I hear you frustration on the 20 state limit. I would suggest that if you are approaching the 20 state limit with a project, then it might be time to consider using code to drive the application, rather than laying everything out in static states. Now, I understand this might be beyond the reach of some users of Flash Catalyst, but you can add some basic code to read a data file (XML) and have the application be driven by that method instead. In that case, you are no longer bound by the 20 state limit. I see this all the time with people developing their portfolio sites.
One secret in using Flash Catalyst well, is to understand where is starts to breakdown, and when to extend it in Flash Builder.
Hope this helps some,