Orders Email Cron CE-1.9.2.0 – Magento Not Sending Order Confirmation Emails to Admin

My guess is the setting of cron.php to run every minute has caused a lot of things to stand on top of each other, ie, not finish before the next task scheduled of the same nature or similar is executed. Since both cron.php would not be aware of each state. The same record could be attempted twice causing some odd exception breaking the queue email sends.

With that said there are Mage::Log in the exceptions of the Queue Mailer, so making sure the logging is enabled would be the best step to help determine if theres any exceptions. It may be wise to also just run php -f cron.php from CLI to see if it is also throwing any exceptions, you may not be seeing with it running behind the scenes.

• https://github.com/OpenMage/magento-mirror/blob/magento-1.9/app/code/core/Mage/Core/Model/Email/Queue.php#L246

I would also start with a simple PHP mail() test to make sure you're not running into any Spam policies or such. Just to be sure its not something lower in the stack causing the issue.

• Magento e-mail sending does not work

Just some speculation, hope it helps!

* EDIT *

Use cron.sh instead of cron.php as it will do grep ps to look to see if a previous process is already running.

• https://github.com/OpenMage/magento-mirror/blob/magento-1.9/cron.sh#L46

Have you checked your Magento logs yet? We recently had a client who reported the same symptom on their 1.9.1 installation. When we checked the Magento logs, we discovered that their system was making calls to a PHP module called mb_string() which were failing.

Fatal error: Call to undefined function mb_convert_encoding() in /public_html/lib/Pelago/Emogrifier.php on line 556

That mb_string() function is used in Magento 1.9.1 to strip out CSS styles from your email templates and inline them into your outbound email HTML code for supporting Mail Clients that won’t render CSS 3 styles : http://www.myintervals.com/blog/2014/12/02/magento-and-the-intervals-emogrifier-class/

Their web host did not have this PHP module installed / enabled, so the function calls were throwing errors before the logic that sends the actual message can be executed, causing emails to not be sent.

If your logs show a similar error, you may need to contact your web hosting provider to see if they can enable support for mb_string()

If they don't support it, you'll need to find another host who offers support for it if you want to continue running 1.9.1

If this error isn't being thrown in your logs, you may find one of the answers submitted in this discussion may apply : New order email confirmation not being sent