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Thread gets tangled and patch gets sucked into needle plate

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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?

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