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Well it seems to be the addition of things...
if you have like 600 subcats then it is lets say "normal that you need more memory".
Why? because the cats..(all 650) are fetched from cache in one big array.. (thats ok..)
then on index the program goes through that array, fetching the subcats for each top category, and placing the title and the link in a template and then rendering that template and placing the rendered stuff in a variable to be outputted in html.
Its like you would be processing 600 pictures to be outputted on each page...
My suggestion, change your structure.
instead of having a 2 level structure like:
Top category
------ sub cat level 1
make a 3 level structure like
Top category
------ sub cat level 1
---------------subcat level 2
and only display 2 levels...
that will lower the memory usage and still give your users a better overview.
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You should still check the other plugins (and maybe add conditionals) to save extra memory.
Luc
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