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I have the very same delphi version, bpls, components, everything. And yet in three machines the resulting executables are different in size. What else can influence in the size of the exe?
In my machine I get this size (Vista 6.0.6001):
4.547.584 bytes In my colleague’s machine, he gets (XP 5.1.2600 SP3):
4.530.688 bytes In a third colleage, he gets: (XP 5.1.2600 SP2)
4.527.104 bytes Does the OS version influence in the compiled exe size?
It would seem that it is configuration differences, or if maybe you have different versions of components installed between the three machines. I would suggest creating a blank form and trying it on all 3 after you verify that the build settings are the same. If that is the same then add some 3rd party components until you find the one that is different.
Additionally you may have a different version of Delphi (major or minor/update version).