You interleave "preprocessing" and "AO Profile" as if the words are interchangeable. They are not.
You ask about load and in my experience the number of AO profiles should have little impact on performance. After all the total impact of an additional profile is evaluating one more profile for a match. If you had 99 profiles and added one more it would only increase the cost of finding a match by a percent.
So, what's important when adding profiles is that you make sure the match is easy to evaluate and that a profile doesn't match too much.
Obviously if you are in a situation where you have a profile that matches everything and then add a second profile that also matches everything, that's a significantly different impact than just having a lot of individual profiles that only match a unique non-overlapping set of messages.
You mention some unpredictableness of the results and that can be the result of not paying attention to the actual impact of overdue age and on arrival processing. consider what happens if you have two profiles set to 5 seconds and 10 seconds overdue age and your nas is 15 seconds behind. Both profiles are then equally eligible to be run and nas does so in the order you specified which, if you didn't intentionally order things, might not be the order you need.
Preprocessing rules are a bit different - nas only runs the first one that matches. So if you have 2 or 100, it is only going to evaluate matches till it finds one.
It would be helpful to know more about why you have created 36 preprocessing rules - On the surface of things it would seem like you only need one.
-Garin