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It is of course different if you are one of those players who produce only to produce; producing 50 heavy modular frames / min, simply because; they can! But I am not that kind of player.
Long story short: do you re-plan and re-construct your factories only because you found an alternative recipe?
If it is saving on resources then it will get rebuild. And since the output should be the same you can then recalculate the needed input. So you aren't keeping the input the same but the output. Meaning that you can either downclock (saving on energy) or use the freed up resources for something else.
For Cast Screw it is simply a saving on space and energy since you can now make screws in one step with less machines than in two with more. And you only need to calculate the machines in this case since the iron to screw ratio is the same.
Diluted fuel is simply to get much more energy. When I replaced the Residual fuel with diluted fuel I got about 5GW more energy (due to my factory being smaller back then).
Not with all recipes, but some of the are actually very important for efficiency. A great example is the Cast Screws alternate, making Screws from Iron Ingots directly instead of Iron Rods. You cut out a whole step from manufacturing, saving you power and space. Later on you get Steel Screws, letting you turn 5 Steel Beams per minute into 260 Screws per minute. You'd need 6.5 Constructors working the standard recipe to match that (plus a bunch more to make the Iron Rods), or 5.2 constructors doing the Cast Screws alternate. And considering how many Screws are needed to make Computers, and how many Computers you need for everything Oil and Trains...
Another example is Oil to Fuel. The standard recipe turns 60/min Crude into 40/min Fuel (and 30/min Polymer Resin). You're losing 1/3 of the mass in the conversion. If you use some extra steps and some alternate recipes you can do much better. The Heavy Oil alternate recipe turns 30/min Crude into 40/min Heavy Oil Residue. This can then be used in 1 of 2 following alternates, depending on what tech you have available. You can use Packagers to create Packaged Water, and run that into a Refinery with the Heavy Oil to use the Diluted Packaged Fuel recipe, or just push the Water and Heavy Oil into the Blender for the Diluted Fuel recipe. The first uses 30/min Heavy Oil (and 60/min Packaged Water) to make 60/min Packaged Fuel (which goes into another Packager to go back to pipes). The second uses 50/min Heavy Oil (and 100/min Water) in a Blender to make 100/min Fuel. Both of the recipes double the volume you start with. This comes with the initial Heavy Oil Residue also producing an extra 10/min. Compared to the default recipe that makes you lose 1/3 of the input for what you get on the output.
Still relating to Oil, there's a pair of recipes that make the most efficient production of Plastic and Rubber. The standard recipes for Rubber and Plastic both use 30/min Crude to make 20/min Rubber or Plastic (and 10/min Heavy Oil). The Recycled Plastic and Recycled Rubber recipes both take in 30/min of the opposite resource and 30/min Fuel to make 60/min of the desired recipe. Once you initially set this up, you only need to supply the system you create with the necessary amount of Fuel -- half the outputs will feed the opposite inputs. And as we discovered previously, you can make a huge profit on Fuel using alternate recipes for extremely efficient conversion of Crude. While Rubber doesn't have as heavy of a demand, there's a *lot* of mid to late game products that require Plastic (like Circuit Boards and Computers), so making a lot of it efficiently is really beneficial.
You should not. The game gives different options and how to play is decided by the player himself. No one bothers to immediately open the necessary alternative recipes. Or build temporary factories to quickly open the milestones and only then build good factories.