Sounds like there is a definite difference between using plastic and cardboard bobbins! We get tons of lint in the bobbin holders-and clean out gunk about every 2-3 bobbins. I wonder if some of it may be caused by static electricity as the bobbins run? Your plastic bobbin may be creating a 'negative' static charge that repels the lint-while cardboard creates a 'positive' that attracts it! I adjust the bobbin so it won't drop on its own-have to 'jiggle' it more than snap it-so it will slowly fall a couple inches and then stop. Course, with my big hands-a jiggle to me might be a snap to you! I know we found right off that if it doesn't drop at all we get bobbin breaks (false) consistently, if it rolls right down to the floor we get horrible looping on top. Magnetic bobbins did stop that-but we're cheap-can't afford them on everything. Heard about 'no sided' bobbins but can easily see that causing problems just sitting in the box! It definitely is a very fine juggling to get the sewing right-between bobbin tension, density, etc. Not doing the same thing over and over makes it harder to set a constant standard for everything. What works on polos yesterday won't work on hats today, etc. Actually yesterday I had run the logo on a couple hats after I digitized it-ran perfect, looked great! And then went to sew the shirts that was the actual order-and that was a disaster. Spent another hour and a half tweaking the design to work just for 4 shirts. Had figured (as I'd been told in training) that if you set up a design for hats-it would work great on shirts! it didn't....this time! But if the customer DOES want it on hats in the future- I have it all done perfectly! Roland