After some testing and checking, I found that the problem was caused by a rule change on the router which has been corrected. We no longer have the SPF issue. A router died and was replaced with a newer model, it was accidentally configured so that all outgoing traffic was from ip address .10, the problem is that the mail server is address .12 so the SPF check was looking in the wrong place in our dns .... thought I would post this in case it helps anyone else.