It kinda sounds like you are trying to combine too many processes into one step/process..
The problems of single file vs. approval/released copy need to be addressed separately.
To achieve your single file requirement about the only realistic method is PDF, if PDF doesn't work for you thats a different issue(have you tried other pdf output methods?). DWF is great if everything is Autocad and your clients are willing to install/use DWF software.
There are tons of software packages that simplify the steps somewhat and manage the process of revision control for you. However, here's a sample Process that doesn't use software specifically but you could follow that might achieve what you are looking for:
Initial Approval Process
- You submit final copy for Managers Review
- Manager Saves File(s) into a "Reviewed Folder" (using folder permissions setup read-only for all, write(not change) for manager).
- Manager directs responsible person to Publish Current Version to Clients (if publication location needs to be different than Reviewed Folder Location)
Revision Process
- Copy released version into a working directory and make modifications
- Change file name to reflect new revision # or date or whatever indicator
- Submit to Manager for Review same as above
Like other things, if people don't follow the process it doesn't work. But it's a simple work flow you can follow and add whatever tech into the process to simplify it for you as need be. (for instance: email notification of new files placed in select folders, link reviewed folder to ftp folder, etc...)