Thanks for the suggestions. 

I'm not sure if the local repo thing will work for us or not. Our system is
end-user configurable. Basically we have a core set of bundles and then
customers can install various bundles to integrate with a wide variety of
end hardware (zigbee, modbus, z-wave, etc.). We've also got customer
specific modules to integrate with proprietary systems. Ultimately we don't
know what modules are going to be installed when the system ships, so we
can't really add them to the local repo and startup config. 

Once the devices are in the field and they get corrupted it is ugly to get
them fixed. It is possible that Karaf may not be the best choice for a
remote device that needs to come back from a power cycle reliably every
time. Which is unfortunate because other than this issue Karaf has been
great.

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