And that was the whole problem,
I had to go to
Configuration --> shipping and packaging
and then set
"Enter the Maximum Package Weight you will ship" to a sensible amount, the default was 50, and as all my products were in grams Zencart was trying to divide my product up into a lo of 50gm packages, i have changed this to 50000gms (50kg) and the problem has gone
You don't want to know how stupid i feel right now!!
Thanks for a great mod



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