully oriented yarn. The degree of dispersion in nanocomposite fibers was analyzed by X-ray diffractometry and scanning electron microscopy. Even though the addition of nanoclay reduced mechanical properties of nanocomposite fibers, dimensional stability could be improved at certain clay contents. The flammability properties were sufficiently improved, and no significant changes were observed with increasing clay content. The main novelty of this paper is the development of a proper approach for the selection of optimum carrier polymer for nanoclay in masterbatch preparation, as well as proper nanoclay for desired polymers. The acid-base approach is used in evaluating the surface free energy of commercial nanoclay and calculation the total interaction energies between polymer and clay surfaces. Such an approach gives adequate information about polymer-clay compatibility and provides a useful tool in the selection of optimum carrier polymer, as well as proper nanoclay for the desired polymer during masterbatch preparations.