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Maximum Usable Table Size & Complexity

My scheduled Table Report ran last night, but the Excel output file is corrupted. We are analyzing Item sales to current inventory levels for re-ordering. The process took 12 hours (usually takes 9). The file was output as Values to save space. The output size of this corrupted file was 39mb, and the earlier 25mb file was readable. The output log does not indicate any errors.

Are there practical limits to the size/complexity of the Table being output?
Should I try using SUMIF or smilar in the Table to group by month (we only need to view the monthly sales)?

Some facts-our last readable Table (26mb) has:

~249,000 rows (line item of each item, each sale)
Four TABLE calculations (IF on Date for last 90 days, TEXT reformatting of the Date for use in the Pivot columns)
Summary Pivot Table (with additional calculations-this could be moved to a separate sheet and reading the Table in an external location)

Any suggestions as to how to trim the fat and get a readable file (in just a few hours)?

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