Dear Alan,
There are two routes to the maximum possible consistency.
One is to work one-shot.
The other is to use a fully 'seasoned' developer, i.e. one that is almost never pitched out, but is constantly replenished. This was how the commercial darkrooms of yore used to work, with the dev kept in 4-gallon tanks with a floating lid. When I started as an assistant in the 70s this was still normal.
The big disadvantage of a 'seasoned' developer is reduced film speed, typically 1 stop, because of bromide build-up. A lesser disadvantage is that if you're not careful they can accumulate crud. Apart from that, they're wonderfully reliable and consistent and very economical.
The compromise -- re-using dev for X rolls/square feet per gallon -- is nothing like as bad an idea as some people say: it works pretty well if you follow the guidelines for extending dev times to compensate for exhaustion and bromide build-up. As, presumably, you have found for yourself. There is little doubt, though, that one-shot is better.
Cheers,
R.