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Imagine you are running through a significant embroidery order. Things seem to be going smoothly, at least until you spot the telltale wad of thread either on the backside or top of the garment!
You have a problem with birdnesting!
Birdnesting is the accumulation of thread caught between an embroidered piece and the needle plate, often catching between the needle plate hole and hook assembly. Birdnesting prevents the free movement of goods. Loops on the surface of embroidery come from top tension or tension problems. Typically either problem occurs when the polyester top thread has been incorrectly tensioned. If bad enough, birdnesting and looping can reduce productivity and possibly ruin the whole embroidery project.
If the embroidery machine is not stopped in time, clusters of thread can ruin the garment, by pulling it slightly through the needle hole in the throat plate. This prevents the product from sliding free, resulting in a garment popping out of the Durkee hoop. Nothing eats up efficiency than an unhooped object with only half of the embroidery design.
On top of the delay, you could have a garment trapped in the throat plate, needing to be cut to be removed.
The main source of birdnesting or looping is improperly inserted or threaded bobbin or running the embroidery machine with no bobbin. Although operating your system without a bobbin is not strictly birdnesting, it can cause similar problems.
If you experience minor damage to the garment from birdnesting, like a small hole, try a repair by using lightweight fusible cut-away.
Before continuing the embroidery design, back up to several stitches just before the last stitch sewn in the design. Check for proper alignment, so you can successfully complete the design. If the design is not aligned, adjust the hoop or needle position with your system’s control panel.
You can rehoop items successfully, but it is not easy. Rehooping the garment for embroidery, you need to hoop at the exact position and fabric tension that you had prior to stopping production. Any distortion or stretching and success will depend solely on the design you are sewing.
Preventing birdnesting and looping:
Of course, it is always best to avoid birdnesting! It is certainly better than recovering after the fact. Four ways to prevent birdnesting:
While you may not be able to avoid every instance of birdnesting, but with attention to detail in the embroidery process, you can certainly prevent it from happening regularly and severely disrupting your production flow.
In commercial embroidery, the best supplies are the key to great results. Colman and Company carries a full line of embroidery supplies for sewing on all substrates. For any questions, visit ColmanAndCompany.com, or call 800-891-1094.
What are your best tips to avoid birdnesting or looping? Let us know in the comments below.
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