40 to 140 processes jump?
Why did this happen?
I have nothing new to add aside from saying the same happened to me after last weeks update.
What builds are you running?
If you give the pfSense shell command # ps ax are there lots of duplicate process names?
Did you upgrade your firmware between there?
The old method of counting processes was undercounting. We changed recently to a more precise count, that includes not just user space processes but also kernel/system threads.