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Ningbo MH

Common Causesand
Solutions for Thread
Breakage in Sewing

1. Poor Quality or Aged Thread

Cause: Inconsistent thread thickness, insufficient tensile strength, or brittleness due to prolonged storage.

Solution:

  • Use high-quality threads (e.g., polyester or silk threads).

  • Inspect the thread for moisture damage or aging, and replace if necessary.

2.Improper Tension Adjustment

Cause: Excessive upper or bobbin thread tension, leading to overstretching during operation.

Solution:

  • Recalibrate the tension dial (start with the midpoint setting and fine-tune based on fabric type).

  • Observe the stitch formation to ensure the upper and bobbin threads interlock evenly within the fabric.

3. Needle Issues

Cause: Needle type incompatible with fabric (e.g., using a fine needle for heavy fabrics). Needle tip wear, bending, or rust.

Solution:

  • Select the appropriate needle size for the fabric (e.g., size 16 for heavy denim, size 9 for delicate silk).

  • Replace needles regularly (recommended every 8-10 hours of sewing).

4. Incorrect Threading

Cause: Thread not properly routed through the guide, tension discs, or needle eye, increasing friction.

Solution:

  • Re-thread the machine according to the manual, ensuring the thread passes through all guides and tension mechanisms.

  • Inspect the needle eye for burrs and replace the needle if necessary.

5. Throat Plate or Bobbin Case Wear

Cause: Burrs on the throat plate hole or wear on the hook or bobbin case, cutting the thread. Solution:

Solution:

  • Smooth the throat plate hole edges with fine-grit sandpaper.

  • Inspect the hook for smoothness and replace worn components if needed.

6. Excessive Sewing Speed

Cause: High-speed sewing generates excessive friction, causing thread breakage (especially with synthetic threads).

Solution:

  • Reduce sewing speed and avoid prolonged high-speed operation.

  • Apply silicone oil or thread lubricant (only for machines that permit lubrication).

7. Bobbin Issues

Cause: Unevenly wound, deformed, or incompatible bobbins.

Solution:

  • Rewind the bobbin evenly and ensure it fits snugly in the bobbin case.

  • Replace deformed or worn bobbins.

8. Fabric Characteristics

Cause: Heavy, dense, or stiff fabrics (e.g., leather, canvas) increase thread stress.

Solution:

  • Use stronger threads (e.g., nylon) and pair with heavier needles.

  • Apply fabric-specific lubricants to reduce friction on materials like leather.

9. Low Humidity Environment

Cause: Low air humidity causes thread brittleness.

Solution:

  • Use a humidifier to regulate humidity levels.

  • Briefly condition the thread in a humid environment (avoid over-moistening).

10. Improper Handling

Cause: Forcibly pulling the fabric, causing the thread to snap against the needle or feed dogs.

Solution:

  • Gently guide the fabric, allowing the feed dogs to advance it naturally.

  • Manually lift the presser foot to adjust positioning at complex corners.

Troubleshooting Summary：

  1. Prioritize checking the needle and threading (accounts for over 60% of thread breakage issues).

  2. Test different fabrics and threads to rule out compatibility issues.

  3. Gradually adjust tension, speed, and other parameters to observe improvements.

  4. Perform regular machine maintenance to prevent dust buildup or component wear.

By systematically addressing these factors, most thread breakage issues can be resolved efficiently

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