The paper compares two serrated plate-fin Heat Exchanger (HE) corrugation modelling methods using Computational Fluid Dynamics (CFD). The first method follows closely recent literature studies and models a finite length single channel of a corrugation layer inside the HE core. The second method utilises the conjugate heat transfer methodology and models a section of the HE core with both cold and hot fluid streams separated by a solid conducting wall (HE corrugation). The results of latter model are then extrapolated for the full dimensions of a HE core layer to obtain flow and heat transfer characteristics. The conjugate heat transfer analysis methodology presented is novel and eliminates the need for analytical/empirical modelling currently widely used within industry. Furthermore, it provides more detailed information about the flow and heat transfer inside the HE core enabling potential for more efficient HE designs. Predictions at the corrugation level were carried out at 88 <= Re-corrug <= 2957 with mesh independence studies completed for all the computational domains. The results obtained in the HE corrugation predictions were then implemented to the multi-scale HE unit model where the flow inside the HE core was modelled using two porous media simplifications whilst the heat transfer was simplified using the effectiveness source term. The HE unit predictions were validated against industrial experimental data with good agreement found between the numerical and experimental results. All the simulations were completed using the open-source CFD package OpenFOAM. (C) 2019 Elsevier Ltd. All rights reserved.