Why Broken Stitch Happens? | 20 Reasons

Selim Reza

24 Jul, 2025

Why Broken Stitch Happens? | 20 Reasons

Why Broken Stitches Happen in Garments – Top 20 Causes Explained Clearly!

🔍 Broken Stitch কী?

Broken Stitch বলতে বোঝায় সেলাইয়ের সেই অংশ যেখানে সুতা ছিঁড়ে গেছে, স্টিচ লাইন কেটে গেছে বা পরস্পরের সাথে সংযুক্ত নেই। এটি শুধু দৃষ্টিকটু নয়, বরং গার্মেন্টসের স্থায়িত্ব ও ব্যবহারযোগ্যতাও কমিয়ে দেয়।

✅ Causes & Solutions of Broken Stitch in Garments

Cause	Solution
1. Needle damage or wrong needle type	✅ Use correct needle size and type as per fabric (e.g., ballpoint for knits)
2. Dull or bent needle	✅ Replace needle regularly after 8-10 hours of use
3. Incorrect thread tension	✅ Adjust upper and bobbin thread tension properly
4. Low-quality or incompatible thread	✅ Use good-quality thread compatible with fabric and needle
5. Improper thread path or threading	✅ Ensure correct threading path and smooth thread flow
6. Bobbin not wound correctly	✅ Use even tension when winding bobbin thread
7. Incorrect machine timing	✅ Calibrate machine timing with help of a mechanic
8. Dirty or worn-out parts (hook, race, feed dog)	✅ Clean machine regularly and replace worn parts
9. Operator handling error	✅ Train operators on proper handling and sewing techniques
10. Machine speed too high	✅ Adjust speed based on fabric and stitch type
11. Needle not inserted properly	✅ Insert needle all the way up and in correct direction
12. Thread too thick or thin for needle	✅ Match needle eye size to thread thickness
13. Faulty presser foot pressure	✅ Calibrate presser foot pressure to avoid excessive pull
14. Vibration or instability in the machine table	✅ Ensure machine is stable and vibration-free
15. Incorrect stitch length	✅ Use recommended stitch length for the fabric type
16. Wrong bobbin size or type	✅ Use correct bobbin type for the specific sewing machine
17. Loosened needle clamp screw	✅ Tighten needle clamp screw before operation
18. Old or fraying thread	✅ Always use fresh thread from reliable suppliers
19. Damaged needle plate or feed dog	✅ Inspect and replace any damaged machine parts
20. Not performing regular machine maintenance	✅ Follow preventive maintenance schedule

🧵 Best Practices to Prevent Broken Stitches

Maintain a regular machine servicing schedule.
Use a checklist for daily machine inspection.
Keep a record of broken stitch incidents for quality improvement.
Train sewing operators continuously.
Use automated sewing machines with break detection sensors in large-scale production

✅ Summary:

Broken stitches result from a combination of technical, material, and human errors. Proper machine setup, regular maintenance, skilled operators, and quality materials are key to preventing this common defect.