Here is a way to 'prevent Ghostscript from rasterizing text'. But its output will be PostScript. You may however succeed convert this PostScript to a PCL5e in an additional step.
The method will convert all glyphs into outline shapes for its PostScript output, and it does not work for its PDF or PCL output. The key here is the -dNOCACHE parameter:
gs -o somepdf.ps -dNOCACHE -sDEVICE=pswrite somepdf.pdf
Of course, converting font glyphs to outlines will take more space than keeping the original fonts embedded, because "fonts" are a space-optimized concept to store, retrieve and render glyph shapes.
Once you have this PostScript, you may be able to convert it to PCL5e with the help of either of the methods you tried before for PDF input (including {Apache?} FOP).
However, I have no idea if the output will be much smaller than versions with rasterized fonts (or even wholesome rasterized pages). But it may be worth a test.
Now vote down this answer too...
Update
Apparently, from version 9.15 (to be released during September/October 2014), Ghostscript will support a new command line parameter:
-dNoOutputFonts
which will cause the output devices pdfwrite
, ps2write
and eps2write
to "to 'flatten' glyphs into 'basic' marking operations (rather than writing fonts to the output)".
That means that the above command should be replaced by this:
gs -o somepdf.ps -dNoOutputFonts -sDEVICE=ps2write somepdf.pdf
Caveats: I've tested this with a few input files using a self-compiled Ghostscript based on current Git sources. It worked flawlessly in each case.