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If it's not that it seems it must be an aliasing issue we haven't thought of - or possibly a font-compatibility issue?
Consider also exporting the buttons without text and then adding text using HTML; unless the font is rare - in which case you can consider sIFR
It's almost certainly because you are using 'export for web'. That option does a particularly bad job. For photos and the like the results are acceptable; but for crisp lines you need to export for print and optimise it yourself.
I always wondered about exporting for the web if that caused the problem. If I export for print, how do I optimize it myself? I have never done this so I am not sure how to cut down the size after it is exported.
Also I notice several people saying they export from Photoshop, is PH that much better than Fireworks for exporting graphics?
Make one file with 5-10 text sizes, different anti-aliasing, different fonts.
Save as jpg, png, gif - see what works best.
Use optimization wizard, different export, save as options.
11 pt in an image is getting pretty small for legibility.