OK, I've solved it - rejoice!
Hi again all,
After checking the mail server log using the email id from a bounce, and noticed the following (edited) entry:
2007-12-30 22 1J8wpU-0003iD-QI ** |/home/username/www/support/api/pipe.php (support@domain.com) R=virtual_aliases_nostar T=virtual_address_pipe: Child process of virtual_address_pipe transport returned 127 (could mean unable to exec or command does not exist) from command: /home/username/www/support/api/pipe.php
I did a quick Google for the key phrase "Child process of virtual_address_pipe transport returned 127", and found a number of forum posts for unrelated-but-similar ticket/email response scripts from users experiencing our exact problem/bounce message
To cut a long story short, the error means that the server is unable to directly execute pipe.php, as it doesn't have a hash-bang specifying what interpreter to use to execute the script.
Rather than modify pipe.php by inserting "#! /usr/bin/php" on the first line, I simply amended the forwarder I was using in cPanel to read as follows:
"|/usr/bin/php /home/username/www/support/api/pipe.php"
This allowed the pipe to execute cleanly, with no problems.
Note that the above isn't able to be entered directly when using the newer themes for cPanel 11 (e.g. "x3") due to validation issues. I recommend temporarily stepping back to an earlier cPanel 10 theme (e.g. "x") and entering the pipe string that way.
I hope this helps everyone else having the same problem!
Kind regards,
Ebonhand