I couldn't find the the answer in either booklet in the Enterprise sets, but after listening to both Canamar and Regeneration, how big were the orchestras in both episodes? Every so often, I'll hit the random button and hear bits of McCarthy's Twilight and stop in my tracks when "End of Kuroda" or "Borg Attack" comes on. It sounds like everyone else is using the standard 40-50 players and Brian is using 80-90. How far off am I?
His scores sound like big motion picture stuff indeed.
But I somehow doubt his orchestra was that much bigger, although I'm not really sure. I always figured he was just simply good at getting the best and biggest sound out of a TV size orchestra.
That question was answered when one of the sets came out. Ford said his orchestras were the same size as those the other composers used. I'm sure it would have been mentioned, even in passing, had they been larger. They made note of the electronic scores.
He had the same sized orchestra, but the difference would be Tyler's production skill and his ability to play multiple instruments. In the liner notes to the second Enterprise Collection he notes that he played and recorded most of the "Regeneration" score himself--drums, percussion, piano, choir--so that the studio orchestra could concentrate on elements like the brass. Tyler is his own orchestra.
It's also worth noting that "Twilight" sounds like it's one of those partially electronic scores. I think the strings are replaced by samples. Not sure about the brass or woodwinds. Tyler had the luxury of writing his score before the budget cuts kicked in.
(And he's just a really good producer and orchestrator.)