MithaJoseph created KAFKA-19704:
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Summary: Kafka Broker Fails to Start After Upgrade to 4.1.0 Due to
Invalid segment.bytes Configuration
Key: KAFKA-19704
URL: https://issues.apache.org/jira/browse/KAFKA-19704
Project: Kafka
Issue Type: Bug
Reporter: MithaJoseph
After upgrading our Kafka brokers to version {*}4.1.0{*}, the broker fails to
start due to a misconfigured topic-level {{segment.bytes}} setting. The new
version enforces a *minimum value of 1MB (1048576 bytes)* for this
configuration, and any value below this threshold causes the broker to
terminate during startup.
*Error Details:*
**
{code:java}
[2025-09-12 14:39:51,285] ERROR Encountered fatal fault: Error starting
LogManager (org.apache.kafka.server.fault.ProcessTerminatingFaultHandler)
org.apache.kafka.common.config.ConfigException: Invalid value 75000 for
configuration segment.bytes: Value must be at least 1048576 at
org.apache.kafka.common.config.ConfigDef$Range.ensureValid(ConfigDef.java:989)
~[kafka-clients-4.1.0.jar:?]
{code}
In our setup, some topics were previously configured with a lower segment.bytes
value (e.g., 75000), which was allowed in earlier Kafka versions but is now
invalid.
As a result Kafka broker cannot start, leading to downtime and
unavailability.No snapshot file exists yet, so the {{kafka-metadata-shell}}
tool cannot be used to patch the config offline.
Please help us with the following:
* Are there any supported methods from Kafka 4.1.0 to override or bypass this
validation at startup to recover without losing data?
* If not, is there a documented approach to fix such configuration issues when
snapshots are not yet available?
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