>#:/etc/postfix# postconf | grep length
>line_length_limit = 50000
>smtp_line_length_limit = 990
>
>header_size_limit = 204800

this is off course madness, and violates RFC.

>have got the following values now, seems to work again.
>All i changed is the line_length_limit. before only 39 address could be
>placed on the to line


>, now around 80 addresses can be placed on the same
>line.

spammers do this, bad practice. limiting header line length is a good way 
to block spam.

>Looking at the offending email, It is from a web based emailer.
>The to: address line puts all addresses on one long line. then also puts
>all thebody text on one long line no wraping!

If the emailer is on one of your customer's servers, tell them you are 
blocking their mail because it violates RFC and that your mail gateway 
enforces RFC and other reasonable limits for the defense of your servers 
and of your clients.

Len


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