Currently we are running on AIX 5.1 CL 5.3 rev3 with 27 sites with the number of prcesses to be between 2 and 6. Each process is managing anywhere between 2 and 20 threads.
I believe you are going down the right track by looking at the limits but it will also comes down to size and number of CPUs, how much data you are trying to process and memory allocation.
Rob