One of the most overlooked aspects of machine embroidery, which can lead to mounds of frustration and horrendous results, is the way the thread comes off the spool or cone. Thread is straight wound on a spool and cross wound on a cone. That means that thread on a spool is meant to come straight off the spool and the thread on a cone is meant to come off the end of the cone. See the picture below.
If the thread comes off the spool or cone opposite of the way it was wound, then severe twisting of the thread will occur as demonstrated in the video below.
The twisted thread coming off an incorrectly positioned spool or cone can cause several different problems. The most likely problem is chronic thread breaks. As the thread passes through the eye of the needle, it will straighten out, but the twists do not go away, they bunch up behind the needle which will eventually cause the thread to break.
A second common occurrence is what many people describe as “bird nesting”, a big, knotted mess of bobbin and top thread on the bottom of the fabric. This occurs when the eye of the needle is larger and allows all the twists to pass through, which then interact with the bobbin thread forming the birds nest.
Take care when setting up your machine to embroider, and whether you are using a spool or cone of thread, make sure the thread is coming off correctly.