Getting a bit beyond my knowledge
I'll answer best of my ability.
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Can it be used for postal use too, like if the old plate was too warn?
No, then it will be a new plate number (as genuine) or if part of plate renewed then a "cliche" depending on how the plate was engineered.
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Does that mean that the new plates need to be less than 75% or more than 150%?
In this thread the size is 100% - does it mean that it's not a reproduction?
Where do "reprints" and "replicas" fit in? Are they not for postal usage?
A: This means that plates used to "reproduce" genuine postage stamps
(eg: stamp albums, catalogues, private souvenir sheets, promotional material)
Without the angled cross bar cancelling the stamps (and in original colours)
Then they must follow that % rating.
Reprints, these can fit in in various guises, original plates, but they may have "secret markings" identifying reprints (China) or use differing colours,
differing papers etc.
Replica is a Facsimile.