Didn't know they even made 40lb fireline. Might not have too much line but the problem is probably worse with a full spool. Pretty sure the problem is arising from stiff coils of line coming off the spool due to slack in the line at some point before casting. If you are using a pencil popper then the temporary slack in the line while retrieving could allow for a loose loop to form on the spool, which can then fall off the spool and wrap around the shaft (that's what happened to me). Keeping tension on the line should solve the problem, which should get better as the line softens anyway.