Speaking frankly.. This error message alone gives no indication of what the issue is.. Given that you've made a LOT of very big changes to your store in a very short period of time, any number things could be creating the error.. Bottomline is that since none of us can see your store code, it's gonna be tough for anyone to offer anything more than GUESSES as to the true source of the issue.. This is not to say that we don't want to help, but to say we may not be MUCH help..

I've only gotten this error twice and narrowed down the issue to two chief causes.
- Invalid characters in the image filenames
- Invalid characters in the PRODUCT names
Dashes
- , slashes
/ , parenthesis
() , as well as single
' , and double quotes
" , are the most often used characters in product names and image filenames.. They cause issues with not only this module, but for many other modules as well..
My suggestion is to go through your product names as well as ALL your category and product images and remove any of these offending characters and see if you get a different result..
Also check that your product attributes also do not contain any of these characters..
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