Kevin,

> The fork error does not happen on this box - but it does happen on a
> test box which has hardly ant swap space.

Swap space should be cheap even on a virtual machine.
Paging out rarely-used memory sections is not bad.
Swap space provides some living room when RAM gets tight.
Processing may be slower, but at least services are still running and
not failing unpredictably. My benchmark showed that amavisd+SA
is still usable with about 1/3 of its virtual memory kept in real memory.

> The errors I'm seeing are probably not terminal - just not enough
> resources as it seems to happen when a user sends an email to 10 or so
> people at the same domain - i.e. they use the server to send out emails
> (which is normal) and cc the rest of the company - and there are not
> enough processes available.

Keep $max_servers below the point where processes start failing.
This way, even burst of mail won't crush the system, it will just
slowly grind its way through a backlog.

  Mark

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