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| SPWRA > SEC Filings for SPWRA > Form 10-Q on 2-Nov-2009 | All Recent SEC Filings |
2-Nov-2009
Quarterly Report
Cautionary Statement Regarding Forward-Looking Statements
This Quarterly Report on Form 10-Q contains forward-looking statements within the meaning of the Private Securities Litigation Reform Act of 1995. Forward-looking statements are statements that do not represent historical facts and may be based on underlying assumptions. We use words such as "may," "will," "should," "could," "would," "expect," "pipeline," "believe," "estimate," "predict," "potential" and "continue" to identify forward-looking statements in this Quarterly Report on Form 10-Q including our plans and expectations regarding future financial results, operating results, business strategies, projected costs, products, competitive positions, management's plans and objectives for future operations, our ability to obtain financing and industry trends. Such forward-looking statements are based on information available to us as of the date of this Quarterly Report on Form 10-Q and involve a number of risks and uncertainties, some beyond our control, that could cause actual results to differ materially from those anticipated by these forward-looking statements. Please see "PART II. OTHER INFORMATION, Item 1A: Risk Factors" and our other filings with the Securities and Exchange Commission, including our Annual Report on Form 10-K for the year ended December 28, 2008, for additional information on risks and uncertainties that could cause actual results to differ. These forward-looking statements should not be relied upon as representing our views as of any subsequent date, and we are under no obligation to, and expressly disclaim any responsibility to, update or alter our forward-looking statements, whether as a result of new information, future events or otherwise.
The following information should be read in conjunction with the Condensed Consolidated Financial Statements and the accompanying Notes to Condensed Consolidated Financial Statements included in this Quarterly Report on Form 10-Q. Our fiscal quarters end on the Sunday closest to the end of the applicable calendar quarter. All references to fiscal periods apply to our fiscal quarters or year which ends on the Sunday closest to the calendar month end.
Business
We are a vertically integrated solar products and services company that designs, manufactures and markets high-performance solar electric power technologies. Our solar cells and solar panels are manufactured using proprietary processes, and our technologies are based on more than 15 years of research and development. Of all the solar cells available for the mass market, we believe our solar cells have the highest conversion efficiency, a measurement of the amount of sunlight converted by the solar cell into electricity. Our solar power products are sold through our components and systems business segments.
Business Segments Overview
Components Segment: Our Components Segment sells solar power products, including solar panels and inverters, which convert sunlight to electricity compatible with the utility network. We believe our solar cells provide the following benefits compared with conventional solar cells:
• superior performance, including the ability to generate up to 50% more power per unit area;
• superior aesthetics, with our uniformly black surface design that eliminates highly visible reflective grid lines and metal interconnect ribbons; and
• more efficient use of silicon, a key raw material used in the manufacture of solar cells.
We sell our solar components products to installers and resellers, including our third-party global dealer network, for use in residential and commercial applications where the high efficiency and superior aesthetics of our solar power products provide compelling customer benefits. We also sell products for use in multi-megawatt solar power plant applications. In many situations, we offer a materially lower area-related cost structure for our customers because our solar panels require a substantially smaller roof or land area than conventional solar technology and half or less of the roof or land area of commercial solar thin film technologies. We sell our products primarily in North America, Europe, Asia and Australia principally in regions where public policy has accelerated solar power adoption.
We manufacture our solar cells at our two facilities in the Philippines, and are developing a third solar cell manufacturing facility, or FAB3, in Malaysia. Our solar cells are then combined into solar panels at our solar panel assembly facility located in the Philippines or by third-party subcontractors.
Systems Segment: Our Systems Segment generally sells solar power systems directly to system owners and developers. When we sell a solar power system, it may include services such as development, engineering, procurement of permits and equipment, construction management, access to financing, monitoring and maintenance. We believe our solar systems provide the following benefits compared with competitors' systems:
• superior performance delivered by maximizing energy delivery and financial return through systems technology design;
• superior systems design to meet customer needs and reduce cost, including non-penetrating, fast roof installation technologies; and
• superior channel breadth and delivery capability including turnkey systems.
Our customers include commercial and governmental entities, investors, utilities, production home builders, dealers and home owners. We work with development, construction, system integration and financing companies to deliver our solar power systems to customers. Our solar power systems are designed to generate electricity over a system life typically exceeding 25 years and are principally designed to be used in large-scale applications with system ratings of typically more than 500 kilowatts. Worldwide, we have more than 500 megawatts of SunPower solar power plant systems operating or under contract.
We have solar power system projects completed in various countries including Germany, Italy, Portugal, South Korea, Spain and the United States. We sell distributed rooftop and ground-mounted solar power systems as well as central-station power plants. In the United States, distributed solar power systems are typically rated at more than 500 kilowatts of capacity to provide a supplemental, distributed source of electricity for a customer's facility. Many customers choose to purchase solar electricity under a power purchase agreement with a financing company which buys the system from us. In Europe, our products and systems are typically purchased by a financing company and operated as a central-station solar power plant. These power plants are rated with capacities of approximately one to twenty megawatts, and generate electricity for sale under tariff to private and public utilities.
In 2008, we began serving the utility market in the United States, as regulated utilities began seeking cost-effective renewable energy to meet governmental renewable portfolio standard requirements. We believe we are well positioned for long-term success, despite difficult near-term economic conditions, with our substantial order pipeline for utility scale projects. While we have contracts for these projects, there are substantial conditions set forth in such contracts, including obtaining financing and proper governmental permits, which must be satisfied in order for the majority of the projects to move forward.
We manufacture certain of our solar power system products at our manufacturing facilities in Richmond, California and at other facilities located close to our customers. Some of our solar power system products are also manufactured for us by third-party suppliers.
Restructuring Costs
In response to deteriorating economic conditions, we reduced our global workforce of regular employees by approximately 80 positions during the first half of fiscal 2009 in order to reduce our annual operating expenses. The restructuring actions included charges of zero and $1.7 million in the three and nine months ended September 27, 2009, respectively, for severance, benefits and related costs. For additional details see Note 9 of Notes to our Condensed Consolidated Financial Statements.
Accounting Changes and Issued Accounting Guidance Not Yet Adopted
For a description of accounting changes and issued accounting guidance not yet
adopted, including the expected dates of adoption and estimated effects, if any,
in our Condensed Consolidated Financial Statements, see Note 1 of Notes to our
Condensed Consolidated Financial Statements.
Results of Operations for the Three and Nine Months Ended September 27, 2009 and
September 28, 2008
Revenue
Three Months Ended Nine Months Ended
September 27, September 28, September 27, September 28,
(Dollars in thousands) 2009 2008 2009 2008
Systems revenue $ 168,412 $ 193,330 $ 383,233 $ 642,774
Components revenue 297,895 184,170 594,505 391,178
Total revenue $ 466,307 $ 377,500 $ 977,738 $ 1,033,952
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Total Revenue: During the three and nine months ended September 27, 2009, our total revenue of approximately $466.3 million and $977.7 million, respectively, represented an increase of 24% and a decrease of 5%, respectively, from total revenue reported in the comparable periods of 2008. The increase in our total revenue during the three months ended September 27, 2009 compared to the same period in 2008 resulted from strong demand in multiple geographies and market segments. The decrease in our total revenue during the nine months ended September 27, 2009 compared to the same period in 2008 is attributable to the difficult economic and credit environment experienced during the first half of fiscal 2009.
Sales outside the United States represented approximately 68% and 54% of our total revenue for the three and nine months ended September 27, 2009, respectively, compared to 51% and 71% in the three and nine months ended September 28, 2008, respectively. The change in geography mix during the three months ended September 27, 2009 as compared to the same period in 2008 is primarily due to: (i) the ongoing construction of a 24 megawatt solar power plant in Montalto di Castro, Italy; and (ii) the expansion of our third-party global dealer network in Germany and Italy. The change in geography mix during the nine months ended September 27, 2009 as compared to the same period is 2008 is primarily due to: (i) the expiration of an attractive governmental feed-in tariff in Spain in September 2008; (ii) the construction of a 25 megawatt solar power plant in Desoto County, Florida in the nine months ended September 27, 2009; and (iii) revenue growth from our Components Segment in the United States, particularly in California, due to federal, state and local government incentives and the growth of our third-party global dealer network.
Concentrations: We have four customers that each accounted for more than 10 percent of our total revenue in one period during the three and nine months ended September 27, 2009 and September 28, 2008 as follows:
Three Months Ended Nine Months Ended
September 27, September 28, September 27, September 28,
(As a percentage of total revenue) 2009 2008 2009 2008
Significant
Customers: Business Segment
SunRay Renewable
Energy ("SunRay") Systems 15% * * *
Florida Power &
Light Company
("FPL") Systems * * 14% *
Naturener Group Systems * 11% * 23%
Sedwick Corporate,
S.L. Systems * * * 15%
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* denotes less than 10% during the period
We generate revenue from two business segments, as follows:
Systems Segment Revenue: Our systems revenue for the three and nine months ended September 27, 2009 was $168.4 million and $383.2 million, respectively, which accounted for 36% and 39%, respectively, of our total revenue. The majority of systems revenue recognized in the third quarter of fiscal 2009 resulted from the ongoing construction of a 24 megawatt solar power plant for SunRay in Montalto di Castro, Italy, in which approximately 48% of the project's revenue was earned in the three months ended September 27, 2009. Also during the third quarter of fiscal 2009, our Systems Segment completed the construction of a 25 megawatt solar power plant for FPL in Desoto County, Florida, the largest solar power plant in North America, and began the construction of a 10 megawatt solar power plant for FPL at the Kennedy Space Center in Florida as well as a 8 megawatt solar power plant for Exelon Corporation in Chicago. Systems revenue for the three and nine months ended September 28, 2008 was $193.3 million and $642.8 million, respectively, which accounted for 51% and 62%, respectively, of our total revenue. In the three and nine months ended September 28, 2008, our Systems Segment benefited from strong power plant scale demand in Europe, primarily in Spain, and reflected the installation of more than 40 megawatts of Spain based projects before the expiration of a governmental feed-in tariff in September 2008. During the three and nine months ended September 27, 2009, our systems revenue decreased 13% and 40%, respectively, as compared to revenue earned in the comparable periods of 2008, due to difficult economic conditions resulting in near-term challenges in financing system projects. However, we are beginning to see improvements in the financial markets as exemplified by an international consortium of banks financing the ongoing construction of the 24 megawatt solar power plant in Montalto di Castro, Italy, our $100 million commercial project financing agreement with Wells Fargo Bank, or Wells Fargo, providing financing for system projects under power purchase agreements with customers, and our progress on financing a number of other solar power plants.
Components Segment Revenue: Components revenue for the three and nine months ended September 27, 2009 was $297.9 million and $594.5 million, respectively, or 64% and 61%, respectively, of our total revenue. Components revenue for the three and nine months ended September 28, 2008 was $184.2 million and $391.2 million, respectively, or 49% and 38%, respectively, of our total revenue. During the three and nine months ended September 27, 2009, our components revenue increased 62% and 52%, respectively, as compared to revenue earned in the comparable periods of 2008, primarily due to growing demand in Germany, Italy and the United States, particularly in California, due to federal, state and local government incentives and the growth of our third-party global dealer network. In the three and nine months ended September 28, 2008, our Components Segment benefited from strong demand in the residential and small commercial roof-top markets through our third-party dealer network in both Europe and the United States.
Cost of Revenue
Details to cost of revenue by segment:
Three Months Ended
Systems Components Consolidated
September 27, September 28, September 27, September 28, September 27, September 28,
(Dollars in thousands) 2009 2008 2009 2008 2009 2008
Amortization of other
intangible assets $ 1,841 $ 1,841 $ 961 $ 1,106 $ 2,802 $ 2,947
Stock-based
compensation 1,494 2,911 2,808 1,964 4,302 4,875
Impairment of
long-lived assets - (1,343 ) - (1,943 ) - (3,286 )
Non-cash interest
expense 87 100 278 144 365 244
Materials and other
cost of revenue 141,437 155,320 228,117 112,087 369,554 267,407
Total cost of revenue $ 144,859 $ 158,829 $ 232,164 $ 113,358 $ 377,023 $ 272,187
Total cost of revenue
as a percentage of
revenue 86 % 82 % 78 % 62 % 81 % 72 %
Total gross margin
percentage 14 % 18 % 22 % 38 % 19 % 28 %
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Nine Months Ended
Systems Components Consolidated
(Dollars in September 27, September 28, September 27, September 28, September 27, September 28,
thousands) 2009 2008 2009 2008 2009 2008
Amortization of other
intangible assets $ 5,523 $ 5,850 $ 2,867 $ 3,216 $ 8,390 $ 9,066
Stock-based
compensation 3,266 7,661 6,489 6,057 9,755 13,718
Impairment of
long-lived assets - - - 2,203 - 2,203
Non-cash interest
expense 664 201 1,441 276 2,105 477
Materials and other
cost of revenue 315,550 497,604 446,443 259,536 761,993 757,140
Total cost of revenue $ 325,003 $ 511,316 $ 457,240 $ 271,288 $ 782,243 $ 782,604
Total cost of revenue
as a percentage of
revenue 85 % 80 % 77 % 69 % 80 % 76 %
Total gross margin
percentage 15 % 20 % 23 % 31 % 20 % 24 %
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Total Cost of Revenue: We had 16 and 10 active solar cell manufacturing lines in our two solar cell manufacturing facilities as of September 27, 2009 and September 28, 2008, respectively, with a total rated annual solar cell manufacturing capacity of 574 megawatts and 334 megawatts, respectively. During the three and nine months ended September 27, 2009, our two solar cell manufacturing facilities operated at approximately 74% and 66% capacity, respectively, producing 109.9 megawatts and 267.2 megawatts, respectively, as compared to the three and nine months ended September 28, 2008 when our facilities operated at approximately 75% and 73% capacity, respectively, producing 65.8 megawatts and 154.1 megawatts, respectively. During the three and nine months ended September 27, 2009, our total cost of revenue was $377.0 million and $782.2 million, respectively, which represented an increase of 39% and zero, respectively, compared to the total cost of revenue reported in the comparable periods of 2008. As a percentage of total revenue, our total cost of revenue increased to 81% and 80% in the three and nine months ended September 27, 2009, respectively, compared to 72% and 76% in the three and nine months ended September 28, 2008, respectively. This increase in total cost of revenue as a percentage of total revenue is reflective of: (i) the sale and write-down of inventory to its estimated market value in the third quarter of fiscal 2009 based upon our assumptions about future demand and market conditions; and (ii) higher amortization of capitalized non-cash interest expense in the three and nine months ended September 27, 2009 as compared to the same periods in 2008. This increase in total cost of revenue as a percentage of total revenue was partially offset by: (i) decreased costs of polysilicon; (ii) reduced expenses associated with the amortization of other intangible assets and stock-based compensation; and (iii) an asset impairment charge of $2.2 million in the nine months ended September 28, 2008 relating to the wind down of our imaging detector product line (the costs associated with the $3.3 million write-down of certain solar product manufacturing equipment taken in the first quarter of fiscal 2008 was recovered from the vendor in the third quarter of fiscal 2008).
Systems Segment Cost of Revenue: Our cost of systems revenue consists primarily of solar panels, mounting systems, inverters and subcontractor costs. The cost of solar panels is the single largest cost element in our cost of systems revenue. Our Systems Segment sourced substantially all of its solar panel installations with SunPower solar panels in the three and nine months ended September 27, 2009, as compared to 69% and 58% for the three and nine months ended September 28, 2008, respectively. Our Systems Segment generally experiences higher gross margin on construction projects that utilize SunPower solar panels compared to construction projects that utilize solar panels purchased from third-parties.
Systems Segment Gross Margin: Gross margin was $23.6 million and $58.2 million
for the three and nine months ended September 27, 2009, respectively, or 14% and
15%, respectively, of systems revenue. Gross margin was $34.5 million and $131.5
million for the three and nine months ended September 28, 2008, respectively, or
18% and 20%, respectively, of systems revenue. Gross margin decreased due to:
(i) lower average selling prices for our solar power systems; (ii) the sale and
write-down of aged third-party solar panels to its estimated market value in the
third quarter of fiscal 2009 based upon our assumptions about future demand and
market conditions; and (iii) our inability to reduce system group department
overhead costs incurred that are fixed in nature when systems revenue decreased
13% and 40% in the three and nine months ended September 27, 2009, respectively,
as compared to the same periods in 2008.
Components Segment Cost of Revenue: Our cost of components revenue consists primarily of silicon ingots and wafers used in the production of solar cells, along with other materials such as chemicals and gases that are needed to transform silicon wafers into solar cells. For our solar panels, our cost of revenue includes the cost of solar cells and raw materials such as glass, frame, backing and other materials, as well as the assembly costs we pay to our third-party subcontractors in China and Mexico. Our Components Segment's gross margin each quarter is affected by a number of factors, including average selling prices for our solar power products, our product mix, our actual manufacturing costs and the utilization rate of our solar cell manufacturing facilities.
Components Segment Gross Margin: Gross margin was $65.7 million and $137.3 million for the three and nine months ended September 27, 2009, respectively, or 22% and 23%, respectively, of components revenue. Gross margin was $70.8 million and $119.9 million for the three and nine months ended September 28, 2008, respectively, or 38% and 31%, respectively, of components revenue. Gross margin decreased due to: (i) lower average selling prices for our solar power products; and (ii) the sale and write-down of inventory to its estimated market value in the third quarter of fiscal 2009 based upon our assumptions about future demand and market conditions. This decrease in gross margin was partially offset by continued reduction in silicon costs. Over the next several years, we expect average selling prices for our solar power products to decline as the market becomes more competitive, as financial incentives for solar power decline as typically planned by local, state, and national policy programs designed to accelerate solar power adoption, as certain products mature and as manufacturers are able to lower their manufacturing costs and pass on some of the savings to their customers.
Other Cost of Revenue Factors: Other factors contributing to cost of revenue include amortization of other intangible assets, stock-based compensation, depreciation, provisions for estimated warranty, salaries, personnel-related costs, freight, royalties, facilities expenses and manufacturing supplies associated with contracting revenue and solar cell fabrication as well as factory pre-operating costs associated with our second solar cell manufacturing facility, or FAB2, and our solar panel assembly facility. Such pre-operating costs included compensation and training costs for factory workers as well as utilities and consumable materials associated with preproduction activities. From fiscal 2005 through 2008, demand for our solar power products was robust and our production output increased allowing us to spread a significant amount of our fixed costs over relatively high production volume, thereby reducing our per unit fixed cost. During the first half of fiscal 2009, we responded to the oversupply of solar power products in the market by temporarily reducing manufacturing output to better match the current demand environment.
Research and Development
Three Months Ended Nine Months Ended
September 27, September 28, September 27, September 28,
(Dollars in thousands) 2009 2008 2009 2008
Research and development $ 8,250 $ 6,049 $ 23,067 $ 15,504
As a percentage of revenue 2 % 2 % 2 % 1 %
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During the three and nine months ended September 27, 2009, our research and development expense was $8.3 million and $23.1 million, respectively, which represented increases of 36% and 49%, respectively, from research and development expense reported in the comparable periods of fiscal 2008. As a percentage of total revenue, research and development expense totaled 2% in each of the three and nine months ended September 27, 2009, compared to 2% and 1% in the three and nine months ended September 28, 2008, respectively. Research and development expense consists primarily of salaries and related personnel costs, depreciation and the cost of solar cell and solar panel materials and services . . .
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