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I have a multi-threaded application that launches an external app to do data conversion in preparation for later parts of the application.

I have an issue that when I set my thread count higher then 6 concurrent threads, the Runtime.getRuntime().exec() fails to launch the external application (I have also tried using ProcessBuilder with the same results). It does not throw any sort of Exception, and nothing is captured on either the standard output stream or standard error stream. What's even stranger is upon rebooting the server, I can run at least 8 concurrent threads for a few minutes without the issue, but then the issue will return.

I have read that Linux's implementation uses the fork() command which can cause an unable to allocate memory error, but I am not getting any such error.

I have written another test app to just launch X number of notespad.exe's without issue with X being as large as 100.

The application is running on a Window 2003 standard x64 server in a VMware environment. JVM version is 1.6.0_11.

I can update the JVM in an attempt to resolve the issue, but would like to leave that as a last effort to prevent needing to test all application with the new JVM version.