Adagio products don't split zip files, but the ZIP component that we're using may react adversely to certain scenarios. Likely, that component is not telling Adagio there is a problem. The Toolkit uses the same technology, so it's not a case of one working and the other not.
I think it's related to one or more of these conditions: very large datasets, networked data, interfering applications and the free space where the 'data' is located. Unfortunately, I haven't be able to recreate the problem. I think we can say that various processes are running in off hours for extended periods of time. For example, the DataCare, the Toolkit, and other Backups. Is there a chance that these processes are overlapping?
I'm sure the next version of DataCare will detect and cleanup after detecting an incomplete backup.