By the way - this is still happening. Every. Day.

It's also started to creep up on our main network, not as often, but it has happened a few times - which makes me very worried.

This seems to be a fatal flaw in Clearos/dansguardian that once the maxchildren processes are maxxed out, the system can't recover. I've received no suggestions that I haven't already tried, I guess I'm going to have to start looking for another content filter solution.