I use Smoothwall on a VIA custom server with 4 NICs. This board can accomodate only CF cards.
One of my observation CF cards lasted just 5 to 7 months, had to carry on Smoothwall maintance for every 6 months.
After some googling worked out following modifications can increase the lifetime of CF cards
1. Move /tmp to RAM by editing /etc/fstab and adding following entry
2. Update file system to ext2 partition, since ext3 does journalling as-well which means high IO.tmpfs /tmp tmpfs size=512000m,exec,nosuid 0 0
Edit fstab and modify partition type.
UUID=a9425b1d-3d67-40fc-b2a7-4a4f686d8be9 / ext3 defaults 1 2
3. Add additional option noatime
UUID=a9425b1d-3d67-40fc-b2a7-4a4f686d8be9 / ext2 errors=remount-ro,noatime 1 2
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