We do a lot of export/import to publish in multiple languages. What has tripped us up is Text animations, these are not captions so do not export, and white text captions, which do export but are white on white in the Word file. I have not seen the font size issue, are you using a "non-standard" font? What happens if you change it to arial.?
For Lilybiri. the export file is not linked to the Captivate title, even in earlier versions any file could be reloaded and the filename was not critical. The only thing the export did inside the Captivate file was to set a flag that an export had been done therefore activating the import command. Theoretically, the import process would read any file but obviously if the indexes did not match, then it would be useless anyway.
