I’m a little hesitant to suggest more $1s - host/dealer is making it work with ~260 right now with a 1/2 game so there doesn’t seem to be a need for more of the lowest denom chips with a higher stakes game that’s even less reliant on $1 chips.
Well I certainly wouldn't go from 260 to 200 on the singles. I am just trying to estimate how long it would take for enough to singles to leave the economy before there are too few in play.
Let's assume the following possible outcomes for how many singles leave the economy. Assuming rake is rounded to a whole dollar and has a five dollar max.
Rake - singles taken (including tip)
$0 - 0 (no-flop, no-drop)
$1 - 1
$2 - 3
$3 - 4
$4 - 5 (4 singles for rake, 1 for tip, I assume these must be tracked separately)
$5 - 1 ($5 chip for rake, 1 single for tip)
Let's weigh these outcomes. For simplicity and reasonability, Let's say max rake is taken on 75% of the hands and the other scenarios account for 5% of the hands each. (One could study drop patterns and get a better idea of how frequently each outcome would be.) But the math with my assumptions above is something like: 0.75(1) + 0.05(5) + 0.05(4) + 0.05(3) + 0.05(2) + 0.05(0) = 1.45 singles leaving the economy each hand on average. Assuming 25 hands per hour, that roughly 36 singles. If the games are lasting 6-7 hours, he's probably left with somewhere between 50-90 singles in play at the end of the night assuming gets all 260 in play over the course of the game. That seems reasonable, especially if the final hours of the game are shorthanded.
So if this is an estimate of the status quo, cutting to 200 is probably not an option. Maybe accepting 300 instead of 400 is an option. But the more singles available, the longer the game can go without having to stop and do a "fill" to recirculate singles. Having less than 10 singles per player in play is the point where it gets tight. And that lost time is money. (Which is why so many of us are frustrated with trying to cheap out on the chips that are making the host profit.)
I have more questions regarding exact specifics, but I’m again hesitant to really drill down on that area.
In this case, your advice should certainly be on the high side, not on trying to minimize the rake/tipping chips needed.
Maybe 280/600/300/100/20 is a compromise? Bank $30,780 with ~1000 chips likely working from the jump, $100s handling rebuys, $500s as backup.
Do 300/600/400/80/20 if you are sure you need $500s. Basically your original breakdown B with me only adding 100 singles instead of 200. 1400 chips in total, bank of $31,300. Could probably lose 1-2 racks of 25s unless he is pretty confident 2-5 games are in the future.