Stomfi, since I'm not a developer, I don't understand your comments.
I did the best I could with google for "remaster" and "Morphix" and
"Knoppix" terms:

http://wiki.grml.org/doku.php?id=remastering
http://www.grml.org/faq/#knoppix
http://lists.mur.at/pipermail/grml/2005-November/000218.html

It is definitely worth your time to ask the grml folks directly, they
have a mailing list, and irc. They seem to be a very slick group.

I think, that if dB has a better system, grml might pick it up
and help you develop it. They seem very open to new ideas. Synergy
is two-way.