| Re: how many and at what denom?
I have a setup similar to what you are looking for - 700 chips 225 $25, 225 $100, 125 $500, and 125 $1000 denominations. My weekly game is a T5000 tournament format, which I think would be almost perfect for you based on your description. Each player begins with 20 $25, 20 $100, and 5 $500 for $5000 total each.
An 800 chip setup along these lines would seem to fit your bill - 300 $25, 300 $100, 100 $500, and 100 $1000 - this would give you a straight 20/20/5 set of chips for up to 15 and you would be able to jockey the numbers to up to 20-25 players easily. This also gives you plenty of $500 and $1000 chips for color-ups. If all your $100 chips are in play, just use the $500's to buy back whatever $100 chips you need and so forth.
I have played up to 16 players with four re-buys with my 700 chip setup and have not had any problems, so I can't imagine the breakdown I describe above not covering your described scenario.
Let me know what you think or if you have any questions. You can even PM me if you would like and I can send you my blinds schedule or any other info you might like.
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