If they're not designed for performer comfort and come with a lot of fancy high tech bells and whistles, I can easily picture a lot of issues. If Hong Kong performers don't have a lot of entertainment unions and/or protections (very conceivable IMO, given the disparity between what I have seen in entertainment at Disney parks in the US vs in Asia), it would help explain why the HK version seemingly went on without issues.
Can't speak for other costumes, but I could easily imagine that, say, whoever was Tinkerbell on the drum float had to be quite uncomfortable.
To me, then, the question is why a company with Disney's resources didn't simply re-design the costumes so that they were less problematic for the performers. I certainly hope that they have done so this time around.