As for flow I don't think it has anything to do with tank volume. All the screen knows is what growing conditions it has in front of it, and it does not care what occurs elsewhere. If stronger flow helps it's because its delivering more nutrients in relation to illumination and the ability of growth to stay attached.
I absolutely believe it does matter. Take this example.
Tank volume, 120 gallons
Previous scrubber, 20" long x 7 " tall. Flow 20x35=700 GPH. 700/120 = 5.8 tank turns/hour.
Current scrubber: 6" long x 4" tall. Flow 6x35=210 GPH. 210/120 = 1.75 tank turn/hour.
That is less than 1/3 of the overall flow rate. The result is that before, there was zero algae in the display. Currently, there are some clumps and pockets of algae growth. Not enough to cause any kind of issues, but it is a noticeable change. The majority of the algae is growing near the surface, on the loc-line plenum, not on the rocks. There is cyano present on some rocks and in some areas of the sand bed, where before there was not.
Feeding stayed the same (type and quantity), as did lighting. N=0 and P=0.02 which is actually lower than it was with the larger scrubber.
I have queried many users and found that situations are similar when the scrubber is sized appropriately for feeding on a large volume tank.
The conclusion I have come to is that there is an upper limit to the feeding based guideline. So if you feed 2 cubes/day, and you have a 4x6 screen, this will do you well as stand-alone filtration for a tank up to about 100 gallons, more if you have a skimmer running as well (120, maybe 150). After that, you need to increase the size of the screen (and flow/lighting, etc) regardless of what you feed in order to keep algae at bay.
Go the the extreme. 2 cubes/day feeding. 40 gallon vs 400 gallon. 200GPH scrubber flow. On the 40g, 5x turnover. on the 400, 0.5x turnover.
Now granted this is simplifying things, because the full tank volume isn't going in and out, there is mixing, etc etc. But the point is that algae is opportunistic, and if the environment allows it, it will grow. The point of the algae scrubber is to take away that environment. IMO there is a fine line where nutrients, regardless of how low they are kept over a long term basis, remain in the water column long enough on a consistent enough basis that algae can survive in the display tank.
The reduction in the screen size, while it does make sense, IMO has presented unintended consequences. They are easy enough to remedy, i.e. make the screen a little bigger.
There may be other factors at work as well, I will admit that - I can't account for everything. But that's what research is for. Still waiting for that grant so I can quit my job and study this stuff full time.