I'd like to build up one of my tourney sets and try a 30 player, 3 table tourney with 12/12/5/6 stacks instead of 8/8/4/7. I'd also like to have an option for 100% rebuys.
First, would the chip set breakdown look like this from the HomePokerTourney calculator? (375/375/150/225/125)
There is no way are you going to have 100% re-buys with T25-base 10k stacks (200bb with 25/50 blinds). Even with 100b stacks (50/100 blinds), re-buys will not exceed 50% of the field size. Unless the re-buy cost is ridiculously low, most similar events see a re-buy rate between 20%-33% (10 re-buys max for 30 players), and set planning for 50% of the field size is more than sufficient.
For 30 players with 12/12/5/6=10k stacks, 15 x T10k re-buys (5x T1000 and 1x T5000), and using T5000s for T25/T100/T500 color-ups, you will need:
360 x T25
360 x T100
150 x T500
255 x T1000 (75x for re-buys)
40 x T5000 (25x color-ups, 15x re-buys)
------------
1,172 total chips, or if rounding up:
1,225 total chips = 375/375/150/275/50
(add 30x more T5000 if insistent on 100% re-buys). You don't need to add more T1000s as color-up chips; you will need the extra T5000s in play.
Note that you can get by with just 350 chips of both T25 and T100 if you seat 27 players with 12/12/5/6 stacks plus 3 players with 8/8/4/7 (place one smaller stack on each table).
I'd recommend these 1,200 chips to best accomplish your goals: 350/350/150/275/75
Second, what would appropriate blind structures be for 100% rebuys or a freezeout with no rebuys? I prefer finishing around 5 hours if possible.
To finish a 30-player 10k event in 5 hours, you can either go with ~40% average increases using 15-minute blind levels, or use ~60% average increases using 20-minute blind levels. You can also go with longer 30-minute blind levels paired with 100% increases. Below are examples of each; where eot = estimated freeze-out max length (re-buy events may require up to one additional level to complete).
15-minute blind levels:
L1 25 50
L2 25 75
L3 50 100
L4 75 150
L5 100 200
L6 150 300
break, remove T25 chips
L7 200 400
L8 300 600
L9 400 800
L10 600 1200
L11 800 1600
L12 1100 2200
L13 1500 3000
break, remove T100/T500 chips
L14 2000 4000
L15 3000 6000
L16 4000 8000
L17 6000 12000
L18 8000 16000 **eot** 4:30 plus breaks
L19 11000 22000
L20 15000 30000
20-minute blind levels:
L1 25 50
L2 50 100
L3 75 150
L4 125 250
break, remove T25 chips
L5 200 400
L6 300 600
L7 500 1000
L8 800 1600
L9 1200 2400
break, remove T100/T500 chips
L10 2000 4000
L11 3000 6000
L12 5000 10000
L13 8000 16000 **eot** 4:20 plus breaks
L14 12000 24000
L15 20000 40000
30-minute blind levels:
L1 25 50
L2 50 100
L3 100 200
break, remove T25 chips
L4 200 400
L5 400 800
L6 800 1600
L7 1500 3000
break, remove T100/T500 chips
L8 3000 6000
L9 6000 12000 **eot** 4:30 plus breaks
L10 12000 24000
L11 25000 50000