I haven't had herolab crash and I run many campaigns to high levels as the GM, I own about 75% of the PF content. There is one person in my group that does crash occasionally, the one thing about his setup that is different then mine is that he has 100% of the content and most of the 3rd party content too. I typically keep unused content unchecked too, whereas he does not.
There may be some conflict between packs that exacerbates the problem, have you tried turning off unused content?
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