Life on Worcester’s production line… Neil and Peter build their boilers

Peter Clayton of Oil Installer with the result of his “Build a Boiler” day at Clay Cross
A lucky installer and a representative of Oil Installer have been given a feel for life on the production line at the Worcester Bosch Group’s specialist oil boiler factory in Clay Cross, Derbyshire – both taking home a brand new appliance built on the day.

Cambridge-based installer Neil Pleasants of The Heating Company was invited to test his skills on the production line having taken top prize in the oil installation category of Worcester’s Environment 2020 Awards for his year-long transformation of a farmhouse heating system in Cambridgeshire. He was accompanied by Peter Clayton, deputy editor of Oil Installer.

Neil and Peter were both given a full tour of the factory’s press shop, paint shop and weld area, before being put to work on the oil boiler track where the manufacturer’s Which? Best Buy award winning boilers are made.

After assisting in the construction and welding of the primary heat exchanger and the secondary condensing heat exchanger, the two “apprentices” were put to work tightening their individual boiler’s burner flange, fitting the condensate trap, and securing the side panels and burner. Then it was over to testing to ensure that their Greenstar Danesmoor condensing boilers passed Worcester’s rigorous standards before being packaged ready to be installed.

Farmhouse project

The project for which Neil won his Build a Boiler experience was far from being a typical domestic installation. He was approached by the owners of an extended farmhouse in Cambridgeshire who wanted to transform their property from a four bedroom house into a five bedroom property with adjoining eight bedroom bed and breakfast accommodation.

Neil and his team took into account the planned hot water demand of the property’s new layout and decided to fit a floor-standing Greenstar Utility 50/70 oil-fired boiler with a 300l Greenstore unvented cylinder in a brand new plant room. With the added benefit of a Greenskies Solar-Lux 6 mounted on the property’s roof, underfloor heating throughout, and zoned control, the system’s performance is kept as efficient as possible.

“The project was certainly one of the most interesting installations I’ve been tasked with, and it was great to be given completely free reign by the owners of the property right from the start.

“Having only fitted Worcester boilers for the last five years, I knew straight away that the Greenstar Utility boiler was perfectly suited,” said Neil.

“The owners of the house couldn’t be happier with their new system and we’re sure the paying customers who stay in their new bed and breakfast will agree!”

Commenting on his Build a Boiler Day experience, Neil added: “My company’s work split has gone from being around 30% oil to more like 60%, so it was fantastic to get a feel for what goes into the boilers before we get our hands on them. We’re hoping to give the boiler itself away to one of our elderly customers this winter, so I’m sure it will be very much appreciated once we’ve found an installation that it is suited to.”


Peter also donated his completed boiler for Neil to install for one of his elderly customers. He commented: “Neil and I both thoroughly enjoyed our day at Clay Cross. I have been writing about Worcester oil boilers for a long time, so it was particularly interesting for me to see exactly how they are made and how each boiler is, in effect, hand-crafted to ensure the quality which has earned Worcester its enviable reputation.”

Jon Watson, plant director at Worcester’s Clay Cross factory, commented: “We’re extremely proud of the boilers we make, and with our entire range of Greenstar oil boilers having recently received a Which? Best Buy award for the very first time, this was a great opportunity to show off all the hard work that goes on behind the scenes.”