Just to follow up on this one, for anyone who has a similar issue.
The powerflush seems to have done the trick!
I've been 'air' free since the job was done.
Cost a bomb though, which is a shame.
Some of the water being flushed out was very dark with corrosion particles, particularly the rad in the downstairs w.c.
The engineer also refitted the expansion leg, back to how it was previously, and also replaced the pump, and changed the expansion piping to be tee'd off a bit closer to the pump than before.
I bled the rads a few weeks later as suggested by the eng, and not even a bubble of air came out. He said he'd inhibited the system (though I didn't actually see the empty containers, so can't be sure).
Thanks to the warmer weather recently, I've not had the heating on much since, but I'm keeping my fingers crossed