Try reversing the spool on the spool pin, just in case that helps. I've decided in general I don't like results with variegated. I'll use up what I have, but...

I changed to NORMAL Floriani thread and the design stitched out beautifully---so as graceandham said---I will try a thread stand and turning it backwards---thanks and God bless all of you Cuties out there.

hope you can work out the problem with the idea from graceandham..

I would use a needle with a larger eye. Also are you by any chance using a sticky stabilizer? I find that causes thread issues similar to what you are having. Hugs. Nan W

Sometimes it is just the spool of thread. I had a similar problem once with a serger thread. After many tries and changes my dealer told me to toss the thread. No more problems.
Good luck and please let us know what works.

Well, if you have tried a larger eye needle and still have the same problem...I would say it is the thread itself...I would send an e-mail with the thread code to Floriani and let them know you have a problem...I might take it back to the dealer I purchased it from, have them run the design on their machine...if the problem exists for them, they should replace the spool of thread...sometimes it is just a problem spool of thread and nothing you do will fix the problem...

I tried the variegated thread on another design on my 4x4 machine---It flopped a bit on the first animal of a design----I stopped the design--flipped the spool backward on the spool spindle----and it flopped less---the design turned out beautifully---NO issues-----I will try the same technique on my 5x7 when I get the chance.
thanks and God bless y'all!!

I have found that Floriani spools are wound the opposite way of most other spools. My embroidery machine (BabyLock) threading instructions show a picture of how the thread should unwind from the spool. I've included a picture of Red Isacord thread and Green Floriani thread so you can see the difference. If you place your thread on the machine the 'wrong' way and do a lot of stitches, your thread will begin to kink. Using Floriani for a small design or portion of a design, I go ahead and place it on my regular spool pin, but when I will be doing a lot of stitches I use a thread stand and put the Floriani thread spool upside down. Hope this helps. I would love to see your finished work.

I was lucky. Before I bought my machine I watched an experienced embroiderer have a lot of trouble with one colour in her stitch out.
The thread had to be placed in one corner of the machine only, otherwise it broke. And it didn't like the thread stands of any sort.
It was the same brand as the rest of the colours used. For some reason, it was misbehaving shockingly.
If it is a spool with a cut in it for slipping the thread into when not in use, then make sure that the cut is not impeding the feeding of the thread.
I have had this happen with a couple of thread spools, but again, not all in that brand.
Also, slow you machine down. It will help you spot a problem before it becomes a disaster.
Good luck.
Pat