Hi there,
I've had 7 of these things running in the past, and for some reason there does seem to be a massive noise difference between the load ones and the quiet ones! Fortunately for us, the ones in the bedrooms seem to be dead quiet, the one that kicks off all the noise is the one in the bathroom.
There does seem to be a connection between the size of the radiator and the noise output - how big is the radiator you're controlling?
Of course that could be coincidence, and it could just be a manufacturing issue - I'm tempted to open one of these things up one day and see what's going on inside, in case it's a simple case of applying some grease?
Russ