Well another restart has it working again but the second set of env are still not working. (scared to re-start it as it seems to change with every reboot!

On an excel related note.

If you have to run packages that use excel in 32bit i take it I will need dtexec 32bit. Its apparently only installed if you add the client tools or SSDT to server!

http://technet.microsoft.com/en-us/library/ms162810(v=sql.105).aspx

"On a 64-bit computer, Integration Services installs a 64-bit version of the dtexec utility (dtexec.exe). If you have to run certain packages in 32-bit mode, you will have to install the 32-bit version of the dtexec utility. To install the 32-bit version of the dtexec utility, you must select either Client Tools or Business Intelligence Development Studio during setup."