Patrice...I have tried an 80 and now 90 needle. The thead is Guttermans...i often use Aurfil for quilting but since I am using Minky I thought Poly would be better.

You lost me with vertical thread pin and horizontal. What is that?

Too much upper tension will stress the thread, causing some fibers to let go. Passing through the needle eye then catches and pushes the breaks back up the thread.

Are using an automatic threader?
For some reason, mine will sometimes do this to certain threads.

Watson

If you thread spool is sitting upright then you have a vertical thread spindle (pin). If the spool is on it's side then you have a horizontal thread spindle.

Try loosening both the upper tension and the presser foot pressure. That worked for me and Minky!

You might try an even feet foot too. A walking foot or an engaged even feed foot might help because minky typically has a pattern that is heavy and light in the design of it. It is much harder to sew as a backing that is for sure. The machine has to adjust all the time to the fluffy and un-fluffy pattern. Make sense?

This has happened to me occasionally. Sometimes the tension discs get very linty. The thread feeding through the tension discs can pick up lint, and the clumps won't go through the eye. So, if you haven't cleaned out the tension discs, try that.

I don't really have a solution for you, but just wanted to mention that I use Aurifil 50 for piecing and quilting. I often use minky and flannel in my quilts and it works just fine. I've not heard that minky needs polyester thread nor have I ever used it. I'm sure someone here will help you figure this out. Good luck!

Some spools of thread have to stand straight up on the pin and some have to be placed on the horizontal pin. It has to do with how they are wound. Sometimes people have to use a thread stand or come up with some kind of way to make the thread behave better. Did you check your bobbin to make sure it is placed the correct way in its holder? Make a few little samples and try different tensions too. Good luck!

Is the pin that you put your spool of thread on vertical or horizontal? It does make a difference with some thread. I've found that on the Bernina most threads prefer the vertical pin that way the thread comes off the side of the spool and doesn't twist as it will with a horizontal pin.

Here's a pic showing both https://images.search.yahoo.com/imag...odege_001&vm=p