CADaver, am I to presume you get charged $2 per sheet for copy costs?
($80 / $2 = 40 sheets)
Our costs, while they are significantly lower than that (about 0.85 per sheet) does add up to significant costs when you are printing hundreds, if not thousands of extra pages per month.
We have a very similar situation to you. We have about 30 D-Size pages of typical details. We used to give every project 8 sets of those pages (8 x 30 x 0.89 = $213.60) ... not to mention the time involved in plotting, binding and delivering them to the client etc. After some considerable debate, we decided to use the method of incorporating only those details needed PER project. Now instead of our average size of plans being 45-50 pages, it is 15-20 pages ~ multiply that times the number of pages, subtracting the extra effort to grab only the details needed we ended up saving nearly $150 per project ... not counting postage and packaging costs.
It also reduced the number of mistakes in the field by people refering to the wrong detail. Sure, it's not our fault that the guy on the site can't tell Detail A from Detail C (even though it is clearly marked) .. but in the end, if the client is not happy, it costs us money in lost revenues and lost reputation.
We design around $75 million in homes every year and even though we are a rather small operation, budget is a HUGE consideration since we supply EVERYTHING.
A simple detail can mean the difference between an 0.85sf ceramic tile and $27sf imported marble. If we have the wrong thing in the detail, it WILL cost us a huge sum of money. To that extent EVERY detail is reviewed and examined to ensure it is proper for the respective project, not by one person, but by a minimum of 3.
Sure it is about profit, but one of the biggest ways to increase profit is to reduce liability and culpability, which is something we have so far managed to do quite well.