This problem happened to us once last week with 4.0.1.  Some non-ASCII
character must have been left in the maildrop since grep kept saying
it was a binary file.   This had never happened  before over the last 
7 years with earlier Qpoppers.  Our setup is AIX 4.3.3 + procmail 3.15
+ sendmail 8.11.3 (built from source).

This week we moved to 4.0.2 and so far so good....

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