I had sort of the same thing happen to me. I finally bought some Aurifil thread and was so excited to use it. I put it in my machine and went to town. For about 3 seconds. I thought HUH. That's weird so I rethreaded and same thing again. I was so upset. I really thought OH GOSH this thread is expensive and AWFUL. Then someone told me to change my needle to a bigger size. Well duh! I didn't even think of that. I was using the 40wt thread and the needle eye was too small so it was shredding. I changed to bigger needle and its been awesome since. Its funny how sometimes we miss the obvious isn't it? Sometimes we just need a different perspective. LOL.