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| LDL > SEC Filings for LDL > Form 10-K on 12-Mar-2009 | All Recent SEC Filings |
12-Mar-2009
Annual Report
CAUTIONARY NOTE CONCERNING FACTORS THAT MAY AFFECT FUTURE RESULTS
This report contains forward-looking statements within the meaning of
Section 21E of the Securities Exchange Act of 1934, as amended. In general, any
statements contained in this report that are not statements of historical fact
may be deemed to be forward-looking statements within the meaning of
Section 21E. Investors should be aware that such forward-looking statements are
intended to provide management's current expectations for the future operating
and financial performance of the Company based on assumptions believed to be
valid at the time. All forward-looking statements involve risks and
uncertainties that are difficult to predict. In particular, any statement
contained in this Annual Report on Form 10-K, in press releases, written
statements or other documents filed with the Securities and Exchange Commission,
or in the Company's communications and discussions with investors and analysts
in the normal course of business through meetings, phone calls and conference
calls are subject to known and unknown risks, uncertainties and contingencies,
many of which are beyond the control of the Company. Without limiting the
generality of the foregoing, the words "believes," "anticipates," "may,"
"plans," "projects," "expects," "estimates," "forecasts," "targets," and other
similar expressions are intended to identify forward-looking statements in
connection with the discussion of future operating or financial performance.
These include, among others, statements relating to:
• Overall economic and business conditions
• Future earnings and other measurements of financial performance
• Future cash flow and uses of cash
• Competitive factors in the industries and geographic markets in which the Company competes or may compete
• Significant changes in the North American or European automotive markets
• The cost and availability of raw materials and energy
• Product development and new business opportunities
• Benefits realized from savings and operating efficiency improvements as a result of Lean Six Sigma and operational excellence initiatives
• Estimates of restructuring costs and future savings to the Company
• Future amounts of stock-based compensation expense
• Pension plan assumptions and future expense and funding requirements
• Future levels of indebtedness and capital spending
• Future effective income tax rates
• The outcome of contingencies
• Future repurchases of the Company's common stock
• Benefits expected to be realized from recent acquisitions
• Future strategic acquisitions, joint ventures, alliances and licensing agreements
All forward-looking statements are inherently subject to a number of risks and uncertainties that could cause the actual results of the Company to differ materially from those reflected in forward-looking statements. See Item 1A. Risk Factors for a number of factors, including, but not limited to those described therein, any one of which could cause Lydall's actual results to vary materially from recent results or from the Company's anticipated future results.
Lydall does not undertake to update any forward-looking statement made in this report or that may from time to time be made by or on behalf of the Company.
OVERVIEW AND OUTLOOK
Lydall, Inc. has been incorporated in Delaware since 1987 after originally being incorporated in Connecticut in 1969. The Company's principal executive offices are located in Manchester, Connecticut. The Company's subsidiaries design and manufacture specialty engineered filtration media, industrial thermal insulating solutions, automotive thermal and acoustical barriers, temperature-control equipment, medical filtration media and devices and biopharmaceutical processing components for demanding thermal/acoustical, filtration/separation and biopharmaceutical applications.
Business Environment Overview
As many of Lydall's operations conduct business on a worldwide basis, Lydall's 2008 financial results were impacted by significant global, regional and industry economic downturns. Lydall has experienced continued pressure on revenues associated with the economic downturn, particularly in the automotive industry. As automotive production and production capacity have been and continue to be reduced, Lydall has seen a decline in demand for the Company's automotive products. Disruptions in financial markets and recent restrictions on liquidity are adversely impacting the availability and cost of incremental credit, thereby adversely affecting the global economy and consumer spending patterns that impact the Company's business. Lydall has been further impacted by foreign currency translation fluctuations. Lydall expects weaker demand with respect to the automotive industry as well as with other markets in which the Company operates to persist in 2009, affecting the Company's revenues and profitability. Given the nature of the global economic downturn and its effects on the markets in which the Company operates, Lydall is unable to predict the likely duration and severity of the current disruptions in the credit and financial markets and adverse global economic conditions.
While global economic conditions negatively impacted the Company's financial results in 2008, the Company took many actions during the year, including the following:
• Initiating and subsequently accelerating the restructuring actions related to the consolidation of the North American automotive businesses, which is expected to save the Company approximately $3.5 million to $4.0 million on an annualized basis;
• Company-wide discretionary cost and workforce reductions. Lydall's global workforce was reduced by approximately 15% in 2008;
• Continuing to focus on executing growth strategies and investing in critical product offerings and technologies; including the commercialization of the membrane technology acquired in the DSM Solutech B.V. acquisition and growing the Company's vital fluids bioprocessing life science business;
• Continuing to focus on Lean Six Sigma and operational excellence initiatives in order to reduce costs and leverage synergies across the Company; and
• Exploring its core markets for suitable strategic acquisitions, joint ventures, alliances and licensing agreements to supplement growth, as well as divesting its Transport business that was not consistent with the Company's strategy.
The Company currently receives approximately 38% of its revenue from its foreign operations denominated in Euros. Therefore, Lydall's reported results of operations and financial condition are subject to changes in the exchange relationship between the U.S. dollar and the Euro. The Company's foreign and domestic operations limit foreign currency exchange transaction risk by completing transactions in functional currencies whenever practical or through the use of foreign currency forward exchange contracts when deemed appropriate. If the Company is not able to successfully hedge its currency exposure, changes in the rate of exchange between foreign currencies and the U.S. dollar may materially impact the Company's results of operations and cash flow.
During the majority of 2008, the Company was negatively impacted by increased raw material commodity pricing and energy costs. Specifically, costs of aluminum, used in most of the Company's heat-shield automotive products, and costs of various fibers, used in a number of the Company's automotive and performance materials products, were volatile in 2008. The Company continues to focus its efforts on mitigating the impact of higher raw material and energy costs to the extent possible through cost savings and operational efficiency gains, as well as passing commodity and energy cost increases to the Company's customers. Further significant increases in raw material commodity and/or energy prices could continue to negatively impact the Company, to the extent the Company is not able to mitigate the cost increases through operational efficiency gains or increased prices.
Operational Matters
Performance Materials Segment
Lydall's filtration and industrial thermal insulation businesses, included in the Performance Materials Segment, are in markets that the Company believes present growth opportunities for Lydall. The Company expects the businesses to grow over the long term, primarily through the introduction of new products, expansion of share in existing markets and penetration of new markets. The Company continually explores its core markets for suitable strategic acquisitions, joint ventures, alliances and licensing agreements to supplement growth. For example, the acquisition of DSM Solutech B.V. in December 2008 allows the Company to manufacture micro-porous films (trade names Solupor® and Solufill®) using proprietary technology. Lydall Solupor® specialty
microporous membranes are utilized in various markets and applications including batteries, fuel cells and supercapacitors, air and liquid filtration, and transdermal drug delivery.
The Company continues to work with customers to deliver value-added products for their specific needs to differentiate its products from competitors. Through the nine months ended September 30, 2008, net sales and operating income from the Company's Performance Materials segment exceeded the comparable period of 2007 by approximately 6% and 13%, respectively, when excluding the impact of foreign currency translation. During the fourth quarter of 2008, the Company's filtration and industrial thermal insulation businesses were impacted by global economic conditions. Specifically, many of the Company's filtration media customers adjusted downward their production schedules and implemented or extended shut-down periods. This was done to reduce their current levels of inventory to better match their expected turnover rates in 2009. In addition, the Company's industrial thermal insulation business continued to be negatively impacted by the slow-down in the construction of new home and commercial buildings markets in the U.S. that began in 2007. These events resulted in a significant decrease in net sales and operating income in the fourth quarter of 2008, as compared to the fourth quarter of 2007. As a result, for the year ended December 31, 2008, net sales and operating income for the Performance Materials Segment were $111.6 million and $15.5 million, respectively, or essentially flat with 2007 amounts when excluding the impact of foreign currency translation.
In 2009, the Company expects overall demand for its filtration and industrial thermal insulation products to be moderately impacted by the continued global economic recession.
Thermal/Acoustical Segment
The Company's Thermal/Acoustical Segment is comprised of Lydall's global automotive parts business. Global automotive net sales represented approximately 54% of the Company's 2008 net sales. Throughout the first half of 2008, the Company's North American automotive business (NA Auto) was impacted by less demand for automobiles by consumers, which resulted in lower production of automobiles by automakers in the U.S. Subsequent to the second quarter of 2008, production of automobiles in the North American automotive market decreased severely compared to typical periods. According to CSM Worldwide, an automotive market forecasting service provided to suppliers, in the last half of 2008 production of cars and light trucks by North American OEMs was lower by approximately 21%, or 1.5 million vehicles, as compared to the comparable period of 2007. Overall, in 2008, production by North American OEMs was down by approximately 16%, or 2.4 million vehicles, as compared to 2007.
A significant reduction in consumer demand for automobiles in Europe began to impact the Company's European automotive business (Euro Auto) in the fourth quarter of 2008. According to CSM Worldwide, in the fourth quarter of 2008 production of cars and light trucks by European OEMs was lower by approximately 27%, or 1.5 million vehicles, as compared to the comparable period of 2007. Overall, in 2008, production in Europe was down by approximately 5% as compared to 2007.
For the year ended December 31, 2008, net sales for the Thermal/Acoustical Segment were $163.7 million or approximately 12% lower than 2007 results when excluding the impact of foreign currency translation. The Thermal/Acoustical segment reported an operating loss of $6.1 million in 2008, as compared to operating income of $16.5 million in 2007. During the fourth quarter of 2008, the Company completed its required annual goodwill impairment testing and cash flow projections and market factors indicated that there was no remaining implied fair value attributable to the Company's NA Auto goodwill. Accordingly, the Company wrote off all of the $12.2 million of NA Auto goodwill during the fourth quarter of 2008 (See Note 2 to the Consolidated Financial Statements). In addition, restructuring related charges, attributable to the consolidation of the NA Auto operations, were $1.6 million in the fourth quarter of 2008. Excluding these fourth quarter of 2008 charges of $13.8 million, operating income for the Thermal/Acoustical segment was $7.7 million in 2008.
Looking forward into 2009, current global economic conditions, including consumer credit restrictions, will continue to impact the consumers' ability to purchase automobiles. Until such time as credit restrictions on consumer loans are eased and consumer spending in the automotive market increases, the Company's automotive parts sales will be adversely impacted. According to CSM Worldwide, production of automobiles in North America and Europe are expected to be approximately 17% lower than 2008 production and approximately 25% lower than 2007 production levels. As a result, the Company expects lower net sales from the Company's global automotive businesses in 2009 as compared to 2008.
There are other risks associated with doing business in the North American automotive market. A large amount of the Company's North American automotive sales are to domestic automakers that are reporting financial losses, announcing near-term liquidity concerns, facility closures and other restructuring actions. The possibility of a bankruptcy filing among a large domestic automaker in 2009 has increased. The Company has significant accounts receivable from automakers at any point in time. Should an
automaker not be able to pay the Company the amounts owed as they become due, or at all, results of operations and cash flows of the Company would be adversely affected. Also, certain domestic automakers have indicated that they may increase the number of parts that they source from lower cost countries in the future, which could negatively impact the Company going forward.
The Company's focus in 2009 will include the completion of its previously announced plan to close its St. Johnsbury, Vermont facility and consolidate its North American automotive parts production into its Hamptonville, North Carolina operation. This consolidation is expected to reduce operating costs, increase efficiency, and enhance the Company's competitive position, while maintaining essentially the same level of manufacturing capacity. The Company commenced the transfer of equipment in the first quarter of 2009 and expects to substantially complete the consolidation by the end of the third quarter of 2009. The Company incurred restructuring related charges of $1.6 million in 2008, and expects to incur approximately $5.8 million in additional charges during 2009. Beginning in the latter part of 2009, the Company expects to start to benefit from reduced costs. On an annualized basis, the Company expects to save approximately $3.5 million to $4.0 million in costs as a result of this consolidation.
The Company will also continue its long-term focus on establishing its position with Asian automotive manufacturers in North America. During 2008, the Company was qualified as a supplier to multiple Asian manufacturers, quoted on automotive platforms, received orders and started to ship a nominal amount of orders. Other areas of focus for 2009 include the development of thermal/acoustical products for non-automotive applications. The Company believes that its specialty engineered products could be adapted to other industries that require thermal or acoustic applications.
Other Products and Services
The Company's vital fluids business, which serves the life science industry, reported net sales of $16.6 million and operating income of $1.1 million in 2008 as compared to $14.7 million of net sales and $0.5 million of operating income in 2007. The Company's strategy for this business is to increase its market share in the bioprocessing market. One of the actions to achieve this strategy includes an investment of approximately $2.2 million for new capital equipment that is expected to be placed in service in 2009 to support this growth.
Throughout 2008, the Company's Affinity® temperature control equipment business (Affinity) was negatively impacted by a slow-down in capital equipment spending in the semiconductor industry, resulting in net sales being lower by $6.8 million as compared to 2007. Cash flow projections and market factors indicated that there was no remaining implied fair value attributable to Affinity's goodwill. As a result, the Company recorded an impairment charge $4.2 million in the fourth quarter of 2008 to write off all of the Affinity goodwill. In addition, the Company determined that certain long-lived assets were impaired and recorded an impairment charge of $1.0 million in the fourth quarter of 2008. Lower net sales in 2008 combined with fourth quarter of 2008 impairment charges of $5.2 million, resulted in an operating loss in 2008 of $7.5 million. The Company expects the slow down in capital equipment spending to continue to negatively impact the Company's Affinity business in 2009.
During 2008, the Company sold its wholly-owned subsidiary, Lydall Transport, Ltd (Transport) for $4.2 million in cash. Transport operated the Company's transport, distribution and warehousing businesses that specialized in time-sensitive shipments and warehouse management services primarily serving the paper and printing industries. The Company recorded a gain on disposal, net of income taxes, of $0.9 million in 2008 related to this sale. The Board of Directors and management concluded that Transport was no longer consistent with the Company's strategic direction. The sale of the Transport business freed up both management time and capital resources for its core businesses. The Consolidated Financial Statements for the years ended December 31, 2008, 2007 and 2006 have been reclassified to reflect Transport as a discontinued operation (See Note 9 to the Consolidated Financial Statements).
CONSOLIDATED RESULTS OF OPERATIONS
Net Sales
Percent Percent
(in thousands of dollars) 2008 Change 2007 Change 2006
Net sales $ 305,716 (4.7 )% $ 320,917 4.8 % $ 306,121
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The decrease in net sales in 2008 of $15.2 million, compared with 2007, was primarily the result of lower net sales from the Thermal/Acoustical segment of $13.7 million, including lower automotive parts net sales of $17.2 million, partially offset by improved automotive tooling net sales of $3.5 million. Also contributing to lower net sales in 2008 was decreased net sales from Other Products and Services (OPS) of $4.9 million. OPS includes the Company's vital fluids business which reported increased net sales of $1.9 million in 2008, which was offset by lower net sales from the Company's Affinity business of $6.8 million. Partially offsetting these decreases were higher Performance Materials segment net sales of $3.0 million in 2008 as compared to 2007. Contributing to this increase was higher filtration media net sales of $2.0 million and industrial thermal insulation products of $1.0 million. Foreign currency translation increased net sales by $9.3 million for the current year, compared with 2007, impacting the Thermal/Acoustical segment by $6.8 million and the Performance Materials segment by $2.5 million.
The increase in net sales in 2007 of $14.8 million, compared with 2006, was primarily the result of increased net sales from the Thermal/Acoustical segment of $7.5 million and the Performance Materials segment of $4.9 million. In addition, OPS net sales increased by $2.2 million. The increase in Thermal/Acoustical segment net sales was due to higher automotive parts net sales of $10.5 million, partially offset by lower automotive tooling net sales of $3.0 million. In the Performance Materials segment, higher net sales of filtration media of $5.9 million in 2007, as compared to 2006, was partially offset by lower net sales of industrial thermal insulation products of $1.0 million. The increase in OPS net sales of $2.2 million in 2007, as compared to the prior year, was due to a $1.7 million increase in Affinity net sales and a $0.5 million increase in vital fluids' products net sales. Foreign currency translation increased net sales by $8.7 million in 2007, compared with 2006, impacting the Thermal/Acoustical segment by $6.3 million and the Performance Materials segment by $2.4 million.
Gross Margin
(in thousands of dollars) 2008 2007 2006
Gross margin $ 62,880 $ 72,433 $ 68,183
Percentage of sales 20.6 % 22.6 % 22.3 %
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The decrease in gross margin percentage by 200 basis points in 2008 as compared to 2007 was caused by lower gross margin percentage from the Company's Thermal/Acoustical segment. Contributing to this reduction was lower net sales of $13.7 million, which resulted in higher per-unit manufacturing costs due to each unit absorbing a greater amount of fixed costs, as well as increased raw material costs in 2008 as compared to 2007. Also, restructuring related charges of $1.5 million in 2008, associated with the consolidation of the Company's St. Johnsbury, VT automotive parts plant into the Company's Hamptonville, NC plant, negatively impacted gross margin percentage by approximately 50 basis points. Gross margin percentage in 2008 for the Company's Performance Materials segment was essentially flat with 2007. OPS gross margin percentage in 2008 was essentially flat with 2007, as improvements in vital fluids' gross margin percentage were offset by reduced gross margin percentage from the Company's Affinity business.
The increase in gross margin percentage of 30 basis points in 2007, as compared to 2006, was primarily from higher net sales of the Company's filtration media products in the Performance Materials segment resulting in improved absorption of manufacturing costs. Gross margin percentage in the Company's Thermal/Acoustical segment and OPS were essentially flat with 2006. In OPS, improvement in gross margin percentage from the Company's vital fluids business resulted in a 60 basis point improvement in the Company's overall gross margin percentage, which was essentially offset by a lower gross margin percentage from the Company's Affinity business. Operational efficiency improvements at the Company's vital fluids business, as well as the absence of inventory obsolescence and quality charges reported in 2006, resulted in improved financial performance during 2007, when compared to 2006. Higher per-unit manufacturing costs for Affinity® temperature control equipment negatively impacted the Company's overall gross margin percentage in 2007 compared to 2006.
Selling, Product Development and Administrative Expenses (in thousands of dollars) 2008 2007 2006 Selling, product development and administrative expenses $ 54,958 $ 57,281 $ 54,667 Percentage of sales 18.0 % 17.8 % 17.9 % |
Excluding the impact of foreign currency translation, selling, product development and administrative expenses decreased by $3.3 million, or 5.7%, in 2008 as compared to 2007. Contributing to this reduction was lower litigation expense of $1.8 million, recorded primarily in Corporate Office expenses, and lower incentive compensation expense of $1.2 million, as well as reductions in sales commission expense of $0.4 million, employee recruiting and relocation costs of $0.3 million and consulting expenses of $0.4 million. Higher salaries and wages expense of $0.5 million and severance related charges of $0.7 million in 2008, as compared to 2007, partially offset these decreases. Lower litigation expense was primarily related to a matter with a former employee that significantly impacted the Company in 2007. Lower sales commission expense and incentive compensation expense was due to lower sales and profitability in 2008 as compared to 2007. Higher salaries and wages expense was primarily due to annual wage adjustments. Higher severance related charges were primarily related to realigning management within the Company's U.S. and European automotive operations by eliminating regional business unit presidents and appointing a global automotive president to better maximize synergies between Lydall's U.S. and European automotive operations.
Contributing to the increase in selling, product development and administrative expenses of $2.6 million in 2007, compared with 2006, were increases in litigation expense of $2.5 million and salaries and wages expense of $1.8 million. These increases were partially offset by reductions in benefit plan expense of $0.7 million, sales commission expense of $0.4 million and incentive compensation expense of $0.6 million. The increase in litigation expense, which was primarily recorded in Corporate Office expenses, was principally due to matters related to a former employee. Higher salaries and wages expense was primarily due to annual wage adjustments. Lower benefit plan expense was a result of previously announced changes to the Company's benefit plans, while lower sales commission and incentive compensation expense was due to changes in operating performance by certain businesses in 2007 as compared to 2006.
Impairment of Goodwill and Long-Lived Assets
(in thousands of dollars) 2008 2007 2006
Goodwill impairment $ 16,380 $ - $ -
Impairment of long-lived assets 1,029 - -
Total impairment $ 17,409 $ - $ -
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During the third quarter of 2008, the Company's NA Auto business, included in the Thermal/Acoustical segment, continued to be adversely impacted by a downturn in the U.S. economy resulting in less consumer demand for automobiles. In addition, Affinity, included in OPS, continued to be impacted by lower net sales and operating losses due to a slow-down in capital equipment spending in the semiconductor industry. Accordingly, as of September 30, 2008, the Company performed an interim assessment of NA Auto's and Affinity's goodwill of $12.2 million and $4.2 million, respectively, for impairment, as disclosed in the . . .
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