Why Do The Threads In My Quilts Keep Breaking?
 

About a year after I had finished a super large bargello quilt, I noticed that some of the quilting had come loose. No big deal, I would just fix it. Then, I noticed last night that my newest quilt, just finished this past summer had the same problem. The bargello was quilted with cotton variegated thread from Coats & Clark and the newer quilt was quilted with 40w embroidery thread from Coats & Clark and that quilt hasn't even been washed yet.

I've had this problem before with Sulky threads but never C&C. I've tried the break test with both threads and they held up, trust me. My finger's still sore. Just not sure what's going on. I'd blame the washer but the newer one hasn't been washed yet and hardly even used. I just put it on my bed recently. Any ideas what's causing the breakage?

First of all, to clarify .... are you meaning the actual "quilting", or the stitches in the piecing? I'm thinking the actual quilting.

Just a thought ...... Is it breaking? or is it coming loose, where the start/end of the thread has not been secured?
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It's probably the quality of the thread. I don't think C&C is extra long staple Egyptian cotton. The long staple is the key. Long staple means that the individual fibers are longer. Egyptian cotton is a type of cotton, not where it's grown.

If you do the math you'll find Aurifil is as cheap to use as C&C and it's finer, has less lint and doesn't have the slubs like C&C does.

Not sure I understand the problem. Is the thread in the seams actually breaking, or it it coming apart at the start or end of quilting seam.

I typically do not use emboidery thread for the quilting, most types are not a strong as a cotton or poly thread. Look at the fiber content of the emboidery thread. Most rayon thread have great sheen , but lacks strenght. Embroidery thread is intended to be decorative, and most brands will not hold up to the stress on the quilting.
A factor in the breakage can also be how far apart you are quilting. If you quilt a good distance apart , when you are using the quilt and tug on it to repostion the quilt , grabbing the top , you can put alot of stress on that single stitch( quilting) line. Quilting closer together , can distribute that stress over more threads.
I would stress test my threads by pulling from each end before quilting , to ensure the thread can stand up to the use in the quilt.
Another factor is the needle size you are using. If the needle is small , there could be some shreading ( not quite enough to break while quilting) but enough to shorten the life of the thread in the quilt.

Just a guess, but I'd say the thread is too tight

I use C&C hand quilting thread in all my hand quilted quilts. Few are over 8 years old no issues. I hope you find the problem! if so I'd love to know just for info. Thanks and so sorry I know how much work goes into hand quilting...slow process but the end result is priceless!

Another question .... is this hand quilting? or machine quilting?

C & C doesn't have a good reputation for quality thread.

do you sit on your quilt while it's on the bed? that too can put pressure on stitches. take your thread from the spool and try to break it with your hands by pulling. if it breaks, don 't use it. good luck.