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I have had a similar experience, but the crash-on-load behaviour wasn't consistent and was cured by repeated attempts to open the app. I have since removed some folders that I figured I wouldn't be using often, and all's hunky-dory now. The total number of Rigs appeared to be unrelated to the problem; it was simply a matter of staying below the critical folder-count.
Interestingly, I was able to tell as soon as RM started loading whether I was above or below the count. If above it by a single folder or perhaps only a couple - uncertain , the folder icons in RM didn't appear. If several folders or more above the limit, the disclosure triangles weren't there either. Functionality was unaffected. Folders could be opened by clicking on the invisible triangles; they were still there. Let's get to the bottom of this, eh? PS: I really don't want to to and fro with support on this; it's not an issue for me but I can see a future where, as we all build our collections and refine them by sub-dividing them into more folders, we're gonna start running into this brick wall, if indeed it exists and is not unique to a small number of setups.
For me this only happened on Mac OS X. On Windows 7 the problem was not existent. Also the log file was not very helpful because at that moment RM was not logging any longer. I send a trace stack to support explaining the problem but no solution yet.
This issues was introduced with RM 1. What I saw from the stack trace was that RM was requesting additional resources from the OS which were not granted. I assume this issue is not based of the Kemper part of the code but in some of the underlying libraries.
Anyways, I changed my workflow so it's not an issue for me. I'm on Too bad. Apparently El Cap isn't too bad, but it's not as good as Yosemite I'd planned on avoiding a complete reinstallation 'cause my system's lean and running well, but if the folder limit really isn't there in El Cap, and if what you say about upgrading vs a clean install is true, G String, I'll bite the bullet and go the whole monkey I mean, hog.