I asked this question on the forum a few months back and Karen pointed me in the right direction as well. Yes, you can email documents that are unmerged with her suggestion.
Like you (it sounds), for most all documents (other than checks), we email the document to the person that initiated the "report" (like a PO print or a Sales Invoice) via a username/email address lookup. Users then can choose what to do with the document (print, forward, review online). Some of these reports have CreateForm overlays, others are just plain old E1 reports.
Many users still just View PDF on reports and get what they need but our need to email a "raw" E1 PDF came from users that have "long running" reports or have scheduled reports that run at night and they just want to have the report in their Inbox in the morning. On long running reports, they dont have to keep checking Submitted Jobs to see if it is done, they just wait for it to show up in their Inbox.
CreateEmail is a HIGHLY used tool in our organization now. With some minor mods to some payroll and AP functions, we also now are able to email employees their Direct Deposit stub and Vendors their EFT Remit Statements. Those departments cut down their snail mailing by well over half! That's a LOT of saved time and postage. As we push more employees to Direct Deposit and vendors to electronic payments (which we know THEY prefer), this number will only increase. By our accounts, we will likely be up to 80% by end of next year.