Embroidering patches

I've got a bunch of 1" patches that I'm trying to embroider and it's bird nesting and breaking the thread. Before I make a huge, unfixable blunder, what specifically do I need to change? Is it just the tension or should I use thicker needles?

Location: 
United States

Well, I can't redigitize the design and I'd rather not spend the money to get something new digitized until I've exhausted all my options. Other than the design being digitized incorrectly for patches, my best guess is the sealant on the back is too thick to allow a smooth run.

SoccerEmb wrote:
I've got a bunch of 1" patches that I'm trying to embroider and it's bird nesting and breaking the thread. Before I make a huge, unfixable blunder, what specifically do I need to change? Is it just the tension or should I use thicker needles?

Send the design file by mailing me. Can let you know my oppinion (if needed) .
For me the reason is the file you using, not needles, nor thread.
Hope you had try a strong enough background.