Thread breaking, not even threaded in needle anymore, thread gets caught on spool sometimes

Thread breaks
first check to see if there is an actual thread break, then check the threading-both needle and thread
Sometimes the machine will signal a thread break when there really isn't one, at least not technically. For example, a mis-threading can cause the thread break sensor to think there is a problem because it is not sensing the proper thread tension. This can also happen if a loop of thread forms suddenly resulting in slack in the thread.
a thread break signal are really a "thread out" indication most often triggered by an empty or low bobbin or the needle becoming unthreaded.
rethread the machine and correct any low thread conditions.
Actual Thread Breaks
Examine the thread break. Is it a clean snap or is it shredded?
Next, examine the thread path. Did the thread get caught on something
A common problem with embroidery thread is that due to its slippery nature, it can slide down the spool and get hung up underneath causing a sudden jerk on the thread. Rayons will probably just snap at this point but some poly threads may be strong enough to resist breaking and instead flex the needle resulting in a broken needle.
Metallic threads often cause more breaks and shredding because they tend to form loops and kinks as they come off the spool. This is exacerbated by small spools with narrow diameters and short thread paths from the spool to the first thread guide. A simple solution for this is to extend the thread path.
Thread Factors
Lets look a little closer at thread. Embroidery threads are more fragile than those used for garment construction or quilting. Start with quality thread and know how to care for it.
Embroidery threads can dry out when exposed to light, heat, drafts, and air conditioning. They can become "bruised" if dropped or handled roughly. As they age, they become more fragile. Due to dying and other processes, certain colors break more easily than others. Check this for yourself. Try breaking a white thread and then a black. Also notice that the black is slightly thicker than the white.
Rayon tends to break easier than poly. Metallics are more temperamental and finicky
Needle-Related Possibilities
On a single needle machine, if you are getting continuous thread breaks with multiple colors and you are sure you can eliminate the thread, then look at the needle.
Is it the right size? For 40 wt rayon or polyester thread, a 70/10 or 75/11 works well on most fabrics.
Embroidery needles have a slightly larger eye to reduce friction on the thread. High quality needles have a well-polished eye that won't snag, abrade, or shred the thread. The thread can pass through the eye of the needle 50 to 60 times before it is laid down on the fabric. Any rough spot on the needle or thread path can literally saw the thread in half
The broken needle is the least of your problem! If your machine doesn't stop the instant the needle breaks, it may severely damage your fabric. Needle breaks can cause scratches and rough spots on the throat plate and in the hook area that can shred thread. Until these problems are smoothed out, thread breaks will be your reality.
It is possible for the fabric and/or stabilizer to the source of thread problems. For example, heavy, stiff fabrics can easily strip some metallic threads
If the lower thread keeps breaking, open out the bobbin hatch and check that there is no lint buildup that is hindering the smooth flow of the thread. If there is any lint, remove the bobbin and clean the area thoroughly with a brush. Also check that the bobbin is wound correctly and that the tension of bobbin thread is even. Poor maintenance and incorrectly wound bobbins are the culprit more often..

Is the thread feeding freely from the spool? Sometimes thread can get caught on something on the thread spool which causes it to snap at the needle. I suggest unthreading, and running your finger around the rim of the spool to be sure there is nothing for the thread to catch on. Then be sure to use your spool pin disks to ensure the thread is feeding well.

These are some causes. The thread guide has been missed so re-thread the machine. Tension is too tight. Needle is blunt or bent. Thread is getting caught on the rough edge of the spool so turn spool around. Hope this helps

these are suggestion, if they don't help then the machine needs to be checked at a sewing machine shop
The top thread breaks


1. the needle thread is not threaded properly


2. The needle thread tension is to tight


3. The needle is bent or blunt


4. The needle is incorrectly inserted


5. The needle thread & the bobbin thread are not set under the presser foot when starting to sew


6. the threads were not drawn to the rear after sewing


7. The thread is either to heavy or to fine for the needle


8. Try a different spool or cone of thread

here are something you might check
upper thread breaks
1.top tension to tight
2.thread to thick or to fine for needle
3.needle not inserted correctly
4.thread caught on something-spool pin, tension area
5.needle damaged
6.needle thread is not threaded properly

Needle breaks
wrong size needle for fabric
wrong foot is attached
needle clamp screw is loose

also check for lint & pieces of broke needle under the needle plate
also the bobbin case area -take the bobbin & case out & check for pieces of broke needle

here is a tip about needle & thread
Cut 6-8 inch piece of thread of the spool you are going to use for your project
Take the needle you are going to use for the project
& insert the thread thru the eye of the needle
& lift one end of the thread to a 45 degree angle
& if the needle is the right size for the thread it will slide down the thread
But if the needle hangs on the thread you need one size larger needle for the thread

try rethreading the machine
the top thread tension might be to tight
needle may not be inserted into needle clamp correctly
thread could be caught on something like--spool pin--notch on spool
needle may be damaged

sometimes the thread can get caught on the spool pin
or on the notch on the thread spool itself
on some machines the thread can come off the thread take up lever
it can also get caught in the top tension area
also check your needle to see if it's bent--roll on flat surface to see if it rolls correctly
there are 3 types of bad needles-bent
blunt--makes a popping sound when going thru fabric
damaged--broke tip
also check your bobbin area for lint or loose threads
check your bobbin to see if it's warped--I've come across some that were warped
check your top thread tension

check the needle to see if it's bent-roll on flat surface to see if it rolls correctly
thread tension maybe to tight-select lower number
sometimes the thread can get caught on the
1.spool pin
2.the notch on the thread spool itself
some times the thread will come off the thread take up lever

check the needle to see if it's in backwards
check to see if the needle is bent
the thread might be hung up in the bobbin case(check area for lint or loose thread)
the tension spring could be bad-if this is the problem it would have to be replaced
check to see if it's threaded correctly(usually rethreading it is the best way to check)
check to see if the thread is caught on the spool pin or on the notch on the spool of thread it's self
make sure thread is not hung up on any of the guides
make sure the thread is not notty-if so replace
sometimes pieces of thread can be caught in the tension area

check to make sure the thread is not winding around the spool pin
also check & see if it's getting caught on the notch on the thread spool
the thread could be coming of the thread take up lever