Hi,
I found the cause of the issue. This is what happens of first boot/login
(i.e., when there is no ~/.pulse directory).

* boot:
/etc/init.d/alsa-utils start # set volume to default levels
* login:
pulseaudio --start # keep current volume (no saved one available)
* logout:
#pulseaudio keeps running!!
* reboot
/etc/init.d/alsa-utils stop # save current volume and mute mixer
kill pulseudio # save current volume (oops, mixer is mute!)


Second boot/login:
* boot:
/etc/init.d/alsa-utils start # set volume to saved one (good!)
* login:
pulseaudio --start # restore volume to saved one (oops, muted!)

Note that alsa and pulseaudio store volume separately.

I am attaching an easy proof-of-concept fix: prevent alsa-utils from
zeroing the mixer. It work for me.

But I would not blame alsa for doing that. I'd rather think that we
should ensure that pulseaudio gets stopped before "alsa-utils stop" is
called or when the user is logged out.

Thanks,
Ludovico

--- /etc/init.d/alsa-utils.orig	2009-12-24 01:42:33.000000000 +0100
+++ /etc/init.d/alsa-utils	2009-12-24 01:43:29.000000000 +0100
@@ -349,7 +349,7 @@
 	esac
 	card_OK "$TARGET_CARD" || log_action_end_msg_and_exit "$( [ ! "$2" ] ; echo $? ; )" "none loaded"
 	store_levels "$TARGET_CARD" || EXITSTATUS=1
-	mute_and_zero_levels "$TARGET_CARD" || EXITSTATUS=1
+	#mute_and_zero_levels "$TARGET_CARD" || EXITSTATUS=1
 	log_action_end_msg_and_exit "$EXITSTATUS"
 	;;
   restart|force-reload)

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