diff --git a/lib/utf8.js b/lib/utf8.js
index 18e8f829..8b2dcdf7 100644
--- a/lib/utf8.js
+++ b/lib/utf8.js
@@ -255,11 +255,15 @@ Utf8DecodeWorker.prototype.flush = function () {
 exports.Utf8DecodeWorker = Utf8DecodeWorker;
 
 /**
- * A worker to endcode string chunks into utf8 encoded binary chunks.
+ * A worker to encode string chunks into utf8 encoded binary chunks.
  * @constructor
  */
 function Utf8EncodeWorker() {
     GenericWorker.call(this, "utf-8 encode");
+    // Store any leftover high surrogate from the previous chunk.
+    // This handles the case where DataWorker splits a surrogate pair
+    // across chunk boundaries (since substring() operates on UTF-16 code units).
+    this.leftOver = null;
 }
 utils.inherits(Utf8EncodeWorker, GenericWorker);
 
@@ -267,9 +271,47 @@ utils.inherits(Utf8EncodeWorker, GenericWorker);
  * @see GenericWorker.processChunk
  */
 Utf8EncodeWorker.prototype.processChunk = function (chunk) {
+    var data = chunk.data;
+
+    // Prepend any leftover high surrogate from the previous chunk
+    if (this.leftOver !== null) {
+        data = this.leftOver + data;
+        this.leftOver = null;
+    }
+
+    // Check if this chunk ends with a high surrogate (0xD800-0xDBFF).
+    // If so, save it for the next chunk to ensure proper UTF-8 encoding.
+    if (data.length > 0) {
+        var lastCharCode = data.charCodeAt(data.length - 1);
+        // High surrogates have the pattern 110110xxxxxxxxxx (0xD800-0xDBFF)
+        if ((lastCharCode & 0xfc00) === 0xd800) {
+            this.leftOver = data.charAt(data.length - 1);
+            data = data.substring(0, data.length - 1);
+        }
+    }
+
     this.push({
-        data : exports.utf8encode(chunk.data),
+        data : exports.utf8encode(data),
         meta : chunk.meta
     });
 };
+
+/**
+ * @see GenericWorker.flush
+ */
+Utf8EncodeWorker.prototype.flush = function () {
+    // If there's a leftover high surrogate with no matching low surrogate,
+    // encode it anyway. In Node.js, the underlying encoder may emit a
+    // replacement character (U+FFFD); in non-Node builds, utf8encode()
+    // will emit a 3-byte UTF-8 sequence for the surrogate code unit
+    // itself (an invalid UTF-8 sequence). In both cases this is
+    // best-effort handling of malformed input.
+    if (this.leftOver !== null) {
+        this.push({
+            data : exports.utf8encode(this.leftOver),
+            meta : {}
+        });
+        this.leftOver = null;
+    }
+};
 exports.Utf8EncodeWorker = Utf8EncodeWorker;
diff --git a/test/asserts/unicode.js b/test/asserts/unicode.js
index c4dfd60a..1678befd 100644
--- a/test/asserts/unicode.js
+++ b/test/asserts/unicode.js
@@ -166,3 +166,50 @@ JSZipTestUtils.testZipFile("Zip text file and UTF-8, Pile Of Poo test", "ref/pil
         done();
     })["catch"](JSZipTestUtils.assertNoError);
 });
+
+QUnit.test("Astral characters at chunk boundary should not produce CESU-8", function(assert) {
+    // Test that surrogate pairs split across chunk boundaries are correctly
+    // encoded as 4-byte UTF-8 sequences, not as two 3-byte CESU-8 sequences.
+    // This bug occurred because DataWorker.substring() can split surrogate pairs.
+    var BLOCK_SIZE = 16 * 1024; // JSZip's internal chunk size
+    
+    // Position an astral character (U+1F600, 😀) right at the chunk boundary
+    var padding = "";
+    for (var i = 0; i < BLOCK_SIZE - 1; i++) {
+        padding += "x";
+    }
+    // U+1F600 is represented as surrogate pair \uD83D\uDE00 in JavaScript
+    var emoji = "\uD83D\uDE00";
+    var testStr = padding + emoji + "end";
+    
+    var zip = new JSZip();
+    zip.file("test.txt", testStr);
+    
+    return zip.generateAsync({type:"uint8array"})
+        .then(function(zipData) {
+            return JSZip.loadAsync(zipData);
+        })
+        .then(function(loadedZip) {
+            return loadedZip.file("test.txt").async("uint8array");
+        })
+        .then(function(bytes) {
+            // Check for CESU-8 sequences (ED xx xx pattern for surrogates)
+            var foundCesu8 = false;
+            for (var j = 0; j < bytes.length - 2; j++) {
+                if (bytes[j] === 0xED && bytes[j+1] >= 0xA0 && bytes[j+1] <= 0xBF) {
+                    foundCesu8 = true;
+                    break;
+                }
+            }
+            assert.ok(!foundCesu8, "No CESU-8 sequences should be present");
+            
+            // Also verify the content round-trips correctly
+            return JSZip.loadAsync(zip.generateAsync({type:"uint8array"}));
+        })
+        .then(function(reloadedZip) {
+            return reloadedZip.file("test.txt").async("string");
+        })
+        .then(function(content) {
+            assert.equal(content, testStr, "Content should round-trip correctly");
+        });
+});