EMC 10: Looping and Bird Nesting

Looping and bird nesting are common embroidery issues that can lead to poor stitch quality, thread breaks, and machine stoppages. On the Melco EMC 10, these problems are often related to thread tension, needle selection, design density, or hook assembly components.

Check Thread Tension First

One of the most common causes of looping is insufficient thread tension.

Looping may appear on either the top or bottom of the design and can be caused by improper upper thread tension or incorrect bobbin tension.

To test the upper tension:

1. Tighten the main tension knob approximately two turns clockwise.
2. Sew a test design.
3. Evaluate whether the looping improves.

Be sure to also verify that the bobbin tension is properly adjusted.

Inspect the Tension Knobs

Check the black tension knobs for looseness on the tensioner posts.

If a knob feels loose:

1. Remove the tension knob.
2. Insert a flat-blade screwdriver into the slot on the tensioner post.
3. Carefully spread the slot slightly.
4. Reinstall the knob and verify that it fits securely.

Loose tension knobs can cause inconsistent tension settings and poor stitch formation.

Evaluate Design Density

Excessively dense designs can contribute to looping and bird nesting.

When stitch density is too high, the needle may struggle to penetrate the material, causing the thread to be pulled excessively during sewing.

Small lettering is especially susceptible to this issue. For designs containing letters approximately 0.50 inches or smaller, reducing stitch density may improve sewing performance.

Verify Needle Size

Using the correct needle size is important for proper thread flow.

If the design is dense, the material is elastic, or specialty thread is being used, a larger needle eye may help prevent looping and thread-related issues.

General guidelines:

• Standard 40-weight thread: 70/10, 75/11, or 80/12 needles
• 30-weight thread: Start with an 80/12 needle
• Metallic thread: Use at least an 80/12 needle; 90/14 may provide better results depending on the garment

A larger needle eye allows the thread to move more freely and reduces friction during stitching.

Check the UTC Assembly

Inspect the retaining finger of the UTC assembly and verify that it is properly positioned within the inner basket indentation.

Improper positioning can affect stitch formation and contribute to looping or bird nesting.

Additional Considerations

Some EMC 10 machines may benefit from upgraded thread guides that improve thread flow and reduce friction. Many later "CE" version machines already include these improvements.

If looping or bird nesting continues after checking tension, needle size, design density, and the UTC assembly, consult the EMC 10 Operation Manual or contact your Melco distributor for additional troubleshooting assistance.

Preventing Looping and Bird Nesting

• Maintain proper upper and bobbin tension
• Use the correct needle size for the thread being sewn
• Avoid excessive design density
• Keep thread guides and tension components clean
• Regularly inspect the hook and UTC assembly

Following these practices can help improve stitch quality and reduce embroidery interruptions on the EMC 10.