UNITED
STATES
SECURITIES AND EXCHANGE
COMMISSION
Washington,
D.C. 20549
FORM
10-K
(Mark
One)
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x
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Annual
Report Pursuant to Section 13 or 15(d) of the Securities Exchange Act of
1934.
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For the
fiscal year ended December 31, 2008 or
oTransition
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
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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 x No ¨
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 ¨ 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 ¨
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 ¨ 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 ¨
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Accelerated
filer x
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Non-accelerated
filer ¨
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Indicate
by check mark whether the registrant is a shell company (as defined in Rule
12b-2 of the Exchange Act).
Yes ¨ No x
As of
March 10, 2009, there were outstanding 54,469,234 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,
2008 was $609,531,907.
The
following documents have been incorporated by reference:
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Form
10-K
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Document
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Part Number
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Proxy
Statement filed pursuant to Regulation 14A in connection with registrant's
Annual Meeting of Shareholders to be held on April 30,
2009.
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III
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INDEX
PART
I
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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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19
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Item
1B.
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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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35
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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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35
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Item
6.
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Selected
Financial Data
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37
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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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38
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Item
7A.
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Quantitative
and Qualitative Disclosures about Market Risk
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59
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Item
8.
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Financial
Statements and Supplementary Data
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60
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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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137
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Item
9A.
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Controls
and Procedures
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137
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Item
9B.
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Other
Information
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138
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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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138
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Item
11.
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Executive
Compensation
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138
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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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139
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Item
13.
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Certain
Relationships, Related Transactions, and Director
Independence
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140
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Item
14.
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Principal
Accounting Fees and Services
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141
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PART
IV
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Item
15.
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Exhibits
and Financial Statement Schedules
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142
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SIGNATURES
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147
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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.
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 and powdered
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 light
(“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.
Discontinued
Operations:
On
February 17, 2006, the Company, 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 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 Euro could
have been received dependent upon the business meeting certain earnings targets
over the next three years. In May 2008, the Company reached a final
agreement with proFagus GmbH, proFagus Grundstuecksverwaltungs GmbH and proFagus
Beteiligungen GmbH (as Guarantor) regarding the aforementioned additional 4.25
million Euro contingent consideration, fixing the amount to be paid to the
Company at 2.8 million Euro. The Company expects to receive this
payment in December 2011. The unpaid balance earns interest at 7%
which is paid annually. The Company had presented the Charcoal/Liquid business
as a discontinued operation for the periods that were impacted and has recorded
a pre-tax gain of $4.8 million or $1.7 million, net of tax, on the sale during
the year ended December 31, 2006. The Company recorded the additional
contingent consideration as an additional pre-tax gain on sale of $4.4 million
or $2.8 million, net of tax, within discontinued operations during the period
ended December 31, 2008.
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 provided 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 sale 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, 2007, the Company recorded a
loss of $0.2 million, net of tax, related to an indemnity
claim. During 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 3 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, including
activated carbon cloth, for everyday use by consumers. Activated
carbon cloth is used in many filtration, adsorption, and separation applications
for use in such markets such as industrial and medical.
Activated Carbon and Service.
The sale of activated carbon is the principle 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 then 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 available in several particles 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 carbons are extruded particles,
cylindrical in shape, and typically used for gas phase applications due to 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 are the
optional services associated with supplying the Company’s products and systems
required for purification, separation, concentration, taste and odor control.
The Company offers a variety of treatment services at customer facilities
including carbon supply, equipment leasing, installation and demobilization,
transportation, and spent carbon reactivation. Other services include
feasibility testing, process design, performance monitoring, and major
maintenance of Company-owned equipment. The central component of the Company’s
service business is reactivation of spent carbon and re-supply. 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. The Company is fully permitted
to handle spent carbons containing hazardous and non-hazardous organic compounds
(see related discussion in Regulatory Matters). This recycling is conducted at
several locations throughout the world. Granular activated carbon is reactivated
for environmental and economic reasons to destroy hazardous 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.
Transportation
services are offered via bulk activated carbon deliveries and spent carbon
returns through the Company’s private fleet of trailers, capable of transporting
both RCRA hazardous and non-hazardous material. The Company will
arrange transportation for smaller volumes of activated carbon in DOT approved
containers and small returnable equipment through a network of
less-than-truckload carriers.
Purification
services provided by the Company are used to improve the quality of water, food,
chemical, pharmaceutical and petrochemical products. These services may be
utilized in permanent installations or in temporary applications, such as pilot
studies for new manufacturing processes or recovery of off-specification
products.
Sales from continuing operations for
the Activated Carbon and Service segment were $342.3 million, $295.6 million,
and $265.3 million for the years ended December 31, 2008, 2007, and 2006,
respectively.
Equipment. Along
with providing activated carbons, the Company has developed 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 ultraviolet (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 (refer to Note 17). The UV light alters the DNA of pathogens, killing
them or making it impossible for the 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 is a leader in the marketplace for 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.
The
Company also produces a wide range of odor control equipment which typically
utilizes catalytic, activated carbon to control odors at municipal wastewater
treatment facilities and pumping stations.
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
proprietary ISEP® (Ionic Separator) continuous ion exchange units are used for
the purification and recovery 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 in industrial settings, as well as in
selected environmental applications including perchlorate and nitrate removal
from drinking water.
Sales from continuing operations for
the Equipment segment were $47.3 million, $41.3 million, and $37.9 million for
the years ended December 31, 2008, 2007, and 2006,
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 material 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 $10.7 million, $14.2
million, and $13.0 million for the years ended December 31, 2008, 2007, and
2006, respectively.
For
further information, see Note 19 to the Financial Statements.
Markets:
The
Company participates in six primary areas: Potable Water, Industrial
Process, Environmental Water, Environmental Air, Food, 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 Market includes catalysis, product recovery and
purification of chemicals, and pharmaceuticals as well as process water
treatment. Remediation of water and VOC removal from vapor are the major sub
segments for the two Environmental markets. Food applications include
brewing, bottling and sweetener purification. Medical, personal
protection, cigarette, automotive, consumer and precious metals applications
comprise the Specialty Market.
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. Ion exchange resins
are sold in both fixed beds and continuous counter-current operations to meet
strict regulatory guidelines for perchlorate in 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, soda
ash, 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
Markets. 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/recycle 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 saves the environment as well as eliminating 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 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 a substantial amount of powdered activated
carbon to coal-fired power plants.
Municipal
sewage treatment plants purchase the Company’s odor control systems and
activated carbon products to remove objectionable odors emanating from
operational facilities and to treat the wastewater to meet discharge
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 the principal purchasers
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 gases 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
Market. 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 serviced.
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
and in Latin America through agent/distributor relationships and maintains
offices in Sao Paulo, Brazil and Mexico City, Mexico. In the Asia Pacific
Region, the Company maintains offices in Singapore; Beijing and Shanghai, China;
Taipei, Taiwan; and Tokyo, Japan (a joint venture relationship) through agents
and distributors to manage sales.
In
Europe, the Company has sales offices in Feluy, Belgium; Ashton-in-Makerfield,
United Kingdom; 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 and
Africa.
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 19 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 $22.3 million and
$11.8 million as of January 31, 2009 and 2008, respectively, in the Equipment
segment. The Company expects to carry less than one-third of the 2009
balance into 2010.
The
Company is 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 Technologies, a division of Siemens AG,
Erlangen, Germany, 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 has primary competition from 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 as well
as 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.
The
Company does not presently anticipate any problems in obtaining adequate
supplies of its 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-in-Makerfield,
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. The Company has
commercial sales of four new products for mercury removal from flue
gas. Other carbons with improved performance for high sulfur oxide
applications are under development. The Company continues to expand its UV
product line with innovative products targeted at emerging
markets. Designs of two new Sentinel® reactors were completed in
2008. Both reactors are designed to disinfect drinking water as well
as to oxidize organic contaminants. The Company also completed the
engineering and manufacture of its new C3 Series™ water reuse
system. The system utilizes cutting edge flow distribution technology
to improve the efficiency of water treatment.
Research
and development expenses were $4.1 million, $3.7 million, and $4.2 million in
2008, 2007 and 2006, respectively.
Patents
and Trade Secrets:
The
Company possesses a substantial body of technical knowledge and trade secrets
and owns 72 United States patent applications and/or patents as well as 267
patent applications and/or patents in other countries. The issued
United States and foreign patents expire in various years from 2009 through
2031.
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. By letter
dated January 22, 2007, the Company received from the United States
Environmental Protection Agency, Region 4 (“EPA”) a report of a hazardous waste
facility inspection performed by the EPA and the Kentucky Department of
Environmental Protection (“KYDEP”) as part of a Multi Media Compliance
Evaluation of the Company’s Big Sandy Plant in Catlettsburg, Kentucky that was
conducted on September 20 and 21, 2005. Accompanying the report was a
Notice of Violation (“NOV”) alleging multiple violations of the Federal Resource
Conservation and Recovery Act (“RCRA”) and corresponding EPA and KYDEP hazardous
waste regulations. The alleged violations mainly concern the
hazardous waste spent activated carbon regeneration facility. The
Company met with the EPA on April 17, 2007 to discuss the inspection report and
alleged violations, and submitted written responses in May and June
2007. In August 2007, the EPA notified the Company that it believes
there were still significant violations of RCRA that are unresolved by the
information in the Company’s responses, without specifying the particular
violations. During a meeting with the EPA on December 10, 2007, the
EPA indicated that the agency would not pursue certain other alleged violations.
Based on discussions during the December 10, 2007 meeting, subsequent
communications with EPA, and in connection with the Comprehensive Environmental
Response, Compensation and Liability Act (“CERCLA”) Notice referred to below,
the Company has taken actions to address and remediate a number of the
unresolved alleged violations. The Company believes that the number
of unresolved issues as to alleged continuing violations cited in the January
22, 2007 NOV has been reduced substantially. The EPA can take formal
enforcement action to require the Company to remediate any or all of the
unresolved alleged continuing violations which could require the Company to
incur substantial additional costs. The EPA can also take formal enforcement
action to impose substantial civil penalties with respect to violations cited in
the NOV, including those which have been admitted or resolved. 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.
On July
3, 2008, the EPA verbally informed the Company that there are a number of
unresolved RCRA violations at the Big Sandy Plant which may render the facility
unacceptable to receive spent carbon for reactivation from sites regulated under
the CERCLA pursuant to the CERCLA Off-Site Rule. The Company received
written notice of the unacceptability determination on July 14, 2008 (the
“Notice”). The Notice alleges multiple violations of RCRA and four
releases of hazardous waste. The alleged violations and releases stem
from the September 2005 multi-media compliance inspections, and are among those
alleged in the January 2007 NOV described in the preceding
paragraph. The Company originally had until September 1, 2008 to
demonstrate to the EPA that the alleged violations and releases are not
continuing, or else the Big Sandy Plant will not be able to receive spent carbon
from CERCLA sites until the EPA determines that the facility is again acceptable
to receive such CERCLA wastes. The Company met with the EPA on August
25, 2008 and the Company submitted a written response to the Notice prior to the
meeting.
By letter
dated August 18, 2008, the Company was notified by the EPA Suspension and
Debarment Division (“SDD”) that because of the alleged violations described in
the CERCLA Notice, the SDD was making an assessment of the Company’s present
responsibility to conduct business with Federal Executive
Agencies. Representatives of the SDD attended the August 25, 2008 EPA
meeting. On August 28, 2008, the Company received a letter from the
Division requesting additional information from the Company in connection with
the SDD’s evaluation of the Company’s potential “business risk to the Federal
Government,” noting that the Company engages in procurement transactions with or
funded by the Federal Government. The Company provided the SDD with
all information requested by the letter in September 2008. The SDD
can suspend or debar a Company from sales to the federal government directly or
indirectly through government contractors or with respect to projects funded by
the federal government. In October 2008, the SDD indicated that it
was still reviewing the matter but that another meeting with the Company was not
warranted at the time. The Company believes that there is no basis
for suspension or debarment on the basis of the matters asserted by the EPA in
the Notice or otherwise.
By letter
dated February 13, 2009, the EPA informed the Company that, based on information
submitted by the Company indicating that the Big Sandy Plant has returned to
physical compliance for the alleged violations and releases, the EPA has made an
affirmative determination of acceptability for receipt of CERCLA wastes at the
Big Sandy Plant. The EPA’s determination is conditioned upon the
Company treating certain residues resulting from the treatment of the carbon
reactivation furnace off-gas as hazardous waste and not sending material dredged
from the onsite wastewater treatment lagoons offsite other than to a permitted
hazardous waste treatment, storage or disposal facility. The Company
has requested clarification from the EPA regarding the
conditions. The Company is also in discussions with the EPA and KYDEP
regarding the classification of these materials. If the Company is
required to treat and/or dispose of the material dredged from the lagoon as
hazardous waste, the costs for doing so could be substantial.
In June
2007, the Company received a Notice Letter from the New York State Department of
Environmental Conservation (“NYSDEC”) stating that the NYSDEC had 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 and the
Company cannot predict with any certainty the outcome of this matter or range of
potential loss. The Company has joined a PRP group and has executed a
Joint Defense Agreement with the group members. In August 2008, the
Company and over 100 PRP’s entered into a Consent Order with the NYSDEC for
additional site investigation directed toward characterization of the Site to
better define the scope of the remedial project. The Company
contributed monies to the PRP group to help fund the work required under the
Consent Order. The field work was initiated in 2008 but suspended due
the onset of winter. The group plans to complete the work in the
spring of 2009.
By letter
dated July 3, 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 directed the
Company to submit a complete and accurate Part B application and related
documents and to respond to the KYDEP’s comments which were appended to the
NOV. The Company submitted a response to the NOV and the KYDEP’s
comments in December 2007 by providing a complete revised permit
application. 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. KYDEP can also
deny the Part B operating permit. 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.
The EPA 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. The EPA can also deny the Part B operating
permit. At this time the Company cannot predict with any certainty
the outcome of this matter or range of loss, if any.
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 Waterlink’s 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, 2008, the balance recorded was $4.0 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. The Company has not incurred any
environmental remediation expense for the years ended December 31, 2008 and
2007, but incurred $0.1 million of expense in 2006. It is reasonably
possible that a change in the estimate of this obligation will occur as
remediation preparation and remediation activity commences in the
future. 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 yet to make a determination
as to when it will proceed with remediation efforts.
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, 2008, the Company employed 943 persons on a full-time basis, 684 of
whom were salaried and non-union hourly production, office, supervisory and
sales personnel. The United Steelworkers represent 227 hourly personnel in the
United States. The current contracts with the United Steelworkers expire on
April 1, 2009 at the Catlettsburg, Kentucky facility, February 15, 2010 at the
Columbus, Ohio facility and July 1, 2011 at the Pittsburgh, PA location. The 32
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, two non-union United States facility one each located in
California and 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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Audit
Committee Charter
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Compensation
Committee Charter
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Corporate
Governance Committee Charter
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Code
of Business Conduct and Ethics
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Code
of Ethical Business Conduct Supplement for Chief Executive and Senior
Financial Officers
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Director
Orientation and Continuing Education
Policy
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Executive
Committee Charter
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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 $4.1 million
and $5.4 million to our U.S. Pension plans and $2.1 million and $2.4 million to
our European pension plans in 2008 and 2007, respectively. We currently expect
to contribute approximately $1.1 million to our U.S. pension plans to meet
minimum funding requirements and $1.7 million to our European pension plans in
2009. The current economic environment is negatively impacting the fair value of
our pension assets which could result in increased funding requirements of our
pension plans. If our cash flow from operations is insufficient to
fund our worldwide pension liability, we may be forced to reduce or delay
capital expenditures or seek additional capital.
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 $1.5 million to $2.1 million over the next three
years.
Our
pension plans in the aggregate are underfunded by approximately $48 million as
of December 31, 2008 (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 $34 million as of December 31, 2008, 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 have significantly increased our funding
requirements, which could have an adverse effect on our cash flow and require us
to reduce or delay our capital expenditures or seek additional capital. See Note
12 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 60% of
our carbon product costs in 2009. 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 ability to meet 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 2008, our
aggregate costs for coal increased by $2.6 million, or 16.2%, compared to 2007.
Based upon the estimated usage of coal in 2009, a hypothetical 10% increase in
the price of coal would result in $1.9 million of additional pre-tax expenses to
us. We may not be able to pass through raw material 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 began April 2008 with
subsequent opportunities for review every April with respect to the twelve
months then completed. A preliminary determination is due no later
than March 31, 2009. 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 27% of our full-time workforce as of December 31, 2008.
Those collective bargaining agreements expire from 2009 through 2011. 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.
Our
business is subject to a number of global economic risks
As widely
reported, financial markets in the United States, Europe and Asia have been
experiencing extreme disruption, including, among other things, extreme
volatility in security prices, severely diminished liquidity and credit
availability, rating downgrades of certain investments and declining valuations
of others. Governments have taken unprecedented actions intending to
address extreme market conditions that include severely restricted credit and
declines in values of certain assets.
An
economic downturn in the businesses or geographic areas in which we sell our
products could reduce demand for our products and result in a decrease in sales
volume that could have a negative impact on our results of
operations. Continued volatility and disruption of financial markets
in the United States, Europe and Asia could limit our customers’ ability to
obtain adequate financing or credit to purchase our products or to maintain
operations, and result in a decrease in sales volumes that could have a negative
impact on our results of operations.
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
2008 net sales, approximately 45% were sales to countries other than the United
States, and 2008 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 in supplying 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 eighteen months 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 2008 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.
Our
current credit facility requires compliance with various affirmative and
negative covenants, including limitations 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 $34.9 million in 2008, including approximately $13.0
million related to the planned re-start of a currently idled production line.
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.
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, 2008, we had consolidated goodwill of approximately $26.3 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 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 had expected increased demand for powdered activated carbon products
beginning in 2009 largely 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 or indefinitely. Even if adoption of a
new Clean Air Mercury Rule is delayed indefinitely by the legal legislative and
regulatory process, existing federal and state laws and regulations, as well as
state or 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. 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 principally
from Norit N.V., Mead/Westvaco Corporation and Siemens Water Technologies, as
well as European and Chinese activated
carbon producers and East Asian producers of coconut-based activated
carbon. Our UV technology products face significant competition from principally
Trojan Technologies, Inc., which is owned by Danaher Corporation, and Wedeco
Ideal Horizons, which is owned by ITT Industries. 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 could
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
hurricanes and 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 (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. 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 2008 and 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. 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 could
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, water discharges, and
solid waste handling. 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 dispose of waste may expose us to cleanup obligations and other
damages. For example, the Company received Notices of Violations
(“NOVs”) from the U.S. EPA in January 2007, October 2007, and June 2008 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 its results of
operations and cash flows. If we receive similar demands in the
future, we may incur significant costs in connection with the resolution of
those matters. Refer to Regulatory Matters within Item 1, Business for a more
detailed discussion.
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 risk factors include, but
are not limited to, taxation, nationalization, inflation, currency fluctuations,
foreign exchange restrictions, increased regulation and quotas, tariffs and
other protectionist measures. Approximately 88% of our sales in 2008
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.
Our
international operations are subject to political and economic risks for
conducting business in corrupt environments.
Although
a portion of our international business is currently in regions where the risk
level and established legal systems in many cases are similar to that in the
United States, we also conduct business in developing countries, and we are
focusing on increasing our sales in regions such as South America, Southeast
Asia, India and the Middle East, which are less developed, have less stability
in legal systems and financial markets, and are generally recognized as
potentially more corrupt business environments than the United States and
therefore, present greater political, economic and operational
risks. We emphasize compliance with the law and have policies in
place, procedures and certain ongoing training of employees with regard to
business ethics and key legal requirements such as the U.S. Foreign Corrupt
Practices Act (“FCPA”); however, there can be no assurances that our employees
will adhere to our code of business conduct, other Company policies or the
FCPA. If we fail to enforce our policies and procedures properly or
maintain internal accounting practices to accurately record our international
transactions, we may be subject to regulatory sanctions. We could
incur significant costs for investigation, litigation, fees, settlements and
judgments for potential violations of the FCPA or other laws or regulations
which, in turn, could negatively affect our results of operations.
Our
ability to utilize our foreign tax credits and net operating losses may be
limited.
As of
December 31, 2008, we had net operating loss carryforwards (“NOLs”) of
approximately $52.5 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 could experience an ownership change in the future as a
result of changes 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.
At
December 31, 2008, we had $12.2 million of foreign tax credit carryforwards for
which we have established a valuation reserve of $7.9 million. If
some or all of these tax credits expire, they will not be available to offset
our tax liability.
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, alone 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
interest.
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; Columbus, Ohio; Feluy, Belgium;
Grays, United Kingdom; and Datong, China. The Company leases one
production facility in each of the following locations: Coraopolis,
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, owns one facility in Fukui,
Fukui Prefecture, Japan. The Company owns two warehouses, one of which is in
Pittsburgh, Pennsylvania and the other is in La Louviere,
Belgium. The Company also leases thirty-two warehouses, service
centers, and sales office facilities. Of these, twenty-three are
located in the United States, four in China, and one each in the United Kingdom,
Germany, Canada, Singapore, and Taiwan. Four of the United States
facilities are located in Pittsburgh, Pennsylvania and one each in the following
locations: Downingtown, Pennsylvania; Johnston, Rhode Island;
Rockdale, Illinois; Santa Fe Springs, California; Marlton, New Jersey; Stockton,
California; Tempe, Arizona; Torrance, California; Ontario, California; Schenley,
Pennsylvania; South Point, Ohio; Muncy, Pennsylvania; Steubenville, Ohio;
Ironton, Ohio; and Sulphur, Louisiana as well as two each in Houston, Texas and
Huntington, West Virginia. The United Kingdom facility is located in
Ashton-in-Makerfield. The facility in Germany is located in
Beverungen. Two of the China facilities are located in Shanghai and
one each in Beijing and Tianjin. The Taiwan facility is located in Taipei. The
Canadian facility is located in Richmond Hill, Ontario. The Company’s
49% owned joint venture, Calgon Mitsubishi Chemical Corporation, leases four
offices, one in each Tokyo and Osaka, and two in Fukuoka
Prefecture. The Company’s 20% owned joint venture, Calgon Carbon
(Thailand) Company Ltd., leases one facility in Nakornrachasima,
Thailand.
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 and powdered activated
carbons for the Activated Carbon and Service segment.
The
Columbus plant occupies approximately 27 acres in Columbus,
Ohio. Operations at the plant include the 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 plant was previously idled and start-up began in November
2008. The primary operation at the plant includes the reactivation of
spent granular activated carbons for the Activated Carbon and Service
segment.
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
Coraopolis, Pennsylvania Engineered Solutions plant is a 44,000 square foot
production facility located near Pittsburgh, Pennsylvania. 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, China plant 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, China plant 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 current operating needs.
Item
3. Legal
Proceedings:
On March
20, 2007, the Company and ADA-ES entered into a Memorandum of Understanding
(“MOU”) providing for cooperation between the companies to attempt to jointly
market powdered activated carbon (“PAC”) to the electric power industry for the
removal of mercury from coal fired power plant flue gas. The MOU
provided for commissions to be paid to ADA-ES in respect of product
sales. The Company terminated the MOU effective as of August 24, 2007
for convenience. Neither party had entered into sales or supply
agreements with prospective customers as of that date. On March 3,
2008, the Company entered into a supply agreement with a major U.S. power
generator for the sale of powdered activated carbon products with a minimum
purchase obligation of approximately $55 million over a 5 year
period. ADA-ES claimed that it is entitled to commissions of an
amount of at least $8.25 million over the course of the
5 year
contract, which the Company denies. On September 29, 2008, the
Company filed suit in the United States District Court for the Western District
of Pennsylvania for a declaratory judgment from the Court that the Company has
no obligation to pay ADA-ES commissions related to this contract or for any
future sales made after August 24, 2007.
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 concluding
the U.S. litigation relating to the UV patents. On March 3, 2008, the
Supreme Court of Canada held that the Company’s Canadian UV patents are invalid
concluding the Canadian UV patent 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
Technologies, Inc. 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. By order dated September 29, 2008, each party nominated an
expert to provide opinions as to questions posed by the Court. The
Court will then choose one of the experts nominated or choose another
expert. 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 2008.
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 1,325 registered shareholders at December 31, 2008.
Quarterly
Common Stock Price Ranges and Dividends
|
|
2008
|
|
|
2007
|
|
Fiscal Quarter
|
|
High
|
|
|
Low
|
|
|
Dividend
|
|
|
High
|
|
|
Low
|
|
|
Dividend
|
|
First
|
|
|
18.92 |
|
|
|
13.19 |
|
|
|
- |
|
|
|
9.52 |
|
|
|
5.43 |
|
|
|
- |
|
Second
|
|
|
20.23 |
|
|
|
12.63 |
|
|
|
- |
|
|
|
12.20 |
|
|
|
7.37 |
|
|
|
- |
|
Third
|
|
|
23.03 |
|
|
|
14.04 |
|
|
|
- |
|
|
|
14.74 |
|
|
|
10.30 |
|
|
|
- |
|
Fourth
|
|
|
21.64 |
|
|
|
9.11 |
|
|
|
- |
|
|
|
16.96 |
|
|
|
11.64 |
|
|
|
- |
|
The
Company did not declare or pay any dividends in 2008 and
2007. 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 plan 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. (2004), Cuno, Inc.(2004-2005), Ionics, Inc.
(2004-2005), 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 2004 and 2005. The data for these companies is included from
the year 2004 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, 2003 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, 2008
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
November
1 – November 30, 2008
|
|
|
23,730 |
|
|
$ |
15.11 |
|
|
|
— |
|
|
|
— |
|
December
1 – December 31, 2008
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
|
|
— |
|
(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)
|
|
2008(5)
|
|
|
2007
|
|
|
2006(4)
|
|
|
2005
|
|
|
2004(3)
|
|
Income
Statement Data:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net
sales
|
|
$ |
400,270 |
|
|
$ |
351,124 |
|
|
$ |
316,122 |
|
|
$ |
290,835 |
|
|
$ |
295,877 |
|
Income
(loss) from continuing operations
|
|
$ |
35,564 |
|
|
$ |
15,453 |
|
|
$ |
(9,012 |
) |
|
$ |
(10,507 |
) |
|
$ |
3,968 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income
(loss) from continuing operations per common share, basic
|
|
$ |
0.80 |
|
|
$ |
0.39 |
|
|
$ |
(0.23 |
) |
|
$ |
(0.27 |
) |
|
$ |
0.10 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income
(loss) from continuing operations per common share,
diluted
|
|
$ |
0.67 |
|
|
$ |
0.31 |
|
|
$ |
(0.23 |
) |
|
$ |
(0.27 |
) |
|
$ |
0.10 |
|
Cash dividends declared per common
share
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
0.09 |
|
|
$ |
0.12 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance
Sheet Data (at year end):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
assets
|
|
$ |
387,596 |
|
|
$ |
348,140 |
|
|
$ |
322,364 |
|
|
$ |
347,868 |
|
|
$ |
363,898 |
|
Long-term debt
|
|
$ |
- |
(1) |
|
$ |
12,925 |
(2) |
|
$ |
74,836 |
|
|
$ |
83,925 |
|
|
$ |
84,600 |
|
|
(1)
|
Excludes
$8.7 million of debt which is classified as current. See Note 8
to the Consolidated Financial Statements for further
information.
|
|
(2)
|
Excludes
$62.5 million of debt which is classified as current. See Note
8 to the Consolidated Financial Statements for further
information.
|
|
(3)
|
Includes
the February 2004 acquisition of Waterlink Specialty
Products.
|
|
(4)
|
Includes
the gain from insurance settlement and the goodwill impairment charge of
$8.1 million and $6.9 million, respectively. See Notes 2 and 6
to the Consolidated Financial Statements for further
information.
|
|
(5)
|
Includes
the gain on AST Settlement of $9.3 million. See Note 17 to the
Consolidated Financial Statements for further
information.
|
Item 7. Management's
Discussion and Analysis of Financial Condition and Results of
Operations:
Overview
Although
overall economic conditions declined throughout the world in 2008, demand for
the Company’s activated carbon products and services continued to remain
strong. Going forward, this is an area of uncertainty for the
Company. The Company will continue to monitor the markets it serves
and take appropriate actions in order to attempt to minimize the effect of any
slowdown.
The
Company reported net income of $38.4 million or $0.72 per diluted share, as
compared to a net income of $15.3 million, or $0.31 per diluted share for
2007. Net sales increased 14.0% to $400.3 million for 2008 from
$351.1 million for 2007. Selling, general and administrative expenses increased
4.6% as compared to 2007, primarily due to higher legal expenses related to the
administrative review of the Department of Commerce’s April 2007 anti-dumping
order on certain activated carbon products from China. Also in 2008, the Company
successfully concluded the AST litigation which began in 1998 and settled for
the receipt of $9.3 million, pre-tax, which was recorded as a gain from
operations in 2008. The Company was also able to reduce debt by $66.6
million to its lowest level since 1995, primarily as a result of the conversion,
into common stock, of a substantial portion of the Company’s Senior Convertible
Notes (“Notes”).
The
Company also recorded income of $2.8 million, net of tax, for the final
adjustment related to the 2006 sale of its Charcoal/Liquid business and has
presented it as income from discontinued operations within its financial
statements for the year ended December 31, 2008.
Results
of Operations
2008
Versus 2007
Continuing
Operations:
Consolidated
net sales increased in 2008 compared to 2007 by $49.1 million or
14.0%. Sales increased in the Activated Carbon and Service segment by
$46.7 million or 15.8%. The increase was primarily due to higher
pricing in all markets as well as increased demand in the food, environmental
air treatment, and potable water markets. Foreign currency
translation had a positive impact of $2.2 million. Sales in the
Equipment segment increased approximately $6.0 million or 14.4%. The
increase was principally due to higher demand for ultraviolet light systems used
for the disinfection of drinking water and carbon adsorption systems of
approximately $6.3 million collectively. Partially offsetting this
increase was a decrease in demand for ISEP® systems of $0.7
million. Foreign currency translation had a positive impact of $0.2
million. Sales for the Consumer segment decreased by $3.5 million or
24.9% due to shipment delays related to performance issues with new production
equipment that limited the output of activated carbon cloth, decreased demand
for activated carbon cloth and PreZerve® products, and the negative impact of
foreign currency translation of $0.5 million. The total sales increase for all
segments attributable to the effect of foreign currency translation was $1.9
million.
Net sales
less cost of products sold, as a percent of net sales, was 33.3% in 2008
compared to 31.0% in 2007, an increase of 2.3%. The increase was
primarily from the Activated Carbon and Service segment which was 33.8% in 2008
versus 31.0% in 2007, an increase of 2.8%. The increase was
principally due to higher selling prices of certain activated carbon products
and service. The Equipment segment was 30.6% in 2008 versus 27.7% in
2007, an increase of 2.9%. The increase was primarily due to the
Company’s movement to standardized product offerings and a more selective bid
process. The Consumer segment reported 30.1% in 2008 versus 39.8% in
2007, a decline of 9.7% primarily due to competitive pricing pressure and
manufacturing inefficiencies at its activated carbon cloth facility. 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 $0.5 million or 3.3% in 2008 as compared to 2007
primarily due to an increase in fully depreciated fixed assets.
Selling,
general and administrative expenses increased by $2.8 million or 4.6% in
2008. The increase was principally due to higher legal expenses which
were primarily related to the administrative review of the Department of
Commerce’s April 2007 anti-dumping order on certain activated carbon products
from China as well as increased employee related expense. On a
segment basis, selling, general and administrative expenses increased in 2008 by
approximately $3.8 million in the Activated Carbon and Service segment which was
primarily related to the aforementioned legal expenses and employee related
expenses. Selling, general and administrative expenses for the
Equipment segment decreased by approximately $0.9 million primarily due to
decreased litigation expense related to the completion of the AST litigation and
such expenses were comparable for the Consumer segment year over
year.
Research
and development expenses increased by $0.4 million or 11.6%. The
increase was primarily due to an increase in both employee related expenses and
laboratory testing services related to mercury removal from flue
gas.
The $9.3
million gain on AST settlement for 2008 relates to the resolution of a lawsuit
involving the Company’s purchase of the common stock of Advanced Separation
Technologies Inc. (“AST”) in 1996 (See Note 17).
Other
expense – net increased in 2008 versus 2007 by $1.3 million or 87.6% primarily
due to non-recurring costs associated with the conversion of a
portion of the Notes as well as the negative impact of foreign
exchange.
Interest
income was comparable in 2008 versus 2007.
Interest
expense decreased $1.8 million or 33.3% as a result of the conversion of a
substantial portion of the aforementioned Notes and the effect of capitalized
interest due to increased capital spending in 2008.
Income
tax expense from continuing operations for 2008 was $18.1 million as compared to
$7.8 million in 2007. The effective tax rate for 2008 was 34.3%
compared to 36.7% in 2007. In 2008, the Company was able to use a
portion of its 2008 foreign tax credits which eliminated the need for a
corresponding valuation allowance; as compared to 2007, in which all foreign tax
credits were subject to a valuation allowance of 65%. This caused the
Company’s effective tax rate to be 4.4% lower than the 2007 effective tax
rate. The 2008 effective tax rate also decreased 3.3% versus 2007 due
to increased income in foreign jurisdictions where the tax rate was lower than
the U.S. rate. In 2007, the Company benefited from deferred tax
related adjustments for changes in tax rates which lowered the 2007 effective
tax rate 5.2%. The 2008 effective tax rate also increased compared to
2007 by 0.4% due to a change in the mix of states in which the Company
operated.
Equity in
income of equity investments decreased in 2008 versus 2007 by $1.1
million. The decrease was principally due to higher product costs
realized in 2008 by the Company’s joint venture with Calgon Mitsubishi Chemical
Corporation in Japan.
Discontinued
Operations:
Income
from discontinued operations was $2.8 million as compared to a loss from
discontinued operations of $0.2 million in 2007. The 2008 results
include the final adjustment to the contingent consideration received from the
sale of the Company’s Charcoal/Liquid business that was sold in the first
quarter of 2006 (See Note 3).
2007
Versus 2006
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 were 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 6 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 was 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 2007 rate was favorably impacted by lower statutory tax rates in its
foreign jurisdictions as well as other deferred tax rate
adjustments.
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.
Working
Capital and Liquidity
Cash
flows provided by operating activities were $25.6 million for the year ended
December 31, 2008 as compared to $29.4 million for the year ended December 31,
2007. The $3.8 million decrease was primarily due to unfavorable
working capital changes of $24.4 million (exclusive of debt) partially offset by
improved operating results of $23.1 million, including the net $5.7 million
impact of the AST settlement (See Note 17).
Total
debt at December 31, 2008 was $10.4 million, a decrease of $66.6 million from
December 31, 2007. The decrease was primarily the result of the
conversion of a substantial portion of the Company’s Senior Convertible Notes as
described below.
5.00%
Convertible Senior Notes due 2036
On August
18, 2006, the Company issued $75.0 million in aggregate principal amount of
5.00% Notes due in 2036 (the “Notes”). The Notes accrue interest at the rate of
5.00% per annum which is 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 all
of the quarterly periods during the years ended December 31, 2008 and 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 ending on the last trading day of each of the
aforementioned quarterly periods. As a result, the holders of
the Notes have had the right to convert the Notes into cash and shares of common
stock throughout 2008. During the period of August 20, 2008 through November 10,
2008, the Company converted and exchanged $69.0 million of the Notes for cash of
$11.0 million and approximately 13.0 million shares of its common
stock. Three million of the shares exchanged for principal amount of
the Notes (in lieu of cash) were not previously included in the Company’s
diluted shares.
Due to
the conversion rights of the holders of the Notes, the Company has classified
the remaining principal amount of outstanding Notes as a current liability as of
December 31, 2008.
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, 2008, no contingent events
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. The Company
incurred original issuance costs of $0.5 million which have been deferred and
are being amortized over a five year period. The Company reclassified
$1.9 million of the discount and $0.3 million of issuance costs to additional
paid in capital as a result of the aforementioned conversions and exchanges of
Notes that occurred during the year ended December 31, 2008. The
Company will continue to amortize the respective remaining balances over the
remainder of the five year period or the date of conversion/exchange, if
sooner. For
the year ended December 31, 2008, the Company recorded interest expense of $3.2
million related to the Notes, of which $0.5 million related to the amortization
of the discount.
Credit
Facility
On August
14, 2008, the Company entered into a third amendment to its Credit Facility (the
“Third Amendment”). The Third Amendment permits borrowings in an
amount up to $60.0 million and includes a separate U.K. sub-facility and a
separate Belgian sub-facility. The Credit Facility permits the total revolving
credit commitment to be increased up to $75.0 million. The facility matures on
May 15, 2011. 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
December 31, 2008, the collateral value of assets pledged was
$57.2 million. The collateral value as of December 31, 2008 for
domestic, U.K., and Belgian borrowers were $46.9 million,
$4.8 million, and $5.5 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
December 31, 2008, total availability was $45.6 million. Availability
as of December 31, 2008 for domestic, U.K., and Belgian borrowers was
$38.3 million, $3.7 million, and $3.6 million, respectively. The
Company can issue letters of credit up to $20 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, 2008 totaled $11.6 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 1.50% to 2.50% and is based upon the Company’s overall availability under
the Credit Facility. The unused commitment fee is equal to 0.375% per annum,
which can increase to 0.50%, and is based upon the unused portion of the
revolving commitment.
The
Credit Facility contains a number of affirmative and negative covenants. As of
December
31, 2008, 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, 2008. As
a result, as of December 31, 2008, the holders of the Notes have the right to
convert the Notes into cash and shares of common stock. Included in
the Credit Facility is a provision which permits the conversion of the
outstanding amount of the Company’s Notes. The Credit Facility also includes a
provision for up to $3.0 million of letters of credit in aggregate 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, 2008.
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, 2008, the weighted average effective
interest rate was 4.48% and current portion of long-term borrowings totaled $8.8
million. The Company is also required to make minimum funding
contributions to its pension plans which are estimated at $2.8 million for the
year ended December 31, 2009. The following table represents the
significant contractual cash obligations and other commercial commitments of the
Company as of December 31, 2008.
|
|
Due
in
|
|
|
|
|
|
|
|
(Thousands)
|
|
2009
|
|
|
2010
|
|
|
2011
|
|
|
2012
|
|
|
2013
|
|
|
Thereafter
|
|
|
Total
|
|
Short-term
debt
|
|
$ |
1,605 |
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
1,605 |
|
Current
portion of long-term debt*
|
|
|
2,925 |
|
|
|
- |
|
|
|
5,851 |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
8,776 |
|
Interest
on Notes
|
|
|
325 |
|
|
|
325 |
|
|
|
190 |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
840 |
|
Operating
leases
|
|
|
5,727 |
|
|
|
5,097 |
|
|
|
4,515 |
|
|
|
4,247 |
|
|
|
3,765 |
|
|
|
7,783 |
|
|
|
31,134 |
|
Unconditional
purchase
obligations**
|
|
|
26,175 |
|
|
|
25,600 |
|
|
|
23,318 |
|
|
|
1,575 |
|
|
|
1,575 |
|
|
|
263 |
|
|
|
78,506 |
|
Total contractual
cash
obligations
|
|
$ |
36,757 |
|
|
$ |
31,022 |
|
|
$ |
33,874 |
|
|
$ |
5,822 |
|
|
$ |
5,340 |
|
|
$ |
8,046 |
|
|
$ |
120,861 |
|
*The 2011
maturity excludes debt discount of $149. This amount is classified as
currently payable at December 31, 2008. See Note 8.
**Primarily
for the purchase of raw materials, transportation, and information systems
services.
The
long-term tax payable of $13.1 million, pertaining to the tax liability related
to 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 special-purpose entities or off-balance sheet
financing arrangements except for the operating leases disclosed above as well
as the indemnities and guarantees disclosed in Note 17.
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 $2.0 million and
$2.4 million for the years ended December 31, 2008 and 2007,
respectively. The Company expects its 2009 pension expense to be $5.4
million. The increase from 2008 is primarily as a result of
investment losses realized in 2008.
The fair
value of the Company’s Qualified Plan assets has decreased from $88.9 million at
December 31, 2007 to $64.5 million at December 31, 2008. The
Pension Protection Act, passed into law in August 2006, prescribes a new
methodology for determining the minimum amount that must be contributed to
defined benefit pension plans in 2008. During the year ended
December 31, 2008, the Company funded its Qualified Plans with $6.2 million in
contributions of which $3.1 million was made voluntarily by the
Company. The Company expects that it will be required to fund the
Qualified Plans with approximately $2.8 million in contributions for the year
ending December 31, 2009. Due
primarily as a result of negative investment returns in 2008, the
Company may make additional contributions to its Qualified Plans in 2009 beyond
the required funding. Additional voluntary contributions would
be dependent upon, among other things, the Company’s ongoing operating results
and liquidity.
The
Company did not declare or pay any dividends in 2008. 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.
Capital
Expenditures and Investments
Capital
expenditures were $34.9 million in 2008 (with $1.9 million of this amount
reflected as a non-cash increase in accounts payable and accrued liabilities),
$11.8 million in 2007, and $12.9 million in 2006. Expenditures for
2008 primarily included $29.3 million for improvements to manufacturing
facilities including approximately $13.0 million related to the planned 2009
re-start of a previously idled production line, $3.0 million for customer
capital, and $1.8 million related to improvements to information
systems. 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 2009 are projected to be
approximately $55.0 million to $60.0
million. The aforementioned expenditures are expected to be funded by
operating cash flows, cash on hand, and borrowings.
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
$0.9 million in 2008 compared to $0.5 million in 2007, and $1.2 million in
2006.
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.
Other
On March
8, 2006, the Company and another U.S. producer of activated carbon formally
requested that the United States Department of Commerce investigate unfair
pricing of certain activated carbon imported from the People’s Republic of
China. The Commerce Department investigated imports of activated
carbon from China that is thermally activated using a combination of heat, steam
and/or carbon dioxide. Certain types of activated carbon from China,
most notably chemically-activated carbon, were not investigated.
On March
2, 2007, the Commerce Department published its final determination (subsequently
amended) that all of the subject merchandise from China was being unfairly
priced, or dumped, and thus that special additional duties should be imposed to
offset the amount of the unfair pricing. The final margins of dumping
ranged from 61.95 percent ad valorem (i.e., of the entered value of the goods)
to 228.11 percent ad valorem. A formal order imposing final duties
was published on April 27, 2007. All imports from China remain
subject to the order and antidumping duties. Importers of subject
activated carbon from China are required to make cash deposits of estimated
antidumping duties at the time the goods are entered into the United States
customs territory. Deposits of duties are subject to future revision
based on retrospective reviews conducted by the Commerce
Department. With one limited exception, the amount of duties owed can
decrease or increase based on the government’s subsequent review of the actual
prices at which the entries were sold.
The
Company is both a domestic producer and one of the largest U.S. importers (from
our wholly-owned subsidiary Calgon Carbon (Tianjin) Co., Ltd.) of the activated
carbon that is subject to this proceeding. As such, the Company is
active both as a domestic producer (a “petitioner”) and as a foreign exporter (a
“respondent”) before the Commerce Department. The Company is
represented by separate counsel in each of these roles and has actively
participated throughout the proceeding.
As one of
two U.S. producers involved in the case, the Company is actively involved in
ensuring the Commerce Department obtains the most accurate information from the
foreign producers and exporters involved in the review, in order to calculate
the most accurate results and margins of dumping for the sales at
issue.
As an
importer of activated carbon from China and in light of the successful
antidumping duty case, the Company was required to pay deposits of estimated
antidumping duties in the amount of 84.45 percent ad valorem to the Bureau of
Customs and Border Protection (“Customs”) on entries made on or after October
11, 2006 through April 9, 2007. Thereafter, deposits have been
paid at 69.54 percent. Because of limits on the government’s legal
authority to impose provisional duties prior to issuance of a final
determination, entries made between April 9, 2007 and April 19, 2007 were not
subject to duties.
The
Company’s role as an importer that is required to pay duties results in a
contingent liability related to the final amount of duties that will be
paid. The Company has made deposits of estimated duties in two
ways. First, estimated duties on entries in the period from October
11, 2006 through April 9, 2007 were covered by a bond. The total
amount of duties that can be paid on entries in this period is capped as a
matter of law, though the Company may receive a refund with interest of any
difference due to a reduction in the actual margin of dumping found in the first
review. The Company’s estimated liability for duties during this
period of $0.8 million is reflected in accounts payable and accrued liabilities
on the consolidated balance sheets at December 31, 2008 and
2007. Second, the Company has been required to post cash deposits of
estimated duties owed on entries of subject merchandise since April 19,
2007. The final amount of duties owed on these entries may change,
and can either increase or decrease depending on the final results of relevant
administrative inquiries. This process is briefly described
below.
As noted
above, following the entry of merchandise, the amount of estimated antidumping
duties paid is subject to later review and adjustment based on the actual amount
of dumping that is found. To do this, the Commerce Department
conducts annual reviews of sales made to the first unaffiliated U.S. customer,
typically over the prior 12 month period. These reviews will be
possible for at least five years, and can result in changes to the antidumping
duty rate (either increasing or reducing the rate) applicable to any given
foreign exporter. Revision of the
margin of dumping has two effects. First, it will alter the actual
amount of duties that Customs will seek to collect, by either increasing or
decreasing the amount to reflect the actual amount of dumping that was
found. Where the actual amount of duties owed increases, the
government will require payment of the difference plus
interest. Conversely, when the duty rate decreases, any difference is
refunded with interest. Second, the revised rate becomes the cash
deposit rate applied to future entries, and as such can either increase or
decrease the amount of deposits an importer will be required to
pay.
The
Company currently is in the midst of the first such review. Because
it is the first review conducted under the antidumping duty order, the review
covers the period from October 11, 2006 through March 31, 2008 instead of the
typical 12 month period. The preliminary results of the review are
due no later than March 31, 2009, and the review must be completed no later than
November 3, 2009. At this time, data submitted by the Company
as well as others is continuing to be reviewed by Customs. Because there are
multiple factors that will influence the final results, the Company is unable to
estimate what, if any, adjustments to the current deposit rate will occur or the
amount of additional deposits or refunds the Company may owe or receive,
respectively.
Related
to this, in early April 2009, the Commerce Department will publish a formal
notice allowing parties to request the second annual administrative review of
the antidumping duty order. Requests for review will be due no later
than April 30, 2009. The Company currently anticipates participating
in the second review.
The
contingent liability resulting from duties paid on imports is somewhat mitigated
by two factors. First and foremost, the antidumping duty order’s
disciplinary effect on the market encourages the elimination of dumping through
fair pricing, and thus tends to provide the Company the ability to obtain an
improved return on its investment and operations. Separately,
pursuant to the Continued Dumping and Subsidy Offset Act of 2000 (repealed
effective Feb. 8, 2006), as an affected domestic producer, the Company is
eligible to apply for a distribution of a share of certain duties collected on
entries of subject merchandise from China from April 27, 2007 to September 30,
2007. In July 2008, the Company applied for such a
distribution. In December 2008, the Company received a distribution
of approximately $0.2 million, which reflected 59.57 percent of the total amount
available. The Company anticipates receiving additional amounts in
2009 and future years, though the exact amount is impossible to
determine.
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 primarily 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
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 $2.0 million in 2008 and $2.4 million in 2007, is
calculated based upon a number of actuarial assumptions, including expected
long-term rates of return on our Qualified Plans’ assets, which range from
5.00% 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 historical returns on asset
classes, investment mix, and investment manager performance. The
expected long-term return on the U.S. Qualified Plans’ assets is based on an
asset allocation assumption of 68.0% with equity managers, 30.0% with
fixed-income managers, and 2% with other investments. The European
Qualified Plans’ assets are based on an asset allocation assumption of 36.7%
with equity managers, 48.3% with fixed-income managers, and 15.0% with other
investments. Because of market fluctuation, the Company’s actual U.S.
asset allocation as of December 31, 2008 was 69.9% with equity managers and
30.1% with fixed-income managers. The Company’s actual European asset
allocation as of December 31, 2008 was 33.5% with equity managers, 50.7% with
fixed-income managers, and 15.8% 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 6.25%
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 4.89% to
5.93% at December 31, 2007 to a range of 5.63% to 6.23% at December 31,
2008. The Company estimates that its pension expense for the
Qualified Plans will approximate $5.4 million in 2009. 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, 2008
|
|
$ |
11,622 |
|
|
$ |
(10,136 |
) |
|
$ |
5,429 |
|
|
$ |
(4,350 |
) |
Pension
Costs for the year ended December 31, 2008
|
|
$ |
401 |
|
|
$ |
(788 |
) |
|
$ |
370 |
|
|
$ |
(289 |
) |
Indexation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension
liabilities at December 31, 2008
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
(690 |
) |
|
$ |
759 |
|
Pension
Costs for the year ended December 31, 2008
|
|
$ |
- |
|
|
$ |
- |
|
|
$ |
(54 |
) |
|
$ |
78 |
|
Expected
return on plan assets
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension
costs for the year ended December 31, 2008
|
|
$ |
674 |
|
|
$ |
(674 |
) |
|
$ |
246 |
|
|
$ |
(246 |
) |
Compensation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
$ |
(847 |
) |
|
$ |
866 |
|
|
$ |
(1,524 |
) |
|
$ |
1,718 |
|
Pension
costs for the year ended December 31, 2008
|
|
$ |
(188 |
) |
|
$ |
196 |
|
|
$ |
(256 |
) |
|
$ |
320 |
|
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 13, 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, 2008, the Company had recorded total deferred tax assets of $35.9
million, of which $15.0 million (before consideration of a $8.0 million
valuation allowance) represents tax benefits resulting from unused foreign tax
credits as well as state NOLs and state tax credits. The foreign tax
credits of $4.3 million, net, can be carried forward 10 years and expire from
2009 through 2018. The Company recorded a valuation allowance of 65%
against its foreign tax credits which represents the portion that does not meet
the more likely than not threshold of being utilized. State operating
loss carryforwards of $2.4 million, net, expire from 2010 to 2027 of which over
90% will not expire before 2019.
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,
2008, 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
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 potentially 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 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
80% of the Company’s deferred tax assets, or $28.8 million, represent temporary
differences associated with pensions, accruals, goodwill, and other
assets. Over 85% of the Company’s
deferred tax liabilities of $13.7 million at December 31, 2008 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.
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 17 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 No. 144, “Accounting for the Impairment or Disposal of Long-Lived
Assets” (“SFAS No. 144”), 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
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 tax 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).
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 statement of
operations 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 statement of operations 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 adopted SFAS No. 160 as required on January 1, 2009 and the adoption did
not have a material impact on its financial position or results of
operations.
In March
2008, the FASB issued SFAS No. 161, “Disclosures about Derivative Instruments
and Hedging Activities,” which changes the disclosure requirements for
derivative instruments and hedging activities. SFAS No. 161 requires
enhanced disclosures about (a) how and why an entity uses derivative
instruments, (b) how derivative instruments and related hedging items are
accounted for under SFAS No. 133, “Accounting for Derivative Instruments and
Hedging Activities”
and its related interpretations, and (c) how derivative instruments and related
hedged items affect an entity’s financial position, financial performance, and
cash flows. This statement’s disclosure requirements are effective
for fiscal years and interim periods beginning after November 15,
2008. The Company is currently evaluating the effects that SFAS No.
161 may have on its consolidated financial statement disclosures.
In April
2008, the FASB issued FSP SFAS 142-3, “Determination of the Useful Life of
Intangible Assets.” FSP SFAS 142-3 amends the factors that should be considered
in developing renewal or extension assumptions used to determine the useful life
of a recognized intangible asset under SFAS No. 142, “Goodwill and Other
Intangible Assets.” Previously, under the provisions of SFAS No. 142, an entity
was precluded from using its own assumptions about renewal or extension of an
arrangement where there was likely to be substantial cost or material
modifications. FSP SFAS 142-3 removes the requirement of SFAS No. 142 for an
entity to consider whether an intangible asset can be renewed without
substantial cost or material modification to the existing terms and conditions
and requires an entity to consider its own experience in renewing similar
arrangements. FSP SFAS 142-3 also increases the disclosure requirements for a
recognized intangible asset to enable a user of financial statements to assess
the extent to which the expected future cash flows associated with the asset are
affected by the entity’s intent or ability to renew or extend the arrangement.
FSP SFAS 142-3 is effective for fiscal years beginning after December 15, 2008
and interim periods within those fiscal years. Early adoption is prohibited. The
guidance for determining the useful life of a recognized intangible asset is
applied prospectively to intangible assets acquired after the effective date.
Accordingly, the Company does not anticipate that the initial application of FSP
SFAS No. 142-3 will have an impact on the Company. The disclosure requirements
must be applied prospectively to all intangible assets recognized as of, and
subsequent to, the effective date.
In
May 2008, the FASB issued FASB Staff Position APB 14-1, “Accounting for
Convertible Debt Instruments That May Be Settled in Cash upon Conversion
(Including Partial Cash Settlement)” (FSP ABP 14-1”). FSP APB 14-1
requires the issuer to separately account for the liability and equity
components of convertible debt instruments in a manner that reflects the
issuer’s nonconvertible debt borrowing rate. The guidance will result in
companies recognizing higher interest expense in the statement of operations due
to amortization of the discount that results from separating the liability and
equity components. FSP APB 14-1 is effective for financial statements issued for
fiscal years beginning after December 15, 2008 and interim periods within
those fiscal years and requires retroactive application to prior financial
statements. The Company is still in the process of evaluating the impact that
the adoption of FSP APB 14-1 will have on its financial
statements. The application of APB 14-1 is not expected to have a
material prospective impact on our financial statements.
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 2009 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 $1.9 million and $0.9 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 9
to the Financial Statements. The value of the cash-flow hedges for
natural gas is disclosed in Note 16 to the Financial Statements.
Interest
Rate Risk
The
Company’s short-term and current portion of 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, 2008, 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 2008 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, 2008, seventy-four foreign currency
forward exchange contracts were outstanding. A hypothetical 10%
strengthening (or weakening) of the U.S. dollar against the British Pound
Sterling, Canadian Dollar, Chinese Yuan, Japanese Yen, and Euro at December 31,
2008 would result in a pre-tax loss (or gain) of approximately $3.9
million. The foreign currency forward exchange contracts purchased
during 2008 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.
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, 2008. 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, 2008, 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, 2008, 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, 2008, based on
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 accompanying
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, 2008, 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, 2008 of the Company and our report dated March
13, 2009 expressed an unqualified opinion on those financial
statements.
DELOITTE
& TOUCHE LLP
Pittsburgh,
Pennsylvania
March 13,
2009
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, 2008 and 2007,
and the related consolidated statements of income (loss) and comprehensive
income, shareholders' equity, and cash flows for each of the three years in the
period ended December 31, 2008. These financial statements are the
responsibility of the Company's management. Our responsibility is to
express an opinion on these financial statements based on our
audits.
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 provide a reasonable basis for our opinion.
In our
opinion, such consolidated financial statements present fairly, in all material
respects, the financial position of Calgon Carbon Corporation and subsidiaries
as of December 31, 2008 and 2007, and the results of their operations and their
cash flows for each of the three years in the period ended December 31, 2008, 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 and the provisions of
Statement of Financial Accounting Standards No. 158, Employers’ Accounting for Defined
Benefit Pension and Other Postretirement Plans, on December 31, 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, 2008, 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 13, 2009 expressed an unqualified
opinion on the Company's internal control over financial reporting.
DELOITTE
& TOUCHE LLP
Pittsburgh,
Pennsylvania
March 13,
2009
CONSOLIDATED
STATEMENTS OF INCOME (LOSS) AND COMPREHENSIVE INCOME
Calgon
Carbon Corporation
|
|
Year Ended December 31
|
|
(Dollars in thousands except per share
data)
|
|
2008
|
|
|
2007
|
|
|
2006
|
|
Net
sales
|
|
$ |
390,066 |
|
|
$ |
341,508 |
|
|
$ |
306,770 |
|
Net
sales to related parties
|
|
|
10,204 |
|
|
|
9,616 |
|
|
|
9,352 |
|
Total
|
|
|
400,270 |
|
|
|
351,124 |
|
|
|
316,122 |
|
Cost
of products sold (excluding depreciation)
|
|
|
266,885 |
|
|
|
242,273 |
|
|
|
236,673 |
|
Depreciation
and amortization
|
|
|
16,674 |
|
|
|
17,248 |
|
|
|
18,933 |
|
Selling,
general and administrative expenses
|
|
|
64,149 |
|
|
|
61,348 |
|
|
|
62,010 |
|
Research
and development expenses
|
|
|
4,129 |
|
|
|
3,699 |
|
|
|
4,248 |
|
Gain
on AST settlement (Note 17)
|
|
|
(9,250 |
) |
|
|
- |
|
|
|
- |
|
Gain
from insurance settlement (Note 2)
|
|
|
- |
|
|
|
- |
|
|
|
(8,072 |
) |
Goodwill
impairment charge (Note 6)
|
|
|
- |
|
|
|
- |
|
|
|
6,940 |
|
|
|
|
342,587 |
|
|
|
324,568 |
|
|
|
320,732 |
|
Income
(loss) from operations
|
|
|
57,683 |
|
|
|
26,556 |
|
|
|
(4,610 |
) |
Interest
income
|
|
|
1,504 |
|
|
|
1,695 |
|
|
|
822 |
|
Interest
expense
|
|
|
(3,673 |
) |
|
|
(5,508 |
) |
|
|
(5,977 |
) |
Other
expense – net
|
|
|
(2,703 |
) |
|
|
(1,441 |
) |
|
|
(2,209 |
) |
Income
(loss) from continuing operations before income taxes and equity in income
of equity investments
|
|
|
52,811 |
|
|
|
21,302 |
|
|
|
(11,974 |
) |
Income
tax provision (benefit) (Note 13)
|
|
|
18,101 |
|
|
|
7,826 |
|
|
|
(2,676 |
) |
Income
(loss) from continuing operations before equity in income of equity
investments
|
|
|
34,710 |
|
|
|
13,476 |
|
|
|
(9,298 |
) |
Equity
in income of equity investments, net
|
|
|
854 |
|
|
|
1,977 |
|
|
|
286 |
|
Income
(loss) from continuing operations
|
|
|
35,564 |
|
|
|
15,453 |
|
|
|
(9,012 |
) |
Income
(loss) from discontinued operations, net (Note 3)
|
|
|
2,793 |
|
|
|
(166 |
) |
|
|
1,214 |
|
Net
income (loss)
|
|
|
38,357 |
|
|
|
15,287 |
|
|
|
(7,798 |
) |
Other
comprehensive (loss) income, net of tax (benefit)provision of
$(9,507),$3,449, and $2,752, respectively
|
|
|
(23,458 |
) |
|
|
6,703 |
|
|
|
9,238 |
|
Comprehensive
income
|
|
$ |
14,899 |
|
|
$ |
21,990 |
|
|
$ |
1,440 |
|
Basic
income (loss) from continuing operations per common share
|
|
$ |
.80 |
|
|
$ |
.39 |
|
|
$ |
(.23 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Income
from discontinued operations per common share
|
|
$ |
.06 |
|
|
$ |
- |
|
|
$ |
.03 |
|
Basic
net income (loss) per common share
|
|
$ |
.86 |
|
|
$ |
.39 |
|
|
$ |
(.20 |
) |
Diluted
income (loss) from continuing operations per common share
|
|
$ |
.67 |
|
|
$ |
.31 |
|
|
$ |
(.23 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Income
from discontinued operations per common share
|
|
$ |
.05 |
|
|
$ |
- |
|
|
$ |
.03 |
|
Diluted
net income (loss) per common share
|
|
$ |
.72 |
|
|
$ |
.31 |
|
|
$ |
(.20 |
) |
Weighted
average shares outstanding, in thousands
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic
|
|
|
44,679 |
|
|
|
39,788 |
|
|
|
39,927 |
|
Diluted
|
|
|
53,385 |
|
|
|
50,557 |
|
|
|
39,927 |
|
The
accompanying notes are an integral part of these consolidated financial
statements.
CONSOLIDATED
BALANCE SHEETS
Calgon
Carbon Corporation
|
|
December 31
|
|
(Dollars in thousands)
|
|
2008
|
|
|
2007
|
|
Assets
|
|
|
|
|
|
|
Current
assets:
|
|
|
|
|
|
|
Cash
and cash equivalents
|
|
$ |
16,750 |
|
|
$ |
30,304 |
|
Receivables,
net of allowance for losses of $1,596 and $2,834
|
|
|
62,300 |
|
|
|
55,195 |
|
Receivables
from related parties
|
|
|
2,215 |
|
|
|
2,353 |
|
Revenue
recognized in excess of billings on uncompleted contracts
|
|
|
8,870 |
|
|
|
7,698 |
|
Inventories
|
|
|
93,725 |
|
|
|
81,280 |
|
Deferred
income taxes – current
|
|
|
9,241 |
|
|
|
9,246 |
|
Other
current assets
|
|
|
7,821 |
|
|
|
3,602 |
|
Total
current assets
|
|
|
200,922 |
|
|
|
189,678 |
|
Property,
plant and equipment, net
|
|
|
122,960 |
|
|
|
105,512 |
|
Equity
investments
|
|
|
11,747 |
|
|
|
8,593 |
|
Intangibles,
net
|
|
|
5,930 |
|
|
|
7,760 |
|
Goodwill
|
|
|
26,340 |
|
|
|
27,845 |
|
Deferred
income taxes – long-term
|
|
|
13,129 |
|
|
|
6,419 |
|
Other
assets
|
|
|
6,568 |
|
|
|
2,333 |
|
Total
assets
|
|
$ |
387,596 |
|
|
$ |
348,140 |
|
Liabilities
and Shareholders’ Equity
|
|
|
|
|
|
|
|
|
Current
liabilities:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accounts
payable and accrued liabilities
|
|
$ |
39,647 |
|
|
$ |
39,436 |
|
Billings
in excess of revenue recognized on uncompleted contracts
|
|
|
4,639 |
|
|
|
3,727 |
|
Accrued
interest
|
|
|
140 |
|
|
|
1,461 |
|
Payroll
and benefits payable
|
|
|
10,522 |
|
|
|
9,182 |
|
Accrued
income taxes
|
|
|
1,088 |
|
|
|
1,944 |
|
Short-term
debt
|
|
|
1,605 |
|
|
|
1,504 |
|
Current
portion of long-term debt
|
|
|
8,776 |
|
|
|
62,507 |
|
Total
current liabilities
|
|
|
66,417 |
|
|
|
119,761 |
|
Long-term
debt
|
|
|
- |
|
|
|
12,925 |
|
Deferred
income taxes – long-term
|
|
|
242 |
|
|
|
1,361 |
|
Accrued
pension and other liabilities
|
|
|
68,199 |
|
|
|
41,844 |
|
Total
liabilities
|
|
|
134,858 |
|
|
|
175,891 |
|
Commitments
and contingencies (Notes 9 and 17)
|
|
|
|
|
|
|
|
|
Shareholders’
equity:
|
|
|
|
|
|
|
|
|
Common
shares, $.01 par value, 100,000,000 shares authorized, 56,961,297 and
43,044,318 shares issued
|
|
|
570 |
|
|
|
430 |
|
Additional
paid-in capital
|
|
|
144,040 |
|
|
|
77,299 |
|
Retained
earnings
|
|
|
143,193 |
|
|
|
104,936 |
|
Accumulated
other comprehensive (loss) income
|
|
|
(6,450 |
) |
|
|
17,008 |
|
|
|
|
281,353 |
|
|
|
199,673 |
|
Treasury
stock, at cost, 2,902,264 and 2,827,301 shares
|
|
|
(28,615 |
) |
|
|
(27,424 |
) |
Total
shareholders’ equity
|
|
|
252,738 |
|
|
|
172,249 |
|
Total
liabilities and shareholders’ equity
|
|
$ |
387,596 |
|
|
$ |
348,140 |
|
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)
|
|
2008
|
|
|
2007
|
|
|
2006
|
|
Cash
flows from operating activities
|
|
|
|
|
|
|
|
|
|
Net
income (loss)
|
|
$ |
38,357 |
|
|
$ |
15,287 |
|
|
$ |
(7,798 |
) |
Adjustments
to reconcile net income (loss) to net cash provided by (used
in) operating activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
Gain
on insurance settlement
|
|
|
- |
|
|
|
- |
|
|
|
(8,072 |
) |
Gain
from divestiture
|
|
|
(4,353 |
) |
|
|
- |
|
|
|
(6,719 |
) |
Depreciation
and amortization
|
|
|
16,674 |
|
|
|
17,248 |
|
|
|
18,935 |
|
Non-cash
impairment and restructuring charges
|
|
|
- |
|
|
|
- |
|
|
|
7,728 |
|
Equity
in income from equity investments
|
|
|
(854 |
) |
|
|
(1,977 |
) |
|
|
(286 |
) |
Distributions
received from equity investments
|
|
|
526 |
|
|
|
739 |
|
|
|
- |
|
Employee
benefit plan provisions
|
|
|
2,063 |
|
|
|
3,076 |
|
|
|
3,285 |
|
Stock-based
compensation
|
|
|
2,884 |
|
|
|
2,887 |
|
|
|
1,309 |
|
Excess
tax benefit from stock-based compensation
|
|
|
(2,578 |
) |
|
|
- |
|
|
|
- |
|
Deferred
income tax expense (benefit)
|
|
|
3,347 |
|
|
|
3,196 |
|
|
|
(973 |
) |
Changes
in assets and liabilities—net of effects from foreign
exchange:
|
|
|
|
|
|
|
|
|
|
|
|
|
(Increase)
decrease in receivables
|
|
|
(9,975 |
) |
|
|
(1,098 |
) |
|
|
3,232 |
|
Increase
in inventories
|
|
|
(14,931 |
) |
|
|
(9,559 |
) |
|
|
(1,508 |
) |
(Increase)
decrease in revenue in excess of billings on uncompleted contracts and
other current assets
|
|
|
(2,074 |
) |
|
|
287 |
|
|
|
2,800 |
|
Decrease
in restructuring reserve
|
|
|
- |
|
|
|
- |
|
|
|
(293 |
) |
Increase
(decrease) in accounts payable and
accrued liabilities
|
|
|
2,610 |
|
|
|
5,390 |
|
|
|
(6,631 |
) |
Pension
contributions
|
|
|
(6,215 |
) |
|
|
(7,787 |
) |
|
|
(11,395 |
) |
Other
items—net
|
|
|
89 |
|
|
|
1,724 |
|
|
|
601 |
|
Net
cash provided by (used in) operating activities
|
|
|
25,570 |
|
|
|
29,413 |
|
|
|
(5,785 |
) |
Cash
flows from investing activities
|
|
|
|
|
|
|
|
|
|
|
|
|
Proceeds
from divestitures
|
|
|
- |
|
|
|
- |
|
|
|
21,265 |
|
Property,
plant and equipment expenditures
|
|
|
(33,006 |
) |
|
|
(11,789 |
) |
|
|
(12,855 |
) |
Proceeds
from insurance settlement for property and equipment
|
|
|
- |
|
|
|
- |
|
|
|
4,595 |
|
Proceeds
from disposals of property, plant and equipment
|
|
|
910 |
|
|
|
513 |
|
|
|
1,205 |
|
Net
cash (used in) provided by investing activities
|
|
|
(32,096 |
) |
|
|
(11,276 |
) |
|
|
14,210 |
|
Cash
flows from financing activities
|
|
|
|
|
|
|
|
|
|
|
|
|
Issuance
of debt obligations
|
|
|
- |
|
|
|
1,504 |
|
|
|
71,911 |
|
Reductions
of debt obligations
|
|
|
(11,000 |
) |
|
|
- |
|
|
|
- |
|
Revolving
credit facility borrowings (repayments),net
|
|
|
- |
|
|
|
- |
|
|
|
(81,000 |
) |
Treasury
stock purchased
|
|
|
(1,191 |
) |
|
|
(187 |
) |
|
|
(108 |
) |
Common
stock issued
|
|
|
5,120 |
|
|
|
3,090 |
|
|
|
464 |
|
Excess
tax benefit from stock-based compensation
|
|
|
2,578 |
|
|
|
942 |
|
|
|
- |
|
Other
|
|
|
(456 |
) |
|
|
- |
|
|
|
- |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net
cash (used in) provided by financing activities
|
|
|
(4,949 |
) |
|
|
5,349 |
|
|
|
(8,733 |
) |
Effect
of exchange rate changes on cash
|
|
|
(2,079 |
) |
|
|
1,187 |
|
|
|
493 |
|
(Decrease)
increase in cash and cash equivalents
|
|
|
(13,554 |
) |
|
|
24,673 |
|
|
|
185 |
|
Cash
and cash equivalents, beginning of year
|
|
|
30,304 |
|
|
|
5,631 |
|
|
|
5,446 |
|
Cash
and cash equivalents, end of year
|
|
$ |
16,750 |
|
|
$ |
30,304 |
|
|
$ |
5,631 |
|
The
accompanying notes are an integral part of these consolidated financial
statements.
CONSOLIDATED
STATEMENTS OF SHAREHOLDERS’ EQUITY
Calgon
Carbon Corporation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accumulated
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Common
|
|
|
|
|
|
Additional
|
|
|
|
|
|
Other
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Shares
|
|
|
Common
|
|
|
Paid-In
|
|
|
Retained
|
|
|
Comprehensive
|
|
|
|
|
|
Treasury
Stock
|
|
|
|
|
(Dollars
in thousands)
|
|
Issued
|
|
|
Shares
|
|
|
Capital
|
|
|
Earnings
|
|
|
Income
(Loss)
|
|
|
Sub-Total
|
|
|
Shares
|
|
|
Amount
|
|
|
Total
|
|
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
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
(7,798 |
) |
|
|
- |
|
|
|
(7,798 |
) |
|
|
- |
|
|
|
- |
|
|
|
(7,798 |
) |
Cumulative
effect adjustment due to the adoption of SFAS No. 158, net of
tax
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
(5,375 |
) |
|
|
(5,375 |
) |
|
|
- |
|
|
|
- |
|
|
|
(5,375 |
) |
Employee
and director stock plans
|
|
|
90,557 |
|
|
|
- |
|
|
|
1,356 |
|
|
|
- |
|
|
|
- |
|
|
|
1,356 |
|
|
|
- |
|
|
|
- |
|
|
|
1,356 |
|
Translation
adjustments, net of tax
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
4,644 |
|
|
|
4,644 |
|
|
|
- |
|
|
|
- |
|
|
|
4,644 |
|
Additional
minimum pension
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
liability,
net of tax
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
4,790 |
|
|
|
4,790 |
|
|
|
- |
|
|
|
- |
|
|
|
4,790 |
|
Unrecognized
loss on
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
derivatives,
net of tax
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
(196 |
) |
|
|
(196 |
) |
|
|
- |
|
|
|
- |
|
|
|
(196 |
) |
Treasury
stock purchased
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
- |
|
|
|
15,190 |
|
|
|
(108 |
) |
|
|
(108 |
) |
Balance,
December 31, 2006
|
|
|
42,550,290 |
|
|
$ |
425 |
|
|