Hi,

A lot to read....

The print count at most printers is by default 1 (If you want the default raised you can do that in the printer settings (Copy Count))

You're printing directly to the printer. I always use just Background:=False (Printout command) and I've never had problems with the queue getting blocked..

Have you tried the option "Start Printing after last page is spooled" of you're printer? (Mine by the way is always on: "Spool print documents so program finishes printing faster" / "Start printing immediatly")

You've made several instances of a printer but have you tried to print manually (Copies 4 or something) to see if the same thing happens with the duplex printing getting out of sequence....? (Make shure you're manual print job is ok before you try to automate it)

Let's first look at this before automating this process...

Enjoy!