Hi insta.gator,

Your code has lots of unneccessary cruft that makes it hard to read, a lot having to do with quotation ... I suggest a closer read through some introductory material such as perlsyn (Perl Syntax).

I cleaned up your code down to your problem line. It's below for your review. Untested and incomplete but should give you some ideas. Some things I did include:

• removing the chomp line (should do that when you build the array)
• using strict and declaring your variables in scope
• letting $file_size_met be a numeric value so 0 is false and anything above that is true
• prefix increment operator
• opening your filehandle with a lexically-scoped variable
• and maybe some other stuff, take a look.

In doing so I can see at least one issue which is that you are opening your OUTFILE1 each time through your while loop. I still can't see exactly what your problem is, but it looks like you want to stop writing to the file if it's reached a certain size, but not split a line. You think you're going to split a line, so you want to back up and start the next file from the start of the broken line. Right? Anyway, it's a lot like an XY Problem, and there are lots of ready-made solutions (check CPAN) that will allow you skip writing all that code yourself.

foreach my $filename (@prfiles) {
    my ( $total_recs, $counter_recs, $previous_rec_ssn, $file_count, $
+file_size_met );

    open ( my $INFILE1, '<', $filename ) or die "Cannot open $filename
+: $!";
    print "Now processing: $filename\n";
     
    while ( <$INFILE1> ) {
       if ( not $file_size_met ) {
           ++$file_count;
           my $mod_filename = $filename . $file_count;
           print "Writing output to: $mod_filename\n\n";
           
           open ( my $OUTFILE1, '>>' $mod_filename ) or die( 201 );
           
           while ( $counter_recs < 50000 ) {
               print $OUTFILE1 $_;
               ++$total_recs;
               ++$counter_recs;
           }
           
           print "$total_recs records have been processed\n";
           $counter_recs=0;
        }

        my $actual_size = (stat($mod_filename))[7];
        ++$file_size_met if $actual_size >= $outsize;
        print "Current file size is $actual_size bytes.\n";
[download]

Hope this helps!