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search_bot conflated MAXTHREADS into two jobs at once - how many chunk files to read (files 0..MAXTHREADS-1) AND how many producer sentinels to wait for - so the two had to match exactly. Set too low it silently skipped trailing chunks; set too high (or with any chunk missing/unreadable) a producer crashed before emitting its sentinel, the consumers' count never reached the threshold, and search_for_doi hung on join() forever. The idle-timeout failsafe that was meant to break a starved consumer was dead code: `if empty_counter > 5: ... elif empty_counter > 10: break` - >10 implies >5, so the elif never ran. Fix, three layers: * auto-discover the chunk files present (discover_chunk_files: <n>_chunk.txt in numeric order) instead of range(0, MAXTHREADS). All files are read regardless of count, and no producer is ever pointed at a missing file; * the sentinel threshold is now the number of producers actually started, so it can't drift from what's emitted; * producers emit their sentinel in a finally, so even a crash (missing/unreadable chunk) can't starve the count; and the idle backstop is reordered so it can actually fire (>EMPTY_LIMIT seconds) as a last resort. MAXTHREADS is deprecated and unused (kept only so old env files don't break); docs/env updated to say chunk files are auto-discovered. For the reported case (MAXTHREADS=40, files 0..43): before, files 40-43 were silently never searched, and any run that referenced a missing chunk hung forever. After, all 44 are searched and it always terminates. Verified in a pytest-only venv (tests/unit/test_search_bot.py): DOI in a trailing chunk is found; an unreadable chunk still terminates; empty dir returns at once; discovery is numeric-sorted. Full unit job 27 passed. Co-Authored-By: Claude Opus 4.8 <noreply@anthropic.com>