So I tried googling this. could not find anything. So must be something im doing :D Its Lin Cable. and I run it through some beeswax a couple of times. is to to much wax? or is it not melted enough?
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I find this happens to me when im stitching really long runs. Happy to hear the tip about letting it unravel and I will also try waxing more. Stitching with really large lengths of thread seriously slows down my work.
@Daniel W. As mentioned by @francescohoward, after a while it's good to drop the needles to let them un-twist as the action of stitching can cause this.
To test this, during stitching, hold the needle next to where you are sewing and observe the thread. Is it twisting around itself?
For a visual of this phenomenon, check out this video at 10:50 exactly, you can see the thread twisting. When it gets really twisted and you pull it through, if it can't unravel fast enough as it is being pulled in on a stitch, it will snag into the clusterf**k of a knot like the one in your picture.
I find that this happens less with poly as even without wax is has less friction than linen
Will let the needle "spin" until the twists come out, but generally find it only continues and gets worse.
Generally, find this happens when I do not wax the Lin Cable thread enough, and don't melt enough the wax. Also, as @fannintexas points out, when the holes are not "open" enough, there is friction as the thread drags repeatedly through each hole. This leads to tension and the thread twisting.
Wax helps prevent this.
This happens to me occasionally. I've noticed that when my thread catches on something when pulling it through it tends to do this. Could it also be that the hole is too small?