Problem with large queue - system not starting

My setup: Pi3B+ with IQAudio Digiamp+
Volumio V.2.565
Music on USB hard drive with it’s own power supply
Plugin - autostart on
Plugin - buttons - enable shutdown GPIO 26
Using GPIO pin 3 for wake up
Using GPIO pin 14 for status led

I have been running the above setup for around 6 months with no real issues. I have updated Volumio versions whenever a new version has been available, without any problems.
The issue I have now is that I discovered that if I have a large number of tracks (100 or so) in the queue when I shut down ( safe shutdown into standby ) the system will not restart again and I have to re-flash the SD card to get the system to work again if I switch off auto play the problem is not there. If I have a smaller number of tracks in the queue then no problem. The problem also existed on the previous 2 versions of Volumio
Any ideas?

Thanks