Re:Why it works, and why other ways are better. (Score 2, Informative)

This is already done with flexo printing where you're working with ink coverage limitations and a stock and printing process that are prone to dot gain. Sometimes it's better to keep a .5pt solid holding rule and fill with a 98% screen with the understanding that 98% is going to gain up to 100%.

That said, ink cost on a press run is an almost negligible part of the equation. It's really not a cost savings on even a large press run.