Just had another thought as I was re-reading the old messages. It is possible to keep within the 'no pair more than twice' rule, but only if you are prepared to have a few pairs who never meet. The best solution I have is:
(2 12 6 3) (10 9 11 7) (4 5 8 1)
(3 10 4 1) (11 7 12 8) (5 6 9 2)
(1 11 5 2) (12 8 10 9) (6 4 7 3)
(4 2 11 12) ( 9 3 1 8) (6 7 5 10)
(5 3 12 10) ( 7 1 2 9) (4 8 6 11)
(6 1 10 11) ( 8 2 3 7) (5 9 4 12)
which has 3 missing pairs: (1 12), (2 10) and (3 11). I guess you could use this to your advantage, if perhaps it is better that some couples should be kept away from others!
Ian.