I'll add my thoughts beyond what has already been discussed. Realize that advice needs to be tailored to the situation, and I do NOT understand your specific situation. In experimentation, there are two sets of factors that you are interested in: The Design factors (the factors that you are manipulating and hoping will be causally related to the response variables) and the Noise. Both sets of factors can affect the response variables. There does seem to be a bias to focus on "optimizing" the design structure (e.g., optimal designs). There should be a increased focus on understanding the Noise. There are many strategies for handling noise in an experiment situation (e.g., repeats, nesting, RCBD, BIB, split-plots, et. al.). I think it worthwhile to spend some of your resources to gain an understanding of the noise while not negatively impacting the precision of the design. That does not mean I would run a bunch of replicates (blocks). In fact, I'm not sure I want to run more than 2 blocks, as I'm certainly not interested in a non-linear polynomial term for Block in a prediction equation. Now you can exaggerate those Block effects (like bold level setting for factors) and get some ideas about the effect of noise and possibly estimate block-by-factor interactions. Ultimately, you want your experiment to be as representative of Real conditions as possible. Unfortunately this means it will likely be noisy, so partitioning the noise will help in expanding the inference space while not negatively affecting design precision. So, I would save your money on the initial experiment, because you'll want to spend it on additional iterations.
"All models are wrong, some are useful" G.E.P. Box