You know I dont mind it when players figure out who the minions are... I think I try to go out of the way to make sure they know.

"A group of thugs grip their blades as they close in. Their stance indicates they have little formal training." This gives the cue that these guys arent hotshots.

I think character’s daily powers should be the most cinematic and used at the biggest dramatic moments. They represent a turning point in a combat encounter. Some may disagree but I think the proposed solution "Mega minions" is actually by definition "Meta gaming." I’m not sold that if you think meta gaming is a problem in your game, more of the same by the DM  is the best solution. I think “mega-minions” are fine if you want to use them but I’m not sure its necessary.

Some look at running the game as a way of creating layers of complex problems and having players utilize resource management play a key role in character success. I think that having players recognize minions as easily dispatched foes helps create a tone of “fantastic realism”  If I can face a dragon down, a group of thugs aren’t very fearsome. They could mess me up if I don’t address them but all things equal… “I got this.”

Part of the gripe against 4th skill system is that it reduces the resource management of skill points as a determining factor. If you prefer a game more focused creating interesting social interactions or story driven events (whether scripted or free-flowing) then Minions (regular ole variety) work their magic… as is.