Ok,
I've found a fix that works for me. I was find that if I didn't shut down my 
computer gracefully (and there letting /etc/init.d/alsa-utils run it's stop 
procedure) that the sound levels would be set and un-muted on next boot.

Therefore, I commented out line 372 in /etc/init.d/alsa-utils:

# mute_and_zero_levels "$TARGET_CARD" || EXITSTATUS=1

Now when I reboot gracefully, the sound levels are correct. I would
suspect that there is a bit a race condition happening. I am supposing
the alsa-utils script is being called twice and as the levels have been
"muted and zero'd" the first time around, the second time around sees
the zero'd levels get saved as the Alsa state.

I think the udev and rc.d is invoking the script twice......

This is however just a theory, but it makes sense!!! (I Hope)

-- 
[jaunty] Sound muted after boot
https://bugs.launchpad.net/bugs/352732
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