fcgi could well be your problem here if you’re using Apache, it gave me nothing but stale processes. I then moved to Lighttpd + FCGI for a while and now our servers use Apache 2.0 + Pound + Mongrel cluster or Apache 2.2 + Mongrel cluster and it’s never been more stable than this (although memory use is a bit higher, but with 2 GB of memory this clearly isn’t an issue).