What are the factors that determine how many cohorts i can recruit without having to pay a penalty for too many?
The supply limit. It varies from region to region, but civilization level raises the limit if I remember correctly.
Global force limit is calculated from global base tax which in turn is half your slave population. It is the same for both army and navy.
Local support limit is calculated from the province population and civilisation value so for every ten population points the province gets one point of supply limit and every twenty points of civilisation also gives one point. For the owner of a province this gets multiplied by five; if you have military access in another country it gets multiplied by four; and a province you have occupied gets multiplied by three.
Enemy territory and empty provinces have no multiplier.
Sorry for the hijack, but since the OP's question has been answered...
Does anyone else think the global force limit is set too high? I never even get close to it, much less go over it. Then again, I haven't played every nation. Maybe it's a bigger problem for some.
Generally speaking though, the real cap on your army size is not your force limit, but your manpower pool.
I think the OP may be referring to the global support limit. I think it's relative to the amount of provinces you hold. In my current game, my empire is 55+ provinces and can support 200+ troops and the same for ships. I don't quite know what the actual factors are, but I'm pretty sure it's number of provinces.
Unless you're referring to supply limit, in which case the above quote is correct.![]()