diff --git a/src/commands/run.js b/src/commands/run.js
index 518566c8..84edf08a 100644
--- a/src/commands/run.js
+++ b/src/commands/run.js
@@ -236,6 +236,7 @@ export async function runCommand(
       message,
       environment: config.build.environment,
       threshold: config.comparison.threshold,
+      minClusterSize: config.comparison.minClusterSize,
       eager: config.eager || false,
       allowNoToken: config.allowNoToken || false,
       wait: config.wait || options.wait || false,
diff --git a/src/tdd/tdd-service.js b/src/tdd/tdd-service.js
index b954fa62..397a1e46 100644
--- a/src/tdd/tdd-service.js
+++ b/src/tdd/tdd-service.js
@@ -1131,6 +1131,20 @@ export class TddService {
     return metadata;
   }
 
+  /**
+   * Upsert a comparison result - replaces existing if same ID, otherwise appends.
+   * This prevents stale results from accumulating in daemon mode.
+   * @private
+   */
+  _upsertComparison(result) {
+    let existingIndex = this.comparisons.findIndex(c => c.id === result.id);
+    if (existingIndex >= 0) {
+      this.comparisons[existingIndex] = result;
+    } else {
+      this.comparisons.push(result);
+    }
+  }
+
   /**
    * Compare a screenshot against baseline
    */
@@ -1248,7 +1262,7 @@ export class TddService {
         properties: validatedProperties,
       });
 
-      this.comparisons.push(result);
+      this._upsertComparison(result);
       return result;
     }
 
@@ -1288,7 +1302,7 @@ export class TddService {
           honeydiffResult,
         });
 
-        this.comparisons.push(result);
+        this._upsertComparison(result);
         return result;
       } else {
         let hotspotAnalysis = this.getHotspotForScreenshot(name);
@@ -1315,7 +1329,7 @@ export class TddService {
           diff: diffInfo,
         });
 
-        this.comparisons.push(result);
+        this._upsertComparison(result);
         return result;
       }
     } catch (error) {
@@ -1356,7 +1370,7 @@ export class TddService {
           properties: validatedProperties,
         });
 
-        this.comparisons.push(result);
+        this._upsertComparison(result);
         return result;
       }
 
@@ -1371,7 +1385,7 @@ export class TddService {
         errorMessage: error.message,
       });
 
-      this.comparisons.push(result);
+      this._upsertComparison(result);
       return result;
     }
   }
@@ -1792,7 +1806,7 @@ export class TddService {
       signature,
     };
 
-    this.comparisons.push(result);
+    this._upsertComparison(result);
     output.info(`Baseline created for ${name}`);
     return result;
   }
diff --git a/tests/commands/run.test.js b/tests/commands/run.test.js
index 2f2ed576..1e2de77b 100644
--- a/tests/commands/run.test.js
+++ b/tests/commands/run.test.js
@@ -435,6 +435,49 @@ describe('commands/run', () => {
       assert.strictEqual(exitCode, 1);
     });
 
+    it('passes minClusterSize from config to runOptions', async () => {
+      // This test verifies the fix for issue #160
+      let output = createMockOutput();
+      let capturedRunOptions = null;
+
+      await runCommand(
+        'npm test',
+        {},
+        {},
+        {
+          loadConfig: async () =>
+            createMockConfig({
+              comparison: { threshold: 2.0, minClusterSize: 5 },
+            }),
+          createServerManager: () => ({
+            start: async () => {},
+            stop: async () => {},
+          }),
+          createUploader: () => ({}),
+          runTests: async ({ runOptions }) => {
+            capturedRunOptions = runOptions;
+            return { buildId: null, screenshotsCaptured: 0 };
+          },
+          detectBranch: async () => 'main',
+          detectCommit: async () => 'abc123',
+          detectCommitMessage: async () => 'test',
+          detectPullRequestNumber: () => null,
+          generateBuildNameWithGit: async () => 'test-build',
+          output,
+          exit: () => {},
+          processOn: () => {},
+          processRemoveListener: () => {},
+        }
+      );
+
+      assert.strictEqual(
+        capturedRunOptions.minClusterSize,
+        5,
+        'minClusterSize should be passed from config to runOptions'
+      );
+      assert.strictEqual(capturedRunOptions.threshold, 2.0);
+    });
+
     it('uses provided git metadata options', async () => {
       let output = createMockOutput();
       let capturedRunOptions = null;
diff --git a/tests/tdd/tdd-service.test.js b/tests/tdd/tdd-service.test.js
index 61435cd8..58a7a34d 100644
--- a/tests/tdd/tdd-service.test.js
+++ b/tests/tdd/tdd-service.test.js
@@ -346,6 +346,98 @@ describe('tdd/tdd-service', () => {
     });
   });
 
+  describe('_upsertComparison', () => {
+    it('replaces existing comparison when ID matches', () => {
+      let mockDeps = createMockDeps();
+      let service = new TddService({}, '/test', false, null, mockDeps);
+
+      // Add initial comparison
+      service.comparisons = [
+        {
+          id: 'comp-1',
+          name: 'homepage',
+          status: 'failed',
+          diffPercentage: 5.0,
+        },
+        { id: 'comp-2', name: 'button', status: 'passed' },
+      ];
+
+      // Upsert with same ID but different status
+      service._upsertComparison({
+        id: 'comp-1',
+        name: 'homepage',
+        status: 'passed',
+        diffPercentage: 0,
+      });
+
+      assert.strictEqual(service.comparisons.length, 2);
+      assert.strictEqual(service.comparisons[0].status, 'passed');
+      assert.strictEqual(service.comparisons[0].diffPercentage, 0);
+    });
+
+    it('appends new comparison when ID does not exist', () => {
+      let mockDeps = createMockDeps();
+      let service = new TddService({}, '/test', false, null, mockDeps);
+
+      service.comparisons = [
+        { id: 'comp-1', name: 'homepage', status: 'passed' },
+      ];
+
+      service._upsertComparison({
+        id: 'comp-2',
+        name: 'button',
+        status: 'new',
+      });
+
+      assert.strictEqual(service.comparisons.length, 2);
+      assert.strictEqual(service.comparisons[1].id, 'comp-2');
+    });
+
+    it('prevents stale results from accumulating in daemon mode', async () => {
+      // This test verifies the fix for issue #158
+      // In daemon mode, re-running tests should replace old results, not accumulate them
+      let mockDeps = createMockDeps({
+        baseline: { baselineExists: () => true },
+        comparison: {
+          compareImages: async () => ({
+            isDifferent: true,
+            diffPercentage: 5.5,
+            diffPixels: 1000,
+            diffClusters: [],
+          }),
+          buildFailedComparison: params => ({
+            id: params.signature ? `comp-${params.signature}` : 'test-id',
+            status: 'failed',
+            ...params,
+          }),
+        },
+        signature: {
+          generateScreenshotSignature: () => 'homepage|1920|chrome',
+          generateBaselineFilename: () => 'homepage_hash.png',
+          generateComparisonId: sig => `comp-${sig}`,
+          sanitizeScreenshotName: name => name,
+          validateScreenshotProperties: props => props,
+          safePath: (...parts) => parts.join('/'),
+        },
+      });
+      let service = new TddService({}, '/test', false, null, mockDeps);
+
+      // First run - screenshot fails
+      await service.compareScreenshot('homepage', Buffer.from('test1'), {});
+      assert.strictEqual(service.comparisons.length, 1);
+      assert.strictEqual(service.comparisons[0].status, 'failed');
+
+      // Second run - same screenshot, still fails (simulating daemon mode re-run)
+      // Without the fix, this would add a second comparison
+      await service.compareScreenshot('homepage', Buffer.from('test2'), {});
+      assert.strictEqual(
+        service.comparisons.length,
+        1,
+        'Should still have only 1 comparison, not 2'
+      );
+    });
+  });
+
   describe('compareScreenshot', () => {
     it('creates new baseline when none exists', async () => {
       let savedBaseline = null;