Hi Deb - I had the same annoying problem with my system, I tried everything and it stressed be out to no end. I was convinced the thread I had was ALL bad, then I felt like I'd been taken advantage of by a little old lady who I bought the system from. I felt exactly the same way you are feeling right now. One thing I NEVER considered would be a real issue was how I loaded my backing on the roller. I used to roll it under, after watching and listening to others I noticed many loaded their backings so it wound OVER the roller. Guess what??? I have not had thread breakage since! Crazy I know. But Im a much happier camper now. Good luck, maybe if you can...take pictures of how you have it loaded, threaded etc... SUE