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The domestic heating landscape requires robust, high-precision thermal components. Among these, the Worcester Greenstar 28i Junior combi boiler remains a highly popular choice for household heating and domestic hot water (DHW) production in the UK and European markets. At the heart of this boiler's performance is its secondary plate heat exchanger—a critical component that isolates clean domestic water from dirty primary system water while executing rapid thermal transfers.
As a leading supplier and exporter based in China, Flotte utilizes decades of experience to manufacture premium-grade Worcester Greenstar 28i Junior plate heat exchangers. Originating from Flotte Thermal Engineering founded in 1995, and officially established as Flotte Energy Saving Company in 2013 with a registered capital of 101 million yuan, our enterprise has consistently driven progress in thermodynamic design. Our components provide seamless compatibility with original boiler specifications while offering enhanced resistance to scaling, high structural integrity, and long service life under stressful domestic operation cycles.
To provide clear value to B2B importers, distributors, and boiler repair technicians, we supply technical specifications for our Worcester Greenstar 28i Junior compatible plates. These components are built with premium materials to resist oxygenated fresh water corrosion, galvanic corrosion, and scale deposits.
| Feature Parameter | OEM Standard Match | Flotte Enhanced Specification | Operational Advantages |
|---|---|---|---|
| Base Plate Material | AISI 304 Stainless Steel | AISI 316L Stainless Steel | Enhanced resistance to pitting corrosion in hard water zones (chlorine-dense environments). |
| Brazing Material | 99.9% Copper Brazing | Vacuum-brazed 99.9% Pure Copper | High physical joints strength, preventing cross-leakage between central heating loop and domestic sanitary loop. |
| Plate Count | 12 / 16 / 18 Plates | Precision Corrugation 12 / 16 Plates | Engineered to fit the exact spatial layout of Worcester 28i Junior chassis without housing interference. |
| Maximum Working Pressure | 2.0 - 2.5 MPa | Up to 3.0 MPa (Tested to 4.5 MPa) | Safety buffer against municipal main water hammer events and pressure spikes. |
| Chevron Angle (Corrugation) | Standard Chevron | Optimized High-Theta Herringbone Angle | High turbulence generation at low flow rates, reducing lime scale attachment by up to 35%. |
| Certification Compliance | Standard CE | ISO9001, ISO14001, ISO45001, CE Mark | Guarantees complete legal and safety compliance in EU, UK, and North American markets. |
The global heating industry is shifting towards low-carbon boilers and smart home systems. Flotte's R&D department is working on a roadmap to support these changes:
As boilers convert to burn up to 20% to 100% hydrogen gas, combustion chamber temperatures shift. Our next-generation secondary heat exchangers are optimized to manage higher thermal loading cycles without degradation.
Applying hydrophobic, nano-structured polymer layers to sanitary water pathways. This technique stops mineral crystallization seeds (Calcium and Magnesium ions) from sticking to stainless steel walls.
Using ANSYS CFX and digital modeling to analyze water distribution within each channel. This helps us refine corrugation patterns, maximizing heat transfer rates while keeping pressure drop low.
Operating from a 70,000 square meter factory space, Flotte manages the manufacturing process from raw material coils to packaged, pressure-tested heating units. With more than 260 company employees and over three decades of engineering experience, our modern facility produces around 4,500 heat exchange units and components each year, generating annual sales revenue of 500 million yuan.
30+
Years Industry Experience
70k+
Land Area (Square Meters)
4.5k+
Annual Production Units
101M
Registered Capital (RMB)
Quality and consistency depend on structural management. We use a step-by-step production flow to make sure every plate heat exchanger meets high performance standards:
High-speed fiber lasers slice stainless-steel sheets with low tolerance, followed by marking for full batch traceability.
Heavy hydraulic presses stamp the corrugated chevron channels, ensuring uniform plate thickness and pattern depth.
Precision micro-forging designs connection nodes, while automated jigs stack the stainless plates and copper foils.
Brazing in high-vacuum, temperature-controlled furnaces fuses the plate structure, preventing internal bypass leaks.
Every unit undergoes hydrostatic testing at 1.5 times the maximum rated pressure to confirm weld integrity.
Applying anti-corrosion outer coats and installing protective rubber gasket pads around connection ports.
In the United Kingdom, boiler repair and component replacement are primary markets. Hard municipal water in regions like the South and East of England accelerates calcium scale build-up inside the secondary plates. Our Worcester Greenstar 28i Junior compatible plate heat exchanger acts as a drop-in replacement, restoring domestic hot water (DHW) output without requiring piping adjustments, helping technicians complete jobs quickly.
In Northern and Eastern Europe, boilers connect with sub-stations to balance pressure differences. Our plate heat exchangers manage pressure differentials up to 3.0 MPa, separating municipal primary energy grids from residential tap lines. This setup ensures stable temperatures even during high-demand mornings.
Beyond typical single-family houses, the Worcester Greenstar series supports small clinics, office kitchens, and multi-occupancy flats. For these setups, we offer 16-plate and 18-plate configurations that increase thermal exchange surfaces, maintaining water temperatures above 55°C to meet legionella control guidelines.
Variable water chemistry presents a major operational challenge. In municipal grids, fluctuations in dissolved solids and oxygen levels can accelerate corrosion. To address this, Flotte uses high-purity AISI 316L stainless steel (containing molybdenum) and specialized plate designs to maintain turbulent flow. This design helps minimize low-velocity stagnant zones where suspended particles and calcium compounds settle, reducing the rate of thermal transfer drop-off over time.
Flotte products comply with major European and global pressure vessel standards, helping to ensure straightforward customs clearance and certification compliance for importers.
We work with national standard committees to maintain safety registrations. Our thermal components hold the Safety Registration for Plate Heat Exchangers from the National Boiler and Pressure Vessel Standardization Technical Committee. We also run certified management systems:
Our raw material suppliers are verified through a strict screening process, ensuring alloy ratios match high standards. Material analysis certificates (MTR) are kept on file for all shipments.
We manage quality through clean facilities, certified raw materials, and continuous production monitoring.
"Product quality and the quality of purchased materials are linked. Therefore, the company requires our purchasing department to maintain a list of qualified, vetted suppliers and strengthen contact with each supplier to ensure incoming chemical consistency."
Our replacement heat exchangers are dimensionally matched to standard Worcester Greenstar 28i Junior combi boilers. When ordering, please confirm your boiler's GC number or part number. We configure plate width, length, and connection studs to match the original layout, allowing technicians to replace the unit without modifying the hydraulic block.
AISI 316L contains 2-3% Molybdenum, which increases resistance to pitting and crevice corrosion from dissolved chlorine and minerals found in municipal fresh water. Standard 304 can suffer localized corrosion over time in hard-water areas, which may lead to cross-contamination of domestic and central heating water.
The main causes of failure are limescale build-up (on the domestic hot water side) and magnetite sludge blockage (on the primary heating loop side). Mineral deposits block narrow pathways, reducing heat transfer and causing temperature fluctuations. Vacuum brazing and optimized herringbone angles generate turbulence, helping to wash away micro-crystallites and extend operating life.
We use a strict logistics framework. Plates are packed in heavy wood boxes with shock-absorbing foam to prevent transport deformation. Additionally, our sales team manages the paperwork to satisfy import certifications like CE and national pressure vessel standards.
Explore our full selection of modular heat exchanger units, pressure regulating stations, and specialized thermal units.
We manufacture a broad range of heavy-duty heat exchangers, concentration units, and district energy sub-stations.
Flotte Energy
