> We have three dedicated servers for solr, two for slaves and one for master,
> all with linux/debian packages installed. 
>
> I understand that replication does always copies over the index in an exact
> form as in master index directory (or it is supposed to do that at least),
> and if the master index was optimized after indexing, one doesn't need to
> run an optimize call again on master to optimize the slave's index. But in
> our case thats what fixed it and I agree it is even more confusing now :s
>   

Thats why I said: try it on the slaves too ;-)
In our case it helped too to shrink 2*index to 1*index.
I think the data which necessary for the replication won't cleanup
before the next replication or before an optimize.
For us it was crucial to shrink the size because of limited
disc-resources and to make sure that the next
replication does not increase the index to >3*times of the initial size.

@muneeb so I think, optimization is not necessary or do you have disc
limitations too?
@Hoss or others: does this explanation sound logically?

> Another problem is, we are serving live services using slave nodes, so I
> dont want to effect the live search, while playing with slave nodes'
> indices. 
>   

What do you mean here? Optimizing is too CPU expensive?

> We will be running the indexing on master node today over the night. Lets
> see if it does it again.
>   

Do you mean increase to double size?

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