How did you come up with 25% smaller? You are going from 55 nm. to 45 nm. and then to 40 nm. and I'd say you would end up about 45% smaller than at 55 nm. at least.
As for die size, they can make a smaller die by ditching Sideport and reducing power draw. The latter would mean that you would need less VDD and GND pins, which will also reduce your minimum necessary die size. So I don't think that a die size of about 200 mm^2 for RV790 would be too far off and entirely possible while still increasing unit count.
Bookmarks