Still trying with this one - but maybe it's obvious to someone .....

When our SUN box  reboots pop3d does not start.
The when you check mail you get
"An error occurred while sending your username to the mail server
......."

All other qmail services appear to start - and when you re-run
/etc/init.d/qmaild stop/start
qmail-popup starts OK.

I think that this is an environment/path problem ........

In /nohup.out is the line
'env: No such file or directory'
caused by the 'nohup /var/qmail/start-pop3d' command.

Any pointers as to the possible cause of this problem would be
appreciated.

Many thanks

The following 4 diagnostics represent two outputs of ps -ef
and the two files that 'do the work'.
=============================
1).
Here are the processes running after reboot:
i.e no qmail-popup process

ps -ef|grep qmail

qmails   179     1  0 08:36:06 ?        0:00 qmail-send
 root   187     1  0 08:36:07 ?        0:00 /usr/local/bin/supervise
/var/lock/qmail-smtpd /usr/local/bin/tcpserver -v -x/v
qmaill   188     1  0 08:36:07 ?        0:00 accustamp
qmaill   189     1  0 08:36:07 ?        0:00 cyclog -s500000
/var/log/qmail/qmail-smtpd
qmaill   181   179  0 08:36:06 ?        0:00 splogger qmail
root   182   179  0 08:36:06 ?        0:00 qmail-lspawn ./Mailbox
qmailr   183   179  0 08:36:06 ?        0:00 qmail-rspawn
qmailq   184   179  0 08:36:06 ?        0:00 qmail-clean
qmaild   191   187  0 08:36:07 ?        0:00 /usr/local/bin/tcpserver -v
-x/var/qmail/etc/tcprules.cdb -uNNN -gNNN 0 25 csh

=============================
2).
Here are the process running after re-starting qmal

ps -ef|grep qmail

qmaill   344     1  0 08:41:10 pts/0    0:00 cyclog -s500000
/var/log/qmail/qmail-smtpd
vpopmail   347     1  0 08:41:13 pts/0    0:00 tcpserver -uNNN -gNNN 0
pop-3 /var/qmail/bin/qmail-popup my.mailserver.com /hom
root   339     1  0 08:41:10 pts/0    0:00 /usr/local/bin/supervise
/var/lock/qmail-smtpd /usr/local/bin/tcpserver -v -x/v
qmailq   343   335  0 08:41:10 pts/0    0:00 qmail-clean
qmaill   342     1  0 08:41:10 pts/0    0:00 accustamp
qmailr   341   335  0 08:41:10 pts/0    0:00 qmail-rspawn
qmaild   340   339  0 08:41:10 pts/0    0:00 /usr/local/bin/tcpserver -v
-x/var/qmail/etc/tcprules.cdb -u110 -g103 0 25 csh
root   338   335  0 08:41:10 pts/0    0:00 qmail-lspawn ./Mailbox
qmaill   336   335  0 08:41:10 pts/0    0:00 splogger qmail
qmails   335     1  0 08:41:10 pts/0    0:00 qmail-send


=============================
3).

#!/bin/sh
#
# /etc/init.d/qmaild
# START BIT ONLY OF  Script for starting and stopping mail service
#
PATH=$PATH:/usr/local/bin:/var/qmail/bin
USERID=<NNN>
GROUPID=<NNN>

case "$1" in

'start')
        echo "Starting qmail local delivery agent..."
        nohup /var/qmail/start-qmaild >/dev/null 2>&1
        echo "Starting qmail SMTP daemon..."
        nohup /var/qmail/start-smtpd >/dev/null 2>&1
        echo "Starting qmail POP3 daemon..."
        nohup /var/qmail/start-pop3d
        echo "Starting qmail IMAP4 daemon..."
        nohup /var/qmail/start-imapd >/dev/null 2>&1
        sleep 2
        echo "Mail Server started."
        ;;

=============================
4).
Here is the script that is called

#!/bin/sh
#
#  /var/qmail/start-pop3d
# Startup script for pop3d using tcpserver and vchkpw
#

exec env - PATH="/var/qmail/bin:/usr/local/bin:$PATH" \
tcpserver -uNNN -gNNN 0 pop-3 /var/qmail/bin/qmail-popup \
my.mailserver.com /home/vpopmail/bin/vchkpw \
/var/qmail/bin/qmail-pop3d Maildir &

=============================

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