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You can do it on one workstation, but it’ll be out of action for a good while, for example at 10sec per frame, you’re talking nearly 40 computer hours.
What you suggest is a good idea, render to individual frames (png is better as it’s not lossy) and recompile in Premiere or something like that. AVI is still a good format, as there are zillions of codecs to choose from, all of which seem to offer something different. Unfortunately I can’t advise on codecs as I’m still figuring that one out myself. I’d suggest not going for anything too exotic though, as you need to be sure it’ll play on your client’s pc.
I wouldn’t worry about the length, 455 seconds is about 7minutes, which should easily compile into less than 250Mb at a decent quality. I set my resolution at standard dvd resolution (720x576 PAL or 720x480NTSC) in case you wish to burn the result to dvd for maximum compatability.
To give your workstation a break, perhaps consider rendering in batches.
For added realism, consider varying the speed, after all most sensible people don’t travel through junctions at 45mph :) - though this may add to the render time, I don’t think you’re stretching things too far with what you’re doing.
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