AstraZeneca Manufacturing Insurance (UK): A Practical Guide for Pharmaceutical Manufacturing Busines

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AstraZeneca Manufacturing Insurance (UK): A Practical Guide for Pharmaceutical Manufacturing Busines

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AstraZeneca Manufacturing Insurance (UK): A Practical Guide for Pharmaceutical Manufacturing Businesses
When someone searches for “AstraZeneca manufacturing insurance”, they’re usually trying to understand what kind of insurance a large, complex pharmaceutical manufacturing operation needs to protect its sites, people, products, data and reputation.
The important point: the insurance programme for a global brand will be bespoke and often multi-layered, but the underlying risks and cover types are highly relevant to pharmaceutical manufacturing businesses of all sizes, including large firms like AstraZeneca.
This guide breaks down the core covers pharmaceutical manufacturers typically consider in the UK, the real-world risks that drive claims (without being alarmist), how underwriting works, common exclusions and gaps to watch for, what affects cost, and a practical risk management checklist you can use before renewal.
Important note: This article is educational. It does not imply that Insure24 insures AstraZeneca or any specific company. Insure24 arranges cover for pharmaceutical manufacturing businesses and related life sciences operations in the UK, subject to insurer appetite, underwriting information and terms.
Why pharmaceutical manufacturing insurance is different
Pharmaceutical manufacturing is not “standard manufacturing with a lab attached”. It combines high-value assets, strict quality requirements, and heavy regulatory oversight. A single incident can trigger multiple loss types at once, such as:
  • Physical damage to buildings, cleanrooms, utilities or specialist equipment
  • Business interruption from downtime, re-validation and delayed batch release
  • Liability exposures involving employees, contractors, visitors and products
  • Regulatory and compliance knock-on costs (documentation, investigations, corrective actions)
  • Cyber disruption affecting both IT and operational technology (OT)
In other words, the financial impact is often less about the initial incident and more about the time and complexity required to return to compliant production. That’s why pharmaceutical manufacturing insurance tends to be detail-driven: definitions, triggers, sub-limits and exclusions matter.
Core covers pharmaceutical manufacturers typically need (UK)
Your exact requirements depend on what you do (API vs finished dose, sterile vs non-sterile, biologics, cold chain reliance, contract manufacturing, export profile, clinical trials involvement, etc.). But the covers below are commonly considered.
  1. Property insurance (buildings, contents, plant and stock)
Property insurance covers physical loss or damage to insured property, typically buildings, contents, plant and machinery, and often stock.
For pharma, the “hidden value” is often in specialist infrastructure: cleanrooms, HVAC, compressed air, purified water systems, electrical resilience, and controlled storage. You’ll want sums insured that reflect real rebuild and replacement costs, not just book values.
Key points to get right:
  • Accurate declared values (including professional fees, debris removal, inflation)
  • Stock valuation basis (raw materials, work-in-progress, finished goods)
  • How temperature-sensitive stock is treated (spoilage/temperature excursion wording)
  • Off-site storage and third-party logistics locations
  • Utilities dependency and any relevant extensions
  1. Business interruption (BI)
BI protects gross profit (or revenue) when an insured event causes downtime. In pharma, recovery can take longer than expected because you may need cleaning, investigation, re-validation, re-qualification and QA release before you can ship product again.
BI is often where the biggest losses sit, so focus on:
  • Indemnity period (12 months may be too short for some operations)
  • Waiting periods (time excess)
  • Supplier/customer dependency extensions
  • Claims preparation costs and increased cost of working
  • How “gross profit” is defined for your business model
  1. Employers’ liability (EL) and public liability (PL)
EL is legally required in most UK cases if you employ staff. It responds to claims from employees who suffer injury or illness arising out of their work.
PL covers third-party injury or property damage arising from your premises or operations (visitors, contractors, delivery drivers, etc.).
Pharma-relevant exposures include:
  • COSHH and hazardous substance handling
  • Contractor management during shutdowns and maintenance
  • Manual handling and repetitive strain in production/warehouse roles
  • Vehicle movements, forklift segregation, site access controls
  1. Product liability
Product liability covers claims alleging injury or property damage caused by your products. For pharmaceutical manufacturers, this can involve complex supply chains, strict quality expectations, and potentially worldwide jurisdiction depending on where products end up.
Underwriters will look closely at:
  • Your role (manufacturer, contract manufacturer, packager, API supplier)
  • Traceability and batch records
  • Complaint handling and pharmacovigilance processes (where relevant)
  • Export territories and jurisdiction (USA/Canada often treated differently)
  • Contractual indemnities you’ve agreed to
  1. Product contamination cover
Some businesses look for specialist product contamination cover (sometimes linked with recall). This is designed to respond to certain contamination events and associated costs, subject to strict triggers and definitions.
The key is to align the policy trigger with your reality: suspected contamination, precautionary withdrawal, and QA-driven quarantine decisions may not always be covered unless specifically included.
  1. Product recall insurance
Product recall cover can help with the costs of recalling products, such as notification, logistics, disposal, and sometimes associated loss of gross profit (depending on wording).
In pharma, recall can be triggered by issues like labelling errors, stability concerns, temperature excursions, packaging faults, or regulatory action requiring withdrawal or quarantine. The policy detail matters: what counts as a “recall”, what triggers it, and what costs are included.
  1. Clinical trials insurance
If you sponsor, manage, or participate in clinical trials, you may need clinical trials liability to address participant injury claims and associated legal costs. Requirements vary by trial phase, geography, protocol, and contractual arrangements with CROs and trial sites.
Even if you’re not the sponsor, contracts may require evidence of cover or specific indemnities.
  1. Directors’ and officers’ (D&O)
D&O protects directors and officers against claims alleging wrongful acts in the management of the company. In regulated sectors, D&O can be relevant due to:
  • Regulatory investigations and governance scrutiny
  • Employment practices allegations
  • Stakeholder disputes and contractual claims
  • Financial reporting and disclosure issues
  1. Cyber insurance
Pharmaceutical manufacturers face cyber risk across IT and OT. Cyber insurance can help with costs and liabilities arising from incidents like ransomware, data breaches, and business interruption.
Underwriters typically want to understand:
  • MFA, backups, patching cadence, endpoint protection
  • Network segmentation between IT and OT
  • Incident response plan and testing
  • Third-party access controls and vendor risk management
  • Ability to restore operations safely (not just “turn systems back on”)
  1. Environmental impairment liability (pollution liability)
Standard liability policies often have pollution exclusions. Environmental impairment liability can cover clean-up costs and third-party claims from pollution incidents, subject to terms.
Relevant exposures include chemical storage, solvents, effluent, waste handling, and accidental releases. Insurers will look at bunding, permits, spill response, and waste contractor controls.
  1. Marine cargo / goods in transit
If you move raw materials, intermediates or finished products, goods in transit cover can be essential, especially with cold chain requirements and high-value shipments.
Key points:
  • Temperature control requirements and monitoring evidence
  • Incoterms and who is responsible for insurance at each stage
  • Security protocols for theft-attractive goods
  • Claims documentation expectations (data loggers, chain of custody)
  1. Engineering breakdown (machinery breakdown) and engineering BI
Engineering breakdown can cover sudden and unforeseen mechanical or electrical breakdown of insured plant and equipment. In pharma, this might include autoclaves, chillers, compressors, boilers, HVAC, packaging lines, and critical utilities.
Engineering BI can be important if a breakdown causes downtime but doesn’t involve a traditional “insured peril” under the property policy.
  1. Terrorism insurance
Depending on location, asset profile, and lender/landlord requirements, terrorism cover may be considered. In the UK it’s often arranged separately from standard property policies. Whether it’s appropriate depends on your circumstances and stakeholder expectations.
Key risks for pharmaceutical manufacturing businesses (including large firms like AstraZeneca)
GMP compliance and quality system failures
GMP is foundational. Deviations, CAPAs, batch rejections and rework can be costly even when there’s no dramatic event like a fire. Underwriters will look at your QMS maturity, training, change control, deviation trends, and supplier qualification.
MHRA scrutiny and regulatory action
Insurance doesn’t typically cover “non-compliance” as a standalone issue, but regulatory action can influence the length and cost of recovery after an insured event. Strong documentation and audit trails can materially affect outcomes.
Cold chain and temperature excursions
Chiller failures, power interruptions, door management, transport delays and handling errors can cause excursions. Whether insurance responds depends on wording and evidence (calibrated monitoring, SOPs, response logs).
Contamination and cross-contamination
Contamination events are operationally complex: investigation, cleaning, environmental monitoring, re-validation, and sometimes recall decisions. Underwriters will focus on segregation, line clearance, cleaning validation, environmental monitoring and controls.
Supply chain disruption
Single-source APIs, specialist packaging components, and long lead times for critical parts can stop production even if your site is fine. Supplier dependency BI may be relevant, but it must be structured around accurate supplier mapping.
Utilities dependency and critical infrastructure
Power quality, water supply, steam, compressed air and HVAC stability can be “make or break”. Many losses are operational failures that cascade into downtime. Redundancy, maintenance and tested contingency plans matter.
IP and data risks
Formulations, process know-how, stability data, supplier terms and customer contracts can be highly valuable. Cyber incidents and insider risks can expose IP. Insurance can help with response, but controls reduce likelihood and severity.
How underwriting works for pharmaceutical manufacturing insurance
Underwriters price and structure cover based on what you do, how you do it, and how resilient you are. Expect questions across:
  1. Operations and products
  • What you manufacture (API, finished dose, sterile, biologics, etc.)
  • Batch sizes, throughput, critical path
  • Contract manufacturing vs own-brand
  • Territories and end markets
  1. Quality and compliance
  • GMP status and inspection history
  • Deviation/CAPA processes and trends
  • Traceability and batch record controls
  • Supplier qualification and incoming QC
  1. Property risk and resilience
  • Construction, fire protection, compartmentation
  • Sprinklers, detection, hot works controls
  • Maintenance regimes and engineering surveys
  • Utilities redundancy and critical spares strategy
  1. Business interruption exposure
  • Gross profit and dependency mapping
  • Realistic recovery times and bottlenecks
  • Alternate manufacturing options and stock buffers
  • Lead times for equipment and validation
  1. Cyber posture
  • MFA, backups, patching, segmentation
  • Incident response readiness and testing
  • Third-party access and vendor governance
A practical way to improve terms is to present a clear “risk story”: what you do, what could go wrong, what you’ve done to reduce likelihood, and how you’d recover.
Common exclusions and coverage gaps to watch for
Every policy differs, but common gap areas include:
  • Contamination and recall triggers: some covers require proven contamination or a defined “product safety” trigger; precautionary withdrawals may not be covered.
  • Temperature excursion/spoilage: may need specific extensions and may require strict evidence (calibrated logs, documented response).
  • Gradual deterioration and maintenance issues: wear and tear, corrosion and poor maintenance are commonly excluded.
  • Cyber exclusions on property/BI: many property policies restrict losses “caused by” cyber events; align property BI and cyber BI so you’re not left exposed.
  • Contractual liability: broad indemnities in contracts may not be automatically covered.
  • Fines and penalties: generally not covered and often not insurable.
  • Product efficacy vs safety: “it didn’t work as intended” or pure financial loss may fall outside product liability.
  • Territory/jurisdiction limits: USA/Canada may be excluded unless specifically included.
  • Pollution: standard policies may exclude it, requiring specialist environmental cover.
  • Communicable disease BI: many policies have exclusions or narrow triggers.
What does pharmaceutical manufacturing insurance cost in the UK? (Cost drivers)
There’s no single premium benchmark. Cost is driven by your exposure profile, limits, sums insured, and insurer appetite. Key drivers include:
  • Complexity of manufacturing (sterile, biologics, high-containment)
  • Turnover, gross profit and BI exposure (and indemnity period length)
  • Asset values (cleanrooms, specialist utilities, high-value equipment)
  • Stock values and temperature sensitivity
  • Fire protection and site resilience (sprinklers, compartmentation, housekeeping)
  • Quality system maturity and inspection outcomes
  • Product and recall exposure (territories, traceability, end-use)
  • Cyber controls and OT/IT separation
  • Claims history and evidence of improvements
Practical tip: renewal outcomes often improve when you provide a concise underwriting pack with site details, fire protection, QA overview, BI exposure, cyber controls, and a clear narrative of improvements.
Risk management checklist (insurer-friendly)
You don’t need perfection. You need consistent controls and evidence. Use this as a practical checklist:
Property and fire
  • Declared values reviewed and updated (buildings, plant, stock)
  • Sprinklers/detection tested; impairment management in place
  • Hot works permits and contractor controls
  • Compartmentation and fire stopping checked after projects
  • Water leak detection where appropriate; isolation valves identified
  • Housekeeping standards and combustible waste controls
Utilities and engineering resilience
  • Preventive maintenance schedules for chillers, boilers, compressors, HVAC
  • Condition monitoring where appropriate (thermography, vibration)
  • Redundancy for critical utilities (N+1 where feasible)
  • Documented response plans for power loss and temperature excursions
  • Critical spares strategy for long lead-time components
GMP, quality and contamination control
  • Clear deviation management and CAPA discipline
  • Robust change control and validation approach
  • Cleaning validation and line clearance controls
  • Environmental monitoring and trending
  • Supplier qualification, audits and incoming QC
  • Mock recall capability and traceability testing
Supply chain and logistics
  • Supplier dependency mapping (single points of failure identified)
  • Alternative suppliers assessed where feasible
  • Cold chain SOPs for storage and transit
  • Data logger use and chain-of-custody documentation
  • Contract clarity on Incoterms and responsibilities
Cyber and data
  • MFA enforced, especially for remote access and admin accounts
  • Backups tested and segregated; recovery time objectives understood
  • Network segmentation between IT and OT
  • Patch management and vulnerability management routines
  • Incident response plan and tabletop exercises
  • Vendor access controls and monitoring
Business continuity
  • Realistic BI scenario planning (not just generic templates)
  • Recovery timelines that include re-validation and QA release steps
  • Communication plans for customers, regulators and stakeholders
  • Documented decision-making process during incidents
FAQs: AstraZeneca manufacturing insurance (UK) and pharma insurance generally
  1. Do I need “AstraZeneca manufacturing insurance” specifically?
    No. The phrase is usually shorthand for a robust pharmaceutical manufacturing insurance programme. The right solution is based on your operations, not a brand name.
  2. Is Employers’ Liability always required?
    In most UK cases, yes if you employ staff. There are limited exemptions, but most operating manufacturers will need EL.
  3. What’s the difference between property BI and cyber BI?
    Property BI usually follows physical damage from an insured peril. Cyber BI responds to disruption caused by a cyber event. Many property policies restrict cyber-related losses, so alignment matters.
  4. Will insurance cover a temperature excursion?
    Sometimes, but it depends on policy wording and evidence. Some covers require an insured peril; others provide specific spoilage/temperature extensions with sub-limits and conditions.
  5. Does product liability cover a recall?
    Not automatically. Recall is often separate. Product liability is typically about injury or damage; recall covers the costs of withdrawing product and related expenses.
  6. Do we need clinical trials insurance if we’re only manufacturing?
    Not always, but it depends on your role and contracts. If you sponsor, manage, or have trial-related responsibilities, you may need it.
  7. Are regulatory fines covered?
    Generally no. Some policies may cover certain defence costs, but fines and penalties are typically excluded and may be uninsurable.
  8. What information will insurers ask for at renewal?
    Operations summary, site details, declared values, fire protection, QA/QMS overview, BI exposure and dependencies, cyber controls, and loss history.
  9. How do insurers assess GMP and MHRA risk?
    They look for evidence of mature systems: deviation/CAPA discipline, change control, training, supplier management, audit outcomes, and documentation quality.
  10. We export. Do we need worldwide cover?
    Possibly. Territory and jurisdiction clauses must match where your products go and where claims could be brought. USA/Canada often need specific inclusion.
  11. What’s “engineering breakdown” and why does it matter?
    It covers sudden mechanical/electrical breakdown of equipment. In pharma, breakdowns can cause long downtime and expensive recovery steps.
  12. Can we insure supply chain disruption?
    Sometimes via contingent business interruption (supplier/customer dependency). It needs careful structuring and accurate dependency mapping.
CTA: Talk to Insure24 about pharmaceutical manufacturing insurance
If you’re a UK pharmaceutical manufacturer (or a related life sciences business) and you want a practical, well-structured insurance programme that reflects GMP realities, MHRA expectations, and the true cost of downtime, we can help you map the risks and place cover that fits.
Call Insure24 on 0330 127 2333
Visit: https://www.insure24.co.uk/
Tell us what you manufacture, where you trade, and what your biggest operational bottlenecks are (utilities, cleanrooms, cold chain, single-source suppliers, validation timelines). We’ll help you build a clear insurance brief for insurers and aim for terms that make sense for your business.

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