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Word 2007 locks up with "out of memory" message during large email mail merge.

Last Modified: 2010-05-18
Our company recently upgraded all PCs to Office 2007.  We have one computer that is dedicated for large mail merge operations to email our contact list.  We send out a weekly announcement that's written in Word and we pull the emails from an Excel spreadsheet.  In Office 2003, we were able to complete the list (which is about 10,000 names) without any problem.  With Office 2007, we receive an error message after about 1,800 emails saying that the computer is out of memory, close applications and try again.  At this point, Word locks up and we have to force close it.

The PC in question has 4gb of memory and at the time that Word locks up, the PC is using about 2.2-2.5gb of memory, Word itself is using 1.6gb of memory.  It seems like Word is not properly closing new emails and so the winword.exe process continues to grow until it eventually locks up and freezes with the above error message.

In event viewer, the only error that's reported is the following:

"Detection of product '{90120000-006E-0409-0000-0000000FF1CE}', feature 'ProductNonBootFilesIntl_1033' failed during request for component '{97E2DA7D-544A-4A58-99A4-C8995F1B6AC2}'"

The PC is running Windows XP Professional 32-bit with Service Pack 3 installed.  Office 2007 has Service Pack 1 installed.

Thanks for your help!
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