I'm also interested in this topic. I've built some small tools but a bit troubled with the installation size. I'd like to reduce it, but still be able to go in and debug when there's problem and to restore a set of packages/classes to add back a removed feature if I later found I need it.
I recently started to look at Dr.Geo to learn how to develop and deploy a Pharo based application. So, I'm thankful to Hilaire for bringing this topic up and I'm looking forward to learn from Dr. Geo and from the outcome of this topic.