When using readfile() -- using PHP on Apache -- is the file immediately read into Apache\'s output buffer and the PHP script execution completed, or does the PHP script exec
You may still have PHP output buffering active while performing the readfile(). Check that with:
if (ob_get_level()) ob_end_clean();
or
while (ob_get_level()) ob_end_clean();
This way theonly remaining output Buffer should be apache's Output Buffer, see SendBufferSize for apache tweaks.
EDIT
You can also have a look at mod_xsendfile (an SO post on such usage, PHP + apache + x-sendfile), so that you simply tell the web server you have done the security check and that now he can deliver the file.