Is there a significant difference between the casino made Paulsons (i.e., Cleveland and Cincinnati Horseshoes) vs. Le Paulson Noir and Pharaoh's for example.
There are three distinct differences -- mold, material, and inlay. All three make a huge difference in how chips look, sound, feel, and handle.
First is the mold -- casino Paulson chips typically use either the
RHC or
THC mold, while fantasy Paulson chips typically use the card pip (suits) or PAULSON CHIPS mold. One exception is the older Paulson fantasy/home sets (pre-2000) which were produced on the
RHC and
THC molds. The
THC mold provides more clay-to-clay contact, it has a deeper and richer sound, and the design includes an outer ring which tends to protect the mold features from chipping. It is generally considered by most to be Paulson's best mold.
Second difference is the materials. Older Paulson chips (both fantasy and casino) were made with a formula that contained quite a large amount of lead. Advantages of doing so included a slightly softer material, a more even wearing pattern (less edge chipping), heavier weight, and slightly deeper sound. Lead was systematically removed from all color formulas from 1999 through 2007 All modern GPI/Paulson chips (2007 and later) use a different formula which is a bit harder, with different sound/feel/wear characteristics than the original formula. Some colors of chips produced from 1999-2007 also use the new lead-free formulas.
Third difference is the inlay, both physical size and material. Chips with larger inlays (
RHC, usually with Grand or Giant size inlays) have less clay-to-clay surface area, and are more slippery than chips with Standard 7/8" inlays. In addition,
RHC and fantasy/home chips use glossy-finish inlays (vs textured). All of these affect how chips look, sound, and feel.
My personal preference is older (leaded, pre-1999)
THC mold chips with textured standard size inlay (preferably shaped) from a real casino in new/mint/near-mint condition with varying spot patterns and relatively vibrant colors. Thus it's no surprise that two of my favorites are the secondary sets of President Casino on the Admiral (
PCA) and Casino Aztar Caruthersville, both of which meets all of those preferences. There is one chip in each set that does not (
PCA $1 and Aztar $5), and I don't own any of either.
On the other hand, none of your cited examples (Cleveland Horseshoe Casino, Cincinnati Horseshoe Casino, Le Paulson Noir, Pharaoh's Club) meet ANY of those criteria. No surprise that I don't own any of those either (other than a few barrels of oversize 43mm Cleveland chips).
if you were to start buying/collecting a new set from scratch, what set would you go after and where would you start?
Easy answer -- I'd go after a set that matches up with my personal preferences for chip sets.
My suggestion to you is that you get samples -- lots of samples -- before you commit a large sum of money on a specific set of chips. How many? You need enough samples to be able to make an educated decision on what you like and dislike. Only then will you be able to determine which sets meet your own criteria.