Jamie, you don't need to create a big playlist and split in manually anymore - just use the new
-n command line option (
http://manual.djsoft.net/radioboss/en/plgen_command_line_interface.htm) to generate multiple playlists. Each new playlist will start from the first category, but no-repeat rule is common for all the playlists. Eg. if you set the "Do not repeat track for 10080 minutes" option, then all tracks in the playlists will be unique for a whole week (7 * 24 * 60 = 10080).
So I think PlGenPro already does what you need