i don't think impedence is an issue
Impedance does have a lot to do with it - 600 Ohm 'phones like the AKG K240 DF are very quiet, even with the headphone level dimed (and this is the case even with a dedicated distribution amp like the Samson). Sony 7506s, whose impedance is in the double digits, are so damned loud, you'd implode your brain far before hitting "10".
If you're doing headphone distribution, then of course you're going to want to use an external box - I wouldn't want to drive even two headphones off the DA7's amp, simply because someone will want it softer, someone else will want it louder, and you've got one knob to do both.
It's possible that the Mackie boards just have a seriously powerful headphone amp, too. Again, check the impedance of your cans, because you may find the same issue, even with distribution amps. If that's the case, you may want to hook up a real amplifier to drive your 'phones.
charlie