Why Does Merged PDF File Size Vary and How to Fix It?

Merging multiple PDF documents into a single file is a common task for professionals and students alike. However, many users notice that the resulting file size doesn't match their expectations—sometimes much larger than the sum of parts, other times surprisingly smaller. This article explains the reasons behind this phenomenon and provides practical solutions.

Why Does the Size of Merged PDF Change?

  1. Embedded Fonts and Resources:
    Different PDFs may use the same fonts but embed them differently, causing duplication in the merged file

  2. Varied Image Compression Settings:
    Source files may use different image compression algorithms (JPEG, JPEG2000, ZIP, etc.), and the merging process may standardize these

  3. Document Structure Changes:
    Each PDF has complex internal structures (bookmarks, metadata, layers, etc.), and how the merger handles these affects final size

  4. Compression Options:
    Most merging tools offer compression settings that significantly impact output file size

Solutions and Best Practices

1. Use Professional Merging Tools

Basic PDF readers often provide simplistic merging functions, while professional tools like PDFSail offer more control options for optimizing file size during merging.

2. Standardize File Settings Before Merging

Where possible, uniform source files first:

  • Convert images to same format and resolution

  • Remove unnecessary metadata, annotations, and form fields

  • Standardize font embedding settings

3. Select Appropriate Compression Level

Most professional tools provide compression options:

  • Low compression: Best quality, larger files

  • Medium compression: Balance between quality and size

  • High compression: Minimum size, possible quality loss

4. Post-Merging Optimization

If the merged file remains too large, consider:

  • Using compression tools for further optimization

  • Removing hidden metadata and unnecessary elements

  • Reducing image resolution (for non-critical images)

Extended PDF Editing Issues

Beyond merging problems, common PDF editing challenges include:

  • Formatting errors: Especially when merging from different sources

  • Lost bookmarks: Navigation bookmarks disappearing after merge

  • Failed search functionality: Improper text layer handling

  • Security issues: Security settings reset after merging

Recommended Tool

For these issues, PDFSail provides comprehensive solutions:

  • Intelligent merging algorithm optimizes file size

  • Preserves important elements like bookmarks and forms

  • Flexible compression options

  • Online processing, no software installation needed

With proper settings and professional tools, you can effectively control the size of merged PDFs while maintaining document quality and usability.