>>Starting with svscan with something like this in 
>>/var/qmail/supervise/qmail-pop3/run:
>>
>>#!/bin/sh
>>HOSTNAME=`hostname -f`
>>exec /usr/local/bin/softlimit -m 20000000 \
>>/usr/local/bin/tcpserver -v -p -x /etc/tcp.smtp.cdb \
>>0 pop-3 /var/qmail/bin/qmail-popup $HOSTNAME \
>>/home/vpopmail/bin/vchkpw /var/qmail/bin/qmail-pop3d ./Maildir/ 2>&1
>>
>>In 90% of all cases popping the mails works fine. The other 10% >>create a 
>>vchkpw process consuming 99% cpu time, staying there till I >>send a 
>>SIGKILL.
>>
>>Any solutions for this scenario?

There are 2 things I can think of:
1) Remove the softlimit line and accept the system default limit
2) Remove the -p flag in your tcpserver to stop reverse DNS lookup

I believe it wasn't a problem with vchkpw. If your configuration allows you 
to use checkpassword, change it and see what happen. I also believe a 
temporarily fix is to NOT supervise it so let the process dies if it has to 
without attempt to restart it (which might be the 99% cpu time consuming)

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