Unassociated Document
UNITED
STATES
SECURITIES
AND EXCHANGE COMMISSION
Washington,
D.C. 20549
FORM
10-K
(Mark
One)
x
Annual Report Pursuant
to Section 13 or 15(d) of the Securities Exchange Act of 1934.
For
the
fiscal year ended December 31, 2007 or
o
Transition Report
Pursuant to Section 12 or 15(d) of the Securities Exchange Act of 1934.
For
the
transition period
from
to
..
Commission
file number 1-10776
Calgon
Carbon Corporation
(Exact
name of registrant as specified in its charter)
Delaware
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25-0530110
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(State
or other jurisdiction of
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(I.R.S.
Employer
|
incorporation
or organization)
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|
Identification
No.)
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400
Calgon Carbon Drive
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Pittsburgh,
Pennsylvania
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15205
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(Address
of principal executive offices)
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(Zip
Code)
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Registrant's
telephone number, including area code: (412) 787-6700
Securities
registered pursuant to Section 12(b) of the Act:
Title
of each class
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|
Name
of each exchange on which registered
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Common
Stock, par value $0.01 per share
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New
York Stock Exchange
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Securities
registered pursuant to Section 12(g) of the Act:
None
(Title
of class)
Indicate
by check mark if the registrant is a well-known seasoned issuer, as defined
in
Rule 405 of the Securities Act.
Yes
o
No x
Indicate
by check mark if the registrant is not required to file reports pursuant to
Section 13 or Section 15(d) of the Exchange Act.
Yes
o
No
x
Indicate
by check mark whether the registrant (1) has filed all reports required to
be
filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during
the
preceding 12 months (or for such shorter period that the registrant was required
to file such reports), and (2) has been subject to such filing requirements
for
the past 90 days.
Yes
x
No o
Indicate
by check mark if disclosure of delinquent filers pursuant to Item 405 of
Regulation S-K is not contained herein, and will not be contained, to the best
of registrant's knowledge, in definitive proxy or information statements
incorporated by reference in Part III of this Form 10-K or any amendment to
this
Form 10-K.
Yes
o
No x
Indicate
by check mark whether the registrant is a large accelerated filer, an
accelerated filer, or a non-accelerated filer. See definition of “accelerated
filer and large accelerated filer” in Rule 12b-2 of the Exchange
Act.
Large
accelerated filer o Accelerated
filer x Non-accelerated
filer
o
Indicate
by check mark whether the registrant is a shell company (as defined in Rule
12b-2 of the Exchange Act).
Yes
o
No x
As
of
February 27, 2008, there were outstanding 40,741,795 shares of Common Stock,
par
value of $0.01 per share.
The
aggregate market value of the voting stock held by non-affiliates as of June
30,
2007 was $404,150,071.
The
following documents have been incorporated by reference:
Document |
Form 10-K
Part
Number
|
|
|
Proxy
Statement filed pursuant to Regulation 14A in connection with
registrant's Annual Meeting of Shareholders to be held on May
1, 2008
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III |
INDEX
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Item
1.
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Business
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5
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Item
1A.
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Risk
Factors
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18
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Item
1B. |
Unresolved
Staff Comments
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29
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|
Item
2.
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Properties
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30
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Item
3.
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Legal
Proceedings
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33
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Item
4.
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Submission
of Matters to a Vote of Security Holders
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34
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PART
II
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Item
5.
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Market
for Registrant’s Common Equity, Related Shareholder
Matters and Issuer Repurchases of Equity Securities
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34
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Item
6.
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Selected
Financial Data
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36
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|
Item
7.
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Management’s
Discussion and Analysis of Financial Condition
and Results of Operations
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37
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Item
7A.
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Quantitative
and Qualitative Disclosures about Market Risk
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56
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Item
8.
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Financial
Statements and Supplementary Data
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57
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Item
9.
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Changes
in and Disagreements with Accountants on Accounting
and Financial Disclosure
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126
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Item
9A.
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Controls
and Procedures
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126
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Item
9B. |
Other
Information
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126
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PART
III
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Item
10.
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Directors,
Executive Officers, and Corporate Governance of
the Registrant
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127
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Item
11.
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Executive
Compensation
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127
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|
Item
12.
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Security
Ownership of Certain Beneficial Owners and Management
and Related Shareholder Matters
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128
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Item
13.
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Certain
Relationships, Related Transactions, and Director Independence
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129
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Item
14.
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Principal
Accounting Fees and Services
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130
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PART
IV
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Item
15.
|
Exhibits
and Financial Statement Schedules
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130
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SIGNATURES
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135
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CERTIFICATIONS
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|
Forward-Looking
Information Safe Harbor
This
Annual Report contains historical information and forward-looking statements.
Forward-looking statements typically contain words such as “expect,” “believes,”
“estimates,” “anticipates,” or similar words indicating that future outcomes are
uncertain. Statements looking forward in time, including statements regarding
future growth and profitability, price increases,
cost savings, broader product lines, enhanced competitive posture and
acquisitions, are included in this Annual Report pursuant to the “safe harbor”
provision of the Private Securities Litigation Reform Act of 1995. They involve
known and unknown risks and uncertainties that may cause the Company’s actual
results in future periods to be materially different from any future performance
suggested herein. Further, the Company operates in an industry
sector where securities values may be volatile and may be influenced by economic
and other factors beyond the Company’s control. Some of the factors that could
affect future performance of the Company are higher energy and raw material
costs, costs of imports and related tariffs, labor relations, capital and
environmental requirements, changes in foreign currency exchange rates,
borrowing restrictions, validity of patents and other intellectual property,
and
pension costs. In the context of the forward-looking information provided in
this Annual Report, please refer to the discussions of risk factors and other
information detailed in, as well as the other information contained in this
Annual Report.
Effective
December 31, 2006, The Company adopted Statement of Financial Accounting
Standards No. 158, “Employers’ Accounting for Defined Benefit Pension and
Other Postretirement Plans, an amendment of FASB Statements Nos. 87, 88,
106 and
132(R)” (“SFAS No. 158”). SFAS No. 158 required the Company to record
a transition adjustment to recognize the funded status of postretirement
defined
benefit plans, measured as the difference between the fair value of plan
assets
and the benefit obligations, in its balance sheet after adjusting for
derecognition of the Company’s minimum pension liability as of December 31,
2006. The Company complied with the provisions of SFAS No. 158; however,
the Company incorrectly presented the effect of this transition adjustment
as
part of 2006 comprehensive income on its Consolidated Statements of Income
(Loss) and Comprehensive Income (Loss) included in Item 8 of its
Annual Report on Form 10-K for the fiscal year ended December 31,
2006. The impact of removing the SFAS No. 158 transition adjustment from
the 2006 Consolidated Statements of Income (Loss) and Comprehensive Income
(Loss) changes the reported comprehensive income (loss) from $(3,935,000)
to
$1,440,000. The Consolidated Statements of Income (Loss) and Comprehensive
Income (Loss) set forth in Item 8: Financial Statements and Supplementary
Data
correctly presents 2006 comprehensive income (loss) excluding the SFAS No.
158 transition adjustment. The reported net loss of $(7,798,000) for 2006
and
the related loss per share of $(.20) are unaffected by this change. There
are no
other changes to the Consolidated Statements of Income (Loss) and
Comprehensive Income (Loss) included in the Company’s Annual Report on
Form 10-K for the fiscal year ended December 31, 2006, other than this
correction of 2006 comprehensive income.
PART
I
Item
1. Business:
The
Company:
The
Company is a global leader in services, products, and solutions for purifying
water and air. The Company has three reportable segments: Activated Carbon
and
Service, Equipment, and Consumer. These reportable segments are composed of
global profit centers that make and sell different products and
services.
The
Activated Carbon and Service segment manufactures granular activated carbon
for
use in applications to remove organic compounds from water, air, and other
liquids and gases. The service aspect of the segment consists of the leasing,
monitoring and maintenance of carbon adsorption equipment (explained below).
The
Equipment segment provides solutions to customers’ air and water purification
problems through the design, fabrication and operation of systems that utilize
a
combination of the Company’s enabling technologies: carbon adsorption,
ultraviolet (“UV”) and advanced ion exchange separation (“ISEP®”) among others.
The Consumer segment primarily consists of the manufacture and sale of carbon
cloth and new consumer products based on the Company’s technologies already
proven in large-scale industrial applications.
Acquisitions:
In
May
2005, the Company formed a joint venture with C. Gigantic Carbon to provide
carbon reactivation services to the Thailand market. The joint venture was
named
Calgon Carbon (Thailand) Ltd., and is 20% owned by the Company after an initial
investment of $0.2 million.
Discontinued
Operations:
On
February 4, 2005, the Company’s Board of Directors approved a re-engineering
plan presented by the Company. The plan included the divestiture of two non-core
businesses in order to allow the Company to increase focus on its core activated
carbon and service-related businesses. In the fourth quarter of 2005, management
concluded such divestitures were probable, and the Company presents the
following businesses as discontinued operations for all periods presented:
Charcoal/Liquid in Bodenfelde, Germany and Solvent Recovery in Columbus, Ohio;
Vero Beach, Florida; and Ashton, United Kingdom. The Charcoal/Liquid and Solvent
Recovery businesses were reported in the Company’s Consumer and Equipment
segments, respectively.
On
February 17, 2006, Calgon Carbon Corporation, through its wholly owned
subsidiary Chemviron Carbon GmbH, executed an agreement (the “Charcoal Sale
Agreement”) with proFagus GmbH, proFagus Grundstuecksverwaltungs GmbH and
proFagus Beteiligungen GmbH (as Guarantor) to sell, and sold, substantially
all
the assets, real estate, and specified liabilities of the Bodenfelde, Germany
facility (the “Charcoal/Liquid business”). The facility includes the production
of charcoal for consumer use and liquids that are recovered during charcoal
production. The products are sold to retail and industrial markets. The
aggregate sales price, based on an exchange rate of 1.19 Dollars per Euro,
consisted of $20.4 million of cash, which included a final working capital
adjustment of $1.3 million. The Company provided guarantees to the buyer related
to pre-divestiture tax liabilities, future environmental remediation costs
related to pre-divestiture activities and other contingencies. Management
believes the ultimate cost of such guarantees is not material. An additional
4.25 million Euros could be received dependent upon the business meeting certain
earnings targets over the next three years. No contingent consideration was
received for the years ended December 31, 2007 and 2006. For the year ended
December 31, 2006, the Company recorded a pre-tax gain of $4.8 million or $1.7
million, net of tax, on the sale of the Charcoal/Liquid divestiture.
On
April
24, 2006, the Company completed the sale of the assets of its Solvent Recovery
business to MEGTEC Systems, Inc. (“MEGTEC”), a subsidiary of Sequa Corporation.
The Solvent Recovery unit provides turnkey on-site regenerable solvent recovery
systems, distillation systems, on-site regenerable volatile organic compound
concentrators, vapor-phase biological oxidation systems, and related services
on
a worldwide basis. The sales price of $1.8 million included cash proceeds of
approximately $0.8 million and $0.7 million of assumed liabilities, primarily
accounts payable. The transaction was also subject to a pre-tax working capital
adjustment of $0.4 million, which management finalized and recorded in the
fourth quarter of 2006. For the year ended December 31, 2006, the Company
recorded a pre-tax gain of $63 thousand or $41 thousand, net of tax, on the
sale
of the Solvent Recovery business.
For
further information, see Note 4 to the Financial Statements.
Products
and Services:
The
Company offers a diverse range of products, services, and equipment specifically
developed for the purification, separation, and concentration of liquids, gases,
and other media through its three business segments. The Activated Carbon and
Service segment primarily consists of activated carbon products, field services,
and reactivation. The Equipment segment designs and builds systems that include
multiple technologies. The Consumer segment supplies carbon products for
everyday use by consumers.
Activated
Carbon and Service. The
sale
of activated carbon is the principal component of the Activated Carbon and
Service business segment. Activated carbon is a porous material that removes
organic compounds from liquids and gases by a process known as “adsorption.” In
adsorption, organic molecules contained in a liquid or gas are attracted and
bound to the surface of the pores of the activated carbon as the liquid or
gas
is passed through.
The
primary raw material used in the production of the Company’s activated carbons
is bituminous coal which is crushed, sized, and processed in low temperature
bakers followed by high temperature furnaces. This heating process is known
as
“activation” and develops the pore structure of the carbon. Through adjustments
in the activation process, pores of the required size for a particular
purification application are developed. The Company’s technological expertise in
adjusting the pore structure in the activation process has been one of a number
of factors enabling the Company to develop many special types of activated
carbon with most available in several particle sizes. The Company also markets
activated carbons from other raw materials, including coconut and
wood.
The
Company produces and sells a broad range of activated, impregnated or acid
washed carbons in granular, powdered or pellet form. Granular Activated Carbon
(“GAC”) particles are irregular in shape and generally used in fixed filter beds
for continuous flow purification processes. Powdered Activated Carbon (“PAC”) is
carbon which has been pulverized into powder and often used in batch
purification processes, in municipal water applications, and for flue gas
emissions control. Pelletized activated carbon has been extruded and each
particle is cylindrical in shape. Pelletized carbon is typically used for gas
phase applications because of the low pressure drop, high mechanical strength,
and low dust content of the product.
Another
important component of the Activated Carbon and Service business segment is
the
various services associated with the supply of products and systems for
purification, separation, concentration, taste and odor control. These services
include carbon reactivation, handling and transportation as well as the supply
of equipment through leasing arrangements. The Company supplies complete process
and treatment services at customers’ facilities which are particularly suited
for treating fluids or gases containing either or both non-hazardous or
hazardous organic compounds. The service is based primarily on reactivation
of
spent carbon and transportation of activated carbon to and from the reactivation
facility, but also includes feasibility testing, process design, on-site
equipment, initial activated carbon supply, performance monitoring and major
maintenance of Company-owned equipment (such equipment is referred to as
“customer capital”). In the reactivation process, the spent carbon is subjected
to high temperature re-manufacturing conditions that destroy the adsorbed
organics and assure the activated carbon is returned to usable quality. This
recycling is conducted at several locations throughout the world. Granular
activated carbon is reactivated for environmental and economic reasons to
destroy adsorbed organic compounds and also to conserve natural resources.
The
Company provides reactivation/recycling services in packages ranging from a
fifty-five gallon drum to truckload quantities.
Purification
services provided by the Company are used to improve the quality of food,
chemical, pharmaceutical and petrochemical products. These services may be
utilized in permanent installations or in temporary applications, such as pilot
studies for a new manufacturing process or recovery of off-specification
products.
Sales
from continuing operations for the Activated Carbon and Service segment were
$295.6 million, $265.3 million, and $241.9 million for the years ended December
31, 2007, 2006, and 2005, respectively.
Equipment.
The
Company has a complete line of standardized, pre-engineered, adsorption systems
- capable of treating liquid flows from 1 gpm to 1,400 gpm - which can be
quickly delivered and easily installed at treatment sites. These self-contained
adsorption systems are used for vapor phase applications such as volatile
organic compound (“VOC”) control, air stripper off-gases, and landfill gas
emissions. Liquid phase equipment systems are used for applications of process
purification, wastewater treatment, groundwater remediation, and
de-chlorination. The Company also custom designs systems to solve unique
treatment challenges, providing equipment for activated carbon, ion exchange
resins or UV technologies each of which can be used for the purification,
separation and concentration of liquids or gases.
More
than
20 years ago, the Company introduced an advanced UV oxidation process to
remediate contaminated groundwater. In 1998, the Company’s scientists invented a
UV disinfection process that could be used to inactivate Cryptosporidium,
Giardia and other similar pathogens in surface water, rendering them harmless
to
humans. Effective in both drinking water and wastewater, UV light alters the
DNA
of pathogens, killing them or making it impossible for pathogens to reproduce
and infect humans. In combination with hydrogen peroxide, UV light is effective
in destroying many contaminants common in groundwater remediation applications.
The Company continues to lead the market with innovative UV technologies with
the Sentinel® line designed to protect municipal drinking water supplies from
pathogens, the C3 Series™ open-channel wastewater disinfection product line for
municipal wastewater disinfection, and Rayox® UV advanced oxidation equipment
for treatment of contaminants such as 1,4-Dioxane, MTBE and Vinyl Chloride
in
groundwater, process water, and industrial wastewater.
UV
oxidation equipment can also be combined with activated carbon to provide
effective solutions for taste and odor removal in municipal drinking water.
Backed by years of experience and extensive research and development, the
Company can recommend the best solution for taste and odor problems, whether
it’s using activated carbon, UV oxidation, or both. The Company also offers a
low cost, non-chemical solution for quenching excess peroxide after our advanced
oxidation processes.
The
Company also produces a wide range of odor control equipment which utilizes
catalytic, activated carbon to control odors at municipal wastewater treatment
facilities and pumping stations.
The
proprietary ISEP® (Ionic Separator) continuous ion exchange units are used for
the purification of many products in the food, pharmaceutical and biotechnology
industries. These ISEP® Continuous Separator units perform ion exchange
separations using countercurrent processing. The ISEP® and CSEP®
(chromatographic separator) systems are currently used at over 300 installations
worldwide in more than 40 applications including Good Manufacturing Processes
(“GMP”), as well as removing nitrate and perchlorate contaminants from drinking
water.
Sales
from continuing operations for the Equipment segment were $41.3 million, $37.9
million, and $36.9 million for the years ended December 31, 2007, 2006, and
2005, respectively.
Consumer.
The
primary product offered in the Consumer segment is carbon cloth. Carbon cloth,
which is activated carbon in cloth form, is manufactured in the United Kingdom
and sold to the medical and specialty markets.
Activated
carbon and carbon cloth are used as the primary raw materials in the Company’s
consumer home products group. The Company currently has two primary product
lines that it markets to the retail channel. The first product line, PreZerve®
storage products, uses carbon cloth to protect and preserve jewelry and
keepsakes from deterioration. The PreZerve® line currently offers over 40
different items. The second product line, AllGone®, is an odor elimination
system that utilizes activated carbon discs to adsorb odors and impurities
from
the air safely and naturally.
Sales
from continuing operations for the Consumer segment were $14.2 million, $13.0
million, and $12.0 million for the years ended December 31, 2007, 2006 and
2005,
respectively.
For
further information, see Note 20 to the Financial Statements.
Markets:
The
Company participates in five primary areas: Potable Water, Industrial Process,
Food, Environmental Water and Air, and Specialty markets. Potable Water
applications include municipal drinking water purification as well as point
of
entry and point of use devices. Applications in the Industrial Process markets
include catalysis, product recovery and purification of chemicals, and
pharmaceuticals as well as process water treatment. Food applications include
brewing, bottling, and sweetener purification. Remediation of water and VOC
removal from vapor are the major sub-segments for the Environmental markets.
Medical, personal protection, cigarette, automotive, consumer, and precious
metals applications comprise the Specialty markets.
Potable
Water Market.
The
Company sells activated carbons, equipment, services, ion exchange technology
and UV technologies to municipalities for the treatment of potable water to
remove pesticides and other dissolved organic and inorganic material to meet
or
exceed current state or federal regulations and to remove tastes and odors
to
make the water acceptable to the public. The Company also sells to OEM
manufacturers of home water purification systems. Granular and powdered
activated carbon products are sold in this market and in many cases the granular
carbon functions both as the primary filtration media as well as an adsorption
media to remove the contaminants from the water. UV oxidation and disinfection
systems are sold for the destruction or inactivation of waterborne contaminants
and organisms.
Industrial
Process Market.
The
Company’s products used in industrial processing are used either for
purification, separation or concentration of customers’ products in the
manufacturing process or for direct incorporation into the customers’ products.
The Company sells a wide range of activated carbons and reactivation services
to
the chemical, petroleum refining, and process industries for the purification
of
organic and inorganic chemicals, amine, antibiotics and vitamins. Activated
carbon products and services are also used to decolorize chemicals such as
hydrochloric acid and remove pollutants from wastewater. Further, activated
carbon is used in treatment of natural gas, flue gas and other vapor streams
for
removal of carbon dioxide, acetylene, hydrogen, sulfur and mercury compounds.
The liquefied natural gas industry uses activated carbons to remove mercury
compounds which would otherwise corrode process equipment. Activated carbons
are
also sold for gasoline vapor recovery equipment.
Environmental
Water and Air Market.
Providing products used for the cleanup of contaminated groundwater, surface
impoundments and accidental spills comprises the significant need in this
market. The Company provides carbon, services, and carbon equipment for these
applications as well as emergency and temporary cleanup services for public
and
private entities, utilizing both activated carbon adsorption and UV oxidation
technologies.
The
Company offers its products and services to private industry to meet stringent
environmental requirements imposed by various government entities. The Company’s
reactivation/recycling service is an especially important element if the
customer has contaminants which are hazardous organic chemicals. The hazardous
organic chemicals which are adsorbed by the activated carbons are decomposed
at
the high temperatures of the reactivation furnace and thereby removed from
the
environment. Reactivation eliminates the customers’ expense and difficulty in
securing long-term containment (such as landfills) for hazardous organic
chemicals.
Activated
carbon is also used in the chemical, pharmaceutical, and refining industries
for
purification of air discharge to remove contaminants such as benzene, toluene,
and other volatile organics. Reduction of mercury emissions from coal-fired
power plants is a growing market for the Company. The planned re-start of B-line
at its Catlettsburg, Kentucky plant to produce up to 70 million pounds of
FLUEPAC® powdered activated carbon represents major progress in a multi-step
program that would enable the Company to provide potentially hundreds of
millions of pounds of powdered carbon to power companies.
Municipal
sewage treatment plants purchase the Company’s odor control systems and
activated carbon products to remove objectionable odors emanating from plants
and to treat the wastewater to meet operating requirements. Granular activated
carbon is used as a filtration/adsorption medium and the powdered activated
carbons are used to enhance the performance of existing biological waste
treatment processes.
The
Company’s UV oxidation systems offer an ideal solution for groundwater
remediation and the treatment of process water and industrial wastewater. The
Company’s Rayox® System is an industry staple for the destruction of organic
compounds in groundwater. Rayox® is also used as a process water and wastewater
treatment option for the removal of alcohol, phenol, acetone, TOC and
COD/BOD.
Food
Market.
Sweetener manufacturers are a principal purchaser of the Company’s products in
the food industry. As a major supplier, the Company’s specialty acid-washed
activated carbon products are used in the purification of dextrose and high
fructose corn syrup. Activated carbons are also sold for use in the purification
of cane sugar. Other food processing applications include de-colorization and
purification of many different foods and beverages and for purifying water,
liquids and gas prior to usage in brewing and bottling. Continuous ion exchange
systems are also used in this market for the production of lysine and vitamin
E
as well as purification of dextrose and high fructose corn syrup.
Specialty
Markets.
The
Company is a major supplier of activated carbon to manufacturers of gas masks
supplied to the United States and European military as well as protective
respirators and collective filters for first responders and private industry.
The markets for collective filters for military equipment, indoor air quality
and air containment in incineration and nuclear applications are also
served.
Other
specialty applications using activated carbons include precious metals producers
to recover gold and silver from low-grade ore, and cigarette manufacturers
in
charcoal filters. The Company’s activated carbon cloth product is used in
medical and other specialty applications.
Sales
and Marketing:
The
Company has a direct sales force in the United States with offices located
in
Pittsburgh, Pennsylvania; Santa Fe Springs, California; and Marlton, New Jersey.
The Company conducts activated carbon related sales in Canada, Brazil, and
Mexico through distributor relationships and maintains offices in Sao Paulo,
Brazil and Mexico City, Mexico. The Company maintains offices in Singapore;
Beijing and Shanghai, China; Taipei, Taiwan; and Tokyo, Japan (joint venture)
to
manage sales in the Asia Pacific Region.
In
Europe, the Company has sales offices in Feluy, Belgium; Ashton and Houghton
Le
Spring, United Kingdom; and Beverungen, Germany. The Company also has a network
of agents and distributors that conduct sales in certain countries in Europe,
the Middle East, Africa, Latin America, the Far East, Australia and New Zealand.
All
offices can play a role in sales of products or services from any of the
Company’s segments.
Geographic
sales information can be found in Note 20 to the Financial
Statements.
Over
the
past three years, no single customer accounted for more than 10% of the total
sales of the Company in any year.
Backlog:
The
Company had a sales backlog from continuing operations of $11.8 million and
$17.1 million as of January 31, 2008 and 2007, respectively, in the Equipment
segment. The Company expects to carry less than one-third of the 2008 balance
into 2009.
Competition:
The
Company has a major global presence with several competitors in the worldwide
market with respect to the production and sale of activated carbon-related
products: Norit, N.V., a Dutch company, Mead/Westvaco Corporation, a United
States company and Siemens Water, a United States company, are the primary
competitors. Chinese producers of coal-based activated carbon and certain East
Asian producers of coconut-based activated carbon participate in the market
on a
worldwide basis and sell principally through numerous resellers. Competition
in
activated carbons, carbon equipment and services is based on quality,
performance and price. Other sources of competition for the Company’s activated
carbon services and systems are alternative technologies for purification,
filtration, and extraction processes that do not employ activated
carbons.
A
number
of other smaller competitors engage in the production and sale of activated
carbons in local markets, but do not compete with the Company on a global basis.
These companies compete with the Company in the sale of specific types of
activated carbons, but do not generally compete with a broad range of products
in the worldwide activated carbon business.
In
the
United States and Europe, the Company competes with several small regional
companies for the sale of its reactivation services and carbon equipment.
The
Company’s UV technologies product line competitors include Trojan Technologies,
Inc., a Canadian company owned by Danaher Corporation, a United States Company,
and Wedeco Ideal Horizons, a German company owned by ITT Industries, a United
States company.
Raw
Materials:
The
principal raw material purchased by the Company for its Activated Carbon and
Service segment is bituminous coal from mines in the Appalachian Region and
mines outside the United States, usually purchased under both long-term and
annual supply contracts.
The
Company purchases natural gas from various suppliers for use in its Activated
Carbon and Service segment production facilities. In both the United States
and
Europe, substantially all natural gas is purchased pursuant to various annual
and multi-year contracts with natural gas companies.
The
Company purchases hydrogen peroxide via an annual supply contract for its UV
technologies business.
The
only
other raw material that is purchased by the Company in significant quantities
is
pitch, which is used as a binder in the carbon manufacturing process. The
Company purchases pitch from various suppliers in the United States and China,
under annual supply contracts and spot purchases.
The
purchase of key equipment components is coordinated through agreements with
various suppliers.
Recent
increases in coal prices and worldwide coal demand, as well as increased
transportation costs, have provided the Company’s coal suppliers with added
incentives to avoid their contractual obligations in some cases. However, to
date, the Company’s coal suppliers have not breached their contracts. The
Company does not presently anticipate any problems in obtaining adequate
supplies of its other raw materials or equipment components.
Research
and Development:
The
Company's primary research and development activities are conducted at a
research center in Pittsburgh, Pennsylvania. This facility is used for the
evaluation of experimental activated carbon and equipment and application
development. Experimental systems are also designed and evaluated at this
location. Facilities in Ashton, United Kingdom supplement the work performed
in
Pittsburgh.
The
principal goals of the Company's research program are to improve the Company's
position as a technological leader in solving customers' problems with its
products, services and equipment; develop new products and services; and provide
technical support to customers and operations of the Company.
The
Company's research programs include new and improved methods for manufacturing
and utilizing new and enhanced activated carbons. New activated carbons are
developed to address specific needs for a given market. For example, in response
to the needs of power plants for a carbon for mercury removal from flue gas,
four new products have been developed and field tested. Two of these products
address the specific needs of utilities that use their fly ash as a concrete
supplement. Research and development activities also include the Company's
Ion
Exchange and UV technologies. A regenerable resin for perchlorate removal has
been successfully piloted using a licensed technology. Commercial systems are
now being proposed. Expansion of the UV technologies product line continued
in
2007 with the development of a new Sentinel® reactor and an innovative Advanced
Oxidation reactor. Improvements to the equipment design continue and additional
patent applications have been filed.
Research
and development expenses were $3.7 million, $4.2 million, and $4.5 million
in
2007, 2006 and 2005, respectively.
Patents
and Trade Secrets:
The
Company possesses a substantial body of technical knowledge and trade secrets
and owns 61 United States patent applications and/or patents and 205 patent
applications and/or patents in other countries. The issued United States and
foreign patents expire in various years from 2008 through 2025.
The
technology embodied in these patents, trade secrets and technical knowledge
applies to all phases of the Company's business including production processes,
product formulations and application engineering. The Company considers this
body of technology important to the conduct of its business.
Regulatory
Matters:
USA.
The
Company is subject to extensive environmental laws and regulations concerning
emissions to the air, discharges to waterways and the generation, handling,
storage, transportation, treatment and disposal of waste materials and is also
subject to other federal and state laws regarding health and safety matters.
The
Company believes it is presently in substantial compliance with these laws
and
regulations. These laws and regulations are constantly evolving, and it is
impossible to predict the effect these laws and regulations may have on the
Company in the future.
The
U.S.
Environmental Protection Agency (“EPA”) has issued certain regulations under the
Resource Conservation and Recovery Act (“RCRA”) dealing with the transportation,
storage and treatment of hazardous waste that impact the Company in its carbon
reactivation services. When activated carbon supplied to a customer can no
longer cost-effectively adsorb contaminants, it is returned to the Company's
facilities for reactivation and subsequent reuse. If the substance(s) adsorbed
by the spent carbon is (are) considered hazardous, under these EPA regulations
the activated carbon used in the treatment process is also considered hazardous.
Therefore, a permit is required to transport the hazardous carbon to the
Company's facility for reactivation. The Company possesses the necessary federal
and state permits to transport hazardous waste. At the Company's reactivation
sites, the hazardous spent activated carbon is placed in temporary storage
tanks. Under the EPA regulations, the Company is required to have a hazardous
waste storage permit. The Company has obtained RCRA Part B permits to store
hazardous waste at its Pittsburgh and Catlettsburg facilities. The process
of
reactivating the spent activated carbon, which destroys the hazardous organic
substances, is
regulated
under RCRA interim status standards for thermal treatment units until a RCRA
Part B permit for a Subpart X miscellaneous treatment unit is issued by the
EPA
or an authorized state. The
Company has been issued a Part B permit for the reactivation process at the
Pittsburgh facility. The Company has filed for a Part B treatment permit
at its Catlettsburg facility and is operating
under the interim status standards while working toward obtaining the
permit with the relevant government agencies. The Company does not accept
carbons containing certain hazardous materials for reactivation.
Each
of
the Company’s U.S. production facilities has permits and licenses regulating air
emissions and water discharges. All of the Company’s U.S. production facilities
are controlled under permits issued by local, state and federal air pollution
control entities. The Company is presently in compliance with these permits.
Continued compliance will require administrative control and will be subject
to
any new or additional standards. In May 2003, the Company partially discontinued
operation of one of its three activated carbon lines at its Catlettsburg,
Kentucky facility known as B-line. The Company will need to install pollution
abatement equipment in order to remain in compliance with state requirements
regulating air emissions before resuming full operation of B-line. On January
15, 2008, the Company announced its intention to restart B-line. The Company
estimates it will invest approximately $20.0 million in this line and that
the
project is estimated to be completed in early 2009.
In
conjunction with the February 2004 purchase of substantially all of Waterlink’s
operating assets and the stock of Waterlink’s U.K. subsidiary, several
environmental studies were performed on the Columbus, Ohio property by
environmental consulting firms which identified and characterized areas of
contamination. In addition, these firms identified alternative methods of
remediating the property, identified feasible alternatives and prepared cost
evaluations of the various alternatives. The Company concluded from the
information in the studies that a loss at this property is probable and recorded
the liability as a component of noncurrent other liabilities in the Company’s
consolidated balance sheet. At December 31, 2005, the balance recorded was
$5.3
million. Liability estimates are based on an evaluation of, among other factors,
currently available facts, existing technology, presently enacted laws and
regulations, and the remediation experience of other companies. During the
first
four months of 2006, the Company undertook a process of evaluating contractors
and securing bids to perform the remediation work on the Columbus, Ohio
property. As a result of the evaluation of the additional information gathered
during that process, the Company reduced its estimate of its liability by $1.3
million to $4.0 million as of December 31, 2006. The reduction of the liability
was recorded as a reduction of selling, general and administrative expenses
on
the Company’s condensed consolidated statement of operations for the year ended
December 31, 2006. The Company has not incurred any environmental remediation
expense for the year ended December 31, 2007 and has incurred a total of $0.2
million of environmental remediation expense to date. It is reasonably possible
that a change in the estimate of this obligation will occur as remediation
preparation and remediation activity commences. The ultimate remediation costs
are dependent upon among other things, the requirements of any state or federal
environmental agencies, the remediation methods employed, the final scope of
work being determined, and the extent and types of contamination which will
not
be fully determined until experience is gained through remediation and related
activities. The accrued amounts are expected to be paid out over the course
of
several years once work has commenced. The Company has not yet determined when
it will proceed with remediation efforts.
In
January 2007, the Company received a Notice of Violation (“NOV”) from the United
States Environmental Protection Agency, Region 4 (“EPA”) alleging multiple
violations of the Federal Resource Conservation and Recovery Act and
corresponding EPA and Kentucky Department of Environmental Protection (“KYDEP”)
hazardous waste management rules and regulations. The alleged violations are
based on information provided by the Company during and after a Multi Media
Compliance Evaluation inspection of the Company’s Big Sandy Plant, located in
Catlettsburg, Kentucky, conducted by the EPA and the KYDEP in September 2005,
and concern the hazardous waste spent activated carbon regeneration facility
located at the Big Sandy Plant. The Company submitted its initial written
response to the NOV in June 2007. In August 2007, the EPA notified the Company
that it believes there are significant RCRA violations that are unresolved
by
the information in the Company’s submittals. The Company met with the EPA in
December 2007 to discuss alleged violations. The EPA indicated at the meeting
that it would evaluate its enforcement options and expects to contact the
Company within the next several months to explore a resolution. The EPA can
take
formal enforcement action to require the Company to remediate alleged
violations, which could involve the assessment of substantial civil penalties
as
well. The Company is awaiting further response from the EPA and cannot predict
with any certainty the probable outcome of this matter or range of potential
loss, if any.
In
June
2007, the Company received a Notice Letter from the New York State Department
of
Environmental Conservation (“NYSDEC”) stating that the NYSDEC has determined
that the Company is a Potentially Responsible Party (“PRP”) at the Frontier
Chemical Processing Royal Avenue Site in Niagara Falls, New York (the “Site”).
The Notice Letter requests that the Company and other PRPs develop, implement
and finance a remedial program for Operable Unit #1 at the Site. Operable Unit
#1 consists of overburden soils and overburden and upper bedrock groundwater.
The selected remedy is removal of above grade structures and contaminated soil
source areas, installation of a cover system, and ground water control and
treatment, estimated to cost between approximately $11 million and $14 million,
which would be shared among the PRPs. The Company has not determined what
portion of the costs associated with the remedial program it would be obligated
to bear, therefore the Company cannot predict with any certainty the outcome
of
this matter or range of potential loss. The Notice Letter also demands payment
of all monies that the NYSDEC has already expended for investigation and
remediation of the Site, but does not specify the amount that the NYSDEC has
expended.
In
July
2007, the Company received an NOV from the KYDEP alleging that the Company
has
violated the KYDEP’s hazardous waste management regulations in connection with
the Company’s hazardous waste spent activated carbon regeneration facility
located at the Big Sandy Plant in Catlettsburg, Kentucky. The NOV alleges that
the Company has failed to correct deficiencies identified by the KYDEP in the
Company’s Part B hazardous waste management facility permit application and
related documents and directs the Company to submit a complete and accurate
Part
B application and related documents and to respond to the KYDEP’s comments which
are appended to the NOV. The Company submitted a response to the NOV and the
KYDEP’s comments in December 2007. The KYDEP has not indicated whether or not it
will take formal enforcement action, and has not specified a monetary amount
of
civil penalties it might pursue in any such action, if any. On October 18,
2007,
the Company received an NOV from the EPA related to this permit application
and
submitted a revised application to both the KYDEP and the EPA within the
mandated timeframe. At this time the Company cannot predict with any certainty
the outcome of this matter or range of loss, if any.
Europe.
The
Company is also subject to various environmental health and safety laws and
regulations at its facilities in Belgium, Germany, and the United Kingdom.
These
laws and regulations address substantially the same issues as those applicable
to the Company in the United States. The Company believes it is presently in
substantial compliance with these laws and regulations.
Indemnification.
The
Company has a limited indemnification agreement with the previous owner of
the
Company which will fund certain environmental costs if they are incurred at
the
Company's Catlettsburg, Kentucky plant. The Company believes that the amount
of
the indemnification is sufficient to fund these liabilities if they
arise.
Employee
Relations:
As
of
December 31, 2007, the Company employed 868 persons on a full-time basis, 591
of
whom were salaried production, office, supervisory and sales personnel. The
United Steelworkers represent 216 hourly personnel in the United States. The
current contracts with the United Steelworkers expire on April 1, 2009 and
February 15, 2010, at the Catlettsburg, Kentucky and Columbus, Ohio facilities,
respectively. The Contract with the United Steelworkers for the Company’s
Neville Island plant located in Pittsburgh, Pennsylvania terminated on February
29, 2008 following two extensions of the expiring agreement. The Company is
operating this facility with its salaried employees and temporary replacement
workers until a new agreement is reached. The 61 hourly personnel at the
Company's Belgian facility are represented by two national labor organizations
with contracts expiring on July 31, 2009. The Company also has hourly employees
at three non-union United Kingdom facilities, one non-union United States
facility located in Mississippi, and at two non-union China facilities.
Copies
of Reports:
The
periodic and current reports of the Company filed with the SEC pursuant to
Section 13(a) of the Securities Exchange Act of 1934 are available free of
charge, as soon as reasonably practicable after the same are filed with or
furnished to the SEC, at the Company’s website at www.calgoncarbon.com. All
other filings with the SEC are available on the SEC’s website at
www.sec.gov.
Copies
of Corporate Governance Documents:
The
following Company corporate governance documents are available free of charge
at
the Company’s website at www.calgoncarbon.com and such information is available
in print to any shareholder who requests it by contacting the Secretary of
the
Company at 400 Calgon Carbon Drive, Pittsburgh, PA 15205.
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Corporate
Governance Guidelines
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·
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Audit
Committee Charter
|
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·
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Compensation
Committee Charter
|
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·
|
Governance
Committee Charter
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·
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Code
of Ethical Business Conduct
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Code
of Ethical Business Conduct Supplement for Chief Executive and Senior
Financial Officers
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Item
1A. Risk
Factors:
Risks
relating to our business
Our
pension plans are currently underfunded, and we expect to be subject to
significant increases in pension contributions to our defined benefit pension
plans, thereby restricting our cash flow.
We
sponsor various pension plans in the United States and Europe that are
underfunded and require significant cash payments. We contributed $5.4 million
and $9.2 million to our U.S. Pension plans and $2.4 million and $2.2 million
to
our European pension plans in 2007 and 2006, respectively. We currently expect
to contribute approximately $3.7 million to our U.S. pension plans and $2.5
million to our European pension plans in 2008. If our cash flow from operations
is insufficient to fund our worldwide pension liability, we may be forced to
reduce or delay capital expenditures, seek additional capital or restructure
or
refinance our indebtedness.
The
funding status of our pension plans is determined using many assumptions, such
as inflation, investment rates, mortality, turnover and interest rates, any
of
which could prove to be different than projected. If the performance of the
assets in our pension plans does not meet our expectations, or if other
actuarial assumptions are modified, or not realized, we may be required to
contribute more to our pension plans than we currently expect. For example,
an
approximate 25-basis point decline in the funding target interest rate under
Section 730 of the Internal Revenue Code, as added by the Pension Protection
Act
of 2006 for minimum funding requirements, would increase our minimum required
contributions to our U.S. pension plans by approximately $1.0 million to $1.5
million over the next three years.
Our
pension plans in the aggregate are underfunded by approximately $24 million
as
of December 31, 2007 (based on the actuarial assumptions used for SFAS No.
87,
“Employers’ Accounting for Pensions,” purposes and comparing our projected
benefit obligation to the fair value of plan assets) and required a certain
level of mandatory contributions as prescribed by law. Our U.S. pension plans,
which were underfunded by approximately $11 million as of December 31, 2007,
are
subject to ERISA. In the event our U.S. pension plans are terminated for any
reason while the plans are less than fully funded, we will incur a liability
to
the Pension Benefit Guaranty Corporation that may be equal to the entire amount
of the underfunding at the time of the termination. In addition, changes in
required pension funding rules that were affected by the enactment of the
Pension Protection Act of 2006 will significantly increase our funding
requirements beginning in 2008, which will have an adverse effect on our cash
flow and could require us to reduce or delay our capital expenditures, seek
additional capital or restructure or refinance our indebtedness. See Note 13
to
our consolidated financial statements contained in Item 8 of this Annual
Report.
Our
financial results could be adversely affected by an interruption of supply
or an
increase in coal prices.
We
use
bituminous coal as the main raw material in our granular activated carbon
production process. We estimate that coal will represent approximately 38%
of
our carbon product costs in 2008. We have various annual and multi-year
contracts in place for the supply of coal that expire at various intervals
from
2008 to 2011. Interruptions in coal supply caused by mine accidents, labor
disputes, transportation delays, breach of supplier contractual obligations,
or
other events for other than a temporary period could have an adverse effect
on
our being able to meet our customer demand. In addition, increases in the prices
we pay for coal under our supply contracts could adversely affect our financial
results by significantly increasing production costs. During 2007, our aggregate
costs for coal increased by $1.3 million, or 8.4%, compared to 2006. Based
upon
the estimated usage of coal in 2008, a hypothetical 10% increase in the price
of
coal would result in $1.2 million of additional pre-tax expenses to us. We
may
not be able to pass through raw materials price increases to our
customers
Our
financial results could be adversely affected by shortages in energy supply
or
increases in energy costs.
The
price
for and availability of energy resources could be volatile as it is affected
by
political and economic conditions that are outside our control. We utilize
natural gas as a key component in our activated carbon manufacturing process
and
have annual and multi-year contracts for the supply of natural gas at each
of
our major facilities. If shortages of or restrictions on the delivery of natural
gas occur, production at our activated carbon facilities would be reduced,
which
could result in missed deliveries or lost sales. We also have exposure to
fluctuations in energy costs as they relate to the transportation and
distribution of our products. For example, natural gas prices have increased
significantly in recent years. We may not be able to pass through natural gas
and other fuel price increases to our customers.
Increases
in U.S. and European imports of Chinese or other foreign manufactured activated
carbon could have an adverse effect on our financial
results.
We
face
pressure and competition in our U.S. and European markets from brokers of low
cost imported activated carbon products, primarily from China. We believe we
offer the market technically superior products and related customer support.
However
in some applications, low cost imports have become accepted as viable
alternatives to our products because they have been frequently sold at less
than
fair value in the market. If the markets in which we compete experience an
increase in these imported low cost carbons, especially if sold at less than
fair value, we could see declines in net sales. In addition, the sales of these
low cost activated carbons may make it more difficult for us to pass through
raw
material price increases to our customers.
In
response to a petition from the U.S. activated carbon industry filed in March
2006, the United States Department of Commerce (the “DOC”) announced the
imposition of anti-dumping duties starting in October 2006. The DOC announcement
was based on extensive economic analysis of the operations and pricing practices
of the Chinese producers and exporters. The DOC announcement required U.S.
Customs and Border Protection to require importers of steam activated carbon
from China to post a provisional bond or cash deposit in the amount of the
duties. The anti-dumping duties are intended to offset the amount by which
the
steam activated carbon from China is sold at less than fair value in the
U.S.
In
March
2007, the International Trade Commission (the “ITC”) determined that these
unfairly priced steam activated carbon imports from China caused material injury
to the U.S. activated carbon industry. This affirmative decision by the ITC
triggered the imposition of significant anti-dumping duties in the form of
cash
deposits, ranging from 62 % to 228 %. The anti-dumping duties will be imposed
for at least five years but are subject to periodic review within that time
frame. The first review period begins April 2008. The significant anti-dumping
duties imposed by the DOC and the affirmative decision by the ITC has had an
adverse impact on the cost of Chinese manufactured activated carbon imported
into the U.S. However, the anti-dumping duties could be reduced or eliminated
in
the future, which could adversely affect demand or pricing for our
product.
Our
inability to successfully negotiate new collective bargaining agreements upon
expiration of the existing agreements could have an adverse effect on our
financial results.
We
have
collective bargaining agreements in place at four of our production facilities
covering approximately 32% of our full-time workforce as of December 31, 2007.
Those collective bargaining agreements expire from 2008 through 2010. Any work
stoppages as a result of disagreements with any of the labor unions or our
failure to renegotiate any of the contracts as they expire could disrupt
production and significantly increase product costs as a result of less
efficient operations caused by the resulting need to rely on temporary labor.
For example, our contract with the United Steelworkers for the Company’s Neville
Island plant located in Pittsburgh, Pennsylvania terminated on February 29,
2008
following two extensions of the expiring agreement. The Company is operating
this facility with its salaried employees and temporary replacement workers
until a new agreement is reached.
We
have operations in multiple foreign countries and, as a result, are subject
to
foreign exchange translation risk, which could have an adverse effect on our
financial results.
We
conduct significant business operations in several foreign countries. Of
our
2007 net sales, approximately 45% were sales to countries other than the
United
States, and 2007 net sales denominated in non-U.S. dollars represented
approximately 34% of our overall net sales. We conduct business in the local
currencies of each of our foreign subsidiaries or affiliates. Those local
currencies are then translated into U.S. dollars at the applicable exchange
rates for inclusion in our consolidated financial statements. The exchange
rates
between some of these currencies and the U.S. dollar in recent years have
fluctuated significantly and may continue to do so in the future. Changes
in
exchange rates, particularly the strengthening of the U.S. dollar, could
significantly reduce our sales and profitability from foreign subsidiaries
or
affiliates from one period to the next as local currency amounts are translated
into fewer U.S. dollars.
Our
European and Japanese activated carbon businesses are sourced from both the
United States and China, which subjects these businesses to foreign exchange
transaction risk.
Our
only
production facilities for virgin granular activated carbon are in the United
States and China. Those production facilities are used to supply all of our
global demand for virgin granular activated carbon. All of our foreign
operations purchase from the U.S. and China operations in U.S. dollars yet
sell
in local currency, resulting in foreign exchange transaction risk. We generally
execute foreign currency derivative contracts of not more than one year in
duration to cover a portion of our known or projected foreign currency exposure.
However, those contracts do not protect us from longer term-trends of a
strengthening U.S. dollar, which could significantly increase our cost of
activated carbon delivered to our European and Japanese markets, and we may
not
be able to offset these costs by increasing our prices.
Our
business includes capital equipment sales which could have extreme fluctuations
due to the cyclical nature of that type of business.
Our
Equipment segment represented approximately 12% of our 2007 net sales. This
business generally has a long project life cycle from bid solicitation to
project completion and often requires customers to make large capital
commitments well in advance of project execution. In addition, this business
is
usually affected by the general health of the overall economy. As a result,
sales and earnings from the Equipment segment could be volatile.
We
could find it difficult to fund the capital needed to complete our growth
strategy due to borrowing restrictions under our current credit
facility.
We
are
extended credit under our current credit facility subject to compliance with
certain financial covenants. For example, our current credit facility contains
various affirmative and negative covenants, including limitations on us with
respect to our ability to pay dividends, make loans, incur indebtedness, grant
liens on our property, engage in certain mergers and acquisitions, dispose
of
assets and engage in certain transactions with our affiliates. Borrowing
availability under our current credit facility is based on the value, from
time
to time, of certain of our accounts receivable, inventory, and equipment. As
a
result, these restrictions may prevent us from being able to borrow sufficient
funds under our current credit facility to meet our future capital needs, and
alternate financing on terms acceptable to us may not be available.
If
our
liquidity would remain constrained for more than a temporary period, we may
need
to either delay certain strategic growth projects or access higher cost capital
markets in order to fund our projects, which may adversely affect our financial
results.
Our
required capital expenditures may exceed our estimates.
Our
capital expenditures were $11.8 million in 2007, primarily including
improvements to our manufacturing facilities and equipment to be utilized in
our
service business. Future capital expenditures may be significantly higher and
may vary substantially if we are required to undertake certain actions to comply
with new regulatory requirements or compete with new technologies. We may not
have the capital to undertake these capital investments. If we are unable to
do
so, we may not be able to effectively compete.
Our
financial results could be adversely affected by the continued idling of one
of
our reactivation facilities.
In
January 2006, we announced the temporary idling of our reactivation facility
in
Blue Lake, California. It is our intention to resume operation of the plant
in
the future as market conditions warrant it. If management should determine
not
to restart the plant, operating results would be adversely affected by
impairment charges.
Declines
in the operating performance of one of our business segments could result in
an
impairment of the segment’s goodwill.
As
of
December 31, 2007, we had consolidated goodwill of approximately $27.8 million
recorded in our business segments, primarily from our Activated Carbon and
Service and Equipment segments. We test our goodwill on an annual basis or
when
an indication of possible impairment exists in order to determine whether the
carrying value of our assets is still supported by the fair value of the
underlying business. To the extent that it is not, we are required to record
an
impairment charge to reduce the asset to fair value. For the year ended December
31, 2006, we recorded a $6.9 million impairment charge associated with our
UV
equipment reporting unit, principally as a result of the fourth quarter decision
by the Federal Court of Canada, which found that our patent for the use of
UV
light to prevent infection from Cryptosporidium in drinking water is invalid.
As
a result, our estimate of future royalty income used in determining the fair
value of the reporting unit declined substantially from the prior year. A
decline in the operating performance of any of our business segments or sale
of
a business at an amount less than book value could result in a goodwill
impairment charge which could have a material effect on our financial
results.
Delays
in enactment of new state or federal regulations could restrict our ability
to
reach our strategic growth targets and lower our return on invested
capital.
Our
strategic growth initiatives are reliant upon more restrictive environmental
regulations being enacted for the purpose of making water and air cleaner and
safer. If stricter regulations are delayed or are not enacted or enacted but
subsequently repealed or amended to be less strict, or enacted with prolonged
phase-in periods, our sales growth targets could be adversely affected and
our
return on invested capital could be reduced.
For
example, stricter regulations surrounding the treatment of Cryptosporidium
and
other disease causing microorganisms in drinking water, as addressed by the
EPA’s promulgation of the Long Term 2 Enhanced Surface Water Treatment Rule
(“LT2”), were expected to be effective as of the fourth quarter of 2004. LT2 was
not ultimately published in the Federal Register until January 2006, thus
delaying municipalities’ requirements for testing and any subsequent need to
fund a plan for remediation by over a year. The effect has been a delay in
the
timing of the expected growth for our UV equipment business.
The
Company has also anticipated increased demand for powdered activated carbon
products beginning in 2009 that would be driven by the EPA's Clean Air Mercury
Rule, which established an emissions trading system to reduce mercury emissions
from coal-fired power plants by approximately 70% over a 10 year period. On
February 8, 2008, the United States Circuit Court of Appeals for the District
of
Columbia vacated the Clean Air Mercury Rule. Additional appeals, litigation,
and
regulatory proceedings could defer implementation of another EPA mercury
reduction regulation for years, although any such regulation could be
substantially more stringent, leading to higher than expected demand for the
Company's products at a later date. Even if adoption of a new Clean Air Mercury
Rule is delayed indefinitely by the legal and regulatory process, existing
federal and state laws and regulations, as well as federal legislation
introduced in response to the Court of Appeals decision and new litigation,
could result in substantially more stringent regulation, resulting in
higher-than expected demand for the Company's products, within the near future.
The Company is unable to predict with certainty when and how the outcome of
these complex legal, regulatory and legislative proceedings will affect demand
for its products.
Our
industry is highly competitive. If we are unable to compete effectively with
competitors having greater resources than we do, our financial results could
be
adversely affected.
Our
activated carbon business faces significant competition from Norit N.V.,
Westvaco Corporation and Siemens Water, together with Chinese producers. Our
UV
technology products face significant competition from Trojan Technologies,
Inc.,
which is owned by Danaher Corporation, and Wedeco Ideal Horizons, which is
owned
by ITT Industries. In each case, our competitors include major manufacturers
and
diversified companies, a number of which have revenues and capital resources
exceeding ours, which they may use to develop more advanced or more
cost-effective technologies, increase market share or leverage their
distribution networks. We may experience reduced net sales as a result of having
fewer resources than these competitors.
Encroachment
into our markets by competitive technologies could adversely affect our
financial results.
Activated
carbon is utilized in various applications as a cost-effective solution to
solve
customer problems. If other competitive technologies, such as membranes, ozone
and UV, are advanced to the stage in which such technologies could cost
effectively compete with activated carbon technologies, we could experience
a
decline in net sales, which could adversely affect our financial
results.
Failure
to innovate new products or applications could adversely affect our ability
to
meet our strategic growth targets.
Part
of
our strategic growth and profitability plans involve the development of new
products or new applications for our current products in order to replace more
mature products or markets that have seen increased competition. If we are
unable to develop new products or applications, our financial results could
be
adversely affected.
A
planned or unplanned shutdown at one of our production facilities could have
an
adverse effect on our financial results.
We
operate multiple facilities, and source product from strategic partners who
operate facilities, which are close to water or in areas susceptible to
earthquakes. An unplanned shutdown at any of our or our strategic partners’
facilities for more than a temporary period as a result of a hurricane, typhoon,
earthquake or other natural disaster, or as a result of fire, explosions, war,
terrorist activities, political conflict or other hostilities, could
significantly affect our ability to meet our demand requirements, thereby
resulting in lost sales and profitability in the short-term or eventual loss
of
customers in the long-term. In addition, a prolonged planned shutdown of any
of
our production facilities due to a change in business conditions could result
in
impairment charges that could have an adverse impact on our financial
results.
An
example of an unplanned shutdown of one of our production facilities was the
shutdown of our Pearl River facility in Pearlington, Mississippi due to damage
caused by Hurricane Katrina in August 2005. The plant did not become operational
again until November 2005 and was not operating again at full capacity until
January 2006. Certain customer shipments were either delayed or cancelled during
the plant outage, the consequences of which adversely affected us during 2006.
We estimated our pre-tax business interruption losses during 2005 and 2006
to be
approximately $4.4 million in the aggregate due to the effect of the unplanned
shutdown of the Pearl River facility.
We
hold a variety of patents that give us a competitive advantage in certain
markets. An inability to defend those patents from competitive attack could
have
an adverse effect on both current results and future growth
targets.
From
time
to time in the course of our business, we have to address competitive challenges
to our patented technology. Following protracted litigation in multiple
jurisdictions, the U.S. Court of Appeals for the Federal Circuit held that
our
process patents for the use of ultraviolet light to prevent infection from
Cryptosporidium and Giardia in drinking water thereby concluding this case
(the
“UV patents”) are invalid in the United States. On March 3, 2008, the Supreme
Court of Canada held that our Canadian UV patents are invalid, thereby
concluding this case. We did not appeal the ruling in the United States. A
German trial court has found that a competitor infringed our UV patents with
respect to medium pressure ultraviolet light, but did not infringe with respect
to low pressure ultraviolet light. The Company appealed the decision relating
to
low pressure ultraviolet light. The competitor did not appeal. Oral argument
is
scheduled for September 2008. The validity of the German UV patents, as
distinguished from issues of infringement which were decided in the trial court,
is the subject of administrative proceedings in Germany. The outcome of these
cases has impaired the Company’s ability to capitalize on substantial future
revenues from the licensing of its UV patents.
With
the
exception of 2007, we have incurred significant legal fees and expenses in
recent years litigating these matters. For example, legal expenses related
to
these patent litigation matters totaled approximately $4.7 million in 2006
and
$3.9 million in 2005. We may be required to incur additional significant legal
expenses to defend our intellectual property in the future.
Furthermore,
these legal disputes over our UV patents may adversely affect our business
and
growth prospects because they may suppress overall demand for UV equipment
as
municipalities may decide to wait for the completion of the litigation to
resolve the resulting uncertainties before making investment
decisions.
Our
products may infringe the intellectual property rights of others, which may
cause us to pay unexpected litigation costs or damages or prevent us from
selling our products.
Although
it is our intention to avoid infringing or otherwise violating the intellectual
property rights of others, our products may infringe or otherwise violate the
intellectual property rights of others. We may be subject to legal proceedings
and claims, including claims of alleged infringement by us of the patents and
other intellectual property rights of third parties. Intellectual property
litigation is expensive and time-consuming, regardless of the merits of any
claim.
If
we
were to discover or be notified that our products potentially infringe or
otherwise violate the intellectual property rights of others, we may need to
obtain licenses from these parties or substantially re-engineer our products
in
order to avoid infringement. We might not be able to obtain the necessary
licenses on acceptable terms, or at all, or be able to re-engineer our products
successfully. Moreover, if we are sued for infringement and lose the suit,
we
could be required to pay substantial damages and/or be enjoined from using
or
selling the infringing products. Any of the foregoing could cause us to incur
significant costs and prevent us from selling our products.
Environmental
compliance and remediation could result in substantially increased capital
requirements and operating costs.
Our
production facilities are subject to environmental laws and regulations in
the
jurisdictions in which they operate or maintain properties. Costs may be
incurred in complying with such laws and regulations. Each of our domestic
production facilities require permits and licenses issued by local, state and
federal regulators which regulate air emissions and water discharges. These
permits are subject to renewal and, in some circumstances, revocation.
International environmental requirements vary and could have substantially
lesser requirements that may give competitors a competitive advantage.
Additional costs may be incurred if environmental remediation measures are
required. In addition, the discovery of contamination at any of our current
or
former sites or at locations at which we disposed of waste may expose us to
cleanup obligations and other damages. For example, the Company received a
Notice of Violation (“NOV”) from the U.S. EPA in January 2007 and from the
Kentucky Department of Environmental Protection in July 2007. While the Company
is attempting to resolve these matters, an unfavorable result could have a
significant adverse impact on financial results. If we receive similar demands
in the future, we may incur significant costs in connection with the resolution
of those matters.
Our
international operations expose us to political and economic uncertainties
and
risks from abroad, which could negatively affect our results of
operations.
We
have
manufacturing facilities and sales offices in Europe, China, Japan, Taiwan,
Singapore, Brazil, Mexico, Canada, and the United Kingdom which are subject
to
economic conditions and political factors within the respective countries which,
if changed in a manner adverse to us, could negatively affect our results of
operations and cash flow. Political factors include, but are not limited to,
taxation, nationalization, inflation, currency fluctuations, increased
regulation and quotas, tariffs and other protectionist measures. Approximately
85% of our sales in 2007 were generated by products sold in the U.S., Canada,
and Western Europe while the remaining sales were generated in other areas
of
the world, such as Asia, Eastern Europe, and Latin America.
We
face risks in connection with compliance with Sarbanes-Oxley Section 404 and
any
other related remedial measures that we may undertake.
During
2006, the Company had identified and subsequently remediated a material weakness
in its internal controls. If we are unable to effectively remediate any other
material weaknesses or significant deficiencies in internal control over
financial reporting that are identified in the future and to assert that
disclosure controls and procedures including internal control over financial
reporting are effective in any future period, we could lose investor confidence
in the accuracy and completeness of our financial reports, which could have
an
adverse effect on our stock price and potentially subject us to litigation.
In
addition, we may be required to incur additional costs including but not limited
to the hiring of additional personnel to improve our existing internal control
system.
We
have significant domestic and foreign net operating tax loss and credit
carryforwards which, if they are not utilized, would have an adverse effect
on
our financial results.
As
of
December 31, 2007, we had $13.1 million of deferred tax assets associated with
net operating loss carryforwards (“NOLs”) and tax credit carryforwards that were
generated from both our domestic and foreign operations. We have established
a
valuation reserve of $6.2 million for these deferred tax assets that are not
deemed more likely than not to be realized. If we do not meet our projections
of
profitability in the future, we may not be able to realize these NOLs or tax
credits, and we may be required to record an additional valuation allowance,
which would adversely affect our financial results. In addition, if some or
all
of these NOLs or tax credits expire, they will not be available to offset our
tax liability.
Our
ability to utilize our NOLs and certain other tax attributes may be
limited.
As
of
December 31, 2007, we had NOLs of approximately $0.5 million for federal income
tax purposes and approximately $61.4 million for state income tax purposes.
Under Section 382 of the Internal Revenue Code, if a corporation undergoes
an
“ownership change,” the corporation’s ability to use its pre-change NOLs and
other pre-change tax attributes to offset its post-change income may be limited.
An ownership change is generally defined as a greater than 50% change in its
equity ownership by value over a three-year period. We may experience an
ownership change in the future as a result of subsequent shifts in our stock
ownership. If we were to trigger an ownership change in the future, our ability
to use any NOLs existing at that time could be limited.
We
may not have sufficient funds necessary to settle conversion of our convertible
notes due in 2036 or to purchase the convertible notes upon a fundamental change
or other purchase date, and our future debt may contain limitations on our
ability to pay cash upon conversion or repurchase of the
notes.
Upon
conversion of the convertible notes, we will be required to pay a settlement
amount in cash and shares of our common stock, if any, based upon a 25
trading-day observation period. In addition, on August 15, 2011, August 15,
2016
and August 15, 2026, holders of the notes may require us to purchase their
notes. Holders may also require us to purchase their notes upon a fundamental
change. A fundamental change may also include an event of default, and result
in
the effective acceleration of the maturity of our then-existing indebtedness
under our current credit facility or other indebtedness we may have in the
future.
We
may
not have sufficient financial resources, or may not be able to arrange
financing, to pay the settlement amount in cash, or the purchase price or
fundamental change purchase price for the notes tendered by the holders in
cash.
Our ability to pay the settlement amount in cash, or the purchase price or
fundamental change purchase price for the notes in cash will be subject to
limitations we may have in our credit facilities, or any other indebtedness
we
may have in the future. If the notes are converted or we are required to
purchase them, we may seek the consent of our lenders or attempt to refinance
our debt, but there can be no assurance that we will be able to do so. At
December 31, 2007, the conversion option was triggered based on the trading
price of our common stock. As such, the note holders have the right to convert
their notes to cash and common stock. Unless we have made alternative financing
arrangements, a portion of the convertible debt will be considered
current.
Failure
by us to pay the settlement amount upon conversion or purchase the notes when
required will result in an event of default with respect to the notes, which
may
also result in a default under existing and future agreements governing our
indebtedness. If the repayment of such indebtedness were to be accelerated
after
any applicable notice or grace periods, we may not have sufficient funds to
repay such indebtedness and the notes.
The
fundamental change provisions in our convertible notes may delay or prevent
an
otherwise beneficial takeover attempt of our company.
The
fundamental change provisions in our convertible notes, including the
fundamental change purchase right and the provisions requiring an increase
in
the conversion rate for conversions in connection with certain fundamental
changes, may in certain circumstances delay or prevent a takeover of our company
and the removal of incumbent management that might otherwise be beneficial
to
investors.
Our
stockholder rights plan and our certificate of incorporation and bylaws and
Delaware law contain provisions that may delay or prevent an otherwise
beneficial takeover attempt of our company.
Our
stockholder rights plan and certain provisions of our certificate of
incorporation and bylaws and Delaware law could make it more difficult for
a
third party to acquire us, even if doing so would be beneficial to our
stockholders. These include provisions:
|
·
|
providing
for a board of directors with staggered, three-year
terms;
|
|
·
|
requiring
super-majority voting to affect certain amendments to our certificate
of
incorporation and bylaws;
|
|
·
|
limiting
the persons who may call special stockholders’
meetings;
|
|
·
|
limiting
stockholder action by written
consent;
|
|
·
|
establishing
advance notice requirements for nominations for election to the board
of
directors or for proposing matters that can be acted upon at stockholders’
meetings; and
|
|
·
|
allowing
our board of directors to issue shares of preferred stock without
stockholder approval.
|
These
provisions, along or in combination with each other, may discourage transactions
involving actual or potential changes of control, including transactions that
otherwise could involve payment of a premium over prevailing market prices
to
holders of our common stock, or could limit the ability of our stockholders
to
approve transactions that they may deem to be in their best
interests.
Item
1b. Unresolved
Staff Comments:
None.
Item
2. Properties:
The
Company owns nine production facilities, two of which are located in Pittsburgh,
Pennsylvania; and one each in the following locations: Catlettsburg, Kentucky;
Pearlington, Mississippi; Blue Lake, California; Feluy, Belgium; Grays, United
Kingdom; Datong, China; and Columbus, Ohio. The Company leases one production
facility in each of the following locations: Pittsburgh, Pennsylvania; Houghton
Le Spring, United Kingdom; Ashton-in-Makerfield, United Kingdom; and Tianjin,
China. The Company’s 49% owned joint venture; Calgon Mitsubishi Chemical
Corporation has one facility in Fukui, Fukui Prefecture, Japan. The Company
also
leases twenty warehouses, service centers, and sales office facilities. Of
these, eighteen are located in the United States and one each in the United
Kingdom and Canada. Six of the United States facilities are located in
Pittsburgh, Pennsylvania and one each in the following locations: Downingtown,
Pennsylvania; Providence, Rhode Island; Rockdale, Illinois; Santa Fe Springs,
California; Houston, Texas; Marlton, New Jersey; Stockton, California; South
Point, Ohio; Huntington, West Virginia; Ironton, Ohio; Wurtland, Kentucky;
and
Sulphur, Louisiana. The facility in the United Kingdom is located in
Ashton-in-Makerfield. The Canadian facility is located in Richmond Hill,
Ontario.
The
Catlettsburg, Kentucky plant is the Company's largest facility, with plant
operations occupying approximately 50 acres of a 226-acre site. This plant,
which serves the Activated Carbon and Service segment, produces granular and
powdered activated carbons and acid washed granular activated carbons and
reactivates spent granular activated carbons.
The
Pittsburgh, Pennsylvania carbon production plant occupies a four-acre site
and
serves the Activated Carbon and Service segment. Operations at the plant include
the reactivation of spent granular activated carbons, the impregnation of
granular activated carbons and the grinding of granular activated carbons into
powdered activated carbons. The plant also has the capacity to produce
coal-based or coconut-based specialty activated carbons.
The
Pearlington, Mississippi plant occupies a site of approximately 100 acres.
The
plant has one production line that produces granular activated carbons and
powdered carbons for the Activated Carbon and Service segment.
The
Columbus plant occupies approximately 27 acres in Columbus, Ohio. Operations
at
the plant include reactivation of spent granular activated carbons, impregnation
of activated carbon, crushing activated carbon to fine mesh, acid and water
washing, filter-filling, and various other value added processes to granular
activated carbon for the Activated Carbon and Service segment.
The
Blue
Lake plant, located near the city of Eureka, California occupies approximately
two acres. The primary operation at the plant includes reactivation of spent
granular activated carbons for the Activated Carbon and Service segment. This
plant has been temporarily idled since December 2005.
The
Pittsburgh, Pennsylvania equipment and assembly plant is located on Neville
Island and is situated within a 16-acre site that includes a 300,000 square
foot
building. The Equipment and Assembly plant occupies 85,000 square feet with
the
remaining space used as a centralized warehouse for carbon inventory. The plant,
which serves the Equipment and Activated Carbon and Service segments,
manufactures and assembles fully engineered carbon equipment for purification,
concentration and separation systems. This plant also serves as the east coast
staging and refurbishment point for carbon service equipment.
The
Pittsburgh, Pennsylvania Engineered Solutions plant is a 37,500 sq. ft.
production facility located on Neville Island. The primary focus of this
facility is the manufacture of UV and Ion Exchange (ISEP®) equipment, including
mechanical and electrical assembly, controls systems integration and validation
testing of equipment. This location also serves as the Pilot Testing facility
for Process Development, as well as the spare parts distribution center for
UV
and ISEP® systems.
The
Feluy
plant occupies a site of approximately 21 acres located 30 miles south of
Brussels, Belgium. Operations at the plant include both the reactivation of
spent granular activated carbons and the grinding of granular activated carbons
into powdered activated carbons for the Activated Carbon and Service segment.
The
Grays
plant occupies a three-acre site near London, United Kingdom. Operations at
the
plant include the reactivation of spent granular activated carbons for the
Activated Carbon and Service segment.
The
Ashton-in-Makerfield plant occupies a 1.6 acre site, 20 miles west of
Manchester, United Kingdom. Operations at the plant include the impregnation
of
granular activated carbons for the Activated Carbon and Service segment. The
plant also has the capacity to finish coal-based or coconut-based activated
carbons.
The
Houghton Le Spring plant, located near the city of Newcastle, United Kingdom,
occupies approximately two acres. Operations at the plant include the
manufacture of woven and knitted activated carbon textiles and their
impregnation and lamination for the Consumer segment.
The
Fukui, Fukui Prefecture, Japan plant is 49% owned by Calgon Carbon as part
of a
joint venture with Mitsubishi Chemical Company. The joint venture is Calgon
Mitsubishi Chemical Corporation. The plant, which serves the Activated Carbon
and Service segment, occupies a site of approximately six acres and has one
production line for carbon reactivation.
The
Datong plant located in Datong, China occupies 15,000 square meters. This plant
produces agglomerated activated carbon intermediate product for the Activated
Carbon and Service segment for use in both the potable and industrial
markets.
The
Tianjin plant is located in Tianjin, China and is licensed to export activated
carbon products. It occupies approximately 35,000 square meters. This plant
finishes, sizes, tests, and packages activated carbon products for the Activated
Carbon and Service segment for distribution both inside China and for
export.
The
Company believes that the plants and leased facilities are adequate and suitable
for its operating needs.
Item
3.
Legal Proceedings:
The
Company purchased the common stock of Advanced Separation Technologies
Incorporated (AST) from Progress Capital Holdings, Inc. and Potomac Capital
Investment Corporation on December 31, 1996. On January 12, 1998, the Company
filed a claim for unspecified damages in the United States District Court for
the Western District of Pennsylvania alleging among other things that Progress
Capital Holdings and Potomac Capital Investment Corporation materially breached
various AST financial and operational representations and warranties included
in
the Stock Purchase Agreement and had defrauded the Company. A jury returned
a
verdict in favor of the Company and against the defendants in the amount of
$10.0 million on January 26, 2007 which has not been recorded in operations
as
of December 31, 2007. After the Court denied all post-trial motions, including
the defendants’ motion for a new trial and the Company’s motion for the award of
prejudgment interest, all parties appealed to the United States Circuit Court
of
Appeals for the Third Circuit. The parties settled the case in January 2008
when
the defendants agreed to pay the Company $9.25 million. This sum was received
in
February 2008.
Following
protracted litigation in multiple jurisdictions, the U.S. Court of Appeals
for
the Federal Circuit held that the Company’s process patents for the use of
ultraviolet light to prevent infection from Cryptosporidium and Giardia in
drinking water (the “UV patents”) are invalid in the United States. On March 3,
2008, the Supreme Court of Canada held that the Company’s Canadian UV patents
are invalid, thereby concluding this case. The Company did not appeal the ruling
in the United States and the Canadian ruling concluded the litigation. In March
2007, the Company and Trojan entered into a settlement whereby in exchange
for a
nominal cash payment and relief from legal fees, the Company granted Trojan
worldwide immunity from all current and future legal action related to the
Company’s UV patents. In 2007, a German trial court found that a competitor
infringed the Company’s UV patents with respect to medium pressure ultraviolet
light, but did not infringe with respect to low pressure ultraviolet light.
The
Company appealed the decision relating to low pressure light. The competitor
did
not appeal. Oral argument is scheduled in this case for September 2008. The
validity of the German UV patents, as distinguished from issues of infringement
which were decided in the trial court, is the subject of pending administrative
proceedings in Germany. The outcome of these cases has impaired the Company’s
ability to capitalize on substantial future revenues from the licensing of
its
UV patents.
In
addition to the matters described above, the Company is involved in various
other legal proceedings, lawsuits and claims, including employment, product
warranty and environmental matters of a nature considered normal to its
business. It is the Company’s policy to accrue for amounts related to these
legal matters when it is probable that a liability has been incurred and the
loss amount is reasonably estimable. Management believes that the ultimate
liabilities, if any, resulting from such lawsuits and claims will not materially
affect the consolidated financial position or liquidity of the Company, but
an
adverse outcome could be material to the results of operations in a particular
period in which a liability is recognized.
Item
4.
Submission of Matters to a Vote of Security Holders:
No
matters were submitted to a vote of security holders during the fourth quarter
of 2007.
PART
II
Item
5. Market
for Registrant's Common Equity, Related Shareholder Matters, and Issuer
Repurchases of Equity Securities:
COMMON
SHARES AND MARKET INFORMATION
Common
shares are traded on the New York Stock Exchange under the trading symbol CCC.
There were 1,345 registered shareholders at December 31, 2007.
Quarterly
Common Stock Price Ranges and Dividends
|
|
2007
|
|
2006
|
|
Fiscal
Quarter
|
|
High
|
|
Low
|
|
Dividend
|
|
High
|
|
Low
|
|
Dividend
|
|
First
|
|
|
9.52
|
|
|
5.43
|
|
|
-
|
|
|
8.69
|
|
|
5.50
|
|
|
-
|
|
Second
|
|
|
12.20
|
|
|
7.37
|
|
|
-
|
|
|
7.94
|
|
|
5.45
|
|
|
-
|
|
Third
|
|
|
14.74
|
|
|
10.30
|
|
|
-
|
|
|
6.14
|
|
|
4.15
|
|
|
-
|
|
Fourth
|
|
|
16.96
|
|
|
11.64
|
|
|
-
|
|
|
6.53
|
|
|
4.35
|
|
|
-
|
|
The
Company did not declare or pay any dividends in 2007 and 2006. Dividend
declaration and payout are at the discretion of the Board of Directors. Future
dividends will depend on the Company’s earnings, cash flows, and capital
investment plans to pursue long-term growth opportunities. The Company’s Credit
Facility contains covenants which include limitation on the ability to declare
or pay cash dividends or make other restricted payments, subject to certain
exceptions, such as dividends declared and paid by its subsidiaries and cash
dividends paid by the Company in an amount not to exceed $6.0 million in the
aggregate during any fiscal year if certain conditions are met.
The
information appearing in Item 12 of Part III below regarding common stock
issuable under the Company’s equity compensation plans is incorporated herein by
reference.
Shareholder
Return Performance Graph
The
following performance graph and related information shall not be deemed “filed”
with the Securities and Exchange Commission, nor shall such information be
incorporated by reference into any future filing under the Securities Act of
1933 or Securities Exchange Act of 1934, each as amended, except to the extent
that the Company specifically incorporates it by reference into such
filing.
The
graph
below compares the yearly change in cumulative total shareholder return of
the
Company’s common stock with the cumulative total return of the Standard &
Poor’s (S&P’s) 500 Stock Composite Index and a Peer Group. The Company
believes that its core business consists of purifying air, water and other
products. As such, the Company uses a comparative peer group benchmark. The
companies included in the group are BHA Group Holdings Inc. (2003-2004), Cuno,
Inc.(2003-2005), Ionics, Inc. (2003-2005) , Clarcor, Inc., Donaldson Co. Inc.,
Esco Technologies Inc., Flanders Corp., Lydall, Inc., Millipore Corp., and
Pall
Corp. BHA Group Holdings Inc., Cuno, Inc., and Ionics, Inc. were acquired during
the time period between 2003 and 2007. The data for these companies is included
from the year 2003 until the point at which they were acquired and their common
stock ceased to be publicly traded.
*Assumes
that the value of the investment in Calgon Carbon Common Stock and the index
and
Peer Group was $100 on December 31, 2002 and that all dividends are
reinvested.
Issuer
Repurchases of Equity Securities
Period
|
|
Total
Number
of Shares
Purchased (a)
|
|
Average
Price Paid
Per Share
|
|
Total Number of
Shares Purchased
as Part of Publicly
Announced
Repurchase Plans
or Programs
|
|
Maximum
Number
(or Approximate
Dollar Value)
of Shares that
May
Yet be Purchased
Under the Plans
or
Programs
|
|
October
1 –
October 31,
2007
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
November
1 – November 30, 2007
|
|
|
1,531
|
|
$
|
15.00
|
|
|
—
|
|
|
—
|
|
December
1 – December 31, 2007
|
|
|
—
|
|
|
—
|
|
|
—
|
|
|
—
|
|
(a)
This
column includes purchases under Calgon Carbon’s Stock Option Plan which
represented withholding taxes due from employees relating to the restricted
share awards issued. Future purchases under this plan will be dependent upon
employee elections and forfeitures.
Item
6. Selected
Financial Data:
FIVE-YEAR
SUMMARY OF SELECTED FINANCIAL DATA
Calgon
Carbon Corporation
(Dollars
in thousands, except per share data)
|
|
2007(1)
|
|
2006
|
|
2005
|
|
2004(2)
|
|
2003
|
|
Income
Statement Data:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net
sales
|
|
$
|
351,124
|
|
$
|
316,122
|
|
$
|
290,835
|
|
$
|
295,877
|
|
$
|
253,178
|
|
Income
(loss) from continuing operations
|
|
$
|
15,453
|
|
$
|
(9,012
|
)
|
$
|
(10,507
|
)
|
$
|
3,968
|
|
$
|
3,810
|
|
Income
(loss) from continuing operations per common share, basic
|
|
$
|
0.39
|
|
$
|
(0.23
|
)
|
$
|
(0.27
|
)
|
$
|
0.10
|
|
$
|
0.10
|
|
Income
(loss) from continuing operations per common share,
diluted
|
|
$
|
0.31
|
|
$
|
(0.23
|
)
|
$
|
(0.27
|
)
|
$
|
0.10
|
|
$
|
0.10
|
|
Cash
dividends declared per common share
|
|
$
|
-
|
|
$
|
-
|
|
$
|
0.09
|
|
$
|
0.12
|
|
$
|
0.12
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance
Sheet Data (at year end):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
assets
|
|
$
|
348,140
|
|
$
|
322,364
|
|
$
|
347,868
|
|
$
|
363,898
|
|
$
|
302,195
|
|
Long-term
debt
|
|
$
|
12,925
|
|
$
|
74,836
|
|
$
|
83,925
|
|
$
|
84,600
|
|
$
|
53,600
|
|
|
(1)
|
Excludes
$62.5 million of debt which is classified as current. See Note 9
to the
Consolidated Financial Statements for further
information.
|
|
(2)
|
Includes
the February 2004 acquisition of Waterlink Specialty
Products
|
Item
7. Management's
Discussion and Analysis of Financial Condition and Results of Operations:
Overview
In
2007,
the Company reported net income of $15.3 million or $0.31 per diluted share,
as
compared to a net loss of $7.8 million, or $(0.20) per diluted share for 2006.
Net sales increased 11.1% to $351.1 million for 2007 from $316.1 million for
2006. Selling, general and administrative expenses decreased 1.1% as compared
to
2006, which was primarily attributable to a decline in litigation expenses
as a
result of the substantial completion of the Company’s UV patent cases and
anti-dumping petitions related to steam activated carbon imports from China.
A
final
determination regarding the anti-dumping ruling (the “Ruling”), as described in
the Company’s Form 8-K filed on March 30, 2007, was issued by the International
Trade Commission (“ITC”) on March 29, 2007. The final anti-dumping duties will
be imposed for at least five years. The imposition of the anti-dumping duties
led to price increases during 2007 that significantly contributed to the overall
profit improvement.
Results
of Operations
2007
Versus 2006
Continuing
Operations:
Consolidated
net sales increased in 2007 compared to 2006 by $35.0 million or 11.1%. Sales
increased in the Activated Carbon and Service segment by $30.3 million or 11.4%.
The increase was primarily due to higher pricing for certain activated carbon
products and services. Increased demand as well as higher pricing in the
industrial process and environmental air treatment markets of $3.9 million
and
$15.5 million, respectively, also contributed to the increase. Foreign currency
translation had a positive impact of $8.3 million. Sales in the Equipment
segment increased approximately $3.4 million or 9.1%. The increase was
principally due to higher demand for the Company’s UV and municipal odor
equipment of approximately $5.0 million collectively. Partially offsetting
this
increase was a decrease in demand for traditional carbon adsorption equipment
of
$1.2 million. Foreign currency translation had a positive impact of $0.2
million. Sales for the Consumer segment increased by $1.2 million or 9.5% due
to
higher demand for activated carbon cloth and the positive impact of foreign
currency translation of $0.8 million. The total sales increase for all segments
attributable to the effect of foreign currency translation was $9.3 million.
Net
sales
less cost of products sold, as a percent of net sales, was 31.0% in 2007
compared to 25.1% in 2006, an increase of 5.9%. The increase was primarily
from
the Activated Carbon and Service segment which was 31.0% in 2007 versus 23.8%
in
2006, an increase of 7.2%. The increase was principally due to higher pricing
of
certain activated carbon products and service. The Equipment segment was 27.7%
in 2007 versus 29.9% in 2006, a 2.2% decline which was primarily related to
an
increase in manufacturing related costs. The Consumer segment reported 39.8%
in
2007 versus 38.0% in 2006, an increase of 1.8% primarily due to volume for
higher value activated carbon cloth. The Company’s cost of products sold
excludes depreciation; therefore it may not be comparable to that of other
companies.
Depreciation
and amortization decreased by $1.7 million or 8.9% in 2007 as compared to
2006
primarily due to an increase in fully depreciated fixed assets.
Selling,
general and administrative expenses decreased by $0.7 million or 1.1% in
2007.
The decline was primarily due to a decrease in litigation expense of $6.9
million which was principally related to the substantial completion of the
Company’s UV patent cases and anti-dumping petition for steam activated carbon
imports from China. Partially offsetting this decrease was an increase in
employee related expenses of $1.1 million, $0.6 million of bad debt expense,
and
$3.3 million of professional service fees principally related to accounting,
tax, and Sarbanes-Oxley compliance and planning projects. The 2006 period
included a $1.3 million reduction related to the change in estimate of the
Company’s environmental liabilities assumed in the 2004 Waterlink acquisition.
On a segment basis, selling, general and administrative expenses increased
in
2007 by approximately $2.9 million in the Activated Carbon and Service segment
which was primarily related to higher employee related expenses. The 2006
period
included the aforementioned $1.3 million reduction in the Company’s
environmental liabilities. Selling, general and administrative expenses for
the
Equipment segment decreased by approximately $3.6 million primarily due to
decreased litigation expense related to the substantial completion of the
UV
patent cases and was comparable for the Consumer segment year over
year.
Research
and development expenses decreased by $0.5 million or 12.9%. The decrease was
primarily due to a reduction in employee related expenses.
The
gain
from insurance settlement of $8.1 million in 2006 related to the claim for
damage to the Company’s Pearlington, Mississippi plant which was caused by
Hurricane Katrina in 2005.
The
Company recorded a $6.9 million impairment charge in 2006 related to the
goodwill associated with the Company’s UV reporting unit of its Equipment
segment which is more fully described in Note 7 to the financial statements.
Interest
income increased in 2007 versus 2006 by $0.9 million or 106.2% primarily as
a
result of the Company’s higher cash balance carried throughout
2007.
Interest
expense decreased in 2007 versus 2006 by $0.5 million or 7.8% as a result of
lower average borrowing levels and lower average interest rates paid on the
Company’s borrowings in 2007 versus 2006.
Other
expense - net decreased in 2007 versus 2006 by $0.8 million or 34.8% primarily
due to the write-off of deferred financing fees associated with the Company’s
former credit facility that occurred in 2006.
Income
tax expense from continuing operations for 2007 was $7.8 million as compared
to
a tax benefit of $2.7 million for 2006. The effective tax rate for 2007 was
36.7% compared to a rate of 22.4% for 2006. The overall increase in tax expense
was caused by pre-tax earnings in 2007 compared to the pre-tax loss incurred
in
2006. The effective tax rate in 2006 was significantly impacted by a
non-deductible goodwill charge which caused the Company’s 2006 effective tax
rate to differ from the U.S. Federal statutory rate of 35% by 17.1%. During
2007, the overall tax rate did not differ significantly from the Federal
statutory rate.
In
part
due to an overall foreign loss, the Company is unable to use its foreign tax
credits and has recorded a valuation allowance related to them which, on a
net
basis, caused the overall tax rate to increase by 4.9% in 2007. In addition, the
Company received a dividend from its Japanese joint venture which increased
the
tax rate by 3.5%. The Company’s rate was lower than the U.S. statutory rate by
3.4% because of lower statutory tax rates in its foreign jurisdictions. The
Company also benefited from other deferred tax rate adjustments in 2007.
Equity
in
income of equity investments increased in 2007 versus 2006 by $1.7 million.
The
increase was principally due to lower cost of products sold and a favorable
mix
for products sold by the Company’s joint venture with Calgon Mitsubishi Chemical
Corporation in Japan.
Discontinued
Operations:
Loss
from
discontinued operations was $0.2 million as compared to income from discontinued
operations of $1.2 million in 2006. The 2006 results include a $1.7 million
gain, net of tax, related to the 2006 sales of the Company’s Charcoal/Liquid and
Solvent Recovery businesses.
2006
Versus 2005
Consolidated
net sales increased in 2006 compared to 2005 by $25.3 million or 8.7%. Sales
increased in the Activated Carbon and Service segment by $23.3 million or 9.6%.
The increase was primarily due to increased sales of activated carbon to the
Company’s joint venture, Calgon Mitsubishi Chemical Corporation, of $4.9 million
as well as higher demand for carbon and service products in the world-wide
environmental water treatment and food markets of $7.6 million and $2.8 million,
respectively. Also contributing to this increase was higher demand in the
potable water market in the U.S. and Europe and in the industrial process market
in Asia and Europe of $3.6 million and $1.7 million, respectively. Higher prices
for certain carbon and service products also contributed to the increase.
Foreign currency translation had a positive impact of $1.3 million. Sales in
the
Equipment segment increased $1.0 million or 2.8%. The increase was principally
due to higher demand for traditional carbon adsorption equipment for municipal
and industrial applications. Foreign currency translation had a positive impact
of $0.1 million. Sales for the Consumer segment increased by $0.9 million or
7.7% due to higher demand for both activated carbon cloth of $0.4 million and
PreZerve® products of $0.5 million. The total sales increase for all segments
attributable to the effect of foreign currency translation was $1.5 million.
Net
sales
less cost of products sold, as a percent of net sales, was 25.1% in 2006
compared to 26.0% in 2005. The decline was primarily from the Activated Carbon
and Service segment which was 23.8% in 2006 versus 25.1% in 2005. The Activated
Carbon and Service segment decline was principally due to higher raw material,
energy, and freight costs of $11.9 million or 3.8%, partially offset by
increased volume of $7.6 million or 2.4%. The Equipment and Consumer segments
reported increases of 29.9% versus 28.7%, and 38.0% versus 34.1%, respectively,
in 2006 as compared to 2005 primarily due to increased volume. The Company’s
cost of products sold excludes depreciation; therefore it may not be comparable
to that of other companies.
Depreciation
and amortization decreased by $2.1 million or 10.0% in 2006 as compared to
2005
primarily due to decreased intangible amortization and decreased depreciation
due to an increase in fully depreciated fixed assets.
Selling,
general and administrative expenses increased by $2.5 million or 4.1% in 2006.
The increase was primarily due to an increase in litigation expenses of $3.5
million which mainly related to the Company’s UV patent cases and
anti-dumping duty
petitions. Partially offsetting this increase was a decrease due to the change
in the estimate of the Company’s environmental liabilities assumed in the
Waterlink acquisition of approximately $1.3 million. On a segment basis,
selling, general and administrative expenses increased in 2006 by approximately
$2.5 million in the Activated Carbon and Service segment and decreased in the
Consumer segment by approximately $1.1 million. The year over year changes
are
primarily due to a redistribution of the corporate overhead allocation that
occurred as a result of the 2006 divestiture of the Charcoal/Liquid business
combined with increased litigation expense for the Activated Carbon and Service
segment relating to the anti-dumping duty
petitions. Selling, general and administrative expenses for the Equipment
segment increased by approximately $1.1 million primarily due to the litigation
expenses relating to the UV patent cases.
Research
and development expenses decreased by $0.3 million or 5.7%. The decrease was
primarily due to a reduction in operating supplies utilized in research and
development efforts.
The
Company recorded a gain of $8.1 million in 2006 versus a loss of $1.0 million
in
2005 as a result of costs recovered in its insurance settlement for damages
sustained by Hurricane Katrina at its Pearl River plant which is more fully
described in Note 2 to the financial statements.
The
Company recorded a $6.9 million impairment charge in 2006 related to the
goodwill associated with the Company’s UV reporting unit of its Equipment
segment which is more fully described in Note 7 to the financial statements.
The
impairment charge for the year 2005 of $2.2 million resulted from the Company’s
decision to cancel the construction of a reactivation facility on the U.S.
Gulf
Coast and to suspend the construction of such a facility for the foreseeable
future.
The
Company recorded a $7 thousand restructuring charge in 2006 versus a charge
of
$0.4 million in 2005. The 2005 charge was primarily related to $0.2 million
of
pension curtailment charges and $0.2 million pertaining to the closure of two
small manufacturing facilities as a result of the Company’s 2005 re-engineering
plan.
Interest
income in 2006 was comparable to 2005.
Interest
expense increased in 2006 versus 2005 by $1.1 million or 22.2% due to the
general trend of increasing interest rates in 2006 and the Company paying higher
interest spreads on its borrowings under its old credit facility during the
first seven months of 2006 as a result of a lower trailing twelve months EBITDA.
Other
expense - net in 2006 was comparable to 2005.
The
effective income tax rate for 2006 was a benefit of 22.4%, or $2.7 million
on a
pre-tax loss from continuing operations of $12.0 million. The statutory federal
income tax rate of 35%, which would have resulted in a tax benefit of $4.2
million, was reduced by several factors, the most significant of which is the
goodwill impairment. Of the total goodwill impairment of $6.9 million, 84%
cannot be deducted for income tax purposes in the foreign jurisdiction to which
it is attributable, reducing the tax benefit by $2.0 million. Other factors
reducing the tax benefit and the effective tax rate include the tax rate
differential on foreign income ($0.7 million or 5.9%) and foreign tax credits
($0.1 million or 1.0%). Partially offsetting these reductions were higher tax
benefits resulting from state income taxes ($0.6 million or 5.2%) and from
the
extraterritorial income exclusion ($0.6 million or 4.8%), as well as the
reversal of tax contingency accruals due to legal statutes expiring during
the
year ($0.5 million or 3.8%).
The
effective tax rate for 2005 was a benefit of 49.8%, or $9.7 million on a pre-tax
loss from continuing operations of $19.5 million. The tax benefit of $6.8
million at the 35% statutory rate was increased by $2.2 million, or 11.1% due
to
the reversal of tax contingency accruals from the expiration of legal statutes
during the year. Also contributing to the recognition of higher tax benefits
were state income taxes ($0.7 million or 3.4%) and foreign tax credits ($0.4
million or 2.0%).
The
change in the effective tax rate between 2006 and 2005 was driven by two primary
factors: 2006 goodwill impairment and higher reversals of tax contingency
accruals in 2005. The 2006 goodwill impairment reduced the 2006 effective tax
rate by 17.1%. Because the 2005 impairment charge relates to the cancellation
of
a construction project, it is deductible for tax purposes and does not impact
the effective tax rate. In 2005, the $2.2 reversal of tax contingency accruals
due to legal statutes expiring during the year increased the effective tax
rate
by 11.1% compared to a rate increase of 3.8% in 2006 on reversals of $0.5
million. Also contributing to the change in the effective tax rate were the
effects of rate differentials on foreign income, extraterritorial income
exclusion, and foreign tax credits. In 2006, the extraterritorial income
exclusion increased the tax benefit rate by 4.8%. In 2005, an adjustment of
the
benefit previously recognized reduced the 2005 benefit to less than $.1 million.
Because this benefit was phased out, no further extraterritorial income
exclusion was recorded in 2007.
Equity
in
income (loss) of equity investments increased in 2006 versus 2005 by $1.0
million. The increase is due to a non-recurring charge of $1.9 million incurred
in 2005 related to the shutdown of a carbon production facility in Japan owned
and operated by the joint venture, Calgon Mitsubishi Chemical Corporation,
partially offset by higher cost of sales for the joint venture in 2006 due
to an
unfavorable sales mix.
Discontinued
Operations:
Income
from discontinued operations was $1.2 million in 2006 compared with $3.1 million
in 2005. The decrease is primarily due to the Company having only approximately
two months of Charcoal/Liquid operations and approximately four months of
Solvent Recovery operations due to the 2006 divestiture of both businesses.
The
2006 results include $1.7 million of gain, net of tax, related to the sales
of
the two discontinued businesses.
Working
Capital and Liquidity
Cash
flows provided by operating activities were $29.4 million for the year ended
December 31, 2007 as compared to cash flows used in operating activities of
$5.8
million for the year ended December 31, 2006. The $35.2 million increase was
primarily due to improved operating results of $23.1 million, decreased pension
contributions of $3.6 million and a $2.9 million increase in operating working
capital (exclusive of debt). The 2006 period included non-cash impairment and
restructuring charges of $7.7 million and gains from the sales of assets of
$6.7
million and a gain on insurance settlement of $8.1 million.
Total
debt, net of currency translation adjustments, increased during the year by
$2.1
million at December 31, 2007. The increase was primarily the result of the
addition of short-term debt of $1.5 million related to the Company’s operations
in China and is more fully described in Note 9. The additional borrowings were
used to finance normal working capital and capital expenditure
activities.
On
August
18, 2006, the Company issued $75.0 million in aggregate principal amount of
5.00% Convertible Senior Notes due in 2036 (the “Notes”) and entered into a new
revolving credit facility (the “Credit Facility”). The Company used $68.4
million of the net proceeds from its offering of the Notes to fully repay
indebtedness under the Company’s prior revolving credit facility. Accordingly,
all parties completed their obligations under the Amended and Restated Credit
Agreement, dated as of January 30, 2006. The material terms of the Notes and
the
Credit Facility are described below.
5.00%
Convertible Senior Notes due 2036
The
Company initially issued $65.0 million in aggregate principal amount of 5.00%
Notes due in 2036 and granted the initial purchaser a 30-day option to purchase
up to an additional $10.0 million principal amount of Notes solely to cover
over-allotments, if any. The initial purchaser exercised this option in full.
Accordingly, $75.0 million in aggregate principal amount of Notes were
issued and sold on August 18, 2006. The Notes accrue interest at the rate
of 5.00% per annum and are payable in cash semi-annually in arrears on each
February 15 and August 15, which commenced February 15, 2007. The Notes will
mature on August 15, 2036.
The
Notes
can be converted under the following circumstances: (1) during any calendar
quarter (and only during such calendar quarter) commencing after September
30,
2006, if the last reported sale price of the Company’s common stock is greater
than or equal to 120% of the conversion price of the Notes for at least 20
trading days in the period of 30 consecutive trading days ending on the last
trading day of the preceding calendar quarter; (2) during the five business
day
period after any 10 consecutive trading-day period (the “measurement period”) in
which the trading price per Note for each day in the measurement period was
less
than 103% of the product of the last reported sale price of the Company’s common
stock and the conversion rate on such day; or (3) upon the occurrence of
specified corporate transactions described in the Offering Memorandum. On or
after June 15, 2011, holders may convert their Notes at any time prior to the
maturity date. Upon conversion, the Company will pay cash and shares of its
common stock, if any, based on a daily conversion value (as described herein)
calculated on a proportionate basis for each day of the 25 trading-day
observation period.
For
the
period ended December 31, 2007, the last reported sale price of the Company’s
common stock was greater than 120% of the conversion price of the Notes for
at
least 20 trading days in the period of 30 consecutive trading days ended
December 31, 2007. As a result, as of December 31, 2007, the holders of the
Notes have the right to convert the Notes into cash and shares of common stock.
Although the Company does not anticipate that a significant amount of these
Notes will be converted, if any, as of December 31, 2007, the Company is
required to reclassify as a current liability, that portion of the Notes that
can not be refinanced on a long-term basis under the Company’s Credit Facility
as provided for by SFAS No. 6, “Classification of Short-Term Obligations
Expected to be Refinanced,” which was $65.0 million at December 31,
2007.
The
initial conversion rate is 196.0784 shares of the Company’s common stock per
$1,000 principal amount of Notes, equivalent to an initial conversion price
of
approximately $5.10 per share of common stock. The conversion rate is subject
to
adjustment in some events, including the payment of a dividend on the Company’s
common stock, but will not be adjusted for accrued interest, including any
additional interest. In addition, following certain fundamental changes
(principally related to changes in control) that occur prior to August 15,
2011,
the Company will increase the conversion rate for holders who elect to convert
Notes in connection with such fundamental changes in certain circumstances.
The
Company considered EITF 00-27 issue 7 which indicates that if a reset of the
conversion rate due to a contingent event occurs the Company would need to
calculate if there is a beneficial conversion and record if applicable. Through
December 31, 2007, no contingent events have occurred.
The
Company may not redeem the Notes before August 20, 2011. On or after that date,
the Company may redeem all or a portion of the Notes at any time. Any redemption
of the Notes will be for cash at 100% of the principal amount of the Notes
to be
redeemed, plus accrued and unpaid interest, including any additional interest,
to, but excluding, the redemption date.
Holders
may require the Company to purchase all or a portion of their Notes on each
of
August 15, 2011, August 15, 2016, and August 15, 2026. In addition, if the
Company experiences specified types of fundamental changes, holders may require
it to purchase the Notes. Any repurchase of the Notes pursuant to these
provisions will be for cash at a price equal to 100% of the principal amount
of
the Notes to be purchased plus any accrued and unpaid interest, including any
additional interest, to, but excluding, the purchase date.
The
Notes
are the Company’s senior unsecured obligations, and rank equally in right of
payment with all of its other existing and future senior indebtedness. The
Notes
are guaranteed by certain of the Company’s domestic subsidiaries on a senior
unsecured basis. The subsidiary guarantees are general unsecured senior
obligations of the subsidiary guarantors and rank equally in right of payment
with all of the existing and future senior indebtedness of the subsidiary
guarantors. If the Company fails to make payment on the Notes, the subsidiary
guarantors must make them instead. The Notes are effectively subordinated to
any
indebtedness of the Company’s non-guarantor subsidiaries. The Notes are
effectively junior to all of the Company’s existing and future secured
indebtedness to the extent of the value of the assets securing such
indebtedness.
The
Company sold the Notes to the original purchaser at a discount of $3.3 million
that is being amortized over a period of five years. During 2007, the Company
recorded interest expense of $4.5 million, of which $3.9 million related to
the
Notes and $0.6 million related to the amortization of the discount. The Company
incurred issuance costs of $1.5 million which have been deferred and are being
amortized over a five year period.
Credit
Facility
The
Credit Facility was initially a $50.0 million facility and included a separate
U.K. sub-facility and a separate Belgian sub-facility. On February 5, 2007,
the
Credit Facility was amended to increase the commitment amount to $55.0 million
and was syndicated to include one additional lender. The facility permits the
total revolving credit commitment to be increased up to $75.0 million. The
facility matures on May 15, 2011. The terms of the syndicated Credit Facility
were not materially different than the original facility prior to the February
5, 2007 syndication. Availability for domestic borrowings under the Credit
Facility is based upon the value of eligible inventory, accounts receivable
and
property, plant and equipment, with separate borrowing bases to be established
for foreign borrowings under a separate U.K. sub-facility and a separate Belgian
sub-facility. Availability under the Credit Facility is conditioned upon various
customary conditions.
The
Credit Facility is secured by a first perfected security interest in
substantially all of the Company’s assets, with limitations under certain
circumstances in the case of capital stock of foreign subsidiaries. Certain
of
the Company’s domestic subsidiaries unconditionally guarantee all indebtedness
and obligations related to domestic borrowings under the Credit Facility. The
Company and certain of its domestic subsidiaries also unconditionally guarantee
all indebtedness and obligations under the U.K. sub-facility.
As
of the
year ended December 31, 2007, the carrying amount of assets pledged as
collateral was $51.1 million. The carrying amount as of the year ended December
31, 2007 for domestic, U.K., and Belgian borrowers were $41.2 million, $5.3
million, and $4.6 million, respectively. The Credit Facility contains a fixed
charge coverage ratio covenant which becomes effective when total domestic
availability falls below $11.0 million. As of the year ended December 31, 2007,
total availability was $34.5 million. Availability as of the year ended December
31, 2007 for domestic, U.K., and Belgian borrowers was $30.4 million, $4.1
million, and zero, respectively.
The
Company can issue letters of credit up to $20.0 million of the available
commitment amount under the Credit Facility. Sub-limits for letters of credit
under the U.K. sub-facility and the Belgian sub-facility are $2.0 million
and $6.0 million, respectively. Letters of credit outstanding at December
31, 2007 totaled $16.6 million.
The
Credit Facility interest rate is based upon Euro-based (LIBOR) rates with other
interest rate options available. The applicable Euro Dollar margin in effect
when the Company is in compliance with the terms of the facility ranges from
1.25% to 2.25% and is based upon the Company’s overall availability under the
Credit Facility. The unused commitment fee is equal to 0.375% per annum and
is
based upon the unused portion of the revolving commitment.
The
Credit Facility contains a number of affirmative and negative covenants. For
the
period ended December 31, 2007, the last reported sale price of the Company’s
common stock was greater than 120% of the conversion price of the Notes for
at
least 20 trading days in the period of 30 consecutive trading days ended
December 31, 2007. As a result, as of December 31, 2007, the holders of the
Notes have the right to convert the Notes into cash and shares of common stock.
Although currently not anticipated by the Company, the ability of holders of
the
Notes to convert could be an event of default of the Credit Facility. Included
in the Credit Facility is a provision for up to $10.0 million where Notes can
be
converted up to that amount and classified as long-term debt as the Company
has
the ability and intent to refinance it under the Credit Facility. The Credit
Facility also includes a provision for up to $3.0 million of letters of credit
under the Company’s U.S., Belgium, and UK sub-limits that can be issued having
expiration dates that are more than one year but not more than three years
after
the date of issuance.
The
negative covenants provide for certain restrictions on possible acts by the
Company related to matters such as additional indebtedness, certain liens,
fundamental changes in the business, certain investments or loans, asset sales
and other customary requirements. The Company was in compliance with all such
negative covenants as of December 31, 2007.
Management
cannot be assured that, after the December 31, 2007 audited financial statements
have been provided to the lenders, there will not be any violation in future
periods of the covenants contained in the Credit Facility. Although not
currently anticipated by the Company, the tendering by holders of a substantial
portion of the Notes as described above would increase the risk of violation
of
the financial covenant related to the fixed charge coverage ratio due to the
increased borrowing under the Credit Facility.
Contractual
Obligations
The
Company is obligated to make future payments under various contracts such as
debt agreements, lease agreements, and unconditional purchase obligations.
The
Company is contractually obligated to make monthly, quarterly, and semi-annual
interest payments on its outstanding debt agreements. At December 31, 2007,
the
weighted average effective interest rate was 5.93% and long-term borrowings
totaled $12.9 million. The Company is also required to make minimum funding
contributions to its pension plans which are estimated at $6.2 million for
the
year ended December 31, 2008. The following table represents the significant
contractual cash obligations and other commercial commitments of the Company
as
of December 31, 2007.
|
|
Due
in
|
|
|
|
|
|
(Thousands)
|
|
2008
|
|
2009
|
|
2010
|
|
2011
|
|
2012
|
|
Thereafter
|
|
Total
|
|
Short-term
debt |
|
$
|
1,504
|
|
$
|
-
|
|
|
|
|
$
|
-
|
|
$
|
-
|
|
$
|
-
|
|
$
|
1,504
|
|
Current
portion of long-debt*
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
65,000
|
|
|
-
|
|
|
-
|
|
|
65,000
|
|
Long-term
debt
|
|
|
-
|
|
|
2,925
|
|
|
-
|
|
|
10,000
|
|
|
-
|
|
|
-
|
|
|
12,925
|
|
Interest
on Notes
|
|
|
3,750
|
|
|
3,750
|
|
|
3,750
|
|
|
2,369
|
|
|
-
|
|
|
-
|
|
|
13,619
|
|
Operating
leases
|
|
|
3,733
|
|
|
3,009
|
|
|
2,409
|
|
|
1,921
|
|
|
1,798
|
|
|
4,711
|
|
|
17,581
|
|
Unconditional
purchase obligations**
|
|
|
21,925
|
|
|
20,725
|
|
|
19,202
|
|
|
16,659
|
|
|
1,575
|
|
|
1,838
|
|
|
81,924
|
|
Total
contractual cash obligations
|
|
$
|
30,912
|
|
$
|
30,409
|
|
$
|
25,361
|
|
$
|
95,949
|
|
$
|
3,373
|
|
$
|
6,549
|
|
$
|
192,553
|
|
*The
2011
maturity excludes debt discount of $2,493. This amount is classified as
currently payable at December 31, 2007. See Note 9.
**Primarily
for the purchase of raw materials, transportation, and information systems
services.
The
long-term tax payable of $12.6 million, pertaining to the tax liability related
to the adoption of FASB Interpretation No. 48, “Accounting for Uncertainty in
Income Taxes, an interpretation of FASB Statement No. 109” (“FIN No. 48”), has
been excluded from the above table due to the fact that the Company is unable
to
determine the period in which the liability will be resolved.
The
Company does not have any significant long-term employment
agreements.
The
Company does not have any special-purpose entities or off-balance sheet
financing arrangements except for the operating leases disclosed above as well
as indemnities and guarantees disclosed in Note 18.
The
Company maintains qualified defined benefit pension plans (the “Qualified
Plans”), which cover substantially all non-union and certain union employees in
the United States and Europe. The
Company’s pension expense for all pension plans approximated $2.4 million and
$6.4 million for the years ended December 31, 2007 and 2006, respectively.
The
fair
value of the Company’s Qualified Plan assets has increased from $81.6 million at
December 31, 2006 to $88.9 million at December 31, 2007. During the year ended
December 31, 2007, the Company funded its Qualified Plans with $7.8 million
in
contributions. The Company expects that it will be required to fund the
Qualified Plans with approximately $6.2 million in contributions for the year
ending December 31, 2008.
The
Company did not declare or pay any dividends in 2007. Dividend declaration
and
payout are at the discretion of the Board of Directors. Future dividends will
depend on the Company’s earnings, cash flow and capital investment plans to
pursue long-term growth opportunities. The Company’s Credit Facility contains
covenants which include limitations on its ability to declare or pay cash
dividends or make other restricted payments, subject to certain exceptions,
such
as dividends declared and paid by its subsidiaries and cash dividends paid
by
the Company in an amount not to exceed $6.0 million in the aggregate during
any
fiscal year if certain conditions are met.
As
of
December 31, 2007, the holders of the Company’s Notes have the right to convert
the Notes into cash and shares of common stock. Although the Company does not
anticipate that a significant amount of these Notes will be converted, if any,
as of December 31, 2007, the Company is required to reclassify as a current
liability, that portion of the Notes that can not be refinanced on a long-term
basis under the Company’s Credit Facility as provided by SFAS No. 6,
“Classification of Short-Term Obligations Expected to be Refinanced.” The
Company expects that cash from operating activities plus cash balances and
available external financing will be sufficient to meet its cash
requirements.
The
cash
needs of each of the Company’s reporting segments are principally covered by the
segment’s operating cash flow on a stand alone basis. Any additional needs will
be funded by cash on hand or borrowings under the Company’s credit facility.
Specifically, the Equipment and Consumer segments historically have not required
extensive capital expenditures; therefore, the Company believes that operating
cash flows, cash on hand, and borrowings will adequately support each of the
segments cash needs.
Capital
Expenditures and Investments
Capital
expenditures were $11.8 million in 2007, $12.9 million in 2006, and $16.0
million in 2005. Expenditures for 2007 primarily included $8.4 million for
improvements to manufacturing facilities and $3.3 million for customer capital.
Expenditures for 2006 primarily included $9.3 million for improvements to
manufacturing facilities, $2.2 million related to the repair of the Company’s
Pearl River plant as a result of Hurricane Katrina, and $1.0 million for
customer capital. Capital expenditures for 2008 are projected to be
approximately $52.0 million which includes approximately $20.0 million related
to the planned re-start of a previously idled production line at the Company’s
Catlettsburg, Kentucky facility. The aforementioned expenditures are expected
to
be funded by operating cash flows, cash on hand, and borrowings.
In
January 2006, the Company announced the temporary idling of its reactivation
facility in Blue Lake, California in an effort to reduce operating costs and
to
more efficiently utilize the capacity at its other existing locations. The
Company conducted an impairment review, in accordance with SFAS No. 144, of
the
plant’s assets having a net book value of $1.5 million in connection with the
temporary idling of the facility and concluded that the assets were not
impaired. It is management’s intention to resume operation of the plant in the
future as market conditions warrant it. If management should determine not
to
re-start the plant, operating results would be adversely affected by impairment
charges.
The
2005
cash outflow for the purchase of a business of $0.9 million, as shown on the
statement of cash flows, represents the Company’s acquisition of the additional
20% interest of Datong Carbon Corporation of $0.7 million and $0.2 million
related to the joint venture that was formed with C. Gigantic Carbon
Corporation.
Other
cash flows from investing activities include the receipt of $21.3 million in
2006 for the sale of the Charcoal/Liquid and Solvent Recovery businesses and
the
2006 receipt of $4.6 million in connection with the insurance settlement for
damage caused to the Company’s Pearlington, Mississippi plant by Hurricane
Katrina. Proceeds for sales of property, plant and equipment totaled $0.5
million in 2007 compared to $1.2 million in 2006 and $1.4 million in
2005.
Critical
Accounting Policies
Management
of the Company has evaluated the accounting policies used in the preparation
of
the financial statements and related footnotes and believes the policies to
be
reasonable and appropriate. The preparation of the financial statements in
accordance with accounting principles
generally accepted in the United States requires management to make judgments,
estimates, and assumptions regarding uncertainties that affect the reported
amounts of assets and liabilities, disclosure of contingent assets and
liabilities, and the reported amounts of revenues and expenses. Management
uses
historical experience and all available information to make
these judgments and estimates, and actual results will inevitably differ from
those estimates and assumptions that are used to prepare the Company’s financial
statements at any given time. Despite these inherent limitations, management
believes that Management’s
Discussion
and Analysis (“MD&A”) and the financial statements and related footnotes
provide a meaningful
and fair perspective of the Company.
The
following are the Company’s critical accounting policies impacted by
management’s judgments, assumptions, and estimates. Management believes that the
application of these policies on a consistent basis enables the Company to
provide the users of the financial statements with useful and reliable
information about the Company’s operating results and financial
condition.
Revenue
Recognition
The
Company recognizes revenue and related costs when goods are shipped or services
are rendered to customers provided that ownership and risk of loss have passed
to the customer.
Revenue
for major equipment projects is recognized under the percentage of completion
method. The Company’s major equipment projects generally have a long project
life cycle from bid solicitation to project completion. The nature of the
contracts are generally fixed price with milestone billings. The Company
recognizes revenue for these projects based on the fixed sales prices multiplied
by the percentage of completion. In applying the percentage-of-completion
method, a project’s percent complete as of any balance sheet date is computed as
the ratio of total costs incurred to date divided by the total estimated costs
at completion.
As
changes in the estimates of total costs at completion and/or estimated total
losses on projects are identified, appropriate earnings adjustments are recorded
during the period that the change or loss is identified. The Company has a
history of making reasonably dependable estimates of costs at completion on
our
contracts that follow the percentage-of-completion method; however, due to
uncertainties inherent in the estimation process, it is possible that estimated
project costs at completion could vary from our estimates. The principal
components of costs include material, direct labor, subcontracts, and allocated
indirect costs. Indirect costs primarily consist of administrative labor and
associated operating expenses, which are allocated to the respective projects
on
actual hours charged to the project utilizing a standard hourly
rate.
Allowance
for Doubtful Accounts
The
Company maintains allowances for doubtful accounts for estimated losses
resulting from the inability of its customers to make required payments. The
amount of allowance recorded is based upon a quarterly review of specific
customer receivables that remain outstanding at least
three months beyond their respective due dates. The Company’s provision for
doubtful accounts and loss experience have not varied materially from period
to
period. However, if the financial condition of the Company’s customers were to
deteriorate resulting in an impairment of their ability to make payments,
additional allowances may be required.
Inventories
The
Company’s inventories are carried at the lower of cost or market. The Company
provides for inventory obsolescence based upon a review of specific products
that have remained unsold for a prescribed period of time. If the market demand
for various products softens, additional allowances may be required.
Goodwill
and Other Intangible Assets
Goodwill
represents the excess of the cost of an acquired business over the fair value
of
the identifiable tangible and intangible assets acquired and liabilities assumed
in a business combination. Identifiable intangible assets acquired in business
combinations are recorded based on their fair values at the date of acquisition.
In accordance with SFAS No. 142, “Goodwill and Other Intangible Assets,”
goodwill and identifiable intangible assets with indefinite lives are not
subject to amortization but must be evaluated for impairment. None of the
Company’s identifiable intangible assets other than goodwill have indefinite
lives.
The
Company tests goodwill for impairment at least annually by initially comparing
the fair value of each of the Company’s reporting units to their related
carrying values. If the fair value of the reporting unit is less than its
carrying value, the Company performs an additional step to determine the implied
fair value of the goodwill. The implied fair value of goodwill is determined
by
first allocating the fair value of the reporting unit to all of the assets
and
liabilities of the unit and then computing the excess of the unit’s fair value
over the amounts assigned to the assets and liabilities. If the carrying value
of goodwill exceeds the implied fair value of goodwill, such excess represents
the amount of goodwill impairment, and the Company recognizes such impairment
accordingly. Fair values are estimated using discounted cash flow and other
valuation methodologies that are based on projections of the amounts and timing
of future revenues and cash flows, assumed discount rates and other assumptions
as deemed appropriate. The Company also considers such factors as historical
performance, anticipated market conditions, operating expense trends and capital
expenditure requirements.
On
November 14, 2006, the Federal Court of Canada found that the Company’s patent
for the use of UV light to prevent infection from Cryptosporidium in drinking
water was invalid. As a result, the Company’s estimate of future royalties used
in determining the fair value of the UV
reporting unit as of December 31, 2006 declined substantially from the prior
year resulting in goodwill impairment of $6.9 million. This impairment
represents the difference between the implied fair value of goodwill for the
UV
reporting unit and the carrying value of the goodwill
before recognition of the impairment.
The
following table summarizes the relevant assumptions used for determining the
fair value for each of the significant reporting units at December 31, 2007
and
2006:
|
|
Discount
Rate
|
|
Capitalization
Rate
|
|
Compound
Annual
Growth
Rate
|
|
Reporting
Unit
|
|
2007
|
|
2006
|
|
2007
|
|
2006
|
|
2007
|
|
2006
|
|
Activated
Carbon and Service Segment:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Americas/Asia
|
|
|
15.0
|
%
|
|
13.0
|
%
|
|
12.0
|
%
|
|
10.0
|
%
|
|
3.0
|
%
|
|
3.0
|
%
|
Europe
|
|
|
15.0
|
%
|
|
13.0
|
%
|
|
12.0
|
%
|
|
10.0
|
%
|
|
3.0
|
%
|
|
3.0
|
%
|
Equipment
Segment:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
15.0
|
%
|
|
14.5
|
%
|
|
12.0
|
%
|
|
11.5
|
%
|
|
3.0
|
%
|
|
14.0
|
%
|
UV
|
|
|
17.0
|
%
|
|
16.5
|
%
|
|
14.0
|
%
|
|
13.5
|
%
|
|
20.2
|
%* |
|
19.0
|
%*
|
*Represents
compound annual growth rate used for the discrete projection period, which
was 5
years for all reporting units
except for the UV reporting unit. Discrete projections for 10 years were used
for the UV reporting unit to enable growth from recent government regulations
to
subside to a normalized long-term rate. The aforementioned government
regulations, which were published in the Federal Register in January 2006,
require water municipalities to install an abatement process to remove certain
harmful bacteria from drinking water.
The
discount rates used in the 2007 impairment analysis for all reporting units
increased due to an overall increase in the Company’s stock beta as well as for
the inherent market risk related to the Equipment segment. The capitalization
rate represents the difference between the discount rate and the long-term
growth rate. Management re-evaluated its growth assumption for the ISEP®
reporting unit in 2007 in accordance with the ISEP® strategic plan. As a result
of this process, the Company concluded that a 3% compound annual growth rate
was
appropriate at December 31, 2007.
Additional
assumptions used in the analysis include the following:
|
·
|
Revenue
assumptions were based on the Company’s historical performance and
anticipated market conditions and the Company’s strategy thereto. These
assumptions varied among reporting
units.
|
|
·
|
Gross
profit generally is expected to increase as revenues improve in most
reporting units.
|
|
·
|
Operating
expenses are expected to increase in absolute dollars but decrease
as a
percentage of revenues.
|
|
·
|
Depreciation
expense is expected to increase as capital expenditures increase
over the
most recent five-year trend.
|
|
·
|
An
effective tax rate of 40% was used for all reporting
units.
|
Except
as
noted above, the assumptions used for the 2007 impairment analysis were
consistent with those used for the 2006 analysis.
The
following table shows the impact on the fair value of each significant reporting
unit of (a) a 1% decrease in revenues and costs and (b) a 1% increase in the
discount rate:
(Dollars
in Thousands)
|
|
Fair
Value at December 31, 2007
|
|
|
|
Reporting
Unit
|
|
Impairment
Analysis
|
|
If 1% Decrease in
Revenues/Costs
|
|
If 1% Increase in
Discount Rate
|
|
Carrying
Value of Unit
|
|
Activated
Carbon and Service Segment:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Americas/Asia
|
|
$
|
267,832
|
|
$
|
258,186
|
|
$
|
248,719
|
|
$
|
134,361
|
|
Europe
|
|
|
78,188
|
|
|
75,115
|
|
|
72,276
|
|
|
53,761
|
|
Equipment
Segment:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
12,545
|
|
|
12,177
|
|
|
11,790
|
|
|
6,273
|
|
UV
|
|
|
12,030
|
|
|
10,781
|
|
|
10,233
|
|
|
10,053
|
|
The
Company’s identifiable intangible assets other than goodwill have finite lives.
Certain of these intangible assets, such as customer relationships, are
amortized using an accelerated methodology while others, such as patents, are
amortized on a straight-line basis over their estimated useful lives. In
addition, intangible assets with finite lives are evaluated for impairment
whenever events or circumstances indicate that their carrying amount may not
be
recoverable, as prescribed by Statement of Financial Accounting Standards (SFAS)
No. 144, "Accounting for the Impairment or Disposal of Long-Lived Assets" ("SFAS
No. 144").
Pensions
The
Company maintains Qualified Plans which cover substantially all non-union and
certain union employees in the United States and Europe. Pension expense, which
totaled $2.4 million in 2007 and $6.4 million in 2006, is calculated based
upon
a number of actuarial assumptions, including expected long-term rates of return
on our Qualified Plans’ assets, which range from 6.45% to 8.00%. In developing
the expected long-term rate of return assumption, the Company evaluated
input from its actuaries, including their review of asset class return
expectations as well as long-term inflation assumptions. The Company also
considered the historical performance of its benchmark portfolio over the
trailing ten and fifteen year period of 7.03% and 9.53%, respectively, as the
best indicator of expected future performance. The Company also considered
its
historical 10-year compounded return which ranges from 5.65% to 7.27%. The
expected long-term return on the U.S. Qualified Plans’ assets is based on an
asset allocation assumption of 75.0% with equity managers and 25.0% with
fixed-income managers. The European Qualified Plans’ assets are based on an
asset allocation assumption of 41.1% with equity managers, 44.4% with
fixed-income managers, and 14.5% with other investments. Because of market
fluctuation, the Company’s actual U.S. asset allocation as of December 31, 2007
was 74.3% with equity managers, 25.1% with fixed-income managers, and 0.6%
with
other investments. The Company’s actual European asset allocation as of December
31, 2007 was 41.7% with equity managers, 42.2% with fixed-income managers,
and
16.1% with other investments. The Company regularly reviews its asset allocation
and periodically rebalances its investments to the targeted allocation when
considered appropriate. The Company continues to believe that the range of
6.45%
to 8.00% is a reasonable long-term rate of return on its Qualified Plans assets.
The Company will continue to evaluate its actuarial assumptions, including
its
expected
rate of return, at least annually, and will adjust as necessary.
The
discount rates that the Company utilizes for its Qualified Plans to determine
pension obligations is based on a review of long-term bonds that receive one
of
the two highest ratings given by a recognized rating agency. The discount rate
determined on this basis has increased
from a range of 4.45% to 5.60% at December 31, 2006 to a range of 4.89% to
5.93%
at December 31, 2007. The Company estimates that its pension expense for the
Qualified Plans will approximate $3.3 million in 2008. Future actual pension
expense will depend on future investment performance, funding levels, changes
in
discount rates and various other factors related to the populations
participating in its Qualified Plans.
A
sensitivity analysis of the projected incremental effect of a hypothetical
1
percent change in the significant assumptions used in the pension calculations
is provided in the following table:
|
|
Hypothetical
Rate
|
|
|
|
Increase
(Decrease)
|
|
|
|
U.S.
Plans
|
|
European
Plans
|
|
(Thousands)
|
|
(1%)
|
|
1%
|
|
(1%)
|
|
1%
|
|
Discount
rate
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension
liabilities at December 31, 2007
|
|
$
|
11,624
|
|
$
|
(10,024
|
)
|
$
|
7,308
|
|
$
|
(5,429
|
)
|
Pension
Costs for the year ended December 31, 2007
|
|
$
|
514
|
|
$
|
(587
|
)
|
$
|
327
|
|
$
|
(261
|
)
|
Indexation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension
liabilities at December 31, 2007
|
|
$
|
-
|
|
$
|
-
|
|
$
|
(753
|
)
|
$
|
829
|
|
Pension
Costs for the year ended December 31, 2007
|
|
$
|
-
|
|
$
|
-
|
|
$
|
(45
|
)
|
$
|
65
|
|
Expected
return on plan assets
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension
costs for the year ended December 31, 2007
|
|
$
|
625
|
|
$
|
(625
|
)
|
$
|
215
|
|
$
|
(213
|
)
|
Compensation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
$
|
(1,098
|
)
|
$
|
1,129
|
|
$
|
(1,384
|
)
|
$
|
2,115
|
|
Pension
costs for the year ended December 31, 2007
|
|
$
|
(210
|
)
|
$
|
220
|
|
$
|
(274
|
)
|
$
|
314
|
|
Income
Taxes
During
the ordinary course of business, there are many transactions and calculations
for which the ultimate tax determination is uncertain. Significant judgment
is
required in determining the Company’s annual effective tax rate and in
evaluating tax positions. As described in Note 14, on January 1, 2007, the
Company adopted FASB Interpretation No. 48, “Accounting for Uncertainty in
Income Taxes - an interpretation of FASB Statement No. 109, Accounting for
Income Taxes” (“FIN 48”). FIN 48 contains a two-step approach to recognizing and
measuring uncertain tax positions accounted for in accordance with SFAS No.
109,
“Accounting for Income Taxes.” The first step is to evaluate the tax position
for recognition by determining if the weight of available evidence indicates
that it is more likely than not that the position will be sustained on audit,
including resolution of related appeals or litigation processes, if any. The
second step is to measure the tax benefit as the largest amount that is more
than 50% likely of being realized upon settlement.
Although
we believe we have adequately reserved for our uncertain tax positions, no
assurance can be given that the final tax outcome of these matters will not
be
different. We adjust these reserves in light of changing facts and
circumstances, such as the closing of a tax audit, the refinement of an
estimate, or a lapse of a tax statute. To the extent that the final tax outcome
of these matters is different than the amounts recorded, such differences will
impact the provision for income taxes in the period in which such determination
is made. The provision for income taxes includes the impact of reserve
provisions and changes to reserves that are considered appropriate, as well
as
the related net interest.
The
Company is subject to varying statutory tax rates in the countries where it
conducts business. Fluctuations in the mix of the Company’s income between
countries result in changes to the Company’s overall effective tax
rate.
The
Company recognizes benefits associated with foreign and domestic net operating
loss and credit carryforwards when the Company believes that it is more likely
than not that its future taxable income in the relevant tax jurisdictions will
be sufficient to enable the realization of the tax benefits. As of December
31,
2007, the Company had recorded a net deferred tax asset of $14.3 million, of
which $13.1 million (before consideration of a $6.2 million valuation allowance)
represents tax benefits from foreign and domestic operating loss and credit
carryforwards. Approximately 80% of the net benefit for the operating loss
and
credit carryforwards relates to: (a) federal operating loss carryforwards,
which
do not begin to expire until 2025, (b) state operating loss carryforwards,
of
which 90% will not expire until 2018 or later; (c) federal alternative minimum
tax credits which do not expire; and(d) foreign tax credits which can be carried
forward 10 years and expire from 2009 through 2017. The remaining 20% relates
to
foreign operating loss carryforwards, which generally have unlimited
carryforward periods but may be subject to limitations based on specific types
of income. Generally, the Company believes that it is more likely than not
that
its future taxable income in the relevant tax jurisdictions will be sufficient
to enable the realization of these tax benefits. However, the Company has
recorded a valuation allowance of $5.9 million related to foreign tax credits
of
$9.1 million to reduce these tax credit carryforwards to an amount more likely
than not to be realized.
The
Company based its conclusions on normalized historical performance and on
projections of future taxable income in the relevant tax jurisdictions.
Normalized historical performance for purposes of this assessment includes
adjustments for those income and expense items that are unusual and
non-recurring in nature and are not expected to affect results in future
periods. Such unusual and non-recurring items include the effects of
discontinued operations, legal fees or settlements associated with specific
litigation matters, pension curtailment costs,
and restructuring costs. For the three-year period ended December 31, 2007,
the
Company’s normalized historical performance on a cumulative basis, indicated a
profit, which supports the likelihood of future federal taxable income. The
Company’s projections of future taxable income for state purposes consider known
events, such as the passage of legislation or expected
occurrences, and do not reflect a general growth assumption. Certain major
assumptions affecting the income projections relate to government standards,
which impact the entire industry. Government regulations passed in 2005 are
expected to expand market opportunities
in both the UV market and the mercury removal market. Also, effective in 2007,
the Department of Commerce notified the Company that tariffs ranging from 62%
to
228% were imposed on all steam activated carbon products imported from China.
The imposition of duties has favorably affected its markets. Incorporation
of
these known or pending events into the projections of future taxable income
results in significant growth in the near term. While management believes the
risks associated with these events not occurring may be low, the ultimate impact
of the events on the Company’s taxable income remains uncertain. For example, if
the Company is unable to achieve its projected share of the expanded markets
resulting from government regulations or anti-dumping duties, the Company’s
projected future taxable income may not be realized. For the 15-year period
beginning in 2012, which generally represents the period after the impact of
the
known or pending events has stabilized, the compound annual growth rate of
projected taxable income is less than 5%. The Company’s projections do not
include income from the reversal of deferred tax liabilities. The Company
believes that its assumptions and the resulting projections are reasonable
and
fully support the recognized deferred tax assets associated with state net
operating loss and credit carryforwards.
Approximately
77% of the Company’s deferred tax assets, or $23.1 million, represent temporary
differences associated with pensions, accruals, goodwill, and other assets.
Over
60% of the Company’s deferred tax liabilities of $15.7 million at December 31,
2007 relate to property, plant and equipment. These temporary differences will
reverse in the future due to the natural realization of temporary differences
between annual book and tax reporting. The Company believes that the deferred
tax liabilities generally will impact taxable income of the same character
(ordinary income), timing, and jurisdiction as the deferred tax
assets.
On
October 22, 2004, the American Jobs Creation Act of 2004 (“AJCA”) was signed
into law. This law repealed an export tax benefit, provided for a 9% deduction
on U.S. manufacturing income, and allowed the repatriation of foreign earnings
at a reduced rate for one year, subject to certain limitations. The Company
did
not benefit from the manufacturing deduction in 2007 due to the Company’s net
operating loss carryforwards.
The
AJCA
also reduced the Federal Income tax rate to 5.25 percent on earnings distributed
from non-U.S. based subsidiaries for a one-year period. In 2005, the Company
repatriated a total of $4.9 million from two of its wholly owned subsidiaries
($1.7 million from Calgon Carbon Canada, Inc. and $3.2 million from Chemviron
Carbon Ltd.). The current income tax included in the 2005 income tax provision
for this repatriation is $0.3 million. The Company has not changed its policy
of
permanent reinvestment under APB No. 23 due to this one-time repatriation of
earnings.
Litigation
The
Company is involved in various asserted and unasserted legal claims. An estimate
is made to accrue for a loss contingency relating to any of these legal claims
if it is probable that a liability was incurred at the date of the financial
statements and the amount of loss can be reasonably estimated. Because of the
subjective nature inherent in assessing the outcome of legal
claims and because the potential that an adverse outcome in a legal claim could
have a material
impact on the Company’s legal position or results of operations, such estimates
are considered
to be critical accounting estimates. The Company will continue to evaluate
all
legal matters as additional information becomes available. Reference is made
to
Note 18 of the financial statements for a discussion of litigation and
contingencies.
Long-Lived
Assets
The
Company evaluates long-lived assets under the provisions of Statement of
Financial Accounting
Standards (SFAS) No. 144, “Accounting for the Impairment or Disposal of
Long-Lived Assets,” which addresses financial accounting and reporting for the
impairment of long-lived assets, and for long-lived assets to be disposed of.
For assets to be held and used, the Company
groups a long-lived asset or assets with other assets and liabilities at the
lowest level for which identifiable cash flows are largely independent of the
cash flows of other assets and liabilities. An impairment loss for an asset
group reduces only the carrying amounts of a long-lived asset or assets of
the
group being evaluated. The loss is allocated to the long-lived assets of the
group on a pro-rata basis using the relative carrying amounts of those assets,
except that the loss allocated to an individual long-lived asset of the group
does not reduce the carrying amount of that asset below its fair value whenever
that fair value is determinable without undue cost and effort. Estimates of
future cash flows used to test the recoverability of a long-lived asset group
include only the future cash flows that are
associated with and that are expected to arise as a direct result of the use
and
eventual disposition of the asset group. The future cash flow estimates used
by
the Company exclude interest charges.
New
Accounting Pronouncements
In
February 2007, the FASB issued Statement of Financial Accounting Standards
(SFAS) No. 159, “The Fair Value Option for Financial Assets and Financial
Liabilities - Including an amendment of FASB Statement No. 115” (“SFAS No.
159”). This Statement permits entities to choose to measure many financial
instruments and certain other items at fair value and report unrealized gains
and losses on these instruments in earnings. SFAS No. 159 is effective as of
January 1, 2008. The Company has chosen not to elect the fair
value option under SFAS No. 159 for financial assets and liabilities as of
December 31, 2007.
In
September 2006, the FASB issued SFAS No. 157, “Fair Value Measurements” (“SFAS
No. 157”), which defines fair value, establishes a framework for measuring fair
value in generally accepted accounting principles (“GAAP”), and expands
disclosure about fair value measurements. SFAS No. 157 is effective for
financial statements issued for fiscal years beginning after November 15, 2007,
and interim periods within those fiscal years, except as it relates to
nonrecurring fair value measurements of non-financial assets and liabilities
for
which SFAS No. 157 is effective for fiscal years beginning after November 15,
2008. The Company will adopt SFAS No. 157 as required for the fiscal year 2008
and expects that the adoption will not have a material
impact on its financial position or results of operations.
In
December 2007, the FASB issued SFAS No. 141 (revised 2007), “Business
Combinations” (“SFAS No.141(R)”), which replaces SFAS No. 141, “Business
Combinations.” SFAS No. 141(R) retains the underlying concepts of SFAS
No. 141 in that all business combinations are still required to be
accounted for at fair value under the acquisition method of accounting, but
SFAS
No. 141(R) changes the method of applying the acquisition method in a
number of significant aspects. Acquisition costs will generally be expensed
as
incurred; noncontrolling interests will be valued at fair value at the
acquisition date; in-process research and development will be recorded at
fair
value as an indefinite-lived intangible asset at the acquisition date;
restructuring costs associated with a business combination will generally
be
expensed subsequent to the acquisition date; and changes in deferred tax
asset
valuation allowances and income tax uncertainties after the acquisition date
generally will affect income tax expense. SFAS No. 141(R) is effective on
a
prospective basis for all business combinations for which the acquisition
date
is on or after the beginning of the first annual period subsequent to
December 15, 2008, with an exception related to the accounting for
valuation allowances on deferred taxes and acquired contingencies related
to
acquisitions completed before the effective date. SFAS No. 141(R) amends
SFAS No. 109 to require adjustments, made after the effective date of this
statement, to valuation allowances for acquired deferred tax assets and income
tax positions to be recognized as income tax expense. Beginning January 1,
2009,
the Company will apply the provisions of SFAS No. 141(R) to its accounting
for
applicable business combinations.
In
December 2007, the FASB issued SFAS No. 160 (“SFAS No. 160”),
“Noncontrolling Interests in Consolidated Financial Statements.” SFAS No. 160
changes the classification of noncontrolling (minority) interests on the
balance sheet and the accounting for and reporting of transactions between
the
reporting entity and holders of such noncontrolling interests. Under the new
standard, noncontrolling interests are considered equity and are to be reported
as an element of stockholders’ equity rather than outside of equity in the
balance sheet. In addition, the current practice of reporting minority interest
expense or benefit also will change. Under the new standard, net income will
encompass the total income before minority interest expense. The income
statement will include separate disclosure of the attribution of income between
the controlling and noncontrolling interests. Increases and decreases in the
noncontrolling ownership interest amount are accounted for as equity
transactions. SFAS No. 160 is effective for fiscal years beginning after
December 15, 2008 and earlier application is prohibited. Upon adoption, the
balance sheet and the income statement should be recast retrospectively for
the
presentation of noncontrolling interests. The other accounting provisions of
the
statement are required to be adopted prospectively. The Company will adopt
SFAS
No. 160 as required and expects that the adoption will not have a material
impact on its financial position or results of operations.
Item
7A. Quantitative
and Qualitative Disclosures About Market Risk:
Commodity
Price Risk
In
the
normal course of its business, the Company is exposed to market risk or price
fluctuations related to the production of activated carbon products. Coal and
natural gas, which are significant to the manufacturing of activated carbon,
have market prices that fluctuate regularly. Based on the estimated 2008 usage
of coal and natural gas, a hypothetical 10% increase (or decrease) in the price
of coal and natural gas, would result in a pre-tax loss (or gain) of $1.2
million and $0.2 million, respectively.
To
mitigate the risk of fluctuating prices, the Company has entered into long-term
contracts to hedge the purchase of a percentage of the estimated need of coal
and natural gas at fixed prices. The future commitments under these long-term
contracts, which provide economic hedges, are disclosed within Note 10 to the
Financial Statements. The value of the cash-flow hedges for natural gas is
disclosed in Note 17 to the Financial Statements.
Interest
Rate Risk
The
Company’s current and long-term debt is based on fixed rates, rates that float
with the Euro Dollar, or prime, and the carrying value approximates fair value.
The Company’s senior convertible notes, which represent the majority of the
Company’s outstanding debt balance at December 31, 2007, are based on a fixed
rate and therefore would not be subject to interest rate risk. A hypothetical
change of 10% in the Company’s effective interest rate from year-end 2007 would
not result in a material change to interest expense.
Foreign
Currency Exchange Risk
The
Company is subject to risk of price fluctuations related to anticipated revenues
and operating costs, firm commitments for capital expenditures, and existing
assets and liabilities
denominated in currencies other than U.S. dollars. The Company enters into
foreign currency forward exchange contracts and purchases options to manage
these exposures. At December 31, 2007, nine foreign currency forward exchange
contracts were outstanding. A hypothetical 10% strengthening (or weakening)
of
the U.S. dollar, British Pound Sterling, Canadian Dollar, and Euro at December
31, 2007 would result in a pre-tax loss (or gain) of approximately $0.3 million.
The foreign currency forward exchange contracts purchased during 2007 have
been
accounted for according to SFAS No. 133, "Accounting for Derivative Instruments
and Hedging Activities" ("SFAS No. 133").
The
Company had also entered into a ten-year foreign currency swap agreement to
fix
the foreign exchange rate on a $6.5 million intercompany loan between the
Company and its subsidiary, Chemviron Carbon Ltd. The swap agreement provides
the offset for the foreign currency fluctuation and neutralizes its effect
on
loan payments and valuation. This swap transaction has been accounted for in
accordance with SFAS No. 133.
Item
8. Financial
Statements and Supplementary Data:
REPORT
OF MANAGEMENT
Responsibility
for Preparation of the Financial Statements and Establishing and Maintaining
Adequate Internal Control Over Financial Reporting.
Responsibility
for Financial Statements
Management
is responsible for the preparation of the financial statements included in
this
Annual Report. The Consolidated Financial Statements were prepared in accordance
with accounting principles generally accepted in the United States of America
and include amounts that are based on the best estimates and judgments of
management. The Notes to the Consolidated Financial Statements contained within
this Annual Report are consistent with the Consolidated Financial
Statements.
Management’s
Annual Report on Internal Control over Financial Reporting
Management
is responsible for establishing and maintaining adequate internal controls
over
financial reporting. The Company’s internal control system is designed to
provide reasonable assurance concerning the reliability of the financial data
used in the preparation of the Company’s financial statements, as well as
reasonable assurance with respect to safeguarding the Company’s assets from
unauthorized use or disposition. However, no matter how well designed and
operated, an internal control system can provide only reasonable, not absolute,
assurance that the objectives of the control system are met.
Management
conducted an evaluation of the effectiveness of the Company’s internal control
over financial reporting as of December 31, 2007. In making this evaluation,
management used the criteria set forth by the Committee of Sponsoring
Organizations of the Treadway Commission (COSO) in Internal Control -
Integrated Framework. Management’s evaluation included reviewing the
documentation of our controls, evaluating the design effectiveness of controls,
and testing their operating effectiveness. Based on this evaluation, management
believes that, as of December 31, 2007, the Company’s internal controls over
financial reporting were effective and provide reasonable assurance that the
accompanying financial statements do not contain any material
misstatement.
The
effectiveness of internal control over financial reporting as of
December 31, 2007, has been audited by Deloitte & Touche LLP, an
independent registered public accounting firm, who also audited our consolidated
financial statements. Deloitte & Touche LLP’s attestation report on the
effectiveness of our internal control over financial reporting appears below.
Changes
in Internal Control
There
have been no changes to our internal control over financial reporting that
occurred that have materially affected, or are reasonably likely to materially
affect, our internal control over financial reporting.
INTERNAL
CONTROLS - REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
To
the
Board of Directors and Shareholders of
Calgon
Carbon Corporation
Pittsburgh,
Pennsylvania
We
have
audited the internal control over financial reporting of Calgon Carbon
Corporation and subsidiaries (the “Company”) as of December 31, 2007, based on
the criteria established in Internal
Control–Integrated
Framework
issued
by the Committee of Sponsoring Organizations of the Treadway Commission.
The Company's management is responsible for maintaining effective internal
control over financial reporting and for its assessment of the effectiveness
of
internal control over financial reporting, included in the accompanying
Management’s
Annual Report on Internal Control over Financial Reporting,
included in the Report
of Management.
Our responsibility is to express an opinion on the Company's internal control
over financial reporting based on our audit.
We
conducted our audit in accordance with the standards of the Public Company
Accounting Oversight Board (United States). Those standards require that
we plan and perform the audit to obtain reasonable assurance about whether
effective internal control over financial reporting was maintained in all
material respects. Our audit included obtaining an understanding of
internal control over financial reporting, assessing the risk that a material
weakness exists, testing and evaluating the design and operating effectiveness
of internal control based on the assessed risk, and performing such other
procedures as we considered necessary in the circumstances. We believe
that our audit provides a reasonable basis for our opinion.
A
company's internal control over financial reporting is a process designed by,
or
under the supervision of, the company's principal executive and principal
financial officers, or persons performing similar functions, and effected by
the
company's board of directors, management, and other personnel to provide
reasonable assurance regarding the reliability of financial reporting and the
preparation of financial statements for external purposes in accordance with
generally accepted accounting principles. A company's internal control
over financial reporting includes those policies and procedures that (1) pertain
to the maintenance of records that, in reasonable detail, accurately and fairly
reflect the transactions and dispositions of the assets of the company; (2)
provide reasonable assurance that transactions are recorded as necessary to
permit preparation of financial statements in accordance with generally accepted
accounting principles, and that receipts and expenditures of the company are
being made only in accordance with authorizations of management and directors
of
the company; and (3) provide reasonable assurance regarding prevention or timely
detection of unauthorized acquisition, use, or disposition of the company's
assets that could have a material effect on the financial
statements.
Because
of the inherent limitations of internal control over financial reporting,
including the possibility of collusion or improper management override of
controls, material misstatements due to error or fraud may not be prevented
or
detected on a timely basis. Also, projections
of any evaluation of the effectiveness of the internal control over financial
reporting to future periods are subject to the risk that the controls may become
inadequate because of changes in conditions, or that the degree of compliance
with the policies or procedures may deteriorate.
In
our
opinion, the Company maintained, in all material respects, effective internal
control over financial reporting as of December 31, 2007, based on the criteria
established in Internal
Control–Integrated
Framework
issued
by the Committee of Sponsoring Organizations of the Treadway Commission.
We
have
also audited, in accordance with the standards of the Public Company Accounting
Oversight Board (United States) the consolidated financial statements as of
and
for the year ended December 31, 2007 of the Company and our report dated March
14, 2008 expressed an unqualified opinion on those financial statements and
included an explanatory paragraph regarding the adoption of Financial Accounting
Standards Board Interpretation No. 48, Accounting
for Uncertainty in Income Taxes.
DELOITTE
& TOUCHE LLP
Pittsburgh,
Pennsylvania
March
14,
2008
FINANCIAL
STATEMENTS - REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING
FIRM
To
the
Board of Directors and Shareholders of
Calgon
Carbon Corporation
Pittsburgh,
Pennsylvania
We
have
audited the accompanying consolidated balance sheets of Calgon Carbon
Corporation and subsidiaries (the "Company") as of December 31, 2007 and 2006,
and the related consolidated statements of income (loss) and comprehensive
income (loss), shareholders' equity, and cash flows for each of the three years
in the period ended December 31, 2007. These financial statements are the
responsibility of the Company's management. Our responsibility is to
express an opinion on the financial statements based on our audits. We did
not
audit the financial statements of Chemviron Carbon Ltd. and subsidiaries
(“Chemviron UK”) (a subsidiary) for the year ended December 31, 2005, which
statements reflect total revenues constituting 12 percent of consolidated total
revenues for the year ended December 31, 2005. Those financial statements were
audited by other auditors whose report has been furnished to us, and our
opinion, insofar as it relates to the amounts included for Chemviron UK, is
based solely on the report of such other auditors.
We
conducted our audits in accordance with the standards of the Public Company
Accounting Oversight Board (United States). Those standards require that
we plan and perform the audit to obtain reasonable assurance about whether
the
financial statements are free of material misstatement. An audit includes
examining, on a test basis, evidence supporting the amounts and disclosures
in
the financial statements. An audit also includes assessing the accounting
principles used and significant estimates made by management, as well as
evaluating the overall financial statement presentation. We believe that
our audits and the report of the other auditors provide a reasonable basis
for our opinion.
In
our
opinion, based on our audits and the report of the other auditors, such
consolidated financial statements present fairly, in all material respects,
the
financial position of Calgon Carbon Corporation and subsidiaries as of December
31, 2007 and 2006, and the results of their operations and their cash flows
for
each of the three years in the period ended December 31, 2007, in conformity
with accounting principles generally accepted in the United States of
America.
As
discussed in Note 1 to the consolidated financial statements, the Company
adopted the provisions of Financial Accounting Standards Board Interpretation
No. 48, Accounting
for Uncertainty in Income Taxes
on
January 1, 2007, the provisions of Statement of Financial Accounting Standards
No. 158, Employers’
Accounting for Defined Benefit Pension and Other Postretirement
Plans
on
December 31, 2006 and the provisions of Statement of Financial Accounting
Standards No. 123(R), Share
Based Payment
on
January 1, 2006.
We
have
also audited, in accordance with the standards of the Public Company Accounting
Oversight Board (United States), the Company's internal control over financial
reporting as of December 31, 2007, based on the criteria established in
Internal Control–Integrated
Framework
issued
by the Committee of Sponsoring Organizations of the Treadway Commission
and our
report dated March 14, 2008 expressed an unqualified opinion on the Company's
internal control over financial reporting.
DELOITTE
& TOUCHE LLP
Pittsburgh,
Pennsylvania
March
14,
2008
FINANCIAL
STATEMENTS - REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING
FIRM
To
the
Board of Directors and Shareholders of
Chemviron
Carbon Limited
We
have
audited the accompanying consolidated statements of income, shareholders'
equity, and cash flows of Chemviron Carbon Limited and subsidiaries for the
year ended December 31, 2005. These consolidated financial statements are the
responsibility of the Company’s management. Our responsibility is to express an
opinion on these consolidated financial statements based on our
audit.
We
conducted our audit in accordance with the standards of the Public Company
Accounting Oversight Board (United States). Those standards require that we
plan
and perform the audit to obtain reasonable assurance about whether the financial
statements are free of material misstatement. An audit includes examining,
on a
test basis, evidence supporting the amounts and disclosures in the financial
statements. An audit also includes assessing the accounting principles used
and
significant estimates made by management, as well as evaluating the overall
financial statement presentation. We believe that our audit provides a
reasonable basis for our opinion.
In
our
opinion, the consolidated financial statements referred to above present fairly,
in all material respects, the results of the operations and cash
flows of Chemviron Carbon Limited and subsidiaries for the year
ended December 31, 2005, in conformity with U.S. generally accepted
accounting principles.
KPMG
LLP
Manchester,
United Kingdom
April
24,
2007
CONSOLIDATED
STATEMENTS OF INCOME (LOSS) AND COMPREHENSIVE INCOME
(LOSS)
Calgon
Carbon Corporation
|
|
Year
Ended December 31
|
|
(Dollars
in thousands except per share data)
|
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
Net
sales
|
|
$
|
341,508
|
|
$
|
306,770
|
|
$
|
286,421
|
|
Net
sales to related parties
|
|
|
9,616
|
|
|
9,352
|
|
|
4,414
|
|
Total
|
|
|
351,124
|
|
|
316,122
|
|
|
290,835
|
|
Cost
of products sold (excluding depreciation)
|
|
|
242,273
|
|
|
236,673
|
|
|
215,330
|
|
Depreciation
and amortization
|
|
|
17,248
|
|
|
18,933
|
|
|
21,042
|
|
Selling,
general and administrative expenses
|
|
|
61,348
|
|
|
62,003
|
|
|
59,547
|
|
Research
and development expenses
|
|
|
3,699
|
|
|
4,248
|
|
|
4,506
|
|
(Gain)
loss from insurance settlement (Note 2)
|
|
|
-
|
|
|
(8,072
|
)
|
|
1,000
|
|
Goodwill
impairment charge (Note 7)
|
|
|
-
|
|
|
6,940
|
|
|
-
|
|
Gulf
Coast impairment charge
|
|
|
-
|
|
|
-
|
|
|
2,158
|
|
Restructuring
charges
|
|
|
-
|
|
|
7
|
|
|
412
|
|
|
|
|
324,568
|
|
|
320,732
|
|
|
303,995
|
|
Income
(loss) from operations
|
|
|
26,556
|
|
|
(4,610
|
)
|
|
(13,160
|
)
|
Interest
income
|
|
|
1,695
|
|
|
822
|
|
|
719
|
|
Interest
expense
|
|
|
(5,508
|
)
|
|
(5,977
|
)
|
|
(4,891
|
)
|
Other
expense - net
|
|
|
(1,441
|
)
|
|
(2,209
|
)
|
|
(2,138
|
)
|
Income
(loss) from continuing operations before income taxes and equity
in income
(loss) of equity investments
|
|
|
21,302
|
|
|
(11,974
|
)
|
|
(19,470
|
)
|
Income
tax provision (benefit) (Note 14)
|
|
|
7,826
|
|
|
(2,676
|
)
|
|
(9,688
|
)
|
Income
(loss) from continuing operations before equity in income (loss)
of equity
investments
|
|
|
13,476
|
|
|
(9,298
|
)
|
|
(9,782
|
)
|
Equity
in income (loss) of equity investments, net
|
|
|
1,977
|
|
|
286
|
|
|
(725
|
)
|
Income
(loss) from continuing operations
|
|
|
15,453
|
|
|
(9,012
|
)
|
|
(10,507
|
)
|
Income
(loss) from discontinued operations, net (Note 4)
|
|
|
(166
|
)
|
|
1,214
|
|
|
3,091
|
|
Net
income (loss)
|
|
|
15,287
|
|
|
(7,798
|
)
|
|
(7,416
|
)
|
Other
comprehensive income (loss), net of tax provision (benefit) of $3,449,
$2,752, and ($3,019), respectively
|
|
|
6,703
|
|
|
9,238
|
|
|
(9,811
|
)
|
Comprehensive
income (loss) (2006 restated)
|
|
$
|
21,990
|
|
$
|
1,440
|
|
$
|
(17,227
|
)
|
|
|
|
|
|
|
|
|
|
|
|
Basic
income (loss) from continuing operations per common share
|
|
$
|
.39
|
|
$
|
(.23
|
)
|
$
|
(.27
|
)
|
|
|
|
|
|
|
|
|
|
|
|
Income
from discontinued operations per common share
|
|
$
|
-
|
|
$
|
.03
|
|
$
|
.08
|
|
Basic
net income (loss) per common share
|
|
$
|
.39
|
|
$
|
(.20
|
)
|
$
|
(.19
|
)
|
Diluted
income (loss) from continuing operations per common share
|
|
$
|
.31
|
|
$
|
(.23
|
)
|
$
|
(.27
|
)
|
|
|
|
|
|
|
|
|
|
|
|
Income
from discontinued operations per common share
|
|
$
|
-
|
|
$
|
.03
|
|
$
|
.08
|
|
Diluted
net income (loss) per common share
|
|
$
|
.31
|
|
$
|
(.20
|
)
|
$
|
(.19
|
)
|
Weighted
average shares outstanding, in thousands
|
|
|
|
|
|
|
|
|
|
|
Basic
|
|
|
39,788
|
|
|
39,927
|
|
|
39,615
|
|
Diluted
|
|
|
50,557
|
|
|
39,927
|
|
|
39,615
|
|
The
accompanying notes are an integral part of these consolidated financial
statements.
CONSOLIDATED
BALANCE SHEETS
Calgon
Carbon Corporation
|
|
December
31
|
|
(Dollars
in thousands)
|
|
|
2007
|
|
|
2006
|
|
Assets
|
|
|
|
|
|
|
|
Current
assets:
|
|
|
|
|
|
|
|
Cash
and cash equivalents
|
|
$
|
30,304
|
|
$
|
5,631
|
|
Receivables,
net of allowance for losses of $2,834 and $1,981
|
|
|
55,195
|
|
|
53,239
|
|
Receivables
from related parties
|
|
|
2,353
|
|
|
1,797
|
|
Revenue
recognized in excess of billings on uncompleted contracts
|
|
|
7,698
|
|
|
7,576
|
|
Inventories
|
|
|
81,280
|
|
|
70,339
|
|
Deferred
income taxes – current
|
|
|
9,246
|
|
|
5,761
|
|
Other
current assets
|
|
|
3,602
|
|
|
4,369
|
|
Total
current assets
|
|
|
189,678
|
|
|
148,712
|
|
Property,
plant and equipment, net
|
|
|
105,512
|
|
|
106,101
|
|
Equity
investments
|
|
|
8,593
|
|
|
6,971
|
|
Intangibles,
net
|
|
|
7,760
|
|
|
8,521
|
|
Goodwill
|
|
|
27,845
|
|
|
27,497
|
|
Deferred
income taxes – long-term
|
|
|
6,419
|
|
|
20,225
|
|
Other
assets
|
|
|
2,333
|
|
|
4,337
|
|
Total
assets
|
|
$
|
348,140
|
|
$
|
322,364
|
|
Liabilities
and Shareholders’ Equity
|
|
|
|
|
|
|
|
Current
liabilities:
|
|
|
|
|
|
|
|
Accounts
payable and accrued liabilities
|
|
$
|
39,436
|
|
$
|
36,614
|
|
Billings
in excess of revenue recognized on uncompleted contracts
|
|
|
3,727
|
|
|
2,516
|
|
Accrued
interest
|
|
|
1,461
|
|
|
1,440
|
|
Payroll
and benefits payable
|
|
|
9,182
|
|
|
6,533
|
|
Accrued
income taxes
|
|
|
1,944
|
|
|
8,423
|
|
Short-term
debt
|
|
|
1,504
|
|
|
-
|
|
Current
portion of long-term debt
|
|
|
62,507
|
|
|
-
|
|
Total
current liabilities
|
|
|
119,761
|
|
|
55,526
|
|
Long-term
debt
|
|
|
12,925
|
|
|
74,836
|
|
Deferred
income taxes – long-term
|
|
|
1,361
|
|
|
1,679
|
|
Accrued
pension and other liabilities
|
|
|
41,844
|
|
|
42,450
|
|
Total
liabilities
|
|
|
175,891
|
|
|
174,491
|
|
Commitments
and contingencies (Notes 10 and 18)
|
|
|
|
|
|
|
|
Shareholders’
equity:
|
|
|
|
|
|
|
|
Common
shares, $.01 par value, 100,000,000 shares authorized, 43,044,318
and
42,550,290 shares issued
|
|
|
430
|
|
|
425
|
|
Additional
paid-in capital
|
|
|
77,299
|
|
|
70,345
|
|
Retained
earnings
|
|
|
104,936
|
|
|
94,035
|
|
Accumulated
other comprehensive income
|
|
|
17,008
|
|
|
10,305
|
|
|
|
|
199,673
|
|
|
175,110
|
|
Treasury
stock, at cost, 2,827,301 and 2,802,448 shares
|
|
|
(27,424
|
)
|
|
(27,237
|
)
|
Total
shareholders’ equity
|
|
|
172,249
|
|
|
147,873
|
|
Total
liabilities and shareholders’ equity
|
|
$
|
348,140
|
|
$
|
322,364
|
|
The
accompanying notes are an integral part of these consolidated financial
statements.
CONSOLIDATED
STATEMENTS OF CASH FLOWS
Calgon
Carbon Corporation
|
|
Year
Ended December 31
|
|
(Dollars
in thousands)
|
|
|
2007
|
|
|
2006
|
|
|
2005
|
|
Cash
flows from operating activities
|
|
|
|
|
|
|
|
|
|
|
Net
income (loss)
|
|
$
|
15,287
|
|
$
|
(7,798
|
)
|
$
|
(7,416
|
)
|
Adjustments
to reconcile net income (loss) to
|
|
|
|
|
|
|
|
|
|
|
net
cash provided by (used in) operating activities:
|
|
|
|
|
|
|
|
|
|
|
Gain
on insurance settlement
|
|
|
-
|
|
|
(8,072
|
)
|
|
-
|
|
Gain
from divestitures
|
|
|
-
|
|
|
(6,719
|
)
|
|
-
|
|
Depreciation
and amortization
|
|
|
17,248
|
|
|
18,935
|
|
|
22,062
|
|
Non-cash
impairment and restructuring charges
|
|
|
-
|
|
|
7,728
|
|
|
2,976
|
|
Equity
in (income) loss from equity investments
|
|
|
(1,977
|
)
|
|
(286
|
)
|
|
725
|
|
Distributions
received from equity investments
|
|
|
739
|
|
|
-
|
|
|
254
|
|
Employee
benefit plan provisions
|
|
|
3,076
|
|
|
3,285
|
|
|
4,046
|
|
Stock-based
Compensation
|
|
|
2,887
|
|
|
1,309
|
|
|
-
|
|
Deferred
income tax expense (benefit)
|
|
|
3,196
|
|
|
(973
|
)
|
|
(6,284
|
)
|
Changes
in assets and liabilities–net of effects from purchase of businesses and
foreign exchange:
|
|
|
|
|
|
|
|
|
|
|
(Increase)
decrease in receivables
|
|
|
(1,098
|
)
|
|
3,232
|
|
|
4,273
|
|
Increase
in inventories
|
|
|
(9,559
|
)
|
|
(1,508
|
)
|
|
(13,009
|
)
|
Decrease
in revenue in excess of billings on uncompleted contracts and
other
current assets
|
|
|
287
|
|
|
2,800
|
|
|
2,787
|
|
Decrease
in restructuring reserve
|
|
|
-
|
|
|
(293
|
)
|
|
(498
|
)
|
Increase
(decrease) in accounts payable and accrued liabilities
|
|
|
5,390
|
|
|
(
6,631
|
)
|
|
5,346
|
|
Pension
contributions
|
|
|
(7,787
|
)
|
|
(11,395
|
)
|
|
(4,532
|
)
|
Other
items–net
|
|
|
1,724
|
|
|
601
|
|
|
2,110
|
|
Net
cash provided by (used in) operating activities
|
|
|
29,413
|
|
|
(5,785
|
)
|
|
12,840
|
|
Cash
flows from investing activities
|
|
|
|
|
|
|
|
|
|
|
Purchase
of businesses (net of cash)
|
|
|
-
|
|
|
-
|
|
|
(856
|
)
|
Proceeds
from divestitures
|
|
|
-
|
|
|
21,265
|
|
|
-
|
|
Property,
plant and equipment expenditures
|
|
|
(11,789
|
)
|
|
(12,855
|
)
|
|
(15,996
|
)
|
Proceeds
from insurance settlement for property and equipment
|
|
|
-
|
|
|
4,595
|
|
|
-
|
|
Proceeds
from disposals of property, plant and equipment
|
|
|
513
|
|
|
1,205
|
|
|
1,356
|
|
Net
cash (used in) provided by investing activities
|
|
|
(11,276
|
)
|
|
14,210
|
|
|
(15,496
|
)
|
Cash
flows from financing activities
|
|
|
|
|
|
|
|
|
|
|
Issuance
of debt obligations
|
|
|
1,504
|
|
|
71,911
|
|
|
-
|
|
Reductions
of debt obligations
|
|
|
-
|
|
|
-
|
|
|
(75
|
)
|
Revolving
credit facility borrowings (repayments), net
|
|
|
-
|
|
|
(81,000
|
)
|
|
(600
|
) |
Treasury
stock purchased
|
|
|
(187
|
)
|
|
(108
|
)
|
|
-
|
|
Common
stock dividends
|
|
|
-
|
|
|
-
|
|
|
(3,555
|
)
|
Common
stock issued
|
|
|
3,090
|
|
|
464
|
|
|
3,050
|
|
Excess
tax benefit from stock-based compensation
|
|
|
942
|
|
|
-
|
|
|
-
|
|
Net
cash provided by (used in) financing activities
|
|
|
5,349
|
|
|
(8,733
|
)
|
|
(1,180
|
)
|
Effect
of exchange rate changes on cash
|
|
|
1,187
|
|
|
493
|
|
|
502
|
|
Increase
(decrease) in cash and cash equivalents
|
|
|
24,673
|
|
|
185
|
|
|
(3,334
|
)
|
Cash
and cash equivalents, beginning of year
|
|
|
5,631
|
|
|
5,446
|
|
|
8,780
|
|
Cash
and cash equivalents, end of year
|
|
$
|
30,304
|
|
$
|
5,631
|
|
$
|
5,446
|
|
The
accompanying notes are an integral part of these consolidated financial
statements.
CONSOLIDATED
STATEMENTS OF SHAREHOLDERS’ EQUITY
Calgon
Carbon Corporation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treasury
Stock
|
|
|
|
|
(Dollars
in thousands)
|
|
|
Common
Shares
Issued
|
|
|
Common
Shares
|
|
|
Additional
Paid-In
Capital
|
|
|
Retained
Earnings
|
|
|
Accumlated
Other
Comprehensive
Income
(Loss)
|
|
|
Sub-Total
|
|
|
Shares
|
|
|
Amount
|
|
|
Total
|
|
Balance,
December 31, 2004
|
|
|
41,958,933
|
|
$
|
420
|
|
$
|
65,523
|
|
$
|
112,804
|
|
$
|
16,253
|
|
$
|
195,000
|
|
|
2,787,258
|
|
$
|
(27,129
|
)
|
$
|
167,871
|
|
2005
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net
loss
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
(7,416
|
)
|
|
-
|
|
|
(7,416
|
)
|
|
-
|
|
|
-
|
|
|
(7,416
|
)
|
Employee
and director stock plans
|
|
|
500,800
|
|
|
5
|
|
|
3,466
|
|
|
-
|
|
|
-
|
|
|
3,471
|
|
|
-
|
|
|
-
|
|
|
3,471
|
|
Common
stock dividends Cash ($0.06 per share)
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
(3,555
|
)
|
|
-
|
|
|
(3,555
|
)
|
|
-
|
|
|
-
|
|
|
(3,555
|
)
|
Translation
adjustments, net of tax
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
(4,799
|
)
|
|
(4,799
|
)
|
|
-
|
|
|
-
|
|
|
(4,799
|
)
|
Additional
minimum pension liability, net of tax
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
(4,856
|
)
|
|
(4,856
|
)
|
|
-
|
|
|
-
|
|
|
(4,856
|
)
|
Unrecognized
loss on derivatives, net of tax
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
-
|
|
|
(156
|
)
|
|
(156
|
)
|
|
-
|
|
|
-
|
|
|
(156
|
)
|
Balance,
December 31, 2005
|
|
|
42,459,733
|
|
$
|
425
|
|
$
|
68,989
|
|
$
|
101,833
|
|
$
|
6,442
|
|
$
|
177,689
|
|
|
2,787,258
|
|
$
|
(27,129
|
)
|
$
|
150,560
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2006
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net
loss
|
|
|
|