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Different PDF sizes generated by same XDP

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We have an XDP that generates an interactive PDF form using a LiveCycle ES2 process to partially pre-populated the form before it's rendered to the browser. On most clients the file size is 846kb but on other clients the size is 1.8Mb. The client machines are essentially identical in that they all use Reader 9.1.3, Win XP, IE6, and are using the same LiveCycle ES2 server to generate the form. The clients are in different geographic locations and the one that generated the larger file is on a slow branch of the network (256k) which is causing timeout issues due to the size of the PDF which is not acceptable to the client.

Why would there be such a dramatic difference in the size of the what is essentially the same PDF being generated by the same server but to different clients?

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