An offsite update from one of the FunPub staff:

There will be a set amount of non-attending packages set aside for when that part of registration begins.

We are making an additional 50 "first 100 pins" for the non-attending packages. So now it is a first 150.

The price of the online registration will drop next year. Once the cost of the system has been covered we will charge a maintenance fee that will, again, be much less.

Another reason we are holding off on the printable forms is because there is no easy way to reconcile those forms with forms that are faxed. Online forms take priority when it comes to classes, tours, first 150 and so on.
http://www.allspark.com/content/view/7109/20/

In other words, if they sell out in the first week before non-attendee registration starts, they will have some sets put aside for that non-attendee registration period. Also tries to explain why fax-in forms won't be taken until later, because they can't easily work out order of receipt with the online registrations (they could, but it could be messy with limited place stuff like the customising classes).

The increase of pin number is probably irrelavant, as I've never seen anyone care about something that proves they were just lucky enough to register within the first few hours (or in this case, first few minutes). I've never seen a demand for the pins as if they were worth anything or mean anything. (I've never actually got one myself in their 4 BotCons I've attended, and haven't cared enough to chase up any of them)

Good to hear that the online registration cost ($10) may just be expensive this year to pay off the set-up, and will be adjusted later (so it won't be profiteering).