>I assume that you run frx to get it to pdf printer. Did you consider to use MTDLL to generate html, and then run off-process EXE to get html printed to pdf? this is the technology you will also see on our demo site (go to Reports tab, and click on PDF icon on one of the report output).

If I recompile the REPORTER.EXE COM component into a multi-threaded REPORTER.DLL, this new DLL still uses almost 100% of the web server CPU time and will not let other requests to the web server be served until the component has finished processing the request.