Hi DUBLA
correct, a .ztl don’t saves the undo history.
Regarding your problem, I think we can compare this with a photoshop file (please correct me if I’m totally wrong with this).
In PS you can have multiple layers with all the fancy things that you can do in this program (I don’t have PS, I use Affinity Photo but it’s in general the same behavior).
The corresponding PSD file is normally much bigger as an exported e.g. PNG file.
During the export all the layers will be combined to one layer (or 2 if you use alpha).
This (and also the PNG loos-less compression) reduce the file size.
In short words, al the tools, subtools etc. in ZBrush request extra memory.
If you export this into a generic 3D format like OBJ then all this different ‘layers’ will combined to ‘one’ object with pure information about the points and polygons.
CU