quality of thread makes a big difference - you didn't say what you were using. And in addition to just a "new needle" you need to be using the right needle - smooth eye, large enough for the thread, etc. I think that Doctor Bob from superior threads once said that a single section of thread moves thru the eye several times before it enters and stays in the thread...and each time it passes thru the eye it is more prone to fraying - therefore the need for an extremely smooth eye that feeds the thread easily.