At InfoComm08 and InfoComm09 I had put together a stack of 20 NIONs connected with XDAB. I wasn't running a lot of channels across it and I didn't have time to thoroughly stress test it, but it came right up and worked out of the box with no issues.
Theoretically, I've seen documents that say you can do up to 30 NIONs... I don't know anyone who has ever tested that theory, nor do I believe it to be very practical. I imagine by the time you get to a project that size, you might want to consider breaking it up into smaller projects and use some project linking and CobraNet to share the relevant control and audio between the separate smaller projects.