somethings wrong. I was practicing today with one I sprayed with sullivans with no problem, probably over spray or like they said, not letting dry maybe. I t shouldn't be causing problems
It may be that you are using too much, as you thought. I use Sullivan's all the time and have never had a problem. Use it for hand quilting also and never noticed any on my needle.
Not a big fan of sprays. My issue though. I end up with more on me than the quilt. I have used it and after letting it dry overnight, didn't have a problem.