What he said! Percentages of black are a nightmare. Too late for this occassion, but what I always advise my clients (and many still ignore the advice) is to get us (the print provider) involved as early as possible in the design stage. Get the first designs shown to the printer before the client so they can advise on the pitfall before someone falls in love with the "on screen" or laser version of the design.
There are many factors as pointed out above that will affect the colour. A higher screen ruling or Stochastic screen may help.
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