It probably has nothing to do with the size, but perhaps with the
ancestry of your classes and how you build the application.
Sometimes a class will fail to compile but you can still build the exe
and pbd's.
Or it could be related to the versions of pb dll's on the client
machine.
I suspect you are doing incremental builds. Switch to FULL builds.
I always do full builds. In fact when I first switched to interpreted
deployments, part of it was due to the extremely long compilations of
my larger applications into machine code.
I work on an enterprise PB system with many PBD's some of which are
larger than 10MB.
How can you be sure that your system is not crashing silently?
If you can reproduce what your users get then try build your app with
the PBD option and run your EXE with the "/pbdebug" flag then inspect
the generated file from bottom upwards to see why it crashed - which
object was last accessed... I've seen our system suddenly disappear
without any error messages (or GPF's) which usually relates to recent
changes that corrupt memory locations.
BTW, what were the latest changes that you made - do you use any
dynamic calls etc...
cheers
H