I have a Babylock Ellisimo and I use it to make patches. It does a great job when it works but sometimes, the thread will get bunched up and then gets pulled into the needle plate. Of course this happens when I walk away otherwise maybe I could stop it before it happens. The tension is between 4 and 6. I clean up under the needle plate before I start and change the needle often to make sure it's tight. Anyone have any idea why this happens?

I found a youtube link where she is describing tricks for it.