How to Reduce Electrical Manufacturing Insurance Premiums

Quick Wins: 10 Ways Manufacturers Often Reduce Premiums Fast

If you want immediate impact, focus on the factors insurers can verify quickly. These typically produce faster underwriting decisions and can improve terms at renewal and mid-term.

1) Reduce Property & Fire Risk (The Biggest Driver for Many Premiums)

For manufacturers, the largest potential losses are often property and business interruption. Electrical manufacturing sites can include significant fire load: packaging, plastics, resins, solvents, stored components, and waste streams. A small ignition can grow rapidly if housekeeping and storage discipline are weak.

What underwriters want to see

• Fire detection and alarm: appropriate alarm system, regular testing, and ideally monitoring where suitable.
• Good separation: keep combustible storage away from heat sources; separate waste areas and charging zones.
• Storage controls: tidy racking, protected aisles, no stock against heaters/electrics, limited high stacking.
• Flammables management: store solvents/cleaners in suitable cabinets; clear COSHH/SDS controls.
• Electrical safety: PAT testing regime where relevant, fixed wiring checks, competent maintenance.
• Hot works discipline: permit system, fire watch, and contractor controls when hot works are unavoidable.

Battery and charging risks

If you handle lithium-ion batteries (or store battery waste/returns), insurers may apply extra scrutiny. The goal is to show you have a safe storage and charging approach: separation, monitoring, and a clear incident response process.

Waste storage

Waste areas are one of the most common sources of risk deterioration. If your waste builds up, is stored internally, or contains flammable materials, insurers will likely price for it. Simple improvements like more frequent collections and separating waste streams can help.

Practical point: take photos of improved housekeeping and storage layouts. Underwriters respond well to visual evidence that risk controls are real and maintained.

2) Fix Business Interruption Underinsurance (And Stop Paying for the Wrong Cover)

It sounds counterintuitive, but correcting business interruption (BI) figures can reduce premiums — because many businesses are paying for BI cover that doesn’t match their real exposure (or they’re underinsured and insurers apply cautious pricing).

Two numbers that matter

• Gross profit sum insured – used to calculate claim payments.
• Indemnity period – maximum time the policy pays after an insured event.

If you are clearly over-insured on gross profit, correcting it can reduce premium immediately. If you are underinsured, the insurer may still price cautiously (and you risk reduced claim payments via average). The best outcome is a defensible figure based on accounts and a realistic indemnity period based on machinery lead times and restart requirements.

Pro tip for manufacturers

BI costs are often driven by how quickly you can restart production. Underwriters respond well when you can demonstrate: spare capacity, alternative suppliers, the ability to outsource certain processes, and a tested continuity plan. These reduce the likelihood of long-duration BI claims.

3) Machinery Breakdown: Reduce Frequency, Not Just Premium

Breakdown risk is a major cost driver because it creates “hidden” losses: repair bills, scrap, late deliveries, and expedited logistics. Even if a breakdown policy is reasonably priced, frequent failures can push premiums up across the programme and damage insurer confidence.

Underwriter-friendly controls

• Planned preventative maintenance on critical machines (with logs available).
• Calibration and test rig controls – evidence that faults will be detected before shipment.
• Condition monitoring where appropriate (vibration/thermal checks on high-value equipment).
• Spares strategy for long lead parts (drives, PLCs, motors, critical sensors).
• Utilities resilience – compressors, chillers, extraction, power stability; single-point-of-failure plans.

If you want to reduce premiums, the best approach is to demonstrate fewer breakdown events and faster recovery times. This can also support better terms for “loss of profits following breakdown” where you need it.

4) Reduce Liability Premiums With Quality, Traceability & Contract Clarity

Electrical components are often embedded into other products and systems. The potential exposure from a defect is not simply the component’s unit cost — it’s the downstream impact: line stoppage, warranty campaigns, system failures, and in some cases property damage or safety issues.

What insurers price in product risk

• End-use sectors (automotive/aerospace/rail tends to be more heavily underwritten than general industrial).
• Territory (including whether USA/Canada is involved).
• Batch exposure (high volume shipments create recall scale risk).
• Quality controls (test regime, sampling approach, calibration, audit trails).
• Traceability (can you identify affected lots quickly and limit recall scope?).

How to reduce premium without reducing protection

The best route is evidence. Insurers often improve terms when you can show:

• Lot tracking and batch traceability across raw materials, WIP and finished goods.
• Documented change control for materials, tooling, software/firmware and processes.
• CAPA and root cause analysis (how you respond to defects and prevent recurrence).
• Supplier management and incoming inspection discipline.
• Contract review to avoid accepting “unlimited” liability or unrealistic penalty terms.

If you’ve had a claim or near miss, underwriters want to hear what changed. A short “lessons learned” summary can materially help pricing.

5) Cyber & OT: Reduce Premiums With Security Hygiene (Not Buzzwords)

Manufacturers increasingly rely on networked production equipment, ERP/MRP systems, CAD/CAM data, and customer portals. Ransomware is not just a data event — it’s a downtime event. Cyber premiums and underwriting have tightened, but many manufacturers can still reduce cost by meeting baseline controls.

Controls that often improve terms

• MFA everywhere (email, VPN, remote access, admin accounts).
• Offline / immutable backups tested regularly (with restore evidence).
• Patch management and removal of end-of-life systems where possible.
• Network segmentation between office IT and production OT where appropriate.
• Least privilege and strong password policies for privileged users.
• Incident response plan (who does what, and who you call).

Even if you don’t buy standalone cyber, these controls can improve overall insurer confidence because they reduce the likelihood of a catastrophic BI scenario caused by IT/OT disruption.

6) Environmental & Waste Risk: Prevent Expensive Claims (And Underwriter Concern)

Pollution incidents and waste disposal disputes can be expensive because they trigger specialist clean-up, regulatory involvement, and potentially third-party claims. Even where you don’t need standalone environmental cover, improving controls can reduce insurer caution and help premium stability.

Controls that insurers like

• Bunded storage and secondary containment for liquids.
• Spill response kit, drain covers and training for supervisors.
• Waste contractor checks and a tidy record trail (transfer/consignment notes).
• Segregation and labelling to prevent incompatible waste mixing.
• Housekeeping in waste areas with clear collection frequency.

This is another area where photos and short documented procedures help underwriting. The easiest way to get a “yes” from an underwriter is to remove doubt that a small leak will become a big problem.

7) Smarter Programme Design: Excess, Limits & Wording (The Safe Levers)

The safest ways to reduce premiums are adjustments that reduce insurer frequency exposure while keeping catastrophic protection intact. Typical levers include:

Increase the excess where it makes financial sense

If you can comfortably absorb smaller losses, a higher excess can reduce premium. The key is to choose a level that is realistic and aligned with cashflow, not so high that you avoid reporting losses and create problems later.

Right-size limits based on contracts and exposure

Many businesses carry “standard” limits that are either too high (wasting premium) or too low (creating contract breach risk). We help align limits to what your customers require and what your business can realistically be exposed to.

Remove overlaps and fix gaps

Overlapping covers can create unnecessary cost. Gaps create claim disputes. A good broker review can often reduce premium by consolidating policies, removing redundant add-ons, and ensuring the remaining cover is coherent.

The objective is not “cheapest at any cost”. It’s “best value with predictable claim response”.

What NOT to Do When Trying to Reduce Premiums

Some “savings” create bigger costs later. Here are common mistakes we help manufacturers avoid:

• Cutting BI or reducing the indemnity period without understanding machinery lead times and restart timelines.
• Undeclaring territory (especially USA/Canada exposure) to get a cheaper products liability premium.
• Accepting contract clauses that push liability beyond what your policy covers.
• Underinsuring stock/WIP to reduce property premium (average clause risk is real).
• Ignoring maintenance to “save money” and then paying more through claims and higher premiums.
• Not reporting incidents or near misses; insurers often find out later and confidence drops.

A sensible premium reduction plan is always paired with a coverage review, so you keep the protections that matter.

Why Insure24 Helps Reduce Premiums (Not Just Find a Price)

How to Reduce Your Premium in Practice (Our Simple Process)

If you want measurable premium improvements, we take a structured approach that underwriters recognise. The goal is a stronger risk presentation, clearer numbers, and a programme that’s easier to insure.