I suspect I'm of little help, but I'll throw out some dumb ideas.

You could try a series of partial writes of a long line to see if that reproduces the problem.

Is there any CRLF or UTF8 processing at play?

Are you able to test using the exact production data?

Is the failure a matter of a truncated line, or premature end of file?

In reply to Re^3: IO::Handle->getline() partial reads from pipe by wazat
in thread IO::Handle->getline() partial reads from pipe by saintmike

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