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I'd venture a guess that the session_start() is sending down a session cookie to the client and it's somehow confusing your java applet into thinking that the cookie is part of the sound.
that's pure speculation though. Have you tried moving the session_start() below the require() function?
session_start send some headers (cookies and cache control) your applet might not understand. Besides that, using require to send out the file to client is, shall I say, questionable practice. Use readfile instead.
I want to be able to call the file path from a session variable, so i can't put session_start() after the require. And the "headers already sent" error would not occur if first ran ob_start(). None of these things help, though.
I agree that its probably sending extra headers to the client, but i don't want it too - all i want is to be able to *read* session variables, i don't need to change them. It shouldn't need to update the cookie.