I've had my ZED from new for just over two years now with no problems.
I also was torn between the Mackie and the ZED but I've no regrets with my choice. You can work round the send return limitations by assigning them to the L/R buss and recording that if need be.
The MIDI control works but it isn't an MCU replacement, which I also have. I tend to use the transport and the buttons assigned to functoins that are useful when tracking such as meter reset, MIDI sync send etc.
The knobs I use for PC/VST control via ACT, I've never realy used it for full DAW control so can't comment on how it works for that. There seems to have been some strange design choices on that front. 16 faders for channels but only 12 knobs? 8 buttons? Eh?
The EQ is fantastic and there's plenty of routing options for send/return from DAW. It's even possible to send tracks out to the channels put the EQ on it and re-record back into the same track on a new layer. A complete OTB mix is also possible or a hybrid of ITB/OTB but I haven't really explored the full OTB side yet. I'm too used to automation I guess.
Surprised you haven't heard much about Allen & Heath, their stuff is considered pretty top notch on the mixer front, certainly this side of the pond anyway.
There's a huge thread on Gearslutz you may find useful.
HERE HTH, any questions just ask.