We're looking to lean up/improve the way we groove our toe kick boards. We use leg levelers, so our toe kick is 3/4" thick material with two grooves on the back. The middle is just a 1/8" kerf cut for the toe clip to be hammered into, and the top rabbet is a notch to avoid hitting the leg socket's top flange.

I'm trying to figure out how to cut both grooves in one pass. We're going to set up a single tablesaw or router table with a power feeder to do nothing but groove toe kicks. We have several major projects about to hit and we're going to be grooving a few hundred linear feet per day of this.

My three options seem to be:
1) Router table and power feeder using a box joint bit stacked just to cut these two notches, or perhaps a custom router bit.

2) Tablesaw with power feeder and use a dado stack, except with spacers between the two grooves. I'm actually skeptical that our old Unisaw has an arbor long enough for this.

3) Williams and Hussey benchtop moulder with a custom blade. The downside here being HSS knives. We groove a LOT of melamine here and those HSS knives are going to take a beating. The cut doesn't have to be particularly pretty since it's never seen but I can't imagine HSS not being wrecked after a few thousand feet. A carbide saw blade will go for most of a year without needing replaced.

Either way, the goal is to cut these the exact same with presicely 0 machine setup other than safety checks. Any suggestions?

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With the spacing of nominally 2" for the two grooves I don't see you being able to fit this on a table saw arbor nor do I think you will be successful with a router bit stack.
This is a shaper job.

I don't think there is enough horse power in a router to make it efficient over the long run. I'd set up a table saw with a feeder for the spline grove and a shaper with a feeder for the bottom rebate. It might be possible to set up a single machine but the effort to do so would far exceed the saw and shaper combination.

If you really want a single machine you could make an arbor that has a shaper cutter and a saw blade mounted on it, that on a set of pillow blocks. Need a pulley, belt and motor to power it. Mount the whole thing and the feeder on a piece of plywood, add some legs.

I used leg levelers for twenty years but finally gave them up. There are faster, easier and simpler ways of setting cabinets on un-even floors. That means I am no longer trying to groove and rebate toe kick parts.

You can get carbide knives made for a Hussy, The carbide is brazed to knife stock. We use a similar knife on our Arch moulder.

This site has them.

Carbide knives