Issue is due to the the GDI usage hitting the limit
Resolution:
Increase GDI limit per process from 10000 to up to 65000 under HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows NT\CurrentVersion\Windows
Increase value to 16384
HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows NT\CurrentVersion\Windows\GDIProcessHandleQuota
Increase value to 16384
HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows NT\CurrentVersion\Windows\USERProcessHandleQuota
Increase value from 3072 to 8192
HKEY_LOCAL_MACHINE\Software\Microsoft\Windows NT\CurrentVersion\Windows\Windows
%SystemRoot%system32csrss.exe…..1024,8192,512…
References:
http://www.belchfire.net/index.php?showtopic=19167
http://blogs.msdn.com/b/rgregg/archive/2007/09/03/outlook-2007-gdi-leak-hotfix.aspx