Black thread is the worst for getting twisting. It is the most stiff thread because of the dyes they use to dye the thread. I always told my production people to change to a new spool of thread halfway into a spool, especially on black. As you use up more and more thread on a spool, it gets stiffer the closer to the end of the spool. They used 1/2 spool left strictly for bobbin winding. Never had any problems following this approach. We used #138 bonded thread in our production. A&E's top nylon thread made for automotive industry. We were building hockey gear. You may be having the same problem. #23 titanium coated needles works great in this application.
glenn