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UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
Form 10-K
FOR ANNUAL AND TRANSITION REPORTS PURSUANT TO
SECTION 13 OR 15(d) OF THE SECURITIES ACT OF 1934
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(Mark One)
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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, 2004 |
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or |
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TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d)
OF THE SECURITIES EXCHANGE ACT OF 1934 |
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For the transition period
from to |
Commission file number 1-14601
Arch Chemicals, Inc.
(Exact name of registrant as specified in its charter)
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Virginia |
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06-1526315
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(State or other jurisdiction of
incorporation or organization) |
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(I.R.S. Employer
Identification No.)
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501 Merritt 7 |
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06851
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Norwalk, CT |
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(Zip Code)
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(Address of principal executive offices) |
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Registrants telephone number, including area code:
(203) 229-2900
Securities registered pursuant to Section 12(b) of the
Act:
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Title of each class |
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Name of each exchange on which registered |
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Common Stock |
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New York Stock Exchange
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Series A Participating Cumulative
Preferred Stock Purchase Rights |
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New York Stock Exchange
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Securities Registered Pursuant to Section 12(g) of the
Act:
None
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 þ No o.
Indicate
by check mark if disclosure of delinquent filers pursuant to
Item 405 of Regulation S-K is not contained herein,
and will not be contained, to the best of registrants
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. þ
Indicate
by check mark whether the registrant is an accelerated filer (as
defined in Rule 12b-2 of the Act).
Yes þ No o.
As
of June 30, 2004, the aggregate market value of
registrants voting and non-voting common equity held by
non-affiliates of registrant was approximately $672,418,000.
As
of January 31, 2005, 23,594,255, shares of the
registrants common stock were outstanding.
DOCUMENTS INCORPORATED BY REFERENCE
Portions of the following documents are incorporated by
reference in this Form 10-K as indicated herein:
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Document |
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Part of 10-K into which incorporated |
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Proxy Statement relating to Archs 2005
Annual Meeting of Shareholders |
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Part III
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TABLE OF CONTENTS
FORM 10-K
1
PART I
General
Arch Chemicals, Inc. (Arch or the
Company) is a specialty chemicals manufacturer which
supplies value-added products and services to many industries on
a worldwide basis. The principal business segments in which the
Company competes are treatment products and performance
products. The Companys ability and willingness to provide
superior levels of technical, regulatory expertise and customer
support, the manufacturing flexibility of many of its
facilities, and the cultivation of close customer relationships
are the common skills on which the Company relies to service its
global markets and customers.
The Company was organized under the laws of the Commonwealth of
Virginia on August 25, 1998 as a wholly-owned subsidiary of
Olin Corporation (Olin) for the purpose of effecting
a tax-free distribution of Olins Specialty Chemical
Businesses (Distribution) to the shareholders of
Olin. The Distribution occurred on February 8, 1999
(Distribution Date) upon which the Company became a
separate, independent company.
As a result of the disposition of the majority of the operations
of the Companys microelectronics materials segment on
November 30, 2004, these businesses were classified as
discontinued operations as is more fully discussed in
Note 5 of Notes to the Consolidated Financial Statements
included in Item 8 Financial Statements and
Supplementary Data of this Report. Accordingly, Item 1 and
Item 2 of this Report describe the Companys
continuing businesses and exclude the microelectronic materials
business that was sold.
The term Company as used in Parts I and II of this
Report means Arch Chemicals, Inc. and its subsidiaries unless
the context indicates otherwise. The Companys products and
services described in this Report may be sold, distributed,
manufactured or provided by Arch Chemicals, Inc. or by one or
more of its subsidiaries, affiliates, or joint ventures.
The Company makes available through its Internet website, which
is located at http://www.archchemicals.com, its Annual Report on
Form 10-K, its Quarterly Reports on Form 10-Q, its
Current Reports on Form 8-K, and amendments to those
reports filed or furnished pursuant to Section 13(a) or
15(d) of the Securities Exchange Act of 1934 as soon as
reasonably practicable after being electronically filed with or
furnished to the Securities and Exchange Commission
(SEC). The Company does not charge any fees to view,
print or access these reports on its website through the
Internet. Interested persons may read and copy these reports,
proxy statements and other information at the SECs Public
Reference Section at 450 Fifth Street, N.W.,
Washington, D.C. 20549 and may obtain information on the
operation of the Public Reference Room by calling the SEC at
1-800-SEC-0330. The SEC also maintains an internet website,
located at http://www.sec.gov, that contains reports,
proxy statements and other information regarding registrants,
such as the Company, that file electronically with the SEC.
2004 Events
On April 2, 2004, the Company completed the acquisition of
Avecias pool & spa and protection &
hygiene businesses. The total purchase price net of cash
acquired, was $230.8 million, inclusive of expenses and a
final working capital adjustment of $7.4 million. The
payment consisted of cash and the issuance of the Companys
common stock with a value of $15.7 million. The purchase
price is further subject to a contingent payment of up to
$5.0 million in cash based upon earnings attributable to
North American sales of certain products. In addition, to the
extent that the unfunded pension liability in the U.K. pension
plan was less than $10.0 million, the purchase price was
adjusted upwards by the difference between $10.0 million
and the unfunded liability, with the consideration to be split
equally between a contingent cash payment and up to 223,250
additional shares of the Companys common stock. The share
consideration component of this adjustment was
74,788 shares of the Companys common stock, which
were issued in January 2005 with a
2
value of $1.7 million. The contingent cash payment will be
earned based upon cumulative global net sales of certain
products through 2005.
In April 2004, the Companys contract to sell hydrazine to
the U.S. Government expired and the U.S. Government
awarded a new 10-year hydrazine propellant supply contract to
another company. The Company protested the award and ultimately
the government agreed to re-bid the contract. The Company
submitted its new bid on January 20, 2005. In addition, in
connection with the re-bidding procedure, the Company filed a
claim in the U.S. Court of Federal Claims protesting
various aspects related to the bidding process. As a result of
this complaint, the court directed the Defense Energy Support
Center (DESC) to add to the price of
competitors bids the shutdown costs related to the
Companys Lake Charles facility that the DESC had agreed to
pay to the Company in the event the Company is not awarded the
new contract. The Company is pleased with the courts
order. However, its impact is uncertain and there is no
assurance that the order will have a significant impact on the
bidding process in favor of the Company. Final revised bids are
currently due on March 15, 2005. The DESC notified the
Company that it anticipates completing its contract-award
decision late in the first quarter or early in the second
quarter of 2005.
On November 30, 2004, the Company sold the majority of the
operations of its microelectronic materials business to Fuji
Photo Film Co., Ltd. for approximately $160 million in
cash, inclusive of an estimated closing working capital
adjustment of $1.1 million. Excluded from the transaction
were the Companys 50% interest in Planar Solutions LLC,
the Companys joint venture with Wacker Chemical
Corporation for the production and sale of chemical mechanical
planarization (CMP) slurries, the
microelectronics-dedicated manufacturing facility in
Brandenburg, Kentucky and the Companys chemical management
services (CMS) business.
Products and Services
The Companys principal products and services fall within
two business segments: treatment products and performance
products. For financial information about each of the
Companys segments, and foreign and domestic and export
sales and long-lived assets, see Note 18 of Notes to
Consolidated Financial Statements contained in Item 8 of
this Report. The principal products of each business are
described below. For customer concentrations, see Business
and Credit Concentrations contained in Note 1 of
Notes to Consolidated Financial Statements contained in
Item 8 of this Report.
Within its treatment products segment, the Company manufactures
and sells water treatment chemicals, biocides and personal care
specialty ingredients, and wood treatment and industrial
coatings chemicals and related services.
HTH Water Products. The Company sells chemicals and
equipment on a worldwide basis for the sanitization and
treatment of residential and commercial pool and spa water,
drinking water and water used in industrial applications. The
Company sells both chlorine-based products (calcium hypochlorite
and chlorinated isocyanurates) and non-chlorine-based products
(polyhexamethylene biguanide (PHMB)) as sanitizers.
With the acquisition of Avecias pool & spa
business in April 2004, the Company is a major manufacturer and
seller of PHMB-based pool and spa treatment chemicals in the
U.S. The pool and spa products are sold primarily to
U.S. pool and spa owners through an extensive network of
authorized, independent retailers, rather than through mass
market retailers. The Companys pool chemical products are
sold primarily under the widely-recognized HTH®
brand name and the Baquacil® and Baqua
Spa® brand names. The Company also sells
commercial pool products under the
Pulsar® brand name and to specialty pool
dealers under the POOLIFE® brand name.
The Companys water chemical products are also distributed
as private label brands. In addition to the pool water
sanitizers, PHMB, calcium hypochlorite and chlorinated
isocyanurates, the Company sells ancillary chemicals and
accessories for the maintenance of residential and commercial
pools, such as algaecides, clarifiers and test strips. The
Company is a leading worldwide producer of calcium hypochlorite
with various concentrations of available chlorine. The Company
has a competitive advantage through ownership of several patents
covering the manufacture and use of pool chemicals and
equipment, as well as through the ownership of strong brand
names.
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The Companys water products are also sold in the municipal
water market for the purification of potable water. The Company
sells calcium hypochlorite to purify potable water mainly in a
number of countries outside the U.S. The Company has plans
to expand its presence in the municipal and industrial water
market both domestically and internationally.
In 2004, approximately 58% of the Companys water products
sales were within North America, and the remaining 42% were
throughout the rest of the world. In North America, the Company
sells water chemical products to retail merchants and to pool
dealers. In 2003, the Company acquired all of its joint venture
partners interest in Aquachlor (Pty.) Ltd., its South
African joint venture. The Company has ownership interests in a
joint venture in Brazil (Nordesclor S.A.) that manufactures
and distributes calcium hypochlorite and other water products to
local markets. The Companys Brazilian subsidiary, Arch
Quimica Brasil Ltda., manufactures and distributes other
water chemical products in Brazil and other South American
countries.
In addition to the manufacture and sale of HTH water products,
the Company manufactures and sells chemicals and equipment and
accessories for pools in Europe mainly through its wholly owned
subsidiary Arch Water Products France, S.A.S., located in France.
Personal Care and Industrial Biocides. The Company is a
leading global supplier of biocides for preservation of
industrial and consumer products. It manufactures biocides that
control dandruff on the scalp and control the growth of
micro-organisms, particularly fungi and algae and with the
acquisition of Avecias protection & hygiene
business in April 2004, also develops, manufactures and markets
biocides for anti-bacterial applications. All biocide products
are marketed under the well-recognized trademarks,
Omadine®,
Omacide®,
Triadine®,
Proxel®, Purista®
and Densil® biocides. A large portion of
the biocide chemicals produced by the Company are based on the
zinc, sodium and copper salts of the pyrithione molecule. These
pyrithione-based biocides include over twenty products with
differing active concentrations, forms and salts, and the
Company believes it is a worldwide leader in these biocide
products. Other biocide chemicals are based on
iodopropargyl-n-butylcarbamate (IPBC), a broad-spectrum
fungicide, and serve the metalworking fluids and coatings
markets. The IPBC-based biocides currently consist of five
variations with others in development stages. The acquisition of
the Avecia protection & hygiene business in 2004
expanded the Companys molecule offerings to include two
well-established, market-leading molecules
benzisothiazolin (BIT) and PHMB. The Company is
a leading supplier of BIT and PHMB into the global biocides
market and now supplies biocides used in health and hygiene
applications. Biocides make up a small portion of the content of
the customers end products, and therefore must be highly
effective at low concentrations as well as compatible with the
formulations other components. Meeting the biocide
customers needs requires a high degree of technical
support and the expertise to do business in a highly regulated
environment. The Companys ability to meet these needs
makes it a preferred supplier in the biocides market. It is also
uniquely positioned as the only pyrithione supplier with
U.S. Environmental Protection Agency registrations for
metalworking fluids, coatings and antifouling paints. The
Company also participates in the personal care market with
actives and functional ingredient products sold primarily to
manufacturers in the global cosmetic, toiletries and personal
care industries. It provides these customers with
biotechnological active ingredients, delivery systems, proteins,
botanicals and functional ingredients, primarily for use in skin
and hair care formulations.
Wood Protection and Industrial Coatings. The Company is a
leading producer of wood treatment chemical solutions that
enhance the properties of wood. Its wood preservatives and fire
retardants are sold under the brand names
WOLMAN®,
Dricon®,
Tanalith®,
Vacsol®, and
Resistol® in markets around the world.
These products protect wood against moisture, fungal decay, or
termites and other insects or retard the combustibility of wood.
The principal customers are sawmills and treaters of softwoods
that require chemical treatment to impart resistance to fungal
and insect damage, giving softwoods the performance of hardwoods
in service. In the U.S. and Canada, the majority of the
customers are licensed wood treaters that operate under
guidelines and standards established by the Company. The license
program includes the use of the brand name for sale of the
products produced by the licensee as well as an extensive
support package comprised of marketing, technical, engineering
and environmental services. The Companys customers sell
their wood-treated products into the construction, utility,
residential and agricultural markets. The products sold by the
Company are critical to the performance and value of the end-use
products. Arch Wood Protection, Inc., a
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subsidiary of the Company, amended its registration with the
U.S. Environmental Protection Agency
(U.S. EPA) for chromated copper arsenate
(CCA) to transition to a new generation of wood
preservatives for use in non-industrial treated wood products by
December 31, 2003. Growing consumer preferences and the
availability of alternative products have moved the industry to
CCA-alternative products and the Company is offering its
WOLMAN®E and
Tanalith®E patented products,
leading CCA-alternative wood treatment products, which are
utilized by wood treaters to make
Wolmanized® Natural
Selecttm
and Tanalized® wood. The Company
continues to supply CCA for industrial purposes such as the
treatment of wood used in utility poles and highway guardrails.
The Company owns 49% of a joint venture with Koppers Industries,
Inc., based in Pittsburgh, Pennsylvania, for the manufacture and
distribution of wood treatment chemicals to the Australian and
Asia-Pacific markets.
The Company also manufactures and sells a wide range of
industrial coatings for a variety of applications for wood and
other materials. These finishes are primarily industrial- or
consumer-applied products for the surface decoration and
protection of wood, including stains, polyester- and
polyurethane-based coatings, and water-based coatings and UV
systems that incorporate new technology. These coatings products
are sold under the name Arch Coatings, including the
brand names Sayerlack® and Linea
Blu®. The major markets for these products
include home and office furniture, window and door frames,
picture frames, and other specialty markets. The Company
believes it is a market leader in France, and has a strong
presence in several other areas of Europe, including the
strategic Italian market and the United Kingdom. The Company
also has operations in Spain and sales and technical support
facilities in the U.S., China and Singapore that support sales
efforts in North America and Asia. The major customers for these
coatings require a high degree of applications assistance, and
the development of a total coatings solution, including product
development, is key to the growth of this business. As a result,
the Company has many long-standing customers and its customer
base includes many of the leading furniture and joinery
manufacturers in Europe.
Performance Urethanes. The Companys performance
products segment includes the manufacture and sale of a broad
range of urethane intermediate products with diverse end uses.
The urethanes products sold by the Company impart physical
characteristics that are critical to the performance and value
of the customers end-use products. Custom manufacturing
services are also provided. The business is characterized by
close customer relationships with entities who are leaders in
the markets in which they compete. The flexibility afforded by
batch manufacturing in some operations, combined with the
Companys ability and willingness to provide superior
technical support, enables it to respond to the specific needs
of a diverse group of customers. This gives the Company an
advantage over competitors whose manufacturing processes and
related cost structure constrain their ability to respond cost
effectively to smaller volume customers.
The Companys performance urethane products business
includes flexible polyols, specialty polyols, urethane systems
and glycols and glycol ethers. Specialty polyols, which are used
as an ingredient for elastomers, adhesives, coatings, sealants
and rigid foam, are manufactured at the Companys
Brandenburg, Kentucky site, as well as by its Venezuelan
subsidiary. The Brandenburg facility also manufactures glycols
and glycol ethers for use as an ingredient in cleaners, personal
care products and antifreeze and provides custom manufacturing
of specialty chemicals for a small group of companies. Flexible
polyols, which are used in the furniture, bedding, carpet and
packaging industries, are manufactured by the Companys
wholly owned Venezuelan subsidiary, Arch Quimica Andina, C.A.,
for South American markets.
Hydrazine. The Company supplies hydrazine hydrates and
hydrazine derivatives. Hydrazine hydrate products are sold for
use in chemical blowing agents, water treatment chemicals,
agricultural products, pharmaceutical intermediates and other
chemical products. The hydrazine hydrates are supplied in
various concentrations and in packaging containers that include
bulk, tote bins and drums. Since early 2004, the hydrazine
hydrates plant has been idled and the Company purchases
hydrazine hydrates from a third party supplier for resale to its
customers and as an ingredient for its formulated hydrazine
products.
5
The Company supplies propellant grade hydrazine and hydrazine
derivatives for use as fuel in satellites, expendable launch
vehicles and auxiliary and emergency power units. These
propellant grade hydrazine products include Ultra
Puretm
Hydrazine (UPH), anhydrous hydrazine
(AH), unsymmetrical dimethyl hydrazine
(UDMH), monomethyl hydrazine
(MMH) and hydrazine fuel blends. Currently, the
Company is not manufacturing or selling AH, UDMH, MMH and
hydrazine fuel blends due to the expiration of the
U.S. Government propellants contract in April 2004. In
addition to space-related applications in satellites and launch
vehicles, auxiliary power from hydrazine-driven units is
supplied to the NASA Space Shuttle for maneuvering its rocket
engine nozzles and for operating valves, control surfaces,
brakes and landing gear on the Shuttle Orbiter. Emergency power
from hydrazine is also provided to jet aircraft like the F-16 to
operate electrical and hydraulic units in the event of an engine
flameout. The Company also supplies launch services and special
packaging containers including cylinders to improve the safe
handling and storage of propellants and to reduce launch costs.
Customers
The Companys customer base is diverse and includes pool
and spa retailers, world-renowned consumer product companies,
major big box retailers, furniture manufacturers, national and
regional chemical and equipment distributors, wood treaters,
sawmills, other chemical manufacturers and the U.S. Government.
While no single customer has accounted for more than 10% of the
Companys total annual sales in 2004, sales to Wal-Mart
Stores, Inc. and its affiliates (collectively,
Wal-Mart) slightly exceeded 10% of the
Companys total annual sales in 2003 and 2002. Further, a
significant portion of sales of the treatment products segment
(approximately 17% in 2004) is dependent upon Wal-Mart and
another customer, with Wal-Mart accounting for a significant
portion of the sales of the HTH water products business and the
other customer accounting for a significant portion of the sales
of the personal care and industrial biocides businesses. For
additional information about customers, see the information
under the caption Business and Credit Concentrations
in Item 7 of this Report.
Raw Materials and Energy
The Company utilizes a variety of raw materials in the
manufacture of products for its businesses. Outlined below are
the principal raw materials for the product businesses. The
majority of the Companys raw material requirements are
purchased and many are provided under the terms and conditions
of written agreements. Overall, principal raw materials are
generally readily available to the Company as a whole.
Treatment Products. The principal raw materials for the
HTH water products line include chlorine, caustic soda, lime and
chlorinated isocyanurates. For other pool chemicals, the primary
raw material is cyanamide liquor.
The principal raw materials for industrial biocide treatment
chemicals and personal care specialty ingredient chemicals are
pyridine, iodine, phthalic anhydride, thionyl chloride,
chlorine, cyanamide liquor, and propargyl butyl carbamate.
The principal raw materials for wood protection products include
chromic acid, scrap copper, tebuconazole, copper carbonate,
arsenic trioxide, cupric oxide, monoethanolamine, and
proprietary organic biocides. The raw materials for the
industrial coatings line include a wide variety of polyester
resin systems, organic solvents, nitrocellulose, acrylic resins,
acrylic and vinyl emulsions, titanium dioxide, isocyanate,
various pigments and colors and stains. The coatings business
uses certain water-borne resins which are sourced from one
supplier and are not readily available.
Performance Products. The principal raw materials for the
urethanes products are primarily propylene, propylene oxide,
ethylene oxide, while chlorine, caustic soda and ammonia are the
key raw materials for the hydrazine business. For this segment,
propylene is the most significant raw material that is subject
to significant price volatility.
Electricity for the Companys manufacturing facilities is
mostly supplied to the Company by public or government utilities
while at shared sites with other companies are supplied by other
third parties. Natural gas
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used for steam production is an important energy source for many
of the Companys U.S. manufacturing sites,
particularly its Brandenburg, Kentucky facility, and is
purchased from multiple suppliers.
Research and Development and Patents
The Companys research activities are conducted at several
sites including Cheshire, Connecticut; South Plainfield, New
Jersey; Conley, Georgia; Blackley, England; and Pianoro, Italy.
Company-sponsored research expenditures were $15.4 million
in 2004, $11.7 million in 2003 and $10.3 million in
2002.
In general, intellectual property is important to the Company,
but no one technology, patent or license or group thereof
related to a specific process or product is of material
importance to the Company as a whole.
The Company believes that its broad patent portfolio in the
treatment products segment provides a sustainable competitive
advantage for the treatment chemical businesses.
The Company has a significant patent portfolio related to HTH
water products that includes 34 U.S. patents and numerous
foreign counterpart patents. Three of these U.S. patents
are for the technology relating to the manufacture of
J3tm
calcium hypochlorite, which enables it to produce calcium
hypochlorite with superior dissolving characteristics, and are
materially important to the HTH water products business. Two of
these three patents expire in 2009 and the other expires in
2010. Most of the remaining patents continue at least until
2012. Another significant patent, which expires in 2015, is for
the multi-functional formulated trichloro-isocyanuric
(trichlor) tablets that enables the Company to offer
important enhanced benefits to its water treatment customers as
distinguished from basic pure trichlor tablets. The Company has
three other material U.S. composition patents for
formulated pool chemical products that provide the Company with
advantages in product shipping and storage. Of these three
composition patents, one expires in 2008, one in 2009 and one in
2022. The other patents cover manufacturing processes, other
multifunctional formulated products, and chemical feeder systems
for residential/commercial pool and municipal water treatment
applications. The Company has recently been awarded a patent
covering a dissolving chamber design for chlorinator systems.
The Company has an expansive biocides patent portfolio that
includes 62 U.S. patents, including process, composition
and application patents and numerous foreign counterpart
patents. The Companys biocides business holds several
U.S. patents relating to antifouling additives for paints.
These patents expire in 2010 and 2012. A substantial majority of
the Companys other biocides patents do not expire until
after 2012. Patents for the Companys key targeted growth
areas in its marine antifouling paint and building product
biocides businesses include those relating to small particle
copper pyrithione process for stable biocide dispersions,
gel-free paint containing zinc pyrithione, and
in-can and dry film coating
antimicrobial compounds. Biocide patents supporting the
Companys personal care ingredients business include those
relating to non-spherical and non-platelet crystalline forms of
zinc pyrithione and a method for producing distinct particles of
pyrithione salts.
With respect to its wood protection business, the Company owns
two significant U.S. composition of matter patents. These
patents include one for an additive to the Companys wood
preservative chromated copper arsenate (CCA) that
improves the climbability of utility poles. This patent expires
in 2008. The other is a patent on the Companys new
preservative formulation (WOLMAN®E,
Natural
Selecttm
and Tanalith®E) which expires in
2014. The Companys patent portfolio also includes patents,
both granted and pending, covering fire retardant and other wood
preservation technologies.
The Company owns two patents covering processes for producing
Ultra
Puretm
Hydrazine, the worlds purest grade of anhydrous hydrazine,
which makes it the preferred propellant for monopropellant
satellite thruster applications. These patents expire in 2006.
Seasonality
The Company as a whole usually experiences its highest sales and
profits in the second quarter primarily due to sales of its HTH
water products line in that quarter. The purchase of water
chemical products by consumers in the residential pool market is
concentrated in the United States of America between Memorial
7
Day and the Fourth of July. The water chemical products business
principally distributes directly to retail merchants. Sales of
these products are strongest in the second and third quarters
with the second quarter being the quarter with the most sales of
these products. In addition, the weather can also have a
significant effect on water chemical and wood treatment sales
during any given year with unseasonable wet or cool weather
negatively impacting sales.
Backlog
The amount of backlog orders is immaterial to the Company as a
whole and to any particular segment.
U.S. Government Contracts and Regulations
In November 2003, the Company secured a 35-month contract,
valued at $4.3 million, with the Defense Energy Support
Center (DESC) for storage and distribution services
of its hydrazine-based propellants products. The contract
performance began May 1, 2004. In February 2004, the
Company was awarded a twenty-five month contract valued at
$11.9 million, with the Department of Defense for Ultra
Puretm
Hydrazine. The contract began January 1, 2005 and will
provide fuel for future satellite programs. In April 2004, the
Companys contract to sell hydrazine to the
U.S. Government expired and the U.S. Government
awarded a new 10-year hydrazine propellant supply contract to
another company. The Company protested the award and ultimately
the government agreed to re-bid the contract. The Company
submitted its new bid on January 20, 2005. In addition, in
connection with the re-bidding procedure, the Company filed a
complaint in the U.S. Court of Federal Claims protesting
various aspects related to the bidding process. As a result of
this complaint, the court directed DESC to add to the price of
competitors bids the shutdown costs related to the
Companys Lake Charles facility that the DESC had agreed to
pay to the Company in the event the Company is not awarded the
new contract. The Company is pleased with the courts
order. However, its impact is uncertain and there is no
assurance that the order will have a significant impact on the
bidding process in favor of the Company. Final revised bids are
currently due on March 15, 2005. The DESC notified the
Company that it anticipates completing its contract-award
decision late in the first quarter or early in the second
quarter of 2005.
As a government contractor, the Company is subject to extensive
and complex U.S. Government procurement laws and
regulations. These laws and regulations provide for ongoing
government audits and reviews of contract procurement,
performance and administration. Failure to comply, even
inadvertently, with these laws and regulations and with laws
governing the export of controlled products and commodities
could subject the Company or one or more of its businesses to
civil and criminal penalties and under certain circumstances,
suspension and debarment from future government contracts and
the exporting of products for a specified period of time.
Several of the Companys products are registered with
U.S. EPA under the Federal Insecticide, Fungicide, and
Rodenticide Act and as such are subject to various regulations
regarding use and disclosure requirements.
Competition
The Companys businesses are in highly competitive
industries, and the Company encounters strong competition with
respect to each of its product lines from other manufacturers
worldwide. This competition, from other manufacturers of the
same products and from manufacturers of different products
designed for the same uses, is expected to continue in both U.S.
and foreign markets. Depending on the product involved, various
types of competition are encountered, including price, delivery,
service, performance, product innovation, product recognition
and quality. Overall, the Company believes its principal product
groups are competitive with many other products of other
producers.
Export Sales
The Companys export sales from the U.S. to unaffiliated
customers were $76.2 million in 2004, $68.6 million in
2003 and $66.7 million in 2002. The financial information
about geographic areas contained in
8
Note 18 of Notes to the Consolidated Financial Statements
found in Item 8 of this Report is incorporated herein by
reference.
Employees
As of December 31, 2004, the Company had approximately
2,675 employees, approximately 1,400 of whom were working in
foreign countries. In addition, the Company also employed at
such date approximately 470 seasonal or temporary employees,
primarily in the HTH water products business. Approximately 170
of the hourly paid U.S. employees of the Company located at
its Brandenburg, Kentucky; Conley, Georgia; and Lake Charles,
Louisiana facilities are represented for purposes of collective
bargaining by several different labor organizations, and the
Company is party to eight labor contracts relating to such
employees. These labor contracts extend for three- or four-year
terms and expire in the years 2006 and 2007. No major work
stoppages have occurred in the last three years. While relations
between the Company and its employees and their various
representatives are generally considered satisfactory, there can
be no assurance that new labor contracts can be entered into
without work stoppages. European hourly employees are also
represented by unions in various countries.
Responsible Care® Commitment
First adopted as a condition of membership by the American
Chemistry Council (ACC) in 1988, the Responsible
Care® initiative was developed to encourage
member companies to continuously improve their performance in
the realms of health, safety and the environment.
The ACCs Responsible Care® initiative
encompasses seven critical performance areas: employee health
and safety, pollution prevention, manufacturing process safety,
security, distribution safety, product stewardship and community
awareness and emergency response. Ultimately, this initiative is
aimed at making health, safety and environmental protection an
integral part of a products life cycle from
manufacture, marketing and distribution to use, recycling and
disposal.
The Company has developed a management system to drive
improvement in all seven areas under Responsible
Care®. To make this complex and multifaceted
process more compelling and to give it a sense of urgency, it
has developed what it calls The Goal is Zero
initiative. It recognizes a fundamental truth at the heart of
Responsible Care® that no amount of
harm to people or the environment is acceptable.
The Companys manufacturing plant in Rochester, New York,
which makes industrial biocides, ingredients for cosmetic and
personal care products and an advanced wood preservative, was
the first plant in America to be certified under the new
Responsible Care® RC 14001 standard that broadly
covers performance in the realms of environmental quality,
workplace health and safety, plant security and community
outreach. The plant received this certification after a rigorous
series of audits by ABS Quality Evaluations, an independent
registrar based in Houston, Texas. Using standards developed by
the Registrars Accreditation Board, auditors from ABS examined
the Companys Rochester plants management systems and
related quality controls in all seven performance areas covered
under the ACCs signature Responsible Care®
initiative. In addition, Arch was the first ACC member whose
corporate headquarters earned certification under the new
Responsible Care® Management System requirements.
As its very name implies, the Companys Goal is
Zero initiative is indeed aimed at achieving zero employee
and contractor injuries, zero manufacturing process incidents,
zero distribution incidents, and zero environmental incidents.
The Companys facilities ranging from Salto, Brazil to
Valparaiso, Indiana have at times achieved the ultimate goal in
each or all of these categories. The following summarizes the
Companys performance in each of the Goal is Zero targeted
areas:
Goal One: Zero Recordable Injuries. While some of the
Companys facilities have achieved this goal, overall, the
Companys rate of employee recordable injuries (the number
of work-related injuries per 200,000 hours worked) has
declined from 3.16 in 1999 to 1.51 in 2004. By contrast, the
average recordable injury rate for all U.S. manufacturers
was 6.7 in 2003. The Company also made excellent progress in
reducing contractor recordables, which have fallen from 6.30 in
1999 to 0.29 in 2004.
Responsible Care® is a registered trademark of
the ACC.
9
Goal Two: Zero Manufacturing Process Safety Incidents.
These incidents are defined to include fires, explosions and
toxic releases that resulted in a lost-time injury, off-site
consequences or greater than $25,000 of damages. Since the
Distribution and until 2004, the Company never had more than one
process incident in a year. However, in 2004 it had four such
incidents.
Goal Three: Zero Environmental Incidents. This goal
refers to incidents such as chemical spills or emissions that
are reportable because they exceed strict limits established in
state, federal or foreign laws and regulations. The
Companys performance has significantly improved, moving
from 18 environmental incidents in 1999 to nine for all of 2004.
Goal Four: Zero Distribution Incidents. Under this goal,
the Company strives to achieve zero significant incidents such
as spills during the transportation of its products. Performance
is measured in terms of distribution incidents per 1,000 U.S.
domestic shipments, and this rate has declined from 4.17 in 1999
to 0.50 in 2004.
The Company is pleased with the progress of and results derived
from its Responsible Care Program. It remains committed,
however, to achieving further improvements and realizing its
ultimate goal the Goal is Zero for each
of the above categories.
Environmental Matters
The Company operates manufacturing facilities throughout the
world and as a result is subject to a broad array of
environmental laws and regulations in various countries. The
Company also implements a variety of voluntary programs to
reduce air emissions, eliminate or reduce the generation of
hazardous wastes and to decrease the amount of wastewater
discharges. The establishment and implementation of
U.S. federal, state and local standards to regulate air and
water quality and to govern contamination of land and
groundwater has affected and will continue to affect
substantially all of the Companys U.S. manufacturing
locations. Federal legislation providing for regulation of the
manufacture, transportation, use and disposal of hazardous and
toxic substances has imposed additional regulatory requirements
on industry in general, and particularly on the chemicals
industry. In addition, the implementation of environmental laws,
such as the Resource Conservation and Recovery Act, the Clean
Air Act and the Comprehensive Environmental Response,
Compensation and Liability Act of 1980, as amended by the
Superfund Amendments and Reauthorization Act of 1986, has
required and will continue to require new capital expenditures
and will increase operating costs.
The Distribution Agreement, dated as of February 1, 1999
(the Distribution Agreement), between the Company
and Olin relating to the Distribution, specifies that the
Company is only responsible for certain environmental
liabilities at the Companys then current facilities and
certain off-site locations with respect to the businesses
acquired from Olin in the Distribution. The Company has also
become subject to environmental exposures and potential
liabilities in the U.S. and abroad with respect to the
businesses it purchased following the Distribution. In
connection with the acquisition of Hickson, the Company acquired
certain environmental exposures and potential liabilities of
current and past operating sites, all of which have been accrued
for in the accompanying consolidated financial statements.
In connection with the disposition of the majority of the
microelectronic materials business on November 30, 2004,
the Company provided indemnification for environmental concerns.
For identified environmental liabilities as of the transition
date, there is no limit to the liability retained by the
Company. The Company estimates such potential liability to be
less than $1.0 million. For other pre-closing environmental
liabilities the purchaser will be liable for the first
$3.0 million of any such liabilities and the parties will
share equally the next $6.0 million of any such liabilities
with the Companys total exposure thus limited to
$3.0 million over a five-year period from the closing date.
In connection with the disposition of the sulfuric acid business
on July 2, 2003, the Company provided environmental
covenants to the purchaser in which the Company is solely liable
for the costs of any environmental claim for remediation of any
hazardous substances that were generated, managed, treated,
stored or disposed of prior to the closing date of the sale. The
Company will be released, under the sales agreement, from its
obligation, which cannot exceed $22.5 million,
20 years from the closing date.
10
Additionally, as part of its environmental indemnifications the
Company will be responsible for damages directly related to the
process sewer system at the Beaumont, Texas plant during the
first five years from the closing date.
As part of the Hickson organics disposition, the Company will
continue to be responsible for known environmental matters. Such
matters have previously been accrued for in its environmental
reserve included in the consolidated financial statements.
Additionally, regarding any unknown environmental matters that
are identified subsequent to the sale, the Company has agreed to
share responsibility with the purchaser over a seven-year
period, with the Companys share decreasing to zero over
the seven-year period. The Companys maximum aggregate
liability for such unknown environmental matters is
£5.0 million.
The Company does not anticipate any material exposure related to
the environmental indemnifications for the microelectronic
materials, the sulfuric acid and the Hickson organics
dispositions. The Company has estimated that the fair value of
any such additional exposure would be immaterial.
Associated costs of investigatory and remedial activities are
provided for in accordance with generally accepted accounting
principles governing probability and the ability to reasonably
estimate future costs. Charges to income for investigatory and
remedial efforts of $2.4 million were recorded in 2004 and
were not material to operating results in 2003 and 2002, but may
be material in future years.
Cash outlays for normal plant operations for the disposal of
waste and the operation and maintenance of pollution control
equipment and facilities to ensure compliance with mandated and
voluntarily imposed environmental quality standards were charged
to income. Cash outlays for remedial activities are charged to
reserves. Historically, the Company has funded its environmental
capital expenditures through cash flows from operations and
expects to do so in the future.
Cash outlays for environmental related activities for 2004, 2003
and 2002 were as follows:
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|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
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| |
|
| |
|
| |
|
|
($ in millions) | |
Environmental Cash Outlays
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital Projects
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|
$ |
1.3 |
|
|
$ |
0.7 |
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|
$ |
3.1 |
|
Plant Operations
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|
|
6.4 |
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|
|
6.7 |
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|
|
7.0 |
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Remedial Activities
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|
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2.7 |
|
|
|
2.3 |
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|
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2.5 |
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|
|
|
|
|
|
|
|
|
|
Total Environmental Cash Outlays
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$ |
10.4 |
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|
$ |
9.7 |
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|
$ |
12.6 |
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|
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|
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The Companys consolidated balance sheets included
liabilities for future environmental expenditures to investigate
and remediate known sites amounting to $8.3 million at
December 31, 2004, of which $3.3 million is classified
as other current liabilities and $5.0 million is classified
as other noncurrent liabilities and $8.6 million at
December 31, 2003, of which $3.3 million is classified
as other current liabilities and $5.3 million is classified
as other noncurrent liabilities. The Companys estimated
environmental liability relates to seven sites, six of which are
in the United States and none of which are on the
U.S. National Priority List. These amounts did not take
into account any discounting of future expenditures, any
consideration of insurance recoveries or any advances in
technology. These liabilities are reassessed periodically to
determine if environmental circumstances have changed or if the
costs of remediation efforts can be better estimated. As a
result of these reassessments, future charges to income may be
made for additional liabilities.
Annual environmental-related cash outlays for site investigation
and remediation, capital projects and normal plant operations
are expected to range from $10 million to $15 million
over the next several years. While the Company does not
anticipate a material increase in the projected annual level of
its environmental-related costs, there is always the possibility
that such increases may occur in the future in view of the
uncertainties associated with environmental exposures.
Environmental exposures are difficult to assess for numerous
reasons, including the identification of new sites, developments
at sites resulting from investigatory studies, advances in
technology, changes in environ-
11
mental laws and regulations and their application, the scarcity
of reliable data pertaining to identified sites, the difficulty
in assessing the involvement and financial capability of other
potentially responsible parties and the Companys ability
to obtain contributions from other parties and the lengthy time
periods over which site remediation occurs. It is possible that
some of these matters (the outcomes of which are subject to
various uncertainties) may be resolved unfavorably against the
Company and may have a materially adverse impact on the
Companys business. At December 31, 2004, the Company
had estimated additional contingent environmental liabilities of
$7.3 million.
The table below sets forth the primary locations where the
Company has offices or conducts operations, including some joint
venture sites, along with a brief description of the activities
conducted at each identified location. A more detailed
description of the Companys principal manufacturing
facilities follows the table. The Company believes that its
facilities are sufficiently maintained and suitable and adequate
for its immediate needs and that additional space is available
to accommodate expansion. Except for locations identified as
relating to a joint venture that are owned or leased by the
joint venture or unless otherwise noted below, the identified
location is owned by the Company.
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Location |
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Primary Activities |
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McIntosh, Alabama(1)
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Blending and storage facility for performance products |
Mesa, Arizona(2)
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|
CMP development, manufacturing and applications center for
Planar Solutions, LLC joint venture |
Cheshire, Connecticut(2)
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|
Research and development facility and offices for treatment
products |
New Castle, Delaware(2)
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|
Research laboratory and testing site for HTH water products |
Norwalk, Connecticut(2)
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|
Worldwide corporate headquarters |
Conley, Georgia
|
|
Technical center and manufacturing facility for wood protection
and industrial coatings |
Smyrna, Georgia(2)
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|
Office facility for treatment products |
Bethalto, Illinois(2)
|
|
Corporate data center |
Brandenburg, Kentucky
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|
Manufacturing facility for performance products and technical
center for wood protection and industrial coatings |
Lake Charles, Louisiana
|
|
Manufacturing facility for performance products |
Adrian, Michigan(3)
|
|
Manufacturing facility for Planar Solutions, LLC joint venture |
South Plainfield, New Jersey
|
|
Research and development facility and office space for personal
care and industrial biocides |
Rochester, New York
|
|
Manufacturing facility for personal care and industrial biocides
and wood protection and industrial coatings |
Charleston, Tennessee(4)
|
|
Manufacturing facility for HTH water products |
Trentham, Victoria, Australia
|
|
Office and manufacturing facility for the treatment
products Koppers Arch joint venture |
Igarassu, Brazil
|
|
Facility of a joint venture for the manufacture of HTH water
products |
12
|
|
|
Location |
|
Primary Activities |
|
|
|
Salto, Brazil
|
|
Manufacturing facility for HTH water products and performance
products |
Suzhou, China
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|
Warehouse, manufacturing facility and technical support center
for personal care and industrial biocides and wood protection
and industrial coatings |
Blackley, England(2)
|
|
Office facility and laboratory for personal care and industrial
biocides |
Castleford, England(4)
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|
Office facility, manufacturing facility and technical center for
treatment products |
Grangemouth, England(3)
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|
Manufacturing facility for personal care and industrial biocides
and HTH water products |
Huddersfield, England(2)
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|
Manufacturing and laboratory facilities for personal care and
industrial biocides |
Knottingley, England(2)
|
|
Office, warehouse, manufacturing facilities and technical center
for wood protection and industrial coatings |
Preston, England
|
|
Wood treatment facility for wood protection and industrial
coatings |
Seal Sands, England
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|
Manufacturing facility for personal care and industrial biocides |
Amboise, France(2)
|
|
Manufacturing, distribution and warehouse facility for HTH water
products |
Les Mureaux, France
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|
Office, manufacturing and laboratory facility for treatment
products |
Amsterdam, Holland(2)
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|
Wood treatment facility for treatment products |
Swords, Ireland
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|
Manufacturing facility for personal care and industrial biocides |
Mariano Comense, Italy
|
|
Manufacturing and research and development facility for wood
protection and industrial coatings |
Pianoro, Italy
|
|
Manufacturing, research and development and office facility for
wood protection and industrial coatings |
Auckland, New Zealand
|
|
Office and manufacturing facility for the Koppers Arch joint
venture |
Kempton Park, South Africa
|
|
Manufacturing facility for the manufacture of HTH water products |
Valencia, Spain
|
|
Manufacturing and distribution facility for wood protection and
industrial coatings |
Maracaibo, Venezuela
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|
Manufacturing facility for performance products |
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(1) |
Land only is leased. |
|
(2) |
Leased facility. |
|
(3) |
Land and building owned by a third party. |
|
(4) |
Portions are leased and portions are owned. |
The Company also leases several sales offices and warehouse
facilities in the U.S. and in foreign countries.
13
Principal Manufacturing Facilities
The principal manufacturing properties of the Company described
below are all owned by the Company, except for the land under
the McIntosh plant and part of the land under the Charleston
facility which are being leased from Olin and except for
properties held by joint ventures or otherwise noted below. The
Company also has products that are produced by third parties
under contract manufacturing arrangements.
McIntosh, Alabama. The Companys facility located in
McIntosh, Alabama blends, packages and stores propellant grade
hydrazine products. Special hydrazine fuel blends are produced
as the principal propellant for several U.S. Air Force
launch vehicle programs, including the Titan and Delta rockets.
Conley, Georgia. This is the Companys major
facility for its wood treatment business in the
U.S. Currently, all of the Companys CCA is produced
at this location and some of it is sent by rail to the
Companys Kalama, Washington facility for distribution to
customers in the Western U.S. CCA is also bulk shipped from
this plant to the Companys other CCA customers and to its
Valparaiso, Indiana facility. A 72% CCA concentrate is also
produced at this facility. This site also produces the
Companys CCA-alternative products. Office facilities and a
technical center for treatment products are also located at this
facility.
Brandenburg, Kentucky. The ISO 9001-2000-certified
Brandenburg plant covers an area of 200 acres, surrounded
by 1,200 acres of land that provides both a buffer zone and
expansion capability. The plant contains multiple manufacturing
facilities producing a wide range of products. Many of these
products are derivatives of ethylene oxide and propylene oxide.
A broad line of specialty polyols are produced in a flexible
batch facility and sold into urethane coatings, adhesives,
sealant and elastomer applications. Under a contract
manufacturing agreement with the purchaser of the majority of
the operations of the Companys microelectronic chemicals
business, the Company produces chemical intermediates for such
microelectronic business in a separate manufacturing facility
dedicated to this purpose at this site. There is a research and
development and technical center at the site that supports the
development and technical service needs of the polyol and glycol
products and wood coatings products. The Company also operates
other facilities on the site to produce commodity and specialty
chemicals for third parties under long-term contractual
arrangements.
Lake Charles, Louisiana. The Companys facility
located in Lake Charles, Louisiana consists of three
manufacturing plants that produce various hydrazine products.
One ISO 9002-certified plant produces solution grade hydrazine
products for use in chemical blowing agents, water treatment
chemicals, agricultural products, pharmaceutical intermediates
and other chemical products. This plant is currently idled. A
second ISO 9002-certified plant which was idled in 2004
following expiration of the hydrazine propellants contract with
the U.S. Government, produced propellant grade hydrazine
products, including anhydrous hydrazine, unsymmetrical dimethyl
hydrazine and monomethyl hydrazine for use as fuel in
satellites, expendable launch vehicles and auxiliary power
units. Additional equipment of the Company at this site produces
propellant grade Ultra
Puretm
Hydrazine, the worlds purest grade of anhydrous hydrazine,
principally for satellite propulsion.
Rochester, New York. This ISO 9002- and RC
14001-certified facility manufactures a large number of
chemicals for the specialty chemicals industry. Many of these
chemicals are biocides used to control dandruff on the scalp and
to control the growth of microorganisms, particularly fungi and
algae. The largest 2-Chloropyridine production facility in the
world is located here. 2-Chloropyridine is the key intermediate
used to produce the Companys
Omadine® biocides. These products are
based on the salts of the pyrithione molecule. The Company
manufactures over a dozen pyrithione products at this site by
modifying these salts by concentration, form or combining them
with other biocides. This plant also manufactures the
Companys Triadine® brand of
biocides which are a combination of pyrithione and triazine, a
bactericide purchased from a supplier. This facility also
produces the Omacide® IPBC brand biocide,
which is based upon iodopropargyl-n-butylcarbamate, a
broad-spectrum fungicide. This facility also manufactures
personal care specialty ingredients for the Companys
personal care product line and Wolman®E
for the Companys wood protection business.
Charleston, Tennessee. The Companys ISO
9002-certified facility located in Charleston, Tennessee
primarily produces, packages and stores calcium hypochlorite for
the HTH water products business. At this
14
plant, products are packaged into containers that range in size
from 5 pounds to 2,000 pounds per container. Liquid and dry pool
maintenance products are also blended, packaged and stored at
this site.
Trentham, Victoria, Australia. This Koppers Arch joint
venture facility produces CCA-based wood preservatives for the
Australian market. The sales office services the Victoria, South
Australian and Western Australian markets. The site is ISO
9002-certified.
Igarassu, Brazil. The Companys facility located in
Igarassu, Brazil is a joint venture operation (Nordesclor S.A.)
that produces and packages calcium hypochlorite for the HTH
water products business within Brazil. Certain other products
for the swimming pool market and the water treatment market are
packaged at this site. The Company also has a small repackaging
facility in Salto, Brazil. The Salto facility also blends and
manufactures products for the performance products business.
Grangemouth, England. This manufacturing site is owned
and operated by Avecia under a toll manufacturing arrangement
with the Company. The Company owns all of the equipment used in
the direct manufacture of PHMB products as well as the HMBDA
(Hexamethylene-1,6-Bis-Dicyandiamide) intermediate. The PHMB
product is produced in various solutions and in a solid format.
It is used by the Companys HTH water products business to
produce Baquacil®,
BaquaSpa® and related swimming pool and
spa treatment chemicals, and it is also used in products sold by
the industrial biocides business under the
Vantocil® and
Reputex® brands for various end-use
applications, including consumer-focused health and hygiene
products. PHMB is also used in products sold under the
Cosmocil® brand for cosmetic and personal
care applications.
Huddersfield, England. This ISO-9001-certified leased
facility produces and packages Proxel®
and Densil® biocide blends (which are
based on BIT) for sale by Archs industrial biocides
business. The facility also ships the BIT active ingredients to
formulators worldwide. This site is one of the worlds
largest BIT production facilities. The products are packed in a
variety of sizes from 25kg to full tank truck shipments. There
are approximately 25 different product offerings.
Seal Sands, England. This ISO-9001 and ISO 14001 facility
produces and packages the intermediate product used at the
Huddersfield site in BIT production. The intermediate is DTBA
(2,2-Dithiodibenzoic Acid). The majority of the product is
consumed internally at Huddersfield. Product is shipped in totes
for easy transport and handling.
Les Mureaux, France. This ISO 9002-certified facility is
located just northwest of Paris, France and serves as European
headquarters for water treatment products and French
headquarters for personal care ingredient products, timber
products and coating products. It also manufactures a limited
supply of coatings for the French furniture market. The site
also repackages and sells a line of industrial coatings produced
by the Companys Italian operations.
Swords, Ireland. This facility is located just north of
Dublin, Ireland. 2-Chloropyridine is imported from the
Companys Rochester, New York plant and other sources and
converted into zinc and copper salts of the pyrithione molecule.
The products are shipped to customers in Europe and over fifty
countries around the world. This facility is both ISO 9002- and
ISO 14001-certified.
Mariano Comense, Italy. This ISO 9002-certified facility
serves as the primary manufacturing location for the
Companys UV-based product line for its coatings business.
It also serves as a distribution location. Some product
development work is also performed here.
Pianoro, Italy. This ISO 9002-certified and ISO
14001-certified facility serves as the primary manufacturing
location and research and development center for the industrial
coatings business. It produces the
Sayerlack® and Linea
Blu® branded products that include both
solvent- and water-borne urethane systems, solvents, stains and
colors. In addition, the central management for the distribution
of these products throughout Italy and various export markets is
located here.
Kempton Park, South Africa. The Companys facility
produces and packages calcium hypochlorite for the HTH water
products business principally within the Southern Africa region.
Products for the swimming pool and water treatment markets are
also packaged at this site.
15
Maracaibo, Venezuela. The Companys ISO
9002-certified facility is a multi-product manufacturing plant
producing a broad range of polyols, demulsifiers, and specialty
surfactants to support regional markets. Specialty polyols are
also produced for local consumption and export.
|
|
Item 3. |
Legal Proceedings |
Koppers Arch Wood Protection (NZ) Limited
(KANZ), a New Zealand joint venture company in which
the Company owns indirectly a 49% interest, is the subject of an
on-going investigation by the New Zealand Commerce Commission
(NZ Commerce Commission) regarding industry
competitive practices. KANZ manufactures and markets wood
preservative products throughout New Zealand. The NZ Commerce
Commission has the authority to assess fines equal to the higher
of (i) NZ$10 million (approximately
US$7 million), (ii) three times the commercial gain
from the contravention or (iii) 10% of the sales of KANZ
(approximately US$2 million). Penalties, if assessed
against KANZ, could have a material adverse effect on the joint
ventures business, financial condition, cash flows and
results of operations. Similarly, Koppers Arch Wood
Protection (Aust) Pty Ltd (KAWP), an Australian
joint venture company in which the Company owns indirectly a 49%
interest and the majority shareholder of KANZ, has made an
application for leniency under the Australian Competition and
Consumer Commissions (ACCC) policy for cartel
conduct. The ACCC has granted immunity to KAWP, subject to the
fulfillment of certain conditions. If the conditions are not
fulfilled, the ACCC may penalize KAWP for any violations of the
competition laws of Australia. Such penalties, if assessed
against KAWP, could have a material adverse effect on
KAWPs business, financial condition, cash flows and
results of operations. As a result of the Companys
ownership in such entities, an unfavorable resolution could have
a material adverse effect on equity in earnings of affiliated
companies and dividends received.
In connection with the Distribution, the Company assumed
substantially all non-environmental liabilities for legal
proceedings relating to the Companys businesses as
conducted prior to the Distribution Date. In addition, in the
normal course of business, the Company is subject to other
proceedings, lawsuits and other claims, including proceedings
under laws and regulations related to environmental and other
matters. All such matters are subject to many uncertainties and
outcomes that are not predictable with assurance. While these
other matters could materially affect operating results when
resolved in future periods, it is managements opinion that
after final disposition, including anticipated insurance
recoveries, any monetary liability or financial impact to the
Company beyond that provided in the consolidated balance sheet
as of December 31, 2004, would not be material to the
Companys financial position or annual results of
operations.
|
|
Item 4. |
Submission of Matters to a Vote of Security Holders |
No matter was submitted to a vote of security holders during the
three months ended December 31, 2004.
Executive Officers
The biographical information of the executive officers of the
Company as of March 1, 2005 is noted below.
|
|
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Name and Age |
|
Office |
|
|
|
Michael E. Campbell (57)
|
|
Chairman of the Board, President and Chief Executive Officer |
Paul J. Craney (56)
|
|
Corporate Executive Vice President |
Louis S. Massimo (47)
|
|
Corporate Executive Vice President and Chief Financial Officer |
Hayes Anderson (44)
|
|
Corporate Vice President, Human Resources |
Sarah A. OConnor (45)
|
|
Corporate Vice President, General Counsel and Secretary |
W. Paul Bush (54)
|
|
Vice President and Treasurer |
Steven C. Giuliano (35)
|
|
Controller |
16
No family relationship exists between any of the above named
executive officers or between any of them and any Director of
the Company. Such officers were elected or appointed to serve as
such, subject to the Bylaws, until their respective successors
are chosen.
Mr. Campbell was elected Chairman of the Board and Chief
Executive Officer on February 7, 1999. On July 27,
2000, he was given the additional title of President. Prior to
the Distribution, he was Executive Vice President of Olin and
had global management responsibility for all of Olins
businesses. Prior to his election as an Executive Vice President
of Olin, Mr. Campbell served as President of Olins
Microelectronic Materials Division. Prior to that time and since
1987, he served as Olins Corporate Vice President, Human
Resources.
Mr. Craney was elected a Corporate Executive Vice President
on January 30, 2003. Prior to that time and since
September 13, 2000, he served as Vice President and General
Manager, Treatment. Prior to that position, he served as Vice
President, Strategic Development since August 31, 1999.
From February 7, 1999 until August 31, 1999, he was
Vice President and General Manager, Urethane Products. Prior to
the Distribution and since May 1996, Mr. Craney served as
Vice President and General Manager, Urethane Products Chemicals
Division, at Olin. Prior to May 1996, he served as Vice
President, Business Development and Materials Management
Chemicals Division, at Olin.
Mr. Massimo was elected a Corporate Executive Vice
President on January 30, 2003 and has held the
position of Chief Financial Officer since January 27, 1999.
Prior to January 30, 2003, Mr. Massimo was a Corporate
Vice President since January 27, 1999. Prior to the
Distribution, he served as Controller of Olin since
April 1, 1996 and, in addition, as Corporate Vice President
since January 1, 1997. From November 1994 until April 1996,
he served as Olins Director of Corporate Accounting. Prior
to November 1994, he was an Audit Senior Manager for KPMG LLP.
Mr. Anderson was elected Corporate Vice President, Human
Resources effective December 1, 2000. Prior to that, he had
served as Vice President and General Manager, Semiconductor
Chemicals and Services since June 8, 1999. Prior to that
position and since February 19, 1999, Mr. Anderson was
Business Director, Process Chemicals and Chemical Management
Services. Prior to serving as Business Director and prior to the
Distribution, Mr. Anderson served as Business Director,
Chemical Management Services of Olin since 1995 and from 1993 to
1995 was Business Manager, Chemical Management Services at Olin.
Ms. OConnor was elected Corporate Vice President,
General Counsel and Secretary on February 7, 1999. She was
elected a Vice President of the Company on October 13, 1998
when the Company was a wholly owned subsidiary of Olin. Prior to
the Distribution and since 1995, Ms. OConnor served
as Olins Director, Planning and Development.
Ms. OConnor became an Associate Counsel in the Olin
Corporate Legal Department in 1989 and was promoted to Counsel
in 1992 and to Senior Counsel in January 1995.
Mr. Bush was elected Treasurer on February 7, 1999 and
also appointed a Vice President on that date. Prior to the
Distribution and since February 1998, Mr. Bush was a
consultant to Olin. Prior to February 1998, and since March
1994, he was Vice President, Treasurer and then Vice President,
Investments of Johnson & Higgins, an insurance
brokerage and benefits consulting firm. Prior to 1994, he held
various managerial positions, including Vice President and
Treasurer and Vice President, Financial Planning and Analysis
for Squibb Corporation.
Mr. Giuliano was elected Controller on January 27,
1999. Prior to the Distribution, Mr. Giuliano was an Audit
Senior Manager for KPMG LLP and prior to that and since 1991, he
held various positions of increasing responsibility for KPMG
LLP, where he had overall responsibility for services provided
in connection with audits, SEC filings, private offerings and
other services for certain domestic and multinational clients.
17
PART II
|
|
Item 5. |
Market for the Registrants Common Equity and Related
Stockholder Matters and Issuer Purchases of Equity
Securities |
As of January 31, 2005, there were approximately 5,650
record holders of the Companys common stock.
The Companys common stock is traded on the New York Stock
Exchange (NYSE) under the symbol ARJ. In
2004, the Company submitted the required Section 303A.12(a)
CEO annual certification to the NYSE and has filed as Exhibits
31.1 and 31.2 to this Report the certifications required by
Section 302 of the Sarbanes-Oxley Act.
Information concerning the high and low sales prices of the
Companys common stock and dividends paid on common stock
during each quarterly period for the last two most recent fiscal
years is set forth in Note 23 of Notes to Consolidated
Financial Statements contained in Item 8 of this Report.
Among the provisions of the credit facility (as defined in
Item 7 of this Report) are restrictions relating to the
payments of dividends and the acquisition of the Companys
Common Stock based on a financial formula. As of
December 31, 2004, dividends and stock repurchases were
limited to approximately $48.7 million. In addition, the
senior unsecured notes issued in March 2002 contain dividend
restrictions, which limit dividends and repurchases to
$37.6 million as of December 31, 2004. See
Note 11 of Notes to Consolidated Financial Statements
contained in Item 8 of this Report for restrictions on
dividends and repurchases under the credit facility and senior
unsecured notes.
See Item 12 of this Report for Equity Compensation Plan
information.
|
|
Item 6. |
Selected Financial Data |
The following table summarizes certain selected historical
financial and operating information with respect to the Company
and is derived from the Consolidated Financial Statements of the
Company. The financial data as of and for each of the years in
the three-year period ended December 31, 2004 were derived
from the audited financial statements included elsewhere herein.
Such historical financial data may not be indicative of the
Companys future performance. The information set forth
below should be read in conjunction with Managements
Discussion and Analysis of Financial Condition and Results of
Operations and the historical Consolidated Financial
Statements and Notes thereto included elsewhere in this
Form 10-K. The following information is qualified in its
entirety by the information and financial statements appearing
elsewhere in this Form 10-K. See Note 1 of the Notes
to Consolidated Financial Statements for additional information.
As a result of the sale of the majority of the microelectronic
materials businesses, the Company has restated its prior year
financial statements to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations in
accordance with the Statement of Financial Accounting Standard
No. 144, Accounting for the Impairment or Disposal of
Long-Lived Assets (SFAS 144). The Company
has retained its 50 percent interest in Planar Solutions
LLC, its joint venture with Wacker Chemical Corporation for the
production and sale of chemical mechanical planarization
(CMP) slurries, the microelectronics-dedicated
manufacturing facility in Brandenburg, Kentucky and its chemical
management services (CMS) business. The Company will pursue
all strategic options for the CMS business, including its sale.
As a result, and in accordance with the accounting requirements
of SFAS 144, the CMS business is reported as an asset held
for sale and the results of operations are included in
discontinued operations in the consolidated financial
statements. The Company will continue to supply certain
18
products for a transition period to the purchaser of the
microelectronic materials businesses from its Brandenburg,
Kentucky facility.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of and For the Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
2001 | |
|
2000 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions, except per share amounts) | |
Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales
|
|
$ |
1,120.9 |
|
|
$ |
863.5 |
|
|
$ |
763.0 |
|
|
$ |
724.4 |
|
|
$ |
668.0 |
|
Cost of Goods Sold(1)
|
|
|
808.0 |
|
|
|
618.1 |
|
|
|
541.9 |
|
|
|
521.0 |
|
|
|
488.2 |
|
Selling and Administration(2)
|
|
|
252.6 |
|
|
|
209.7 |
|
|
|
184.6 |
|
|
|
173.4 |
|
|
|
134.1 |
|
Research and Development
|
|
|
15.4 |
|
|
|
11.7 |
|
|
|
10.3 |
|
|
|
11.4 |
|
|
|
5.0 |
|
Other (Gains) and Losses(3)
|
|
|
1.4 |
|
|
|
(3.0 |
) |
|
|
(1.5 |
) |
|
|
1.0 |
|
|
|
(8.1 |
) |
Impairment and Restructuring(4)
|
|
|
4.6 |
|
|
|
0.4 |
|
|
|
5.7 |
|
|
|
0.7 |
|
|
|
25.1 |
|
Interest Expense, net
|
|
|
18.6 |
|
|
|
16.6 |
|
|
|
16.0 |
|
|
|
17.8 |
|
|
|
13.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income (Loss) from Continuing Operations Before Taxes, Equity in
Earnings of Affiliated Companies And Cumulative Effect of
Accounting Change
|
|
|
20.3 |
|
|
|
10.0 |
|
|
|
6.0 |
|
|
|
(0.9 |
) |
|
|
10.6 |
|
Equity in Earnings of Affiliated Companies
|
|
|
4.0 |
|
|
|
5.6 |
|
|
|
3.1 |
|
|
|
2.5 |
|
|
|
2.3 |
|
Income Tax Expense
|
|
|
7.0 |
|
|
|
5.5 |
|
|
|
2.7 |
|
|
|
1.0 |
|
|
|
1.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income from Continuing Operations Before Cumulative Effect of
Accounting Change
|
|
|
17.3 |
|
|
|
10.1 |
|
|
|
6.4 |
|
|
|
0.6 |
|
|
|
11.1 |
|
Income (Loss) from Discontinued Operations, net of tax(5)
|
|
|
2.6 |
|
|
|
17.7 |
|
|
|
(3.4 |
) |
|
|
(1.7 |
) |
|
|
(10.6 |
) |
Cumulative Effect of Change in Accounting, net of tax(6)
|
|
|
|
|
|
|
(0.4 |
) |
|
|
|
|
|
|
(0.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income (Loss)
|
|
$ |
19.9 |
|
|
$ |
27.4 |
|
|
$ |
3.0 |
|
|
$ |
(1.3 |
) |
|
$ |
0.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Diluted Income (Loss) Per Share
|
|
$ |
0.84 |
|
|
$ |
1.21 |
|
|
$ |
0.13 |
|
|
$ |
(0.06 |
) |
|
$ |
0.02 |
|
Common Dividends Per Share
|
|
|
0.80 |
|
|
|
0.80 |
|
|
|
0.80 |
|
|
|
0.80 |
|
|
|
0.80 |
|
Other
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital Expenditures
|
|
|
18.3 |
|
|
|
17.0 |
|
|
|
28.2 |
|
|
|
32.9 |
|
|
|
44.0 |
|
Depreciation
|
|
|
41.7 |
|
|
|
37.5 |
|
|
|
37.4 |
|
|
|
35.9 |
|
|
|
30.0 |
|
Amortization of Intangibles
|
|
|
5.2 |
|
|
|
1.9 |
|
|
|
2.0 |
|
|
|
7.0 |
|
|
|
2.3 |
|
Effective Tax Rate(7)
|
|
|
28.8 |
% |
|
|
35.3 |
% |
|
|
29.7 |
% |
|
|
62.5 |
% |
|
|
14.0 |
% |
Financial Position
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Working Capital(8)
|
|
$ |
99.6 |
|
|
$ |
79.3 |
|
|
$ |
38.1 |
|
|
$ |
75.2 |
|
|
$ |
91.9 |
|
Property, Plant and Equipment, net
|
|
|
211.6 |
|
|
|
207.9 |
|
|
|
222.2 |
|
|
|
228.5 |
|
|
|
190.4 |
|
Total Assets
|
|
|
1,100.0 |
|
|
|
976.4 |
|
|
|
939.1 |
|
|
|
968.2 |
|
|
|
1,073.6 |
|
Long-Term Debt
|
|
|
215.2 |
|
|
|
218.5 |
|
|
|
220.8 |
|
|
|
265.1 |
|
|
|
247.6 |
|
Shareholders Equity
|
|
|
359.8 |
|
|
|
337.7 |
|
|
|
330.0 |
|
|
|
387.5 |
|
|
|
419.8 |
|
Capitalization
|
|
|
584.1 |
|
|
|
556.9 |
|
|
|
553.2 |
|
|
|
691.1 |
|
|
|
763.2 |
|
|
|
(1) |
Cost of Goods Sold for 2003 includes an insurance settlement of
$3.3 million for the reimbursement of past and future
repairs of one of the Companys manufacturing locations. |
|
(2) |
Selling and Administration expenses for 2004 include a
$6.1 million settlement from a favorable legal judgment. |
|
(3) |
Other (Gains) and Losses for 2004 principally includes a charge
for a Brazilian state import tax claim of $2.1 million in
the performance urethanes, HTH water products and hydrazine
businesses, offset by the pre- tax gain of $0.6 million on
the sale of a building in the personal care business. 2003
principally includes the pre-tax gain on the sale of excess land
of $2.5 million. 2002 consists of the pre-tax gain on the
sales of excess land. 2001 includes a $1.0 million
write-off of an investment in GlobalBA.com, Inc. |
19
|
|
|
2000 consists of a pre-tax gain on the sale of Superior Pool
Products of $10.6 million and certain acquisition-related
costs of $2.5 million related to the acquisition and
integration of Hickson. |
|
|
(4) |
Impairment and Restructuring consist of the following: |
|
|
|
Impairment Charge
|
|
2004 includes a $2.9 million charge for the fully-dedicated
manufacturing assets of the microelectronic materials business
located in Brandenburg, Kentucky which the Company continues to
own. These assets will no longer be utilized except for a
transition period and have limited, if any, use thereafter. |
Restructuring
|
|
2004 includes $2.1 million for severance costs related to
headcount reductions in the hydrazine business due to the
expiration of the government contract, offset by a reduction of
$0.4 million of prior year restructuring reserves. 2003
includes severance cost of $1.4 million for headcount
reductions related to the performance products segment,
$1.1 million of severance costs for additional headcount
reductions associated with a revision to the 2002 original
restructuring program offset by a reduction of the prior
years restructuring reserves of $2.1 million.
Restructuring charges for 2002 include $4.7 million related
to headcount reductions of approximately 140 employees in the
performance urethanes and HTH water products businesses, as well
as a $1.0 million charge related to the consolidation of
several treatment products segment operations. The non-cash
portion of the restructuring charge was approximately
$1.0 million. 2001 charges include $2.4 million for
headcount reductions, offset by a $1.5 million reduction of
the 2000 reserve and $0.2 million of reimbursement of
certain severance costs. 2000 charges include a
$25.1 million charge, which consists of $14.1 million
related to the write-off of certain costs associated with the
biocides business, and $11.0 million related to other
headcount reductions. |
|
|
(5) |
The following details the components of Income (Loss) from
discontinued operations: |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
For the Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
2001 | |
|
2000 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Discontinued Operations, Results of Operations:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Microelectronic Materials(a)
|
|
$ |
10.0 |
|
|
$ |
5.0 |
|
|
$ |
(0.1 |
) |
|
$ |
(1.8 |
) |
|
$ |
(15.4 |
) |
Hickson organics(b)
|
|
|
|
|
|
|
(2.9 |
) |
|
|
(3.3 |
) |
|
|
(2.9 |
) |
|
|
|
|
Sulfuric Acid(c)
|
|
|
|
|
|
|
1.1 |
|
|
|
1.5 |
|
|
|
3.0 |
|
|
|
4.8 |
|
Gain (Loss) on Sale of Businesses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Microelectronic Materials
|
|
|
(1.6 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Hickson organics(d)
|
|
|
(7.3 |
) |
|
|
(2.0 |
) |
|
|
(1.5 |
) |
|
|
|
|
|
|
|
|
Sulfuric Acid(e)
|
|
|
1.5 |
|
|
|
16.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total Income (Loss) from Discontinued Operations, net of tax
|
|
$ |
2.6 |
|
|
$ |
17.7 |
|
|
$ |
(3.4 |
) |
|
$ |
(1.7 |
) |
|
$ |
(10.6 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(a) |
Represents the results of operations, net of tax, for all years
presented through the date of sale on November 30, 2004.
2000 includes restructuring expense ($8.9 million) and an
impairment charge ($31.0 million) due to the process
chemicals restructuring. |
|
|
(b) |
Represents the results of operations, net of tax, of the Hickson
organics division for 2003 through the date of sale on
August 11, 2003, 2002 and September through December 2001. |
|
|
(c) |
Represents the results for all years presented through the date
of sale on July 2, 2003. |
|
|
(d) |
2004 includes an adjustment on the loss on the sale of the
Hickson organics Castleford operations principally due to the
establishment of a reserve on the outstanding working capital
receivable and a charge for probable future commitments as a
result of the uncertainty concerning the viability of the
purchaser. 2003 represents the initial loss on the sale of the
Hickson organics Castleford operations. 2002 represents the loss
on the sale of the DanChem organics operation in Danville,
Virginia. |
|
|
(e) |
2004 principally represents a tax refund related to the sale of
the sulfuric acid business. |
|
|
(6) |
2003 reflects the impact of adoption of SFAS No. 143,
Accounting for Asset Retirement Obligations. 2001
reflects the impact of adoption of SFAS No. 133,
Accounting for Derivative Instruments and Hedging
Activities. |
20
|
|
(7) |
The effective tax rate is based on continuing operations before
cumulative effect of accounting change. |
|
(8) |
Working capital excludes cash, short-term debt and assets held
for sale. In addition, the Company sells certain accounts
receivable through an accounts receivable securitization program
entered into in March 2002. As a result, accounts receivable
have been reduced, the Companys undivided interest in such
receivables have been reflected as a short-term investment and
proceeds from the sales have been used to pay down debt. As of
December 31, 2004 and 2003, the Company had not sold any
participation interests in accounts receivable. As of
December 31, 2002, the Company had sold $33.5 million
of participation interests in $55.1 million of accounts
receivable. |
|
|
Item 7. |
Managements Discussion and Analysis of Financial
Condition and Results of Operations |
This Managements Discussion and Analysis of Financial
Condition and Results of Operations should be read in
conjunction with the Companys historical Consolidated
Financial Statements and Notes thereto included elsewhere
herein. Sales consist of sales to third parties net of any
discounts. Gross Margin is defined as Sales less Cost of Goods
Sold, which includes raw materials, labor, overhead and
depreciation associated with the manufacture of the
Companys various products and shipping and handling costs.
In addition, segment operating income includes the equity in
earnings of affiliated companies and excludes restructuring
(income) expense, impairment and certain unallocated expenses of
the corporate headquarters. The Company includes the equity
income (loss) of affiliates in its segment operating results as
it believes it to be relevant and useful information for
investors as these affiliates are the means by which certain
segments participate in certain geographic regions. Furthermore
equity income (loss) is included as a component of segment
operating results because the Company includes it to measure the
performance of the segment. Other gains and (losses) that are
directly related to the segments are included in segment
operating results.
As a result of the sale of the majority of the microelectronic
materials businesses, the Company has restated its prior year
financial statements to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations in
accordance with the Statement of Financial Accounting Standard
No. 144, Accounting for the Impairment or Disposal of
Long-Lived Assets (SFAS 144). The Company
has retained its 50 percent interest in Planar Solutions
LLC, its joint venture with Wacker Chemical Corporation for the
production and sale of chemical mechanical planarization
(CMP) slurries, the microelectronics-dedicated
manufacturing facility in Brandenburg, Kentucky and its chemical
management services (CMS) business. The Company will pursue
all strategic options for the CMS business, including its sale.
As a result, and in accordance with the accounting requirements
of SFAS 144, the CMS business is reported as an asset held
for sale and the results of operations are included in
discontinued operations in the consolidated financial
statements. The Company will continue to supply certain products
for a transition period to the purchaser of the microelectronic
materials businesses from its Brandenburg, Kentucky facility.
Results of Operations
Consolidated
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
(In millions, except per share | |
|
|
amounts) | |
Sales
|
|
$ |
1,120.9 |
|
|
$ |
863.5 |
|
|
$ |
763.0 |
|
Gross Margin
|
|
|
312.9 |
|
|
|
245.4 |
|
|
|
221.1 |
|
Selling and Administration
|
|
|
252.6 |
|
|
|
209.7 |
|
|
|
184.6 |
|
Research and Development
|
|
|
15.4 |
|
|
|
11.7 |
|
|
|
10.3 |
|
Other (Gains) and Losses
|
|
|
1.4 |
|
|
|
(3.0 |
) |
|
|
(1.5 |
) |
Restructuring Expense
|
|
|
1.7 |
|
|
|
0.4 |
|
|
|
5.7 |
|
Impairment Charge
|
|
|
2.9 |
|
|
|
|
|
|
|
|
|
Interest Expense, net
|
|
|
18.6 |
|
|
|
16.6 |
|
|
|
16.0 |
|
Equity in Earnings of Affiliated Companies
|
|
|
4.0 |
|
|
|
5.6 |
|
|
|
3.1 |
|
Income Tax Expense
|
|
|
7.0 |
|
|
|
5.5 |
|
|
|
2.7 |
|
Income (Loss) from Discontinued Operations, net of tax
|
|
|
10.0 |
|
|
|
3.2 |
|
|
|
(1.9 |
) |
21
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
(In millions, except per share | |
|
|
amounts) | |
Gain (Loss) on the Sales of Discontinued Operations, net of tax
|
|
|
(7.4 |
) |
|
|
14.5 |
|
|
|
(1.5 |
) |
Cumulative Effect of Accounting Change, net of tax
|
|
|
|
|
|
|
(0.4 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income
|
|
$ |
19.9 |
|
|
$ |
27.4 |
|
|
$ |
3.0 |
|
|
|
|
|
|
|
|
|
|
|
Basic Income Per Share
|
|
$ |
0.86 |
|
|
$ |
1.21 |
|
|
$ |
0.13 |
|
Diluted Income Per Share
|
|
$ |
0.84 |
|
|
$ |
1.21 |
|
|
$ |
0.13 |
|
Weighted Average Common Stock Outstanding:
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic
|
|
|
23.2 |
|
|
|
22.6 |
|
|
|
22.5 |
|
Diluted
|
|
|
23.5 |
|
|
|
22.6 |
|
|
|
22.6 |
|
The Company is a global specialty chemicals manufacturer
supplying value-added products and services to consumer products
and industrial markets on a worldwide basis. The Company
operates in two segments: Treatment Products and Performance
Products. In 2004, the Company sharpened the focus on its core
growth platform Treatment Products by
acquiring Avecias pool & spa and
protection & hygiene businesses and by divesting the
majority of its microelectronic materials businesses.
Archs Treatment Products business segment generates
approximately 85% of the Companys annual sales. It
includes three reportable business units: HTH water products,
personal care and industrial biocides, and wood protection and
industrial coatings. The results of the pool & spa
business are included in the HTH water products business unit
and the results of the protection & hygiene business
are included in the personal care and industrial biocides
business unit.
The Treatment Products segment drives growth by its superior
product formulation skills, technical customer support
capabilities and its expertise in helping customers respond to
key regulatory trends aimed at improving the environment or
protecting human health and safety. For example, the
Companys environmentally preferable zinc and copper
Omadine® biocides are rapidly being formulated into marine
antifouling paints to replace tributyl tins, whose toxicity to
marine life has led to international bans on their use in marine
paints. The Company is also a global market leader in supplying
biocides for incorporation into interior and exterior paints,
wallboard, ceiling tiles and other building products to deter
the growth of mold and mildew, the major cause of the Sick
Building Syndrome.
The Companys major sales, distribution and production
facilities are located in North America and Europe. Additional
facilities are based in Latin America, Australia, Asia and South
Africa. Approximately 50% of sales and total long-lived assets,
excluding goodwill, are outside the U.S. Accordingly, the
Company has exposure to fluctuations in foreign currency
exchange rates. These fluctuations impact the translation of
sales, earnings, assets and liabilities from the local
functional currency to the U.S. dollar. Operating units
outside the U.S. that purchase raw materials in
U.S. dollars are also impacted by fluctuations in foreign
currency exchange rates.
Critical success factors for the Company include managing its
overall global manufacturing facilities to maximize efficiencies
in the manufacturing processes; fixing or eliminating
unprofitable businesses; reducing overall product sourcing
costs; and growing the businesses organically and through
strategic acquisitions. In addition, several of its customers
generally require that the Company demonstrate improved
efficiencies, through cost reductions and/or price decreases.
Finally, the Companys continued growth will be based on
its ability to develop new products to meet its customers
needs. See Results of Operations for more details on the factors
that drive year-over-year performance.
The Company has an annual compensation plan and a long-term
incentive compensation plan for its executives and other
employees. The annual plans financial targets are diluted
earnings per share and cash flow. The numerator for diluted
earnings per share is net income adjusted for any extraordinary
income or expense, special charges or gains, and gains or losses
on sales of businesses or sales not in the ordinary course of
business (adjusted net income). Cash flow is defined
as EBITDA, plus or minus the change in working capital, less
capital spending. The Companys long-term incentive plan
target is Return on Equity (ROE).
22
ROE is defined as adjusted net income divided by average
shareholders equity (the average calculated using the
shareholders equity at the beginning and the end of the
fiscal year, excluding the impact on ending shareholders
equity of any adjustments to net income). These financial
metrics are key performance indicators utilized by the Company
to evaluate its performance against stated goals. In addition,
the estimated and actual performance against such targets can
have a significant impact on the amount of incentive
compensation expense recorded by the Company.
The Company has a disciplined acquisition strategy that is aimed
at complementing existing strengths and under which all
candidates must meet stringent strategic and financial criteria.
First, any acquisition must strengthen the Company and be
focused on the core business areas. Secondly, any acquisition
must be cash accretive in year one and earnings accretive
no later than the end of the first year. Lastly, there must
be a detailed integration plan established prior to the
acquisition.
The Companys 2004 full year net sales were
$1,120.9 million, up approximately 30% from 2003. The
Company benefited from acquisitions and from organic growth in
its core businesses, which is evidenced by the strong demand for
biocides used in marine antifouling paints, antidandruff
shampoos and building products that deter the growth of mold and
mildew. In 2004, the Company continued to see savings from prior
restructuring programs that were combined with other
cost-reduction initiatives; thereby enabling the Company to
offset rising costs in its pension and health-care plans, as
well as continued raw material price pressures. The Company
remains focused on reducing costs and managing cash wisely, so
it has sufficient resources to drive growth both organically and
through additional complementary acquisitions.
|
|
|
Year Ended December 31, 2004 Compared to 2003 |
Sales increased $257.4 million, or 29.8%, due in part to
the acquisition of Avecias pool & spa and
protection & hygiene businesses and Aquachlor
($126.0 million or 14.6%). Excluding the impact of
acquisitions, sales increased $131.4 million, or 15.2%,
principally due to an increase in volumes (approximately
12 percent), favorable foreign exchange (approximately
four percent), partially offset by lower pricing
(approximately one percent). Sales volumes were higher in
the wood protection business due to the addition of new
customers and favorable product mix as higher volumes of
Wolman® E and Tanalith® E
(CCA-alternative products) and moldecides more than offset lower
volumes of traditional CCA products. Sales volumes also
increased in the industrial biocides business as a result of
strong demand for biocides used in building products,
antidandruff shampoos and marine antifouling paints. The sales
increase attributable to the favorable effect of foreign
exchange was principally in the industrial coatings and HTH
water products businesses.
Gross margin percentage was 27.9% and 28.4% for 2004 and 2003,
respectively. The impact of acquisitions on gross margin was an
increase of 0.9%. The decrease in margin percentage was
primarily a result of lower propellant sales in the hydrazine
business as a result of the expiration of a government contract
and higher raw material costs in the wood protection and
performance urethanes businesses. Additionally, included in the
performance products margins in 2003 is income for an insurance
settlement of $3.0 million for the reimbursement of past
and future repairs and maintenance expense for storm damage at
one of the Companys manufacturing facilities.
Selling and administration expenses as a percentage of sales
decreased to 22.5% in 2004 from 24.3% in 2003. Excluding the
impact of acquisitions, selling and administration expenses as a
percentage of sales were 22.4% in 2004. These expenses increased
by $42.9 million primarily due to acquisitions
($29.9 million). Excluding the impact of acquisitions,
selling and administration expenses increased $13.0 million
due to unfavorable foreign exchange of approximately
$5 million, incentive compensation, audit expenses
associated with the Sarbanes-Oxley Act ($2.7 million) and
higher costs associated with converting customers to
CCA-alternative preservatives in the wood treatment business.
Lower legal expenses in the personal care and wood protection
businesses were slightly offset by higher legal expenses for HTH
water products business and the Coatings business. The personal
care business benefited from the recognition of a
$6.1 million settlement of a favorable judgment obtained
earlier in the year against a former owner of an acquired
company, which was partially offset by higher reserves for
self-insurance liabilities for HTH water products. The
industrial biocides
23
business also benefited from data compensation for toxicology
studies of $1.7 million. Included in selling and
administration expense for 2004 is $3.3 million of
amortization expense due to the acquisition of Avecias
pool & spa and protection & hygiene businesses.
Research and development expenses increased by $3.7 million
primarily due to the acquired protection & hygiene
businesses as well as increased spending in the other treatment
products businesses to support growth initiatives.
Other (gains) and losses in 2004 principally includes a
charge for a Brazilian state import tax claim of
$2.1 million in the performance urethanes, HTH water
products and hydrazine businesses, offset by the pre-tax gain of
$0.6 million on the sale of a building in the personal care
business. Other (gains) and losses in 2003 principally
represents the pre-tax gain on the sale of excess land of
$2.5 million.
Restructuring expense of $1.7 million in 2004 includes
$2.1 million for severance costs related to headcount
reductions in the hydrazine business due to the expiration of
the government contract, offset by a reduction of
$0.4 million of prior year restructuring reserves.
Restructuring in 2003 includes $1.4 million of severance
costs for additional headcount reductions associated with the
performance products segment, a $1.1 million revision to
the 2002 restructuring program, offset by a reduction of the
prior years restructuring reserves of $2.1 million
due to revisions to previous plans estimates.
Impairment charge of $2.9 million in 2004 is for the
fully-dedicated manufacturing assets of the microelectronic
materials business located in Brandenburg, Kentucky that the
Company continues to own that were not sold in the recent
divestiture of the majority of the operations of the
microelectronic materials business to Fuji Photo Film Co., Ltd.
(Fuji). These assets will be utilized by the Company
solely to supply certain raw materials to Fuji for a transition
period of up to two years. Based upon the Companys current
operations, these assets will have limited use, if any, after
such transition period. As a result, the Company was required to
review these long-lived assets for recoverability. Based upon an
undiscounted cash-flow analysis, including an estimate of
salvage value, these assets were determined to be impaired (not
recoverable) as the carrying value of the assets was greater
than the expected cash flows. Therefore, during the fourth
quarter of 2004, the Company incurred an impairment charge to
write-down such assets to fair value. Fair value was determined
based upon estimated discounted cash flows directly related to
the assets, including an estimate of salvage value.
Interest expense, net increased $2.0 million due to the
higher debt levels during the year as a result of the purchase
of Avecias pool & spa and protection &
hygiene businesses.
Equity in earnings of affiliated companies decreased
$1.6 million due to unfavorable operating results of the
Planar Solutions and Nordesclor joint ventures. The operating
results of the Planar Solutions joint venture decreased
approximately $0.9 million due to higher manufacturing
costs principally related to the start-up of a second copper
slurry production facility to meet growing customer demand. The
decrease in operating results of the Nordesclor joint venture is
a result of continued strong competition in Latin America.
The tax rate on income from continuing operations for 2004 and
2003 was 29% and 35%, respectively. The decrease in rate is
primarily due to the benefit of lower foreign taxes.
Income (loss) from discontinued operations, net of tax, reflects
the results of operations of the microelectronics business
through November 30, 2004 (the date of sale). Net income
was $10.0 million in 2004 compared to net income of
$5.0 million in 2003. The increase in net income is
primarily the result of improved operating results of the
FUJIFILM Arch joint venture, higher sales, favorable raw
material pricing and lower legal costs.
Income (loss) from discontinued operations in 2003 also includes
the results of operations and allocated interest of the Hickson
organics business through August 11, 2003. Net loss was
$2.9 million in 2003, which includes a $4.0 million
impairment charge to adjust the net asset value to its estimated
selling price, less costs to dispose. Income (loss) from
discontinued operations also includes the results of the
sulfuric acid business through July 2, 2003 (the date of
sale). Net income was $1.1 million in 2003.
24
Gain (loss) on the sale of discontinued operations, net of tax,
in 2004 includes the after-tax loss of $1.6 million on the
sale of substantially all the net assets of the Companys
microelectronics business. It includes the after-tax loss of
$7.3 million related to the previous sale of the Hickson
organics business. The Company provided a reserve for the unpaid
post-closing working capital adjustment related to the
previously sold Hickson organics business, associated legal
expenses due to an independent third party arbitrators
decision and incurred a charge of $4.0 million related to
probable future commitments. These losses were slightly offset
by a $1.5 million tax refund related to the sale of the
sulfuric acid business.
Gain on sales of discontinued operations, net of tax, in 2003
includes the after-tax gain of $16.5 million on the sale of
substantially all the net assets of the Companys sulfuric
acid business. Also included in the gain on sale of discontinued
operations is the after-tax loss of $2.0 million on the
sale of the Companys Hickson organics operations in
Castleford, England.
The Company expects higher raw material costs in its HTH water
products business, in particular from purchased chlorinated
isocyanurates. However, these cost increases should be more than
offset by continued market expansion in the professional pool
dealer and the mass merchant markets, a full year contribution
from the pool & spa acquisition and further realization
of cost and revenue synergies from the acquisition. Also, the
Company expects its personal care and industrial biocides
business to benefit from continued strong demand for the
biocides used in marine antifouling paints, in building products
and in antidandruff markets, in addition to the full year
contribution from the protection and hygiene acquisition. Wood
protection is expected to continue to benefit from increased
market share in both the CCA-alternative residential products
market and the industrial CCA-market. As a result, the Company
anticipates that sales for the full year will increase by
approximately eight to ten percent. Earnings per share for the
full-year 2005 are forecast to be in the $1.20 to $1.30 per
share range, compared to $0.74 in 2004, which included a $0.12
loss for restructuring and impairment. Depreciation and
amortization is estimated to be approximately $45 million.
Capital spending is anticipated to be approximately
$25 million. Pension expense is expected to increase by
approximately $6 million and the effective tax rate is
assumed to be 35 percent.
In 2004, the Company was notified by the U.S. Defense
Energy Support Center (DESC) that it had not been
awarded the 10-year hydrazine propellant supply contract which
the Company had anticipated receiving. The Company had a
debriefing with the DESC and submitted a formal protest of the
award. In July 2004, the U.S. Government Accountability
Office (GAO) informed Arch and the DESC that the GAO
will sustain the Companys formal protest of the
DESCs decision to award the governments next 10-year
hydrazine propellant supply contract to a competing firm. As a
result of the GAOs decision, the DESC has notified the
Company that it has taken corrective action by re-opening the
bidding process. The Company submitted its new bid on
January 20, 2005. Final revised bids are currently due
March 15, 2005. The DESC has notified the Company that it
anticipates completing its contract-award decision late in the
first quarter or early in the second quarter of 2005. The 2005
forecast assumes no revenue from the award of a new propellants
contract. The hydrazine business as a whole is not core to the
Companys portfolio, is not a growth business and has been
managed for cash for several years. The failure to obtain this
contract would require the Company to assess the potential
impairment of its hydrazine business. The Company may incur a
non-cash impairment charge for the long-lived assets of the
hydrazine business. The estimate of the amount of the impairment
is approximately $13.0 million, including the assets
associated with the propellants product line. In addition, the
Company may incur cash costs for shutdown and the present value
of certain presumed contractual obligations that are assumed to
no longer have any benefit to the Company. (Such annual
contractual payments are approximately $2.3 million through
2011.) The estimated amount of the pre-tax cash charge resulting
from these costs is approximately $15 million. These
one-time cash costs are expected to be more than offset by
payments to be received from the U.S. Government upon the
shut down of the Lake Charles, LA and McIntosh, AL propellants
facilities. The present values of such payments are
approximately $19.0 million. The net aggregate pre-tax
charge for one-time items could be approximately
$9 million, net of the payments to be received from the
U.S. Government. (See Note 21 of Notes to Consolidated
Financial Statements.)
25
Additionally, included in the Companys 2005 outlook is an
estimate of incentive compensation expense for 2005, which is
based on the estimated financial performance of the Company. The
financial targets are set annually by the Companys
compensation committee. The annual incentive plans financial
targets are earnings per share and cash flow. Cash flow is
defined as EBITDA, plus or minus the change in working capital,
less capital expenditures. The Company also has a long-term
incentive plan which has a financial target based on return on
equity to be achieved in three years, which can be accelerated
to be earned in two years. If there were a change in the
Companys estimated financial performance, it could have a
significant impact on the amount of compensation expense
recorded by the Company.
The Companys 2005 outlook is also based on assumptions
regarding the Companys pension and postretirement benefit
obligations, which are recorded based on actuarial valuations.
Inherent in these valuations are key assumptions, including
discount rates, rates of increase in compensation levels,
expected return on plan assets and trends in health care costs,
which are updated annually. Market conditions and interest rates
significantly impact future assets, liabilities and expense of
the Companys pension and postretirement benefit plans.
Therefore, any changes in such assumptions could impact the
Companys estimate of expense and/or funding which may be
material to the Companys future results.
|
|
|
Year Ended December 31, 2003 Compared to 2002 |
Sales increased $100.5 million, or 13.2%, due to favorable
foreign exchange (approximately six percent), an increase in
volumes (approximately five percent) and higher pricing
(approximately two percent). The sales increase attributable to
the favorable effect of foreign exchange was principally in the
industrial coatings and HTH water products businesses. Sales
volumes were higher in the HTH water products business
principally due to the Aquachlor acquisition (approximately
$18 million) and the industrial biocides business as a
result of continued strong demand for biocides used in building
products and marine antifouling paint markets. The increase in
sales volumes was partially offset by lower volumes in the
performance products segment.
Gross margin percentage was 28.4% and 29.0% for 2003 and 2002,
respectively. The decrease in margin percentage was primarily a
result of higher raw material costs in the performance urethanes
business, lower sales volume in the hydrazine business and
unfavorable product mix for the personal care business. These
decreases were partially offset by higher margins in the HTH
water products business due to lower manufacturing costs.
Margins also increased in the industrial biocides business due
to the increased sales volume. Additionally, included in the
performance products margins is income for an insurance
settlement of $3.0 million for the reimbursement of past
and future repairs and maintenance expense for storm damage at
one of the Companys manufacturing facilities.
Selling and administration expenses as a percentage of sales
increased slightly to 24.3% in 2003 from 24.2% in 2002 and
increased in amount by $25.1 million. The increase in
amount was primarily due to higher customer conversion costs
associated with CCA-alternative preservatives in the wood
protection business, higher legal-related costs in the wood
protection and personal care businesses, higher pension and
insurance costs (approximately $7 million), the acquisition
of Aquachlor ($2.7 million) and the unfavorable effect of
foreign exchange (approximately $8 million). 2002 includes
the write-off of the assets associated with a cancelled
expansion of the HTH water products J3 plant of
approximately $2 million, offset by a favorable legal
decision in a 1994 raw material spillage lawsuit of
$1.9 million.
Research and development expenses increased by $1.4 million
primarily due to increased spending in the treatment products
segment to support various growth initiatives.
Other (gains) and losses in 2003 principally represent the
pre-tax gain on the sale of excess land of $2.5 million.
2002 represents the pre-tax gain on sales of excess land of
$1.5 million.
Restructuring expense in 2003 includes $1.4 million for
severance costs related to headcount reductions in the
performance products segment. The headcount reductions are due
to the reorganization related to the sale of the sulfuric acid
business and the temporary idling of the Companys
hydrazine hydrate plant in Lake Charles, Louisiana. 2003 also
includes $1.1 million of severance costs for additional
headcount reductions
26
associated with a revision to the 2002 organizational
restructuring program, offset by a reduction of the prior
years restructuring reserves of $2.1 million due to
revisions to previous plans estimates. Restructuring
expense in 2002 includes employee-related costs for headcount
reductions in the treatment products and performance products
segments and expenses related to the consolidation of several
treatment products operations.
Equity in earnings of affiliated companies increased
$2.5 million due to favorable operating results of all the
joint ventures, in particular the Koppers and Planar Solutions
joint ventures. Operating results of the Planar Solutions joint
venture increased due to increased sales of CMP copper slurries
used in advanced chip manufacturing processes. The improvement
in operating results of the Koppers joint venture was the result
of increased sales volumes in Australasia.
The tax rate on income from continuing operations for 2003 and
2002 was 35% and 30%, respectively. The impact of restructuring
decreased the effective tax rate on income from continuing
operations by 4% for 2002.
Income (loss) from discontinued operations includes the results
of the microelectronic materials business. Net income was
$5.0 million in 2003 compared to a loss of
$0.1 million in 2002. The improvement in operating results
is due to higher sales, lower legal costs and improved operating
results of the FUJIFILM Arch joint venture.
Income (loss) from discontinued operations also includes the
results of the sulfuric acid business through July 2, 2003
(the date of sale). Net income was $1.1 million in 2003
compared to $1.5 million in 2002.
Income (loss) from discontinued operations, net of tax, also
reflects the results of operations and allocated interest of the
Hickson organics business through August 11, 2003 (the date
of sale). Net loss was $2.9 million in 2003 compared to a
net loss of $3.3 million in 2002. 2003 includes a
$4.0 million impairment charge to adjust the net asset
value to its estimated selling price, less costs to dispose.
2002 included $1.9 million of restructuring charges.
Gain (loss) on the sale of discontinued operations, net of tax,
in 2003 includes the after-tax gain of $16.5 million on the
sale of substantially all the net assets of the Companys
sulfuric acid business. Also included in gain (loss) on sales of
discontinued operations is the after-tax loss of
$2.0 million on the Companys Hickson organics
operations in Castleford, England. The 2002 loss on the sales of
discontinued operations, net of tax, includes the after-tax loss
on the sale of the organics operation located in Danville,
Virginia.
Segment Operating Results
As a result of the sale of the majority of the microelectronic
materials businesses, the Company has restated its prior year
financial statements to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations in
accordance with SFAS 144. The Company has retained its
50 percent interest in Planar Solutions LLC, its joint
venture with Wacker Chemical Corporation for the production and
sale of CMP slurries, the microelectronics-dedicated
manufacturing facility in Brandenburg, Kentucky and its
CMS business. The Company will pursue all strategic options
for the CMS business, including its sale. As a result, and in
accordance with the accounting requirements of SFAS 144,
the CMS business is reported as an asset held for sale and the
results of operations are included in discontinued operations in
the consolidated financial statements. The results of its CMP
joint venture have been included in General Corporate Expenses.
In addition, as a result of the sale, the Company has
reallocated certain centralized service costs to the
Companys segments that were previously allocated to the
microelectronic materials segment.
The Company has organized its business portfolio into two
operating segments to reflect the Companys business
strategy. The two segments are treatment products and
performance products. The treatment products segment includes
three reportable business units: the HTH water products
business, the personal care and industrial biocides business,
and the wood protection and industrial coatings business. Segment
27
operating income includes the equity in earnings of affiliated
companies and excludes restructuring (income) expense,
impairment expense and certain unallocated expenses of the
corporate headquarters.
The Company includes the equity income (loss) of affiliates in
its segment operating results as it believes it to be relevant
and useful information for investors as these affiliates are the
means by which certain segments participate in certain
geographic regions. Furthermore, the Company includes it to
measure the performance of the segment. Other gains and (losses)
that are directly related to the segments are included in
segment operating results.
Treatment Products
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Results of Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
366.0 |
|
|
$ |
289.7 |
|
|
$ |
243.1 |
|
|
Personal Care & Industrial Biocides
|
|
|
234.6 |
|
|
|
149.3 |
|
|
|
124.5 |
|
|
Wood Protection & Industrial Coatings
|
|
|
351.1 |
|
|
|
268.3 |
|
|
|
233.2 |
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
$ |
951.7 |
|
|
$ |
707.3 |
|
|
$ |
600.8 |
|
|
|
|
|
|
|
|
|
|
|
Operating Income (Loss)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
7.2 |
|
|
$ |
7.6 |
|
|
$ |
(2.3 |
) |
|
Personal Care & Industrial Biocides
|
|
|
50.1 |
|
|
|
28.3 |
|
|
|
28.0 |
|
|
Wood Protection & Industrial Coatings
|
|
|
24.1 |
|
|
|
13.9 |
|
|
|
15.9 |
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
$ |
81.4 |
|
|
$ |
49.8 |
|
|
$ |
41.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended December 31, 2004 Compared to 2003 |
Sales increased $244.4 million, or 34.6%, and operating
income increased $31.6 million. The increase in sales is
due to acquisitions ($126.0 million or approximately
18 percent), higher volumes (approximately 15 percent)
and favorable foreign exchange (approximately four percent) that
was partially offset by lower pricing (approximately two
percent). The increase in volumes is due to increased volumes in
the wood protection business and the continued strong demand for
all product lines in the industrial biocides business. Operating
income increased due to the higher sales volumes, partially
offset by higher raw material costs in the wood protection
business. In addition, the personal care business benefited from
the recognition of a $6.1 million settlement of a favorable
judgment obtained against a former owner of an acquired company,
which was partially offset by higher self-insurance reserves for
HTH water products.
Sales increased $76.3 million, or 26.3%, and operating
income decreased $0.4 million. The increase in sales was
due primarily to the acquisitions of Avecias
pool & spa business and Aquachlor ($62.7 million).
Excluding the impact of acquisitions, sales increased
approximately four percent principally due to increased volumes.
The favorable foreign currency rates (approximately three
percent) were offset by lower pricing (approximately three
percent). The higher volumes were attributable to higher North
American residential swimming pool volumes, which include
branded calcium hypochlorite (HTH® and
J3TM),
pool maintenance products and accessories and non-branded
calcium hypochlorite. The lower pricing is principally due to
lower prices for branded chlorinated isocyanurates
(Pace®).
Operating income decreased by $0.4 million as the higher
sales including the positive contributions of the acquisitions
were more than offset by higher raw material, freight and
distribution costs, lower contribution from the Nordesclor joint
venture and increased selling and administration expenses. The
increase in selling
28
and administration expenses is due to higher reserves for
self-insured liabilities and legal expenses ($3.2 million),
increased selling and advertising expenses which includes pool
dealer integration initiatives (approximately $2 million),
the acquisition of Aquachlor ($2.8 million), and the
unfavorable impact of foreign exchange. In addition, 2004
includes unfavorable manufacturing maintenance costs related to
an unscheduled outage.
|
|
|
Personal Care and Industrial Biocides |
Sales increased $85.3 million, or 57.1%, and operating
income increased $21.8 million. The sales increase is
primarily due to the acquisition of Avecias
protection & hygiene business ($63.3 million).
Excluding the impact of the acquisition, sales increased
approximately 15 percent principally due to higher volumes
(approximately 16 percent) and favorable foreign currency
rates (approximately two percent), partially offset by lower
pricing (approximately three percent) for antidandruff products.
The higher volumes are attributable to continued strong demand
for biocides used in building products markets, antidandruff
shampoos and marine antifouling paint.
Operating income increased $21.8 million due to the higher
sales, including the positive contribution from the acquisition
and lower legal expenses. The improvement was partially offset
by higher selling and administration costs to support various
growth initiatives throughout the businesses. In addition, the
operating results benefited from a $6.1 million settlement
of a favorable judgment obtained earlier this year against a
former owner of an acquired company and from compensation for
toxicology data of $1.7 million.
|
|
|
Wood Protection and Industrial Coatings |
Sales increased $82.8 million, or 30.9%, primarily due to
higher volumes (approximately 25 percent) and favorable
foreign currency rates (approximately seven percent), which were
slightly offset by lower pricing (approximately one percent).
The increase in sales is a result of the favorable product mix,
as higher volumes of CCA-alternative products (Wolman® E
and Tanalith® E) and moldecides more than offset lower
volumes of traditional CCA products. Sales also increased from
the addition of new customers in the wood protection business.
The improvement in product mix is a result of the transition to
a new generation of wood preservatives for use in the
residential market, driven by the voluntary withdrawal in the
U.S. by wood treatment manufacturers of their CCA
registrations for non-industrial uses as of December 31,
2003. Higher sales in the industrial coatings business were
principally the result of favorable foreign exchange.
Operating income increased $10.2 million over the prior
year due to higher sales, lower legal expenses and favorable
foreign currency, partially offset by higher raw material costs
and increased costs associated with converting customers to
CCA-alternative preservatives.
|
|
|
Year Ended December 31, 2003 Compared to 2002 |
Sales increased $106.5 million, or 17.7%, and operating
income increased $8.2 million. The increase in sales is due
to higher volumes (approximately nine percent), favorable
foreign exchange (approximately eight percent) and higher
pricing (approximately one percent). The increase in volumes of
approximately $53 million is due to the Aquachlor
acquisition (approximately $18 million) in the HTH water
products business and the continued strong demand for all
product lines in the industrial biocides business. The favorable
foreign exchange effect on sales is primarily in the industrial
coatings and HTH water products businesses. Operating income
increased due to the higher sales volumes, partially offset by
higher selling and administration costs due to increased legal
expenses and additional investments to support growth
initiatives.
Sales increased $46.6 million, or 19.2%, and operating
results improved by $9.9 million. The increase in sales was
due to the acquisition of Aquachlor (approximately
$18 million), increased volumes of approximately four
percent due to stronger international volumes of branded calcium
hypochlorite and chlorinated isocyanurates and increased pool
maintenance products and accessories volumes and favorable
foreign currency rates (approximately seven percent).
29
Operating results improved significantly. The improved results
were due to the higher sales, lower manufacturing and product
sourcing costs, partially offset by higher selling and
administration costs. Selling and administration costs increased
due to higher litigation-related costs associated with property
damage claims (see Note 20 Commitments and Contingencies),
partially offset by lower advertising costs. 2002 included the
write-off of the assets associated with a cancelled expansion of
the
J3TM
plant of approximately $2 million.
|
|
|
Personal Care and Industrial Biocides |
Sales increased $24.8 million, or 19.9%, due to continued
strong demand for all product lines, in particular the biocides
used in the marine antifouling paint, antidandruff shampoo and
building products markets. Operating income increased
$0.3 million due to the higher sales, partially offset by
higher selling and administration costs. Selling and
administration costs increased to support various growth
initiatives related to the expansion of the personal care
business into new markets and increased legal expenses in the
personal care product line relating to litigation in which the
Company asserted claims against a former owner and several
former employees of an acquired business. In addition, 2002
benefited from the pre-tax gain on the sale of excess land of
$0.8 million.
|
|
|
Wood Protection and Industrial Coatings |
Sales increased $35.1 million, or 15.1%, primarily due to
favorable foreign currency rates (approximately 12%). Excluding
the favorable impact of foreign currency, sales increased as
higher volumes of Wolman® E and Tanalith® E (both
CCA-alternative products) and favorable pricing for industrial
coatings, were partially offset by lower volumes of traditional
CCA products. This improvement in product mix is a result of the
transition to a new generation of wood preservatives for use in
the residential market driven by the voluntary withdrawal in the
U.S. by the wood treatment manufacturers of their CCA
registrations for non-industrial uses by December 31, 2003.
Operating income decreased $2.0 million due to higher
ongoing legal defense expenses associated with CCA
product-related lawsuits and customer conversion costs
associated with CCA-alternative preservatives. 2002 benefited
from a favorable legal decision in a 1994 raw material spillage
lawsuit of $1.9 million.
Performance Products
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Results of Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
$ |
145.0 |
|
|
$ |
122.2 |
|
|
$ |
120.2 |
|
|
Hydrazine
|
|
|
24.2 |
|
|
|
34.0 |
|
|
|
42.0 |
|
|
|
|
|
|
|
|
|
|
|
Total Performance Products
|
|
$ |
169.2 |
|
|
$ |
156.2 |
|
|
$ |
162.2 |
|
|
|
|
|
|
|
|
|
|
|
Operating Income (Loss)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
$ |
(5.2 |
) |
|
$ |
(6.0 |
) |
|
$ |
(1.4 |
) |
|
Hydrazine
|
|
|
(2.6 |
) |
|
|
1.9 |
|
|
|
5.5 |
|
|
|
|
|
|
|
|
|
|
|
Total Performance Products
|
|
$ |
(7.8 |
) |
|
$ |
(4.1 |
) |
|
$ |
4.1 |
|
|
|
|
|
|
|
|
|
|
|
30
|
|
|
Year Ended December 31, 2004 Compared to 2003 |
Sales increased approximately eight percent and operating
results decreased by $3.7 million.
Performance urethanes sales increased $22.8 million,
approximately 19%, and operating results improved by
$0.8 million. The increase in sales is the result of
improved pricing and higher volumes due to stronger demand for
glycol and specialty polyol products and higher contract
manufacturing volumes. The improved pricing was principally due
to the successful price increases to mitigate higher raw
material costs. Operating results improved slightly as the
higher sales and lower selling and administration expenses
resulting from cost-reduction initiatives were mostly offset by
higher raw material and energy costs as well as a charge for a
Brazilian state import tax claim ($1.6 million). In
addition, the 2003 results included income for an insurance
settlement of approximately $3 million for reimbursement of
past and expected future repairs and maintenance expense for
storm damage at one of the Companys manufacturing
facilities that was partially offset by increased bad debt
expense related to a customer in Venezuela.
Hydrazine sales decreased $9.8 million and operating
results decreased by $4.5 million. The lower sales were due
to lower propellant revenues as a result of the expiration of a
long-term propellants supply contract with the
U.S. government on April 30, 2004, partly offset by
increased demand for Ultra Pure Hydrazine. Operating
income was lower than prior year due to the lower hydrazine
propellant revenues.
|
|
|
Year Ended December 31, 2003 Compared to 2002 |
Performance urethanes sales increased $2.0 million and
operating results decreased by $4.6 million. Sales
increased due to higher polyol volumes and higher contract
manufacturing, partially offset by lower Latin American sales,
as a result of poor economic conditions and political
instability in Venezuela, the withdrawal from a Middle Eastern
market and lower propylene glycol sales.
Operating results decreased due to significantly higher raw
material and energy costs, slightly offset by lower selling and
administration expenses resulting from cost reduction
initiatives. 2003 also includes income for an insurance
settlement of approximately $3 million for reimbursement of
past and expected future repairs and maintenance expense for
storm damage at one of the Companys manufacturing
facilities that was partially offset by increased bad debt
expense related to a customer in Venezuela.
Hydrazine sales decreased $8.0 million and operating income
decreased by $3.6 million. Sales decreased due to lower
hydrate volumes resulting from the temporary idling of the
plant, partly offset by favorable hydrate pricing. Operating
income was lower than prior year primarily due to the lower
sales and higher manufacturing costs.
Corporate Expenses (Unallocated)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Results of Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
Unallocated Corporate Expenses
|
|
$ |
26.1 |
|
|
$ |
13.1 |
|
|
$ |
14.9 |
|
31
|
|
|
Year Ended December 31, 2004 Compared to 2003 |
The increase in unallocated corporate expenses is principally
due to the increase in incentive compensation expense of
$3.8 million associated with the Companys incentive
plans and increased audit fees of $2.7 million associated
with the Sarbanes-Oxley Act. In addition, the Company incurred
additional environmental costs associated with idle properties
of approximately $2.4 million. 2003 included a gain on the
sale of excess land of $2.5 million. Included in the
unallocated corporate costs are the results of operations of the
Companys Planar Solutions joint venture which decreased
$1.0 million as a result of higher manufacturing costs
related to the start-up of a second copper slurry production
facility to meet growing customer demand.
|
|
|
Year Ended December 31, 2003 Compared to 2002 |
The decrease in unallocated corporate expenses is principally
due to the gain on the sale of excess land of $2.5 million.
The gain more than offset the increase in incentive compensation
expense of $2.0 million associated with the Companys
long-term incentive plan. In addition, lower expenses associated
with the Companys accounts receivable securitization
program were principally offset by higher audit fees.
Environmental
The Company operates manufacturing facilities throughout the
world and as a result is subject to a broad array of
environmental laws and regulations in various countries. The
Company also implements a variety of voluntary programs to
reduce air emissions, eliminate or reduce the generation of
hazardous wastes and to decrease the amount of wastewater
discharges. The establishment and implementation of
U.S. federal, state and local standards to regulate air and
water quality and to govern contamination of land and
groundwater has affected, and will continue to affect,
substantially all of the Companys U.S. manufacturing
locations. Federal legislation providing for regulation of the
manufacture, transportation, use and disposal of hazardous and
toxic substances has imposed additional regulatory requirements
on industry in general, and particularly on the chemicals
industry. In addition, the implementation of environmental laws,
such as the Resource Conservation and Recovery Act, the Clean
Air Act and the Comprehensive Environmental Response,
Compensation and Liability Act of 1980, as amended by the
Superfund Amendments and Reauthorization Act of 1986, has
required, and will continue to require, new capital expenditures
and will increase operating costs.
The Distribution Agreement specifies that the Company is only
responsible for certain environmental liabilities at the
Companys current facilities and certain off-site
locations. In connection with the acquisition of Hickson, the
Company acquired certain environmental exposures and potential
liabilities of current and past operating sites, all of which
have been accrued for in the accompanying Consolidated Financial
Statements.
In connection with the disposition of the majority of the
microelectronic materials business on November 30, 2004,
the Company provided indemnification for environmental concerns.
For identified environmental liabilities as of the transition
date, there is no limit to the liability retained by the
Company. The Company estimates such potential liability to be
less then $1.0 million. For other pre-closing environmental
liabilities the purchaser will be liable for the first
$3.0 million of any such liabilities and the parties will
share equally the next $6.0 million of any such liabilities
with the Companys total exposure thus limited to
$3.0 million over a five-year period from the closing date.
In connection with the disposition of the sulfuric acid business
on July 2, 2003, the Company provided environmental
covenants to the purchaser in which the Company is solely liable
for the costs of any environmental claim for remediation of any
hazardous substances that were generated, managed, treated,
stored or disposed of prior to the closing date of the sale. The
Company will be released, under the sales agreement, from its
obligation, which cannot exceed $22.5 million,
20 years from the closing date. Additionally, as part of
its environmental indemnifications, the Company will be
responsible for damages directly related to the process sewer
system at the Beaumont, Texas plant during the first five years
from the closing date.
32
As part of the Hickson organics disposition, the Company will
continue to be responsible for known environmental matters. Such
matters have previously been accrued for in its environmental
reserve included in the Consolidated Financial Statements.
Additionally, regarding any unknown environmental matters that
are identified subsequent to the sale, the Company has agreed to
share responsibility with the purchaser over a seven-year
period, with the Companys share decreasing to zero over
the seven-year period. The Companys maximum aggregate
liability for such unknown environmental matters is
£5.0 million.
The Company does not anticipate any material exposure related to
the environmental indemnifications for the microelectronic
materials, the sulfuric acid and the Hickson organics
dispositions. The Company has estimated that the fair value of
any such additional exposure would be immaterial.
Associated costs of investigatory and remedial activities are
provided for in accordance with generally accepted accounting
principles governing probability and the ability to reasonably
estimate future costs. Charges to income for investigatory and
remedial efforts of $2.4 million were recorded in 2004 and
were not material to operating results in 2003 and 2002, but may
be material in future years.
Cash outlays for normal plant operations for the disposal of
waste and the operation and maintenance of pollution control
equipment and facilities to ensure compliance with mandated and
voluntarily imposed environmental quality standards were charged
to income. Cash outlays for remedial activities are charged to
reserves. Historically, the Company has funded its environmental
capital expenditures through cash flows from operations and
expects to do so in the future.
Cash outlays for environmental related activities for 2004, 2003
and 2002 were as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Environmental Cash Outlays
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital Projects
|
|
$ |
1.3 |
|
|
$ |
0.7 |
|
|
$ |
3.1 |
|
Plant Operations
|
|
|
6.4 |
|
|
|
6.7 |
|
|
|
7.0 |
|
Remedial Activities
|
|
|
2.7 |
|
|
|
2.3 |
|
|
|
2.5 |
|
|
|
|
|
|
|
|
|
|
|
Total Environmental Cash Outlays
|
|
$ |
10.4 |
|
|
$ |
9.7 |
|
|
$ |
12.6 |
|
|
|
|
|
|
|
|
|
|
|
The Companys Consolidated Balance Sheets included
liabilities for future environmental expenditures to investigate
and remediate known sites amounting to $8.3 million at
December 31, 2004, of which $3.3 million is classified
as current liabilities and $8.6 million at
December 31, 2003, of which $3.3 million is classified
as current liabilities. The Companys estimated
environmental liability relates to seven sites, six of which are
in the United States and none of which are on the
U.S. National Priority List. These amounts did not take
into account any discounting of future expenditures, any
consideration of insurance recoveries or any advances in
technology. These liabilities are reassessed periodically to
determine if environmental circumstances have changed or if the
costs of remediation efforts can be better estimated. As a
result of these reassessments, future charges to income may be
made for additional liabilities.
Annual environmental-related cash outlays for site investigation
and remediation, capital projects and normal plant operations
are expected to range from $10 million to $15 million
over the next several years. While the Company does not
anticipate a material increase in the projected annual level of
its environmental-related costs, there is always the possibility
that such increases may occur in the future in view of the
uncertainties associated with environmental exposures.
Environmental exposures are difficult to assess for numerous
reasons, including the identification of new sites, developments
at sites resulting from investigatory studies and remedial
activities, advances in technology, changes in environmental
laws and regulations and their application, the scarcity of
reliable data pertaining to identified sites, the difficulty in
assessing the involvement and financial capability of other
potentially responsible parties and the Companys ability
to obtain contributions from other parties and the lengthy time
periods over which site remediation occurs. It is possible that
some of these matters (the outcomes of which are subject to
various uncertainties) may be resolved unfavorably against the
Company. At
33
December 31, 2004, the Company had estimated additional
contingent environmental liabilities of $7.3 million.
Legal Matters
There are a variety of non-environmental legal proceedings
pending or threatened against the Company. In connection with
the acquisition of Hickson, the Company assumed certain legal
obligations, including a trial court judgment, in favor of a
railroad, of approximately $8.5 million plus interest in a
lawsuit associated with a wood preservative spillage in 1994. In
2002, a new trial resulted in a judgment of $2.6 million
plus interest. The railroad appealed the judgment, and in
February 2005 the court of appeals affirmed the judgment. The
judgment and related interest is included in Accrued Liabilities
in the accompanying Consolidated Balance Sheets. The Company
does not expect any final resolution of this case to have a
material adverse effect on the results of operations or the
financial position of the Company.
The Company is a co-defendant in consolidated litigation arising
from a fire in August 2000, which destroyed a warehouse in which
the Companys water treatment products were stored. The
parties have reached an agreement to settle a portion of the
litigation that involves claims by plaintiffs who are
individuals. This agreement has received court approval and the
settlement amount has been paid by the Company. The balance of
the litigation primarily involves claims by a number of
businesses for property damage. The Company has provided for its
exposure in this litigation, $3.0 million, including the
amount of its participation in the settlement, and does not
expect any final resolution of these cases, net of an expected
insurance recovery, to have a material adverse effect on results
of operations or financial position of the Company. Given that
the Companys applicable insurance policies provide
coverage on a reimbursement basis, there may be a lag between
any payment ultimately paid to the remaining plaintiffs by the
Company and reimbursement of such payment from the
Companys insurers.
The Company and/or its CCA-formulating subsidiary Arch Wood
Protection, Inc. were named, along with several other CCA
manufacturers, several CCA customers and various retailers, in
five putative class action lawsuits filed in various state and
federal courts regarding the marketing and use of CCA-treated
wood. Three of these cases have been dismissed without
prejudice. In the fourth case (Jacobs v. Osmose, Inc.
et. al.), the federal district court has ruled that the
requirements for a class action have not been met and has denied
class action status in this case. Subsequently, the court
entered an order granting plaintiffs motion for voluntary
dismissal of their claims against the Company, its subsidiaries
and several other defendants.
In March 2004, in the fifth putative class action lawsuit
(Ardoin v. Stine Lumber Company et. al.), the
federal district court ruled that the requirements for a class
action were not met and denied class action status to the case.
The parties entered an agreement to settle the claims of the
individual plaintiffs for a nominal amount, and the case was
dismissed with prejudice.
In addition, there are fewer than ten other CCA-related lawsuits
in which the Company and/or one or more of the Companys
subsidiaries is involved. These additional cases are not
putative class actions. They are actions by individual claimants
alleging various personal injuries allegedly due to exposure to
CCA-treated wood.
The Company and its subsidiaries deny the material allegations
of all the various CCA-related claims and have vigorously
defended and will continue to vigorously defend them. As a
result, legal defense and related costs associated with these
cases were significant in 2004, 2003 and 2002, and may be
significant in the future.
All CCA-related cases are subject to a number of uncertainties.
As a result, their impact, if any, is difficult to assess. Based
on the information currently available to the Company, however,
the Company does not believe the resolution of these cases is
likely to have a material adverse effect on its consolidated
financial condition, cash flow or results of operations.
In March 2004, a jury in the U.S. District Court for the
District of New Jersey awarded Arch Personal Care Products, a
wholly-owned subsidiary of the Company, approximately
$7.0 million in damages after finding, among other things,
one of the defendants had breached his non-compete obligations
to Arch Personal
34
Care Products. In July 2004, the parties reached agreement to
settle $6.6 million of the judgment for $6.1 million,
all of which has been recognized in the results for the year
ended December 31, 2004.
In April 2004, the Company was served with a complaint by two
parents, their minor child and the parents acting as personal
representatives of the estates of their two other children. In
the complaint, which was initially filed in Oregon state court
against the Company, two of its subsidiaries, and others,
plaintiffs allege that a fire caused by a spontaneous exothermic
chemical reaction of the Companys pool chlorination
products with other common household products erupted in the
parents vehicle while occupied by the family. Plaintiffs
ask for damages, including non-economic damages of
$40.0 million per plaintiff. The Company is effectively
self-insured for the first $3.0 million in this case,
regardless of the number of plaintiffs. The case has been
removed to the U.S. district court in Oregon by the Company
and plaintiffs have moved to return the case to state court. The
court denied the motion, and plantiffs have moved to reargue.
During the second quarter of 2004, the Company recorded
$3.0 million of self-insurance reserves related to its
potential exposure in this case and does not expect any final
resolution of these cases, net of an expected insurance
recovery, to have a material adverse effect on results of
operations or financial position of the Company. Given that the
Companys applicable insurance policies provide coverage on
a reimbursement basis, there may be a lag between any payment
ultimately paid by the Company and reimbursement of such payment
from the Companys insurers.
In Brazil, the Company uses a third-party agent to process and
pay certain state import duties. In July 2004, the Company was
notified of a claim for unpaid state import duties, including
interest and potential penalties. The Company has accrued
$2.1 million for the estimated taxes and related interest
for this claim. As of December 31, 2004, the Company had
estimated contingent liabilities related to this claim up to
$1.8 million.
In May 2004, the U.S. Department of Commerce and the
U.S. International Trade Commission initiated antidumping
duty investigations of Chinese and Spanish suppliers of
chlorinated isocyanurates and related chemicals as a result of
petitions filed by domestic producers who asserted that these
products were being imported and sold in the U.S.A. at prices
below normal value. One of the suppliers being investigated is a
major supplier of chlorinated isocyanurates to the Company. In
December 2004, the Department of Commerce issued a preliminary
determination and estimated antidumping duties margins ranging
from approximately 126% to 180% for Chinese producers and 12%
for Spanish producers. In February 2005, the rate for the
Chinese producer who currently supplies the Company was reduced
to 87%. As the importer of record, the Company is obliged to
post a bond or cash deposit of these preliminary duties until
the investigation is concluded. If the final finding is that no
dumping occurred or that those imports did not injure the
domestic industry, the duties will terminate and be refunded if
paid. The final results of the investigations, and the order if
issued, are expected in June 2005. The producers may annually
request a review of the final results which may result in a
further adjustment of the duties.
Koppers Arch Wood Protection (NZ) Limited
(KANZ), a New Zealand joint venture company in which
the Company owns indirectly a 49% interest, is the subject of an
on-going investigation by the New Zealand Commerce Commission
(NZ Commerce Commission) regarding industry
competitive practices. KANZ manufactures and markets wood
preservative products throughout New Zealand. The NZ Commerce
Commission has the authority to assess fines equal to the higher
of (i) NZ$10 million (approximately
US$7 million), (ii) three times the commercial gain
from any contravention or (iii) 10% of the sales of KANZ
(approximately US$2 million). Penalties, if assessed
against KANZ, could have a material adverse effect on the joint
ventures business, financial condition, cash flows and
results of operations.
Similarly, Koppers Arch Wood Protection (Aust) Pty Ltd
(KAWP), an Australian joint venture company in which
the Company owns indirectly a 49% interest and the majority
shareholder of KANZ, has made an application for leniency under
the Australian Competition and Consumer Commissions
(ACCC) policy for cartel conduct. The ACCC has
granted immunity to KAWP, subject to fulfillment of certain
conditions. If the conditions are not fulfilled, the ACCC may
penalize KAWP for any violations of the competition laws of
Australia. Such penalties, if assessed against KAWP, could have
a material adverse effect on KAWPs business, financial
condition, cash flows and results of operations.
35
As a result of the Companys ownership in such entities, an
unfavorable resolution, could have a material adverse effect on
equity in earnings of affiliated companies and dividends
received.
Business and Credit Concentrations
A significant portion of sales of the treatment products segment
(approximately 17%) is dependent upon two customers, one of
which accounts for a significant portion of the sales of the HTH
water products business and the other of which accounts for a
significant portion of the sales of the personal care and
industrial biocides businesses. Sales to these two customers are
individually less than 10% of the Companys 2004
consolidated sales. However, the loss of either of these
customers could have a material adverse effect on the sales and
operating results of the respective segment and businesses if
such customer was not replaced.
Sales of the HTH water products segment are seasonal in nature
as its products are primarily used in the U.S. residential
pool market. Historically, approximately 40% 50% of
the sales in the HTH water products business occur in the second
quarter of the fiscal year, as retail sales in the
U.S. residential pool market are concentrated between
Memorial Day and the Fourth of July. Therefore, interim results
for this segment are not necessarily indicative of the results
to be expected for the entire fiscal year.
Liquidity, Investment Activity and Other Financial Data
Cash Flow Data
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Provided By (Used For)
|
|
|
|
|
|
|
|
|
|
|
|
|
Accounts Receivable Securitization Program
|
|
$ |
|
|
|
$ |
(33.5 |
) |
|
$ |
33.5 |
|
Change in Working Capital
|
|
|
10.8 |
|
|
|
4.9 |
|
|
|
13.0 |
|
Net Operating Activities from Continuing Operations
|
|
|
76.3 |
|
|
|
13.8 |
|
|
|
88.5 |
|
Change in Net Assets Held for Sale
|
|
|
11.8 |
|
|
|
4.8 |
|
|
|
20.1 |
|
Capital Expenditures
|
|
|
(18.3 |
) |
|
|
(17.0 |
) |
|
|
(28.2 |
) |
Businesses Acquired, net of Cash
|
|
|
(215.8 |
) |
|
|
(2.5 |
) |
|
|
|
|
Proceeds from Sales of Businesses
|
|
|
158.5 |
|
|
|
61.2 |
|
|
|
25.0 |
|
Proceeds from Sales of Land and Property
|
|
|
0.9 |
|
|
|
2.8 |
|
|
|
2.1 |
|
Net Investing Activities
|
|
|
(74.8 |
) |
|
|
45.4 |
|
|
|
1.1 |
|
Debt Borrowing (Repayments), net
|
|
|
7.8 |
|
|
|
(2.5 |
) |
|
|
(86.0 |
) |
Net Financing Activities
|
|
|
(6.5 |
) |
|
|
(14.0 |
) |
|
|
(103.0 |
) |
Operating Activities:
For 2004, the $62.5 million increase in cash flow provided
by operating activities from continuing operations was primarily
attributable to the improvement in working capital for 2004
compared to 2003 and higher income. In addition, 2003 cash flow
had a negative impact of $33.5 million from not utilizing
the accounts receivable securitization program. The improvement
in working capital is the result of higher levels of payables
and accrued liabilities. The Companys cash flows has
benefited over the past three years as a result of its focus on
reducing its investment in working capital.
For 2003, the $74.7 million decrease in cash flow provided
by operating activities from continuing operations was primarily
attributable to the Company not utilizing the accounts
receivable securitization program as of December 31, 2003,
compared to the benefit of selling receivables as of
December 31, 2002 ($67.0 million). The remaining
decrease in cash flow was attributable to a lower reduction in
working capital for 2003 compared to 2002. The lower reduction
was due to higher receivables as a result of increased sales in
the fourth quarter of 2003.
36
Cash provided by the operations of assets held for sale was
$11.8 million in 2004 compared to $4.8 million in
2003. The favorable comparison is due to the use of cash in 2003
related to the Hickson organics business that was sold.
Cash provided by the operations of assets held for sale was
$4.8 million in 2003 compared to $20.1 million in
2002, primarily due to a decrease in working capital of the
microelectronic materials businesses offset by an increase in
working capital of the Hickson organics Castleford business and
the sulfuric acid business.
Investing Activities:
Capital expenditures for 2004 increased 7.6% as compared to 2003
due to higher expenditures in the HTH water products and wood
protection businesses.
Capital expenditures for 2003 decreased 39.7% as compared to
2002 due to lower expenditures in the HTH water products
business and the performance products segment.
Capital expenditures for 2005 are expected to be approximately
$25 million.
In December 2004, the Company acquired the working capital of a
small water products distributor, Arkema, S.A., in Colombia for
approximately $0.7 million in cash.
On November 30, 2004, the Company completed the sale of
substantially all of the net assets of its microelectronic
materials business to Fuji Photo Film Co., Ltd. Net proceeds
from the sale were $158.5 million, after transaction costs
and certain non-income taxes paid at closing. A portion of the
proceeds was used to pay down debt.
On April 2, 2004, the Company completed the acquisition of
Avecias pool & spa and protection &
hygiene businesses. The total purchase price net of cash
acquired, was $230.8 million, inclusive of expenses and a
final working capital payment of $7.4 million. The payment
consisted of cash and the issuance of the Companys common
stock with a value of $15.7 million. The purchase price is
further subject to a contingent payment of up to
$5.0 million in cash based upon earnings attributable to
North American sales of certain products. An interim payment is
to be made based on 2004 results, and as of December 31,
2004 the Company has accrued $2.5 million with a
corresponding increase to goodwill. In addition, to the extent
that the unfunded pension liability in the U.K. pension plan was
less than $10.0 million, the purchase price was adjusted
upwards by the difference between $10.0 million and the
unfunded liability, with the consideration to be split equally
between a contingent cash payment and up to 223,250 additional
shares of the Companys common stock. The share
consideration component of this adjustment was
74,788 shares of common stock, which were issued in January
2005 with a value of $1.7 million. The contingent cash
payment will be earned, a maximum of $1.7 million, based
upon cumulative global net sales of certain products through
2005. An interim payment will be made in 2005 based on 2004
results and the Company has accrued $0.5 million as of
December 31, 2004. The acquisition was financed principally
from borrowings under the Companys credit facility. For
additional information concerning the acquisition see the
footnotes included in the 10-K (see Note 19 of Notes to
Consolidated Financial Statements) as well as the
Form 8-K/A filed by the Company on June 16, 2004.
In 2004, the Company sold a building and excess land for cash
proceeds of $0.9 million.
In February 2004, the Company funded rabbi trusts relating to
three compensation deferral plans. During 2004, the trusts have
purchased marketable securities of $2.4 million and
Companys common stock of $2.4 million, which are
included in investing and financing activities, respectively.
In December 2003, the Company sold warehouses for proceeds of
approximately $0.8 million. On September 30, 2003, the
Company sold excess land. Total proceeds from the sale were
$6.5 million. Proceeds consisted of cash of
$2.0 million and a note of $4.5 million. In September
2002, the Company sold excess land in China and Ireland for cash
proceeds of approximately $2.1 million.
On August 11, 2003, the Company completed the sale of the
Hickson organics operations in Castleford, England. Total
proceeds from the sale were £12.5 million
($20.1 million), subject to a post-closing working capital
adjustment. Proceeds consist of cash of £11.0 million
($17.7 million) and two notes for £1.5 million
37
($2.4 million), of which one note for
£1.0 million ($1.6 million) is contingent on
future operating results from January 1, 2003 through
December 31, 2005. A portion of the proceeds were used to
pay down debt (see Note 5 of Notes to Consolidated
Financial Statements). On November 3, 2004, the Company
received approximately $2.1 million of the post-closing
working capital adjustment. During the fourth quarter there was
significant uncertainty concerning the viability of the
purchaser, and as a result, the Company provided a reserve for
the remaining portion of the working capital adjustment and the
outstanding note.
On August 1, 2003, the Company completed the purchase of
the remaining 50% share of Aquachlor (Proprietary) Limited in
South Africa from its joint venture partner Sentrachem Limited
for $2.5 million (see Note 19 of Notes to Consolidated
Financial Statements).
On July 2, 2003, the Company completed the sale of
substantially all of the net assets of its sulfuric acid
business to Peak Sulfur, Inc. Net proceeds from the sale were
$47.6 million, after a post-closing working capital
payment. A portion of the proceeds was used to pay down debt.
In March 2002, the Company completed the sale of its DanChem
operations in Danville, Virginia for approximately
$25 million. Proceeds from the sale of these assets have
been used to pay down debt. (See Note 5 of Notes to
Consolidated Financial Statements.)
Financing Activities:
Cash used by financing activities in 2004 was principally due to
dividends paid to shareholders of $18.5 million, partially
offset by cash proceeds from foreign short-term borrowings of
$7.8 million.
Cash used by financing activities in 2003 was principally due to
net repayments of debt of $2.5 million and dividends paid
to shareholders of $18.0 million. 2003 also includes the
cash proceeds from the termination of interest rate swap
agreements of $7.1 million, which represented the market
value of the contracts on the date of termination.
Cash used by financing activities in 2002 was principally due to
net repayments of debt of $86.0 million and dividends paid
to shareholders of $17.9 million.
Liquidity
In June 2003, the Company entered into an unsecured
$210.0 million senior revolving credit facility
(credit facility) which expires in June 2006. In
connection with the acquisition of Avecias pool &
spa and protection & hygiene businesses, the Company
amended its quarterly leverage ratio (debt/ EBITDA) for its
revolving credit facility. The amendment was put in place to
take into account the fact that the acquisition would occur
during the Companys seasonal build of receivables and
inventory. The quarterly leverage ratio was amended to 4.25 for
the quarter ending March 31, 2004, 4.00 for the quarter
ending June 30, 2004, returning to 3.50 thereafter. Such
amendments became effective on April 2, 2004, the date the
Company completed the acquisition of Avecias
pool & spa and protection & hygiene
businesses. The credit facility also contains an interest
coverage ratio (EBITDA/ total interest expense) covenant not to
be less than 3.0. Additionally, the credit facility restricts
the payment of dividends and repurchase of stock to $65.0 plus
50% of cumulative net income (loss) subject to certain
limitations beginning June 20, 2003 ($48.7 million at
December 31, 2004). As of December 31, 2004, facility
fees payable on the credit facility are 0.35%. The facility fees
can range from 0.2% to 0.4% depending on the Companys
quarterly leverage ratios. The Company may select various
floating rate borrowing options, including, but not limited to,
LIBOR plus a spread that can range from 0.55% to 1.35% depending
on the Companys quarterly leverage ratios. At
December 31, 2004, the Company had $207.2 million of
available borrowings under the credit facility.
In May 2003, the Company terminated its interest rate swap
agreements that were entered into in April 2002. As a result,
the Company received cash proceeds of $7.1 million, which
represented the market value of the contracts on the date of
termination. The Company utilized the proceeds to pay down debt
and reduced the amount recorded in Other Assets for such
derivative instruments to zero. There was no gain or loss on the
transaction.
38
Simultaneous with the termination of the interest rate swap
agreements, the Company entered into new interest rate swap
agreements, pursuant to which it swapped its 7.94% fixed
interest rate on $80.0 million principal amount of
unsecured senior notes for floating rate interest based upon
six-month LIBOR plus 5.4539% (7.5339% at December 31,
2004). The counter parties to these agreements are major
financial institutions. The agreements expire in March 2007. The
Company has designated the swap agreements as fair value hedges
of the risk of changes in the value of fixed rate debt due to
changes in interest rates for a portion of its fixed rate
borrowings under SFAS 133. Accordingly, the swap agreements
have been recorded at their fair market value of
$1.6 million and are included in Other Liabilities on the
accompanying Consolidated Balance Sheets, with a corresponding
decrease in the carrying amount of the related debt. No gain or
loss has been recorded as the contracts met the criteria of
SFAS 133 to qualify for hedge accounting treatment with no
ineffectiveness.
In March 2002, the Company issued $211.0 million of
unsecured senior notes to certain institutional investors in two
series. The Series A notes of $149.0 million are due
in March 2007 and the Series B notes of $62.0 million
are due in March 2009 and bear fixed interest rates of 7.94% and
8.24%, respectively. In connection with the acquisition of
Avecias pool & spa and protection &
hygiene businesses, the Company amended its quarterly leverage
ratio (debt/EBITDA) covenants and the debt to total
capitalization ratio requirement for its senior notes. The
amendment was put in place to take into account the fact that
the acquisition would occur during the Companys seasonal
build of receivables and inventory. The quarterly leverage ratio
was amended to 4.00 as of the last day of the quarter ending
June 30, 2004, returning to 3.50 thereafter. The debt to
total capitalization ratio was amended to 65% beginning on
April 2, 2004 to and including June 30, 2004, 60%
beginning on July 1, 2004 to and including
September 30, 2004, returning to 55% beginning on
October 1, 2004. Such amendments became effective on
April 2, 2004, the date the Company completed the
acquisition of Avecias pool & spa and
protection & hygiene businesses. In addition, the notes
contain a fixed charge coverage ratio covenant of 2.25 and a
covenant that restricts the payment of dividends and repurchases
of stock to $65.0 million less cumulative dividends and
repurchases of stock plus 50% of cumulative net income (loss)
subject to certain adjustments beginning January 1, 2002
($37.6 million at December 31, 2004). Proceeds from
the issuance of these notes were used to pay down debt,
including the Companys $225 million revolving credit
facility which expired in March 2002 and which was used to
finance the Hickson acquisition and refinance a portion of the
assumed Hickson debt. See Note 11 of Notes to Consolidated
Financial Statements.
In March 2002, the Company completed arrangements to sell,
without recourse, certain accounts receivable through its
wholly-owned subsidiary, Arch Chemicals Receivables Corp., a
special-purpose corporation. Arch Chemicals Receivables Corp.
entered into a trade accounts receivable securitization
agreement with an independent financial institution whereby it
can sell, on an ongoing basis, participation interests in
accounts receivable for a maximum purchase price of up to
$80.0 million. Such agreement is renewable annually. As of
December 31, 2004 and 2003, the Company had not sold any
participation interests in accounts receivable under this
program. The amount of participation interests sold under this
arrangement is subject to change based on the level of eligible
receivables. The accounts receivable sold are reflected as a
sale of accounts receivable in accordance with
SFAS No. 140, Accounting for Transfers and
Servicing of Financial Assets and Extinguishments of
Liabilities. The costs of the program of $1.1 million
and $0.8 million for the year ended December 31, 2004
and 2003, respectively, are included in Selling and
Administration expenses in the accompanying Consolidated
Statement of Income. The costs of the accounts receivable
securitization program are a percentage of the fair market value
of the participation interests sold. The percentage is variable
and was approximately equivalent to the one-month LIBOR rate
plus 0.45% (1.9%, 1.7% and 2.2% in 2004, 2003 and 2002,
respectively). See Note 2 of Notes to Consolidated
Financial Statements. The accounts receivable securitization
program provides another source of funding for the Company and
lowers overall funding costs.
At December 31, 2004, the Company had $22.3 million of
outstanding letters of credit. In addition, the Company had
$6.0 million of letters of guarantee for borrowings of its
joint venture Planar Solutions. The Company has agreed to
guarantee up to $8.5 million of Planar borrowings.
39
The Company believes that the credit facility, accounts
receivable securitization program and cash provided by
operations are adequate to satisfy its liquidity needs for the
near future. However, if Company earnings or cash generation
were to fall significantly below current expectations, a risk
exists that the Company would not meet its quarterly leverage,
interest coverage, fixed charge coverage or debt to total
capitalization ratio covenants, which could trigger a default
condition under its debt agreements.
The Company is a co-defendant and/or defendant in several cases
at December 31, 2004, and has provided for its exposure for
these cases. The Company does not expect any final resolution of
these cases, net of an expected insurance recovery, to have a
material adverse effect on results of operations or financial
position of the Company. However, given that the Companys
applicable insurance policies provide coverage on a
reimbursement basis, there may be a lag between any payment
ultimately paid by the Company and reimbursement of such payment
from the Companys insurers.
Government Contract
In 2004, the Company was notified by the U.S. Defense
Energy Support Center (DESC) that it had not been
awarded the 10-year hydrazine propellant supply contract which
the Company had anticipated receiving. The Company had a
debriefing with the DESC and submitted a formal protest of the
award. In July, 2004, the U.S. Government Accountability
Office (GAO) informed Arch and the DESC that the GAO
will sustain Archs formal protest of the DESCs
recent decision to award the governments next 10-year
hydrazine propellant supply contract to a competing firm. As a
result of the GAOs decision, the DESC notified the Company
that it has taken corrective action by re-opening the bidding
process. The Company submitted its new bid on January 20,
2005. Final revised bids are currently due on March 15,
2005. The DESC anticipates completing its contract-award
decision late in the first quarter or early in the second
quarter of 2005.
For 2004 and 2003, sales and operating (loss) income for the
hydrazine business were $24.2 million and
$34.0 million, and $(2.6) million and
$1.9 million, respectively. Of these historical sales,
approximately $5.4 million and $22.1 million, related
to the previous propellant supply agreement that expired
April 30, 2004.
The hydrazine business as a whole is not core to the
Companys portfolio, is not a growth business and has been
managed for cash for several years. As of December 31,
2004, the Company reassessed the potential impairment of its
entire hydrazine business, which consists of a hydrazine
propellant and a hydrazine hydrate product line, as a result of
the original DESC decision. This assessment was based upon a
weighted average probability of cash flows, which included an
estimate of obtaining the new contract. As a result of such
reassessments at December 31, 2004, the Company did not
incur an impairment charge.
If the Company does not win the contract after the re-opening
the bidding process, the Company estimates the potential
one-time pre-tax charge related to these decisions to be the
following:
The Company may incur a non-cash impairment charge for the
long-lived assets of the hydrazine business in 2005 if it is
unsuccessful in obtaining the government contract. As of
December 31, 2004, the estimate of the amount of the
impairment would be approximately $13 million, including
the assets associated with the propellants product line. In
addition, the Company may incur cash costs for shutdown costs
and the present value of certain presumed contractual
obligations that are assumed to no longer have any benefit to
the Company. (Such annual contractual payments are approximately
$2.3 million through 2011.) The estimated amount of the
pre-tax cash charge resulting from these costs is approximately
$15 million. These one-time cash costs are expected to be
more than offset by payments to be received from the
U.S. Government upon the shut down of the Lake Charles,
Louisiana and McIntosh, Alabama propellants facilities. The
present values of
40
such payments are approximately $19 million. The projected
annual cash flows relating to these decisions are estimated to
be the following over the next three years and beyond:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 | |
|
2006 | |
|
2007 | |
|
Thereafter | |
|
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Cash Inflow (Outflow)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Contractual obligations
|
|
$ |
(2.3 |
) |
|
$ |
(2.3 |
) |
|
$ |
(2.3 |
) |
|
$ |
(9.2 |
) |
Shutdown costs
|
|
|
(1.0 |
) |
|
|
|
|
|
|
(2.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sub-total
|
|
|
(3.3 |
) |
|
|
(2.3 |
) |
|
|
(4.3 |
) |
|
|
(9.2 |
) |
U.S. government receipts
|
|
|
8.5 |
|
|
|
|
|
|
|
13.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Cash Flows
|
|
$ |
5.2 |
|
|
$ |
(2.3 |
) |
|
$ |
9.2 |
|
|
$ |
(9.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
The net aggregate pre-tax charge for one-time items is expected
to be approximately $9 million, net of the payments to be
received from the U.S. Government.
The 35-month contract secured in November 2003 for storage and
distribution services of the DESCs hydrazine-based
propellants products, valued at $4.3 million, is not
affected by its decision nor is the award in February 2004 to
the Company of the $11.9 million Ultra
Puretm
hydrazine 25-month supply contract. Although the Company does
not currently manufacture hydrazine, it will continue to
manufacture and sell Ultra
Puretm
hydrazine from existing hydrazine inventory. The Company also
provides proprietary blends using hydrazine sourced through
third party producers.
Commitments
The following table details the Companys contractual
obligations as of December 31, 2004:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments Due by Period | |
|
|
($ in millions) | |
|
|
|
|
Less than 1 | |
|
1 to 3 | |
|
3 to 5 | |
|
More than | |
|
|
Total | |
|
Year | |
|
Years | |
|
Years | |
|
5 Years | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
Debt and capital lease obligations(1)
|
|
$ |
220.1 |
|
|
$ |
9.1 |
|
|
$ |
148.7 |
|
|
$ |
62.3 |
|
|
$ |
|
|
Operating lease commitments
|
|
|
37.5 |
|
|
|
9.3 |
|
|
|
10.3 |
|
|
|
8.7 |
|
|
|
9.2 |
|
Other contractual purchase obligations
|
|
|
29.0 |
|
|
|
15.2 |
|
|
|
4.6 |
|
|
|
4.6 |
|
|
|
4.6 |
|
Other long-term liabilities
|
|
|
8.3 |
|
|
|
|
|
|
|
4.0 |
|
|
|
|
|
|
|
4.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
$ |
294.9 |
|
|
$ |
33.6 |
|
|
$ |
167.6 |
|
|
$ |
75.6 |
|
|
$ |
18.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(1) |
The debt and capital lease obligations excludes the unamortized
fair value adjustment related to the interest rate swaps that
were terminated in May 2003. The Company received proceeds of
$7.1 million, which is being amortized over the life of the
senior notes (through March 2007) using the effective-interest
yield method. At December 31, 2004, the unamortized fair
value adjustment was $4.2 million. |
|
|
|
Excluded from the debt and capital lease obligations are the
related interest payments, which are estimated to be
$17.4 million in 2005, $24.6 million in 2006 and 2007,
$6.4 million in 2008 and 2009 and $0 thereafter. The
Company has used the contractual fixed interest rate on the
portion of its debt that is not hedged. The interest payments on
the portion of debt that have been effectively converted to
variable rate indebtedness through use of interest rate swaps,
have been calculated using the variable interest rate in effect
as of December 31, 2004. |
The amounts above exclude the Companys minimum pension
funding requirements as set forth by ERISA, which is expected to
be $6.0 million in 2005 and $32.0 million in 2006 for
the U.S. pension plan. Our minimum funding requirements
after 2005 are dependent on several factors, including the
discount rate. The Company also has payments due under other
postretirement benefit plans. These plans are pay as you go, and
therefore not required to be funded in advance. The Company also
has minimum funding requirements for its U.K. pension plan,
which are expected to be approximately $10.0 million in
2005 and 2006.
41
Other Financial Data
On October 28, 1999, Archs Board of Directors
approved a stock repurchase program whereby the Company is
authorized to buy back up to 1.2 million shares of its
common stock, representing approximately 5% of outstanding
shares. The program was suspended in 2000. In October 2003, the
Board of Directors unanimously agreed to continue the previous
suspension of its stock repurchase program. The Company had
repurchased approximately 893,000 shares of the
1.2 million authorized, or approximately 75%, at a cost of
approximately $16 million. In connection with the
acquisition of the Avecia pool & spa and
protection & hygiene businesses, the Company reissued
669,750 shares with a value of $15.7 million.
On February 9, 2005, the Company declared a quarterly
dividend of $0.20 on each share of the Companys common
stock. The dividend is payable on March 24, 2005 to
shareholders of record at the close of business on
February 23, 2005.
Critical Accounting Policies
The Companys consolidated financial statements are based
on the accounting policies used. Certain accounting policies
require that estimates and assumptions be made by management for
use in the preparation of the financial statements. Critical
accounting policies are those that are central to the
presentation of the Companys financial condition and
results and that require subjective or complex estimates by
management. These include the following:
|
|
|
Goodwill and Other Intangible Assets |
The Company evaluates goodwill and identified intangible assets
on a business-by-business basis (reporting unit) for
impairment. The Company evaluates each reporting unit for
impairment based upon a two-step approach. First, the Company
compares the fair value of the reporting unit with its carrying
value. Second, if the carrying value of the reporting unit
exceeds its fair value, the Company compares the implied fair
value of the reporting units goodwill to its carrying
amount to measure the amount of impairment loss. In measuring
the implied fair value of goodwill, the Company would allocate
the fair value of the reporting unit to each of its assets and
liabilities (including any unrecognized intangible assets). Any
excess of the fair value of the reporting unit over the amounts
assigned to its assets and liabilities is the implied fair value
of goodwill.
The Company measures the fair value of a reporting unit as the
estimated discounted future cash flows, including a terminal
value, which assumes the business continues in perpetuity. The
long-term terminal growth assumptions reflect our current
long-term view of the marketplace. The discount rate is based
upon our weighted average cost of capital of each reporting
unit. Each year the Company re-evaluates the assumptions in the
discounted cash flow model to address changes in the business
and marketplace conditions.
Based upon the annual impairment analysis, which is completed in
the first quarter, the estimated fair value of the reporting
units exceeded their carrying value and as a result, the Company
did not need to proceed to the second step of the impairment
test.
Considerable management judgment is necessary to estimate
discounted future cash flows in conducting an impairment test
for goodwill and other intangible assets, which may be impacted
by future actions taken by the Company and its competitors and
the volatility in the markets in which the Company conducts
business. A change in assumptions in the Companys cash
flows could have a significant impact on the fair value of the
Companys reporting units, which could then result in a
material impairment charge to the Companys results of
operations. See Note 8 of Notes to Consolidated Financial
Statements for additional information.
The Companys effective tax rate is based on pre-tax
income, statutory tax rates and tax planning strategies.
Significant management judgment is required in determining the
effective tax rate and in evaluating the Companys tax
position.
42
The Companys accompanying Consolidated Balance Sheets
include certain deferred tax assets resulting from net operating
loss carryforwards and deductible temporary differences, which
are expected to reduce future taxable income. These assets are
based on managements estimate of realizability based upon
forecasted taxable income. Realizability of these assets is
reassessed at the end of each reporting period based upon the
Companys forecast of future taxable income and available
tax planning strategies, and may result in the recording of a
valuation reserve. Failure to achieve forecasted taxable income
could affect the ultimate realization of certain deferred tax
assets. For additional information, see Note 14 of Notes to
Consolidated Financial Statements.
|
|
|
Pension and Postretirement Benefits |
The Companys accompanying Consolidated Balance Sheets
include significant pension and postretirement benefit
obligations, which are recorded based on actuarial valuations.
Inherent in these valuations are key assumptions, including
discount rates, future compensation levels, expected return on
plan assets and trends in health care costs, which are updated
annually. The Company evaluates these assumptions annually with
its actuarial advisors and believe that they are within
acceptable industry ranges, although an increase or decrease in
the assumptions or economic events outside the control of the
Company could have a material impact on the results of
operations.
The assets, liabilities and assumptions used to measure expense
for any fiscal year are determined as of January 1 of the
current plan year (measurement date). The discount
rate assumption used in the pension and postretirement benefit
plans accounting is based on current interest rates for
high-quality, long-term corporate debt as determined on each
measurement date. The expected return on plan assets is based on
the current and expected asset allocations, as well as
historical and expected returns on various categories of plan
assets
|
|
|
Valuation of Long-Lived Assets |
The impairment of tangible and intangible assets is assessed
when changes in circumstances (such as, but not limited to, a
decrease in market value of an asset, current and historical
operating losses or a change in business strategy) indicate that
their carrying value may not be recoverable. This assessment is
based on estimates of future cash flows, salvage values or net
sales proceeds. These estimates take into account
managements expectations and judgments regarding future
business and economic conditions, future market values and
disposal costs. Actual results and events could differ
significantly from management estimates.
|
|
|
Environmental Liabilities |
Liabilities for environmental matters are accrued for when it is
probable that a liability has been incurred and the amount of
the liability can be reasonably estimated, based upon current
law and existing technologies. These estimates take into account
current law, existing technologies and managements
judgment about future changes in regulation.
Each quarter the Company formally evaluates known and potential
sites, and when there are changes in circumstances. The Company
reviews estimates for future remediation, and maintenance and
management costs directly related to remediation, to determine
appropriate environmental reserve amounts. For each site, a
determination is made of the specific measures that are believed
to be required to remediate the site, the estimated total cost
to carry out the remediation plan, the portion of the total
remediation costs to be borne by the Company and the anticipated
time frame over which payments toward the remediation plan will
occur. The Companys estimate of environmental remediation
liabilities may change in the future should additional sites be
identified, further remediation measures be required or
undertaken or current laws and regulations be changed. For
additional information, see the Environmental discussion in
Item 7 of this Report.
|
|
|
Restructuring Program Liabilities |
The Company has recorded charges in connection with various
restructuring programs. Management judgment is used to estimate
the various costs involved in these programs including severance
costs, inventory
43
and fixed asset disposal costs and settlements of contractual
obligations. These liability estimates are reassessed at the end
of each reporting period. Actual experience has been and may
continue to be different from original estimates. For additional
information, see Note 22 of Notes to Consolidated Financial
Statements.
The Company is subject to proceedings, lawsuits and other claims
in the normal course of business. Each quarter, the Company
formally evaluates its current proceedings, lawsuits and other
claims with counsel and when there are changes in circumstances.
These contingencies require management judgment in order to
assess the likelihood of any adverse judgments or outcomes and
the potential range of probable losses. Liabilities for legal
matters are accrued for when it is probable that a liability has
been incurred and the amount of the liability can be reasonably
estimated, based upon current law and existing information.
Estimates of contingencies may change in the future due to new
developments or changes in legal approach. For additional
information, see Note 20 of Notes to Consolidated Financial
Statements.
For additional information about significant accounting
policies, see Note 1 of Notes to Consolidated Financial
Statements.
New Accounting Standards
In December 2004, the FASB issued revised
SFAS No. 123, Share-Based Payment which
replaces SFAS No. 123, Accounting for
Stock-Based Compensation and supersedes APB Opinion
No. 25, Accounting for Stock Issued to
Employees. This statement, which requires the cost of all
share-based payment transactions be recognized in the financial
statements, establishes fair value as the measurement objective
and requires entities to apply a fair-value-based measurement
method in accounting for share-based payment transactions. The
statement applies to all awards granted, modified, repurchased
or cancelled after July 1, 2005, and unvested portions of
previously issued and outstanding awards. The Company has no
unvested portions of previously issued or outstanding awards and
the Company currently does not intend to issue any stock awards
to employees. Therefore, the Company does not believe that this
standard will have any impact on its consolidated financial
statements.
In November 2004, the FASB issued SFAS No. 151,
Inventory Costs an amendment of ARB
No. 43, Chapter 4, which clarifies the
accounting for abnormal amounts of idle facility expense,
freight, handling costs, and wasted material (spoilage) and also
requires that the allocation of fixed production overhead be
based on the normal capacity of the production facilities.
SFAS No. 151 is effective for inventory costs incurred
during fiscal years beginning after June 15, 2005. The
Company is currently evaluating the impact of adopting this
statement.
Derivative Financial Instruments
The Company enters into forward sales and purchase contracts and
currency options to manage currency risk resulting from purchase
and sale commitments denominated in foreign currencies
(principally British pound, euro, Canadian dollar and Japanese
yen) and relating to particular anticipated but not yet
committed purchases and sales expected to be denominated in
those currencies. All the currency derivatives expire within one
year. At December 31, 2004, the Company had forward
contracts to sell foreign currencies with notional amounts of
$13.8 million and no forward contracts to buy foreign
currencies outstanding. At December 31, 2003, the Company
had no forward contracts to either buy or sell foreign
currencies. The fair value of these forward contracts is
included in Accrued Liabilities. At December 31, 2004 and
2003 the Company had no outstanding option contracts to sell or
buy foreign currencies.
In accordance with Statement of Financial Accounting Standards
No. 133 (SFAS 133), Accounting for
Derivative Instruments and Hedging Activities, as amended
by SFAS No. 137 and SFAS No. 138, derivative
instruments are recognized as assets or liabilities in the
Companys Consolidated Balance Sheets and are measured at
fair value. The change in the fair value of a derivative
designated as a fair value hedge and the change in the fair
value of the hedged item attributable to the hedged risk are
recognized in earnings. For
44
derivatives, which qualify for designation as cash flow hedges,
the effective portion of the changes in fair value is recognized
as part of other comprehensive income until the underlying
transaction that is being hedged is recognized in earnings. The
ineffective portion of the change in fair value of cash flow
hedges is recognized in earnings currently. Changes in fair
value for other derivatives, which do not qualify as a hedge for
accounting purposes, are recognized in current period earnings.
In May 2003, the Company terminated its interest rate swap
agreements that were entered into in April 2002. As a result,
the Company received cash proceeds of $7.1 million, which
represented the market value of the contracts on the date of
termination. The Company utilized the proceeds to pay down debt
and reduced the amount recorded in Other Assets for such
derivative instruments to zero. There was no gain or loss on the
transaction.
Simultaneous with the termination of the interest rate swap
agreements, the Company entered into new interest rate swap
agreements, under which it swapped its 7.94% fixed interest rate
on $80.0 million principal amount of unsecured senior notes
for floating rate interest based upon six-month LIBOR plus
5.4539%. The counter parties to these agreements are major
financial institutions. The agreements expire in March 2007. The
Company has designated the swap agreements as fair value hedges
of the risk of changes in the value of fixed rate debt due to
changes in interest rates for a portion of its fixed rate
borrowings under SFAS 133. Accordingly, the swap agreements
have been recorded at their fair market value of
$1.6 million and are included in Other Liabilities on the
accompanying Consolidated Balance Sheets, with a corresponding
decrease in the carrying amount of the related debt. No gain or
loss has been recorded as the contracts meet the criteria of
SFAS 133 to qualify for hedge accounting treatment with no
ineffectiveness.
Cautionary Statement under Federal Securities Laws
The information in this Form 10-K contains forward-looking
statements that are based on managements beliefs, certain
assumptions made by management and managements current
expectations, outlook, estimates and projections about the
markets and economy in which the Company and its various
businesses operate. Words such as anticipates,
believes, estimates,
expects, forecasts, opines,
plans, predicts, projects,
should, targets and variations of such
words and similar expressions are intended to identify such
forward-looking statements. These statements are not guarantees
of future performance and involve certain risks, uncertainties
and assumptions (Future Factors), which are
difficult to predict. Therefore, actual outcomes and results may
differ materially from what is expected or forecasted in such
forward-looking statements. The Company undertakes no obligation
to update publicly any forward-looking statements, whether as a
result of future events, new information or otherwise. Future
Factors which could cause actual results to differ materially
from those discussed include but are not limited to: general
economic and business and market conditions; lack of moderate
growth or recession in U.S. and European economies; increases in
interest rates; economic conditions in Asia; worsening economic
and political conditions in Venezuela; changes in foreign
currencies against the U.S. dollar; customer acceptance of
new products; efficacy of new technology; changes in
U.S. laws and regulations; increased competitive and/or
customer pressure; the Companys ability to maintain
chemical price increases; higher-than-expected raw material
costs for certain chemical product lines; an increase in
anti-dumping duties on certain products; increased foreign
competition in the calcium hypochlorite markets; unfavorable
court, arbitration or jury decisions or tax matters; the
supply/demand balance for the Companys products, including
the impact of excess industry capacity; failure to achieve
targeted cost-reduction programs; capital expenditures in excess
of those scheduled; environmental costs in excess of those
projected; the occurrence of unexpected manufacturing
interruptions/outages at customer or company plants; reduction
in expected government contract orders and/or the failure to be
awarded a new U.S. government contract for hydrazine
propellants; unfavorable weather conditions for swimming pool
use; inability to expand sales in the professional pool dealer
market; and gains or losses on derivative instruments.
|
|
Item 7A. |
Quantitative and Qualitative Disclosures about Market
Risk |
The Company is exposed to various market risks, including
changes in foreign currency exchange rates, interest rates and
commodity prices. The Company does not enter into derivatives or
other financial instruments for trading or speculative purposes
in the normal course of business.
45
Interest Rates
The Company is exposed to interest rate risk on approximately
40% of its outstanding borrowings, including, for this purpose,
the participation interests sold under its accounts receivable
securitization program, which are subject to floating rates.
Based upon the Companys expected 2005 borrowing levels, an
increase in interest rates of 100 basis points would
decrease the Companys results of operations and cash flows
by approximately $0.5 million.
Foreign Currency Risk
Approximately 40 percent of the Companys sales and
expenses are denominated in currencies other than the
U.S. dollar. As a result, the Company is subject to risks
associated with its foreign operations, including currency
devaluations and fluctuations in currency exchange rates. These
exposures from foreign exchange fluctuations can affect the
Companys equity investments and its respective share of
earnings (losses), the Companys net investment in foreign
subsidiaries, translation of the Companys foreign
operations for U.S. GAAP reporting purposes and purchase
and sales commitments denominated in foreign currencies. The
Company enters into forward sales and purchase contracts and
currency options to manage currency risk from actual and
anticipated purchase and sales commitments denominated or
expected to be denominated in a foreign currency (principally
British pound, euro, Canadian dollar and Japanese yen). It is
the Companys policy to hedge up to 80% of these
transactions during a calendar year. The counterparties to the
options and contracts are major financial institutions.
At December 31, 2004, the Company had forward contracts to
sell foreign currencies with notional amounts of
$13.8 million and no forward contracts to buy foreign
currencies outstanding.
Holding other variables constant, if there were a
10 percent change in foreign currency exchange rates, the
net effect on the Companys annual cash flows would be a
increase (decrease) of between $1 million to
$2 million related to the unhedged portion, as any increase
(decrease) in cash flows resulting from the Companys hedge
forward contracts would be offset by an equal (decrease)
increase in cash flows on the underlying transaction being
hedged. The application of SFAS 133 may cause increased
volatility in the Companys results of operations for
interim periods in the future if the Company changes its
policies, or if some of the derivative instruments do not meet
the requirements for hedge accounting.
Commodity Price Risk
The Company is exposed to commodity price risk related to the
price volatility of natural gas utilized at certain
manufacturing sites. Depending on market conditions, the Company
may purchase derivative commodity instruments to minimize the
risk of price fluctuations. It is the Companys policy to
hedge up to 80 percent of its natural gas purchases during
a calendar year. At December 31, 2004 and 2003, the Company
had no forward contracts to purchase natural gas. In addition,
the Company is exposed to price risk related to the price
volatility of certain other raw materials including the ongoing
purchase of propylene, copper metal and monoethanolamine
(MEA). Holding other variables constant, a
10 percent adverse change in the price of propylene would
decrease the Companys results of operations and cash flows
by approximately $4 million. Holding other variables
constant, a 10 percent adverse change in the price of
copper metal, MEA and natural gas would decrease the
Companys results of operations and cash flows between
$1 million to $2 million each.
46
|
|
Item 8. |
Financial Statements and Supplementary Data |
REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
The Board of Directors and Shareholders
Arch Chemicals, Inc.
We have audited the accompanying consolidated balance sheets of
Arch Chemicals, Inc. and subsidiaries as of December 31,
2004 and 2003, and the related consolidated statements of
income, shareholders equity, and cash flows for each of
the years in the three-year period ended December 31, 2004.
These consolidated financial statements are the responsibility
of the Companys management. Our responsibility is to
express an opinion on these consolidated 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, the consolidated financial statements referred
to above present fairly, in all material respects, the financial
position of Arch Chemicals, Inc. and subsidiaries as of
December 31, 2004 and 2003, and the results of their
operations and their cash flows for each of the years in the
three-year period ended December 31, 2004, in conformity
with U.S. generally accepted accounting principles.
We also have audited, in accordance with the standards of the
Public Company Accounting Oversight Board (United States), the
effectiveness of Arch Chemicals, Inc. and subsidiaries internal
control over financial reporting as of December 31, 2004,
based on criteria established in Internal
Control Integrated Framework issued by the
Committee of Sponsoring Organizations of the Treadway Commission
(COSO), and our report dated March 14, 2005 expressed an
unqualified opinion on managements assessment of, and the
effective operation of, internal control over financial
reporting.
Stamford, CT
March 14, 2005
47
ARCH CHEMICALS, INC. and SUBSIDIARIES
CONSOLIDATED BALANCE SHEETS
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
(in millions, except | |
|
|
per share amounts) | |
ASSETS |
Current Assets:
|
|
|
|
|
|
|
|
|
|
Cash and Cash Equivalents
|
|
$ |
74.6 |
|
|
$ |
64.8 |
|
|
Accounts Receivables, net
|
|
|
125.6 |
|
|
|
100.3 |
|
|
Short-Term Investment
|
|
|
53.3 |
|
|
|
43.3 |
|
|
Inventories, net
|
|
|
151.1 |
|
|
|
110.9 |
|
|
Other Current Assets
|
|
|
37.9 |
|
|
|
26.7 |
|
|
Assets Held For Sale
|
|
|
15.9 |
|
|
|
179.9 |
|
|
|
|
|
|
|
|
|
|
Total Current Assets
|
|
|
458.4 |
|
|
|
525.9 |
|
Investments and Advances Affiliated Companies at
Equity
|
|
|
15.5 |
|
|
|
16.0 |
|
Property, Plant and Equipment, net
|
|
|
211.6 |
|
|
|
207.9 |
|
Goodwill
|
|
|
192.4 |
|
|
|
110.4 |
|
Other Intangibles
|
|
|
151.2 |
|
|
|
60.6 |
|
Other Assets
|
|
|
70.9 |
|
|
|
55.6 |
|
|
|
|
|
|
|
|
|
|
Total Assets
|
|
$ |
1,100.0 |
|
|
$ |
976.4 |
|
|
|
|
|
|
|
|
|
LIABILITIES AND SHAREHOLDERS EQUITY |
Current Liabilities:
|
|
|
|
|
|
|
|
|
|
Short-Term Borrowings
|
|
$ |
9.1 |
|
|
$ |
0.7 |
|
|
Accounts Payable
|
|
|
160.2 |
|
|
|
121.7 |
|
|
Accrued Liabilities
|
|
|
108.1 |
|
|
|
80.2 |
|
|
Liabilities Associated with Assets Held For Sale
|
|
|
12.2 |
|
|
|
26.5 |
|
|
|
|
|
|
|
|
|
|
Total Current Liabilities
|
|
|
289.6 |
|
|
|
229.1 |
|
Long-Term Debt
|
|
|
215.2 |
|
|
|
218.5 |
|
Other Liabilities
|
|
|
235.4 |
|
|
|
191.1 |
|
|
|
|
|
|
|
|
|
|
Total Liabilities
|
|
|
740.2 |
|
|
|
638.7 |
|
Commitments and Contingencies
|
|
|
|
|
|
|
|
|
Shareholders Equity:
|
|
|
|
|
|
|
|
|
|
Common Stock, par value $1 per share, Authorized
100.0 shares:
|
|
|
|
|
|
|
|
|
|
|
23.4 shares issued and outstanding (22.5 in 2003)
|
|
|
23.4 |
|
|
|
22.5 |
|
|
Additional Paid-in Capital
|
|
|
418.2 |
|
|
|
398.2 |
|
|
Retained Earnings
|
|
|
14.8 |
|
|
|
13.4 |
|
|
Accumulated Other Comprehensive Loss
|
|
|
(96.6 |
) |
|
|
(96.4 |
) |
|
|
|
|
|
|
|
|
|
Total Shareholders Equity
|
|
|
359.8 |
|
|
|
337.7 |
|
|
|
|
|
|
|
|
|
|
Total Liabilities and Shareholders Equity
|
|
$ |
1,100.0 |
|
|
$ |
976.4 |
|
|
|
|
|
|
|
|
See accompanying notes to the consolidated financial statements.
48
ARCH CHEMICALS, INC. and SUBSIDIARIES
CONSOLIDATED STATEMENTS OF INCOME
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
(in millions, except | |
|
|
per share amounts) | |
Sales
|
|
$ |
1,120.9 |
|
|
$ |
863.5 |
|
|
$ |
763.0 |
|
Cost of Goods Sold
|
|
|
808.0 |
|
|
|
618.1 |
|
|
|
541.9 |
|
Selling and Administration
|
|
|
252.6 |
|
|
|
209.7 |
|
|
|
184.6 |
|
Research and Development
|
|
|
15.4 |
|
|
|
11.7 |
|
|
|
10.3 |
|
Other (Gains) and Losses
|
|
|
1.4 |
|
|
|
(3.0 |
) |
|
|
(1.5 |
) |
Restructuring Expense
|
|
|
1.7 |
|
|
|
0.4 |
|
|
|
5.7 |
|
Impairment Charge
|
|
|
2.9 |
|
|
|
|
|
|
|
|
|
Interest Expense
|
|
|
19.8 |
|
|
|
17.2 |
|
|
|
16.9 |
|
Interest Income
|
|
|
1.2 |
|
|
|
0.6 |
|
|
|
0.9 |
|
|
|
|
|
|
|
|
|
|
|
|
Income From Continuing Operations Before Taxes, Equity in
Earnings of Affiliated Companies and Cumulative Effect of
Accounting Change
|
|
|
20.3 |
|
|
|
10.0 |
|
|
|
6.0 |
|
Equity in Earnings of Affiliated Companies
|
|
|
4.0 |
|
|
|
5.6 |
|
|
|
3.1 |
|
Income Tax Expense
|
|
|
7.0 |
|
|
|
5.5 |
|
|
|
2.7 |
|
|
|
|
|
|
|
|
|
|
|
|
Income From Continuing Operations Before Cumulative Effect of
Accounting Change
|
|
|
17.3 |
|
|
|
10.1 |
|
|
|
6.4 |
|
Income (Loss) from Discontinued Operations (net of tax expense
of $2.7, $2.3 and $0.4, respectively)
|
|
|
10.0 |
|
|
|
3.2 |
|
|
|
(1.9 |
) |
Gain (Loss) on Sales of Discontinued Operations (net of tax
(expense) benefit of $(0.8), $(10.3) and $0.9, respectively)
|
|
|
(7.4 |
) |
|
|
14.5 |
|
|
|
(1.5 |
) |
Cumulative Effect of Accounting Change (net of tax benefit of
$0.2)
|
|
|
|
|
|
|
(0.4 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income
|
|
$ |
19.9 |
|
|
$ |
27.4 |
|
|
$ |
3.0 |
|
|
|
|
|
|
|
|
|
|
|
Net Income (Loss) Per Common Share Basic:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Continuing Operations Before Cumulative Effect of Accounting
Change
|
|
$ |
0.75 |
|
|
$ |
0.45 |
|
|
$ |
0.28 |
|
|
Income (Loss) From Discontinued Operations
|
|
|
0.43 |
|
|
|
0.14 |
|
|
|
(0.08 |
) |
|
Gain (Loss) on Sales of Discontinued Operations
|
|
|
(0.32 |
) |
|
|
0.64 |
|
|
|
(0.07 |
) |
|
Cumulative Effect of Accounting Change
|
|
|
|
|
|
|
(0.02 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Basic Net Income Per Common Share
|
|
$ |
0.86 |
|
|
$ |
1.21 |
|
|
$ |
0.13 |
|
|
|
|
|
|
|
|
|
|
|
Net Income (Loss) Per Common Share Diluted:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Continuing Operations Before Cumulative Effect of Accounting
Change
|
|
$ |
0.74 |
|
|
$ |
0.45 |
|
|
$ |
0.28 |
|
|
Income (Loss) From Discontinued Operations
|
|
|
0.42 |
|
|
|
0.14 |
|
|
|
(0.08 |
) |
|
Gain (Loss) on Sales of Discontinued Operations
|
|
|
(0.32 |
) |
|
|
0.64 |
|
|
|
(0.07 |
) |
|
Cumulative Effect of Accounting Change
|
|
|
|
|
|
|
(0.02 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Diluted Net Income Per Common Share
|
|
$ |
0.84 |
|
|
$ |
1.21 |
|
|
$ |
0.13 |
|
|
|
|
|
|
|
|
|
|
|
Weighted Average Common Stock Outstanding Basic
|
|
|
23.2 |
|
|
|
22.6 |
|
|
|
22.5 |
|
Weighted Average Common Stock Outstanding Diluted
|
|
|
23.5 |
|
|
|
22.6 |
|
|
|
22.6 |
|
See accompanying notes to the consolidated financial statements.
49
ARCH CHEMICALS, INC. and SUBSIDIARIES
CONSOLIDATED STATEMENTS OF CASH FLOWS
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Operating Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income
|
|
$ |
19.9 |
|
|
$ |
27.4 |
|
|
$ |
3.0 |
|
Adjustments to Reconcile Net Income to Net Cash and Cash
Equivalents Provided by Operating Activities, Net of Businesses
Acquired:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(Income) Loss from Discontinued Operations
|
|
|
(10.0 |
) |
|
|
(3.2 |
) |
|
|
1.9 |
|
|
(Gain) Loss on Sales of Discontinued Operations
|
|
|
7.4 |
|
|
|
(14.5 |
) |
|
|
1.5 |
|
|
Cumulative Effect of Accounting Change
|
|
|
|
|
|
|
0.4 |
|
|
|
|
|
|
Equity in Earnings of Affiliates
|
|
|
(4.0 |
) |
|
|
(5.6 |
) |
|
|
(3.1 |
) |
|
Other (Gains) Losses
|
|
|
1.4 |
|
|
|
(3.0 |
) |
|
|
(1.5 |
) |
|
Depreciation and Amortization
|
|
|
46.9 |
|
|
|
39.4 |
|
|
|
39.4 |
|
|
Deferred Taxes
|
|
|
(3.6 |
) |
|
|
1.3 |
|
|
|
(1.4 |
) |
|
Restructuring Expense
|
|
|
1.7 |
|
|
|
0.4 |
|
|
|
5.7 |
|
|
Impairment Charge
|
|
|
2.9 |
|
|
|
|
|
|
|
|
|
|
Restructuring Payments
|
|
|
(4.8 |
) |
|
|
(4.5 |
) |
|
|
(6.6 |
) |
|
Change in Assets and Liabilities, Net of Purchases and Sales of
Businesses:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accounts Receivable Securitization Program
|
|
|
|
|
|
|
(33.5 |
) |
|
|
33.5 |
|
|
|
Receivables
|
|
|
(0.3 |
) |
|
|
(10.8 |
) |
|
|
17.7 |
|
|
|
Inventories
|
|
|
(7.4 |
) |
|
|
13.7 |
|
|
|
(10.9 |
) |
|
|
Other Current Assets
|
|
|
(1.7 |
) |
|
|
1.9 |
|
|
|
|
|
|
|
Accounts Payable and Accrued Liabilities
|
|
|
20.2 |
|
|
|
0.1 |
|
|
|
6.2 |
|
|
|
Noncurrent Liabilities
|
|
|
1.9 |
|
|
|
(1.6 |
) |
|
|
(0.8 |
) |
Other Operating Activities
|
|
|
5.8 |
|
|
|
5.9 |
|
|
|
3.9 |
|
|
|
|
|
|
|
|
|
|
|
|
Net Operating Activities from Continuing Operations
|
|
|
76.3 |
|
|
|
13.8 |
|
|
|
88.5 |
|
Change in Net Assets Held for Sale
|
|
|
11.8 |
|
|
|
4.8 |
|
|
|
20.1 |
|
|
|
|
|
|
|
|
|
|
|
|
Net Operating Activities
|
|
|
88.1 |
|
|
|
18.6 |
|
|
|
108.6 |
|
|
|
|
|
|
|
|
|
|
|
Investing Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
Capital Expenditures
|
|
|
(18.3 |
) |
|
|
(17.0 |
) |
|
|
(28.2 |
) |
Businesses Acquired in Purchase Transactions, Net of Cash
Acquired
|
|
|
(215.8 |
) |
|
|
(2.5 |
) |
|
|
|
|
Proceeds from Sales of Businesses
|
|
|
158.5 |
|
|
|
61.2 |
|
|
|
25.0 |
|
Proceeds from Sales of Land and Property
|
|
|
0.9 |
|
|
|
2.8 |
|
|
|
2.1 |
|
Other Investing Activities
|
|
|
(0.1 |
) |
|
|
0.9 |
|
|
|
2.2 |
|
|
|
|
|
|
|
|
|
|
|
|
Net Investing Activities
|
|
|
(74.8 |
) |
|
|
45.4 |
|
|
|
1.1 |
|
|
|
|
|
|
|
|
|
|
|
Financing Activities:
|
|
|
|
|
|
|
|
|
|
|
|
|
Long-Term Debt Borrowings
|
|
|
207.0 |
|
|
|
|
|
|
|
|
|
Long-Term Debt Repayments
|
|
|
(207.0 |
) |
|
|
(0.8 |
) |
|
|
(69.7 |
) |
Short-Term Borrowings (Repayments), net
|
|
|
7.8 |
|
|
|
(1.7 |
) |
|
|
(227.3 |
) |
Issuance of Unsecured Senior Notes
|
|
|
|
|
|
|
|
|
|
|
211.0 |
|
Dividends Paid
|
|
|
(18.5 |
) |
|
|
(18.0 |
) |
|
|
(17.9 |
) |
Other Financing Activities
|
|
|
4.2 |
|
|
|
6.5 |
|
|
|
0.9 |
|
|
|
|
|
|
|
|
|
|
|
|
Net Financing Activities
|
|
|
(6.5 |
) |
|
|
(14.0 |
) |
|
|
(103.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
Effect of Exchange Rate Changes on Cash and Cash Equivalents
|
|
|
3.0 |
|
|
|
2.6 |
|
|
|
1.5 |
|
|
|
|
|
|
|
|
|
|
|
|
Net Increase in Cash and Cash Equivalents
|
|
|
9.8 |
|
|
|
52.6 |
|
|
|
8.2 |
|
Cash and Cash Equivalents, Beginning of Year
|
|
|
64.8 |
|
|
|
12.2 |
|
|
|
4.0 |
|
|
|
|
|
|
|
|
|
|
|
Cash and Cash Equivalents, End of Year
|
|
$ |
74.6 |
|
|
$ |
64.8 |
|
|
$ |
12.2 |
|
|
|
|
|
|
|
|
|
|
|
Cash Paid During the Year for:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Income Taxes (Refunds), net
|
|
$ |
11.9 |
|
|
$ |
12.1 |
|
|
$ |
(1.3 |
) |
|
Interest
|
|
$ |
21.7 |
|
|
$ |
17.6 |
|
|
$ |
15.1 |
|
See accompanying notes to the consolidated financial statements.
50
ARCH CHEMICALS, INC. and SUBSIDIARIES
CONSOLIDATED STATEMENTS OF SHAREHOLDERS EQUITY
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Retained | |
|
Accumulated | |
|
|
|
|
|
|
Common Stock | |
|
Additional | |
|
Earnings | |
|
Other | |
|
Total | |
|
Comprehensive | |
|
|
| |
|
Paid-in | |
|
(Accumulated | |
|
Comprehensive | |
|
Shareholders | |
|
Income | |
|
|
Shares | |
|
Amount | |
|
Capital | |
|
Deficit) | |
|
Loss | |
|
Equity | |
|
(Loss) | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
(in millions, except per share amounts) | |
Balance at December 31, 2001
|
|
|
22.2 |
|
|
$ |
22.2 |
|
|
$ |
424.4 |
|
|
$ |
(12.5 |
) |
|
$ |
(46.6 |
) |
|
$ |
387.5 |
|
|
|
|
|
Net Income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
3.0 |
|
|
|
|
|
|
|
3.0 |
|
|
$ |
3.0 |
|
Foreign Currency Translation Adjustments
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
13.6 |
|
|
|
13.6 |
|
|
|
13.6 |
|
Change in Fair Value of Derivatives
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
0.3 |
|
|
|
0.3 |
|
|
|
0.3 |
|
Minimum Pension Liability Adjustment, net of taxes of $29.0
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(60.4 |
) |
|
|
(60.4 |
) |
|
|
(60.4 |
) |
Tax Benefit on Stock Options
|
|
|
|
|
|
|
|
|
|
|
0.2 |
|
|
|
|
|
|
|
|
|
|
|
0.2 |
|
|
|
|
|
Stock Options Exercised
|
|
|
0.2 |
|
|
|
0.2 |
|
|
|
3.5 |
|
|
|
|
|
|
|
|
|
|
|
3.7 |
|
|
|
|
|
Cash Dividends ($0.80 per share)
|
|
|
|
|
|
|
|
|
|
|
(17.9 |
) |
|
|
|
|
|
|
|
|
|
|
(17.9 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2002
|
|
|
22.4 |
|
|
|
22.4 |
|
|
|
410.2 |
|
|
|
(9.5 |
) |
|
|
(93.1 |
) |
|
|
330.0 |
|
|
|
(43.5 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
27.4 |
|
|
|
|
|
|
|
27.4 |
|
|
|
27.4 |
|
Foreign Currency Translation Adjustments
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
20.5 |
|
|
|
20.5 |
|
|
|
20.5 |
|
Change in Fair Value of Derivatives
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(0.3 |
) |
|
|
(0.3 |
) |
|
|
(0.3 |
) |
Minimum Pension Liability Adjustment, net of taxes of $11.2
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(23.5 |
) |
|
|
(23.5 |
) |
|
|
(23.5 |
) |
Stock Options Exercised and Other Stock Awards
|
|
|
0.1 |
|
|
|
0.1 |
|
|
|
1.5 |
|
|
|
|
|
|
|
|
|
|
|
1.6 |
|
|
|
|
|
Cash Dividends ($0.80 per share)
|
|
|
|
|
|
|
|
|
|
|
(13.5 |
) |
|
|
(4.5 |
) |
|
|
|
|
|
|
(18.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2003
|
|
|
22.5 |
|
|
|
22.5 |
|
|
|
398.2 |
|
|
|
13.4 |
|
|
|
(96.4 |
) |
|
|
337.7 |
|
|
|
24.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Income
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
19.9 |
|
|
|
|
|
|
|
19.9 |
|
|
|
19.9 |
|
Foreign Currency Translation Adjustments
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
19.5 |
|
|
|
19.5 |
|
|
|
19.5 |
|
Change in Fair Value of Derivatives
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(0.2 |
) |
|
|
(0.2 |
) |
|
|
(0.2 |
) |
Minimum Pension Liability Adjustment, net of taxes of $10.1
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(19.5 |
) |
|
|
(19.5 |
) |
|
|
(19.5 |
) |
Stock Issued
|
|
|
0.7 |
|
|
|
0.7 |
|
|
|
15.0 |
|
|
|
|
|
|
|
|
|
|
|
15.7 |
|
|
|
|
|
Tax Benefit on Stock Options
|
|
|
|
|
|
|
|
|
|
|
0.9 |
|
|
|
|
|
|
|
|
|
|
|
0.9 |
|
|
|
|
|
Stock Options Exercised
|
|
|
0.3 |
|
|
|
0.3 |
|
|
|
6.4 |
|
|
|
|
|
|
|
|
|
|
|
6.7 |
|
|
|
|
|
Stock Purchases Rabbi Trust
|
|
|
(0.1 |
) |
|
|
(0.1 |
) |
|
|
(2.3 |
) |
|
|
|
|
|
|
|
|
|
|
(2.4 |
) |
|
|
|
|
Cash Dividends ($0.80 per share)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
(18.5 |
) |
|
|
|
|
|
|
(18.5 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2004
|
|
|
23.4 |
|
|
$ |
23.4 |
|
|
$ |
418.2 |
|
|
$ |
14.8 |
|
|
$ |
(96.6 |
) |
|
$ |
359.8 |
|
|
$ |
19.7 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
See accompanying notes to the consolidated financial statements.
51
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS
|
|
1. |
Description of Business and Summary of Significant Accounting
Policies |
Formation of Arch Chemicals, Inc.
Arch Chemicals, Inc. (Arch or the
Company) was organized under the laws of the
Commonwealth of Virginia on August 25, 1998 as a
wholly-owned subsidiary of Olin Corporation (Olin)
for the purpose of effecting the distribution of Olins
Specialty Chemical Businesses (Distribution) to the
shareholders of Olin. The Company is a specialty chemicals
manufacturer, which supplies value-added products and services
to several industries on a worldwide basis, servicing both the
consumer products and industrial products markets. The principal
businesses in which the Company competes are treatment products
and performance products. During 2004, the Company strengthened
its treatment products businesses with the acquisition of
Avecias pool & spa and protection &
hygiene businesses. The treatment products segment includes
three reportable business units: the HTH water products, which
includes the pool & spa business, the personal care and
industrial biocides products, which includes the
protection & hygiene business, and the wood protection
and industrial coatings products businesses. The performance
segment includes two reportable business units: the performance
urethanes business and the hydrazine business.
The Company has organized its segments around differences in
products and services, which is how the Company manages its
businesses.
The treatment products businesses manufacture and sell water
treatment chemicals, industrial biocides and personal care
specialty ingredients and wood treatment and industrial coatings
products. HTH water products produces chemicals for the
sanitization and treatment of residential pool and commercial
pool and spa water, and the purification of potable water. With
the acquisition of Avecias pool & spa business,
the Company sells both chlorine-based products (calcium
hypochlorite and chlorinated isocyanurates) and
non-chlorine-based products (polyhexamethylene biguanide
(PHMB)) as sanitizers. Consumer brands include
HTH®, Baquacil®, Baqua
Spa®, Sock It®, Super Sock
It®, Duration®,
POOLIFE®, and Pace®. The
personal care and industrial biocides business manufactures
biocides that control dandruff on the scalp and control the
growth of micro-organisms, particularly fungi and algae. It
markets products such as Zinc Omadine®, the most
widely used antidandruff agent in the world, as well as actives
and functional products sold primarily to manufacturers of skin
care and hair care products. The Companys industrial
biocides are used in mildew-resistant paints, coatings and
lubricants. With the acquisition of Avecias
protection & hygiene business, the Company also
develops, manufactures and markets biocides for anti-bacterial
applications. It is a leading global supplier of biocides for
the industrial preservation and consumer segments of the
biocides market and products are marketed under the
well-recognized trademarks, Omadine®,
Omacide®, Proxel®,
Purista® and Densil® biocides.
The Companys wood protection business sells wood treatment
chemicals solutions that enhance the properties of wood. Its
industrial wood preservatives and fire retardants are sold under
the brand names Wolmanized®,
Thompsonized®, Tanalised®,
Vacsol®, Resistol® and
Dricon®. The Companys industrial coatings
business manufactures a wide range of coatings for a variety of
applications for wood and other materials, which are industrial
or consumer applied products for the surface decoration and
protection of wood. These products are sold under brand names
such as Sayerlack® and Linea
Blu®.
Performance products consist of performance urethanes and
hydrazine. Performance urethanes manufacture a variety of
specialty polyols, which are used as an ingredient for
elastomers, adhesives, coatings, sealants and rigid foam. The
business also manufactures glycols and glycol ethers for use as
an ingredient in cleaners, personal care products and
antifreeze. Hydrazine hydrates are used in chemical blowing
agents, water treatment chemicals, agricultural products and
pharmaceutical intermediates. Propellant-grade hydrazine and
hydrazine derivatives are used by NASA, the Air Force and other
customers as fuel in satellites, expendable launch vehicles and
auxiliary and emergency power units. Ultra
Puretm
hydrazine propellants are the highest purity anhydrous
propellant in the industry and can extend the working life of
satellites.
52
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Basis of Presentation
The Consolidated Financial Statements include the accounts of
the Company and its majority-owned subsidiaries. Intercompany
balances and transactions between entities included in these
Consolidated Financial Statements have been eliminated.
Investments in 20-50% owned affiliates are accounted for on the
equity method.
As a result of the sale of the majority of the microelectronic
materials businesses, the Company has restated its prior year
financial statements to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations in
accordance with the Statement of Financial Accounting Standard
No. 144, Accounting for the Impairment or Disposal of
Long-Lived Assets (SFAS 144). The Company
has retained its 50 percent interest in Planar Solutions
LLC, its joint venture with Wacker Chemical Corporation for the
production and sale of chemical mechanical planarization
(CMP) slurries, the microelectronics-dedicated
manufacturing facility in Brandenburg, Kentucky and its chemical
management services (CMS) business. The Company will
pursue all strategic options for the CMS business, including its
sale. As a result, and in accordance with the accounting
requirements of SFAS 144, the CMS business is reported as
an asset held for sale and the results of operations are
included in discontinued operations in the consolidated
financial statements. The Company will continue to supply
certain products for a transition period to the purchaser of the
microelectronic materials businesses from its Brandenburg,
Kentucky facility. In addition, as a result of the sale the
Company has reallocated certain centralized service costs to the
Companys segments that were previously allocated to the
microelectronic materials segment.
Reclassifications of prior-year data have been made, where
appropriate, to conform to the 2004 presentation.
Use of Estimates
The preparation of the Consolidated Financial Statements
requires estimates and assumptions that affect amounts reported
and disclosed in the Consolidated Financial Statements and
related Notes. Estimates are used when accounting for allowance
for uncollectible accounts receivable, inventory obsolescence,
valuation of assets held for sale, depreciation and
amortization, employee benefit plans, performance-based
incentive compensation, taxes, impairment of assets,
environmental and legal liabilities and contingencies, among
others. Actual results could differ from those estimates.
Cash and Cash Equivalents
Cash equivalents consist of highly liquid investments with an
original maturity of three months or less.
Inventories
Inventories are stated at the lower of cost or net realizable
value. Inventories are valued by the dollar value last-in,
first-out (LIFO) method of inventory accounting for
the domestic operations of the HTH Water Products, Personal Care
and Industrial Biocides, Performance Urethanes and Hydrazine
businesses. Costs for all other inventories have been determined
principally by the first-in, first-out (FIFO)
method. Elements of costs in inventories include raw materials,
direct labor and manufacturing overhead.
Assets Held for Sale
The Company accounts for assets held for sale in accordance with
SFAS 144. SFAS 144 addresses financial accounting and
reporting for the impairment or disposal of long-lived assets.
As of December 31, 2003, the Company has accounted for the
Hickson organics business and the sulfuric acid business as
assets held for sale in accordance with SFAS 144.
Additionally, as a result of the sale of the majority of the
53
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
microelectronic materials businesses, the Company has restated
its prior year results to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations in
accordance with the SFAS 144. The Company has retained its
CMS business. The Company will pursue all strategic options for
the CMS business, including its sale. In accordance with the
accounting requirements of SFAS 144, the CMS business is
reported as an asset held for sale and the results of operations
are included in discontinued operations in the consolidated
financial statements. As such, the assets and liabilities of the
discontinued operations have been presented separately on the
face of the consolidated financial statements.
Property, Plant and Equipment
Property, plant and equipment are recorded at cost. Depreciation
is computed on a straight-line basis over the following
estimated useful lives:
|
|
|
Improvements to land
|
|
5 to 20 years |
Building and building equipment
|
|
5 to 40 years |
Machinery and equipment
|
|
3 to 12 years |
Leasehold improvements are amortized over the term of the lease
or the estimated useful life of the improvement, whichever is
shorter. Start-up costs are expensed as incurred.
As of January 1, 2003 the Company adopted Statement of
Financial Accounting Standards No. 143, Accounting
for Asset Retirement Obligations, which addresses
financial accounting requirements for retirement obligations
associated with tangible long-lived assets. On January 1,
2003 the Company recorded an asset and liability of
$0.4 million and $0.6 million, respectively. A
one-time cumulative effect charge, net of tax benefit, of
$0.4 million, was also recorded. These adjustments reflect
the cost of retirement obligations related to facilities,
certain equipment used in the manufacturing process, underground
tanks and a landfill. Certain other asset retirement obligations
associated with owned or leased buildings and manufacturing
facilities have not been recorded because these retirement
obligations have an indeterminate settlement date, and
accordingly, the retirement obligation cannot be reasonably
estimated. The ongoing annual incremental expense resulting from
the adoption of SFAS No. 143 is not significant. At
December 31, 2004, the change in the fair value of the
liability for asset retirements compared to the original value
of the liability recorded at the date of adoption of
SFAS No. 143 was not significant.
Goodwill
Goodwill represents the excess of the purchase price of acquired
businesses over the fair value of the respective net assets.
The Company accounts for goodwill in accordance with Statement
of Financial Accounting Standards No. 142, Goodwill
and Other Intangible Assets (SFAS 142),
which requires that goodwill no longer be amortized, but instead
be tested for impairment at least annually in accordance with
the provisions of SFAS 142. The Company tests goodwill for
impairment as of January 1 of each year and when an event occurs
or circumstances change that would more likely than not reduce
the fair value of a reporting unit below its carrying amount. An
impairment charge is recognized for the amount, if any, by which
the carrying amount of goodwill exceeds its fair value. Fair
values are established using discounted cash flows. When
available and as appropriate, comparative market multiples are
used to corroborate discounted cash flow results.
Other Intangibles
Other intangibles consist primarily of trademarks, developed
technology, toxicology database, non-compete agreements and
customer relationships.
54
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
In accordance with SFAS 142, intangible assets with
indefinite useful lives are not amortized. Intangible assets
with definite useful lives are amortized over their respective
estimated useful lives to their estimated residual values in
proportion to the economic benefits consumed, principally over 2
to 29 years and generally on a straight-line basis.
Intangible assets with an indefinite life are reviewed at least
annually for impairment in accordance with SFAS 142.
Securitizations and Transfers of Financial Instruments
The Company may sell trade accounts or notes receivables with or
without recourse in the normal course of business. In accordance
with Statement of Financial Accounting Standards No. 140,
Accounting for Transfers and Servicing of Financial Assets
and Extinguishments of Liabilities
(SFAS 140), the Companys sale of
receivables associated with its accounts receivable
securitization program is removed from the Consolidated Balance
Sheets at the time of sale. Sales and transfers that do not meet
the criteria for surrender of control would be accounted for as
secured borrowings. The value assigned to the undivided interest
retained in securitized trade receivables is the allocated
carrying amount based on the relative fair values of the
interests retained and sold in the securitization, and is
classified as a Short-Term Investment on the accompanying
Consolidated Balance Sheets.
Long-Lived Assets
The impairment of tangible assets other than goodwill and
intangible assets with definite lives is assessed when changes
in circumstances indicate that their current carrying value may
not be recoverable. Under SFAS 144, a determination of
impairment, if any, is made based on the undiscounted value of
estimated future cash flows, salvage value or expected net sales
proceeds, depending on the circumstances. Asset impairment
losses are measured as the excess of the carrying value over the
estimated fair value of such assets.
Environmental Liabilities and Expenditures
Accruals for environmental matters are recorded when it is
probable that a liability has been incurred and the amount of
the liability can be reasonably estimated, based upon current
law and existing technologies. These amounts, which are not
discounted and are exclusive of claims against third parties,
are adjusted periodically as assessment and remediation efforts
progress or additional technical or legal information becomes
available. Environmental remediation costs are charged to
reserves. Environmental costs are capitalized if the costs
increase the value of the property and/or mitigate or prevent
contamination from future operations.
Financial Instruments
The carrying values of cash and cash equivalents, accounts
receivable, accounts payable and short-term borrowings
approximated fair values due to the short-term maturities of
these instruments. The fair value of the Companys
borrowings under its credit facility approximate book value due
to their floating rate interest rate terms. The fair value of
the Companys senior notes is estimated based on year-end
prevailing market interest rates for similar debt instruments.
The fair value of the Companys interest rate swaps is
based upon prevailing market values for similar instruments. The
fair values of currency forward and option contracts, if any,
are estimated based on quoted market prices for contracts with
similar terms.
Derivative Instruments
The Company accounts for derivative instruments in accordance
with SFAS No. 133 (SFAS 133),
Accounting for Derivative Instruments and Hedging
Activities, as amended by SFAS No. 137,
SFAS No. 138 and SFAS No. 149, which
establishes accounting and reporting standards for derivative
instruments, including certain derivative instruments embedded
in other contracts, and hedging activities.
55
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
In accordance with SFAS 133, derivative instruments are
recognized as assets or liabilities in the Companys
Consolidated Balance Sheets and are measured at fair value. The
change in the fair value of a derivative designated as a fair
value hedge and the change in the fair value of the hedged item
attributable to the hedged risk are recognized in earnings. For
derivatives, which qualify for designation as cash flow hedges,
the effective portion of the changes in fair value is recognized
as part of other comprehensive income until the underlying
transaction that is being hedged is recognized in earnings. The
ineffective portion of the change in fair value of cash flow
hedges is recognized in earnings currently. Changes in fair
value for other derivatives which do not qualify as hedges for
accounting purposes are recognized in current period earnings.
Revenue Recognition
Substantially all of the Companys revenues are derived
from the sale of products. Revenue is recognized when risk of
loss of, and title to, the product is transferred to the
customer, which usually occurs at the time shipment is made. The
majority of the Companys products are sold FOB (free
on board) shipping point or on an equivalent basis. There
are certain limited situations where the risk of loss and
transfer of title passes upon delivery to the customer. In those
circumstances, sales are recognized upon receipt by the
customer. Allowances for estimated returns, discounts and
retailer promotions and incentives are recognized when sales are
recorded and are based on various market data, historical trends
and information from customers. Actual returns, discounts and
retail promotions and incentives have not been materially
different from estimates. Certain of the Companys product
lines have extended payment terms due to the seasonal nature of
the business. There are no conditions of acceptance, warranties
and price protection that prohibit revenue recognition when risk
of loss of, and title to, the product is transferred to the
customer.
Shipping and Handling Costs
Shipping and handling fees billed to customers are included in
Sales and shipping and handling costs are included in Cost of
Goods Sold in the accompanying Consolidated Statements of Income.
U.S. Government Contracts
The Company has supply and storage contracts with the U.S.
Defense Energy Support Center and the Department of Defense
which principally consist of a fixed-price facility management
fee for which revenue is recognized ratably over the contract
period and the sale of product whereby the Company supplies
product at a fixed price per pound, adjusted annually for
agreed-upon cost escalations. Revenue is recognized for the
Governments product purchases when risk of loss of, and
title to, the product is transferred to the Government. (See
Note 21 for more information.)
Foreign Currency Translation
Foreign affiliates generally use their local currency as their
functional currency. Accordingly, foreign affiliate balance
sheet amounts are translated at the exchange rates in effect at
year-end, and income statement and cash flow amounts are
translated at the average rates of exchange prevailing during
the year. Translation adjustments are included in the Other
Accumulated Comprehensive Loss component of shareholders
equity. Where foreign affiliates operate in highly inflationary
economies, non-monetary amounts are translated to
U.S. dollars at historical exchange rates while monetary
assets and liabilities are translated to U.S. dollars at
the current rate with the related adjustments reflected in the
Consolidated Statements of Income.
Stock Options
The Company accounts for stock-based compensation under
SFAS No. 123, Accounting for Stock-Based
Compensation (SFAS 123). As allowed under
SFAS 123, the Company has chosen to account for
56
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
stock-based compensation cost using the intrinsic value method,
in accordance with APB No. 25, Accounting for Stock
Issued to Employees and related interpretations. Pro forma
information regarding net income and earnings per share, as
calculated under the provisions of SFAS 123, is disclosed
in Note 16. In December 2002, the Company adopted the
disclosure provisions of SFAS No. 148,
Accounting for Stock-Based Compensation
Transition and Disclosure (see Note 16).
In December 2004, the FASB issued revised
SFAS No. 123, Share-Based Payment which
replaces SFAS No. 123, Accounting for
Stock-Based Compensation and supersedes APB Opinion
No. 25, Accounting for Stock Issued to
Employees. This statement, which requires the cost of all
share-based payment transactions be recognized in the financial
statements, establishes fair value as the measurement objective
and requires entities to apply a fair-value-based measurement
method in accounting for share-based payment transactions. The
statement applies to all awards granted, modified, repurchased
or cancelled after July 1, 2005, and unvested portions of
previously issued and outstanding awards. The Company has no
unvested portions of previously issued or outstanding awards and
the Company currently does not intend to issue any stock awards
to employees. Therefore, the Company does not believe that this
standard will have any impact on its consolidated financial
statements.
Income Taxes
The Company provides for deferred taxes on temporary differences
between the financial statement and tax bases of assets using
the enacted tax rates, which are expected to apply to taxable
income when the temporary differences are expected to reverse.
Earnings Per Common Share
All earnings per share computations and presentations are in
accordance with SFAS No. 128, Earnings Per
Share. Basic earnings per common share are computed by
dividing net income available to common shareholders by the
weighted-average number of common shares outstanding during the
period. Diluted earnings per common share are calculated in a
similar manner except that the weighted-average number of common
shares outstanding during the period includes the potential
dilution that could occur if stock options or other contracts to
issue common stock were exercised.
The reconciliation between basic and diluted shares outstanding
for the years ended December 31, 2004, 2003 and 2002 are as
follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended | |
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
(In millions) | |
Basic
|
|
|
23.2 |
|
|
|
22.6 |
|
|
|
22.5 |
|
Common equivalent shares from stock options using the treasury
stock method
|
|
|
0.3 |
|
|
|
|
|
|
|
0.1 |
|
|
|
|
|
|
|
|
|
|
|
Diluted
|
|
|
23.5 |
|
|
|
22.6 |
|
|
|
22.6 |
|
|
|
|
|
|
|
|
|
|
|
Stock options of approximately 1.0 million,
1.4 million and 1.3 million with exercise prices
greater than the average market price of the Companys
common stock are not included in the computation of diluted
earnings per share for the years ended December 31, 2004,
2003 and 2002, respectively.
In 2004, the Company established a Rabbi Trust for several
deferred compensation plans (see Note 15 for more
information). The Companys stock held in the Rabbi Trust
is treated in a manner similar to treasury stock and the shares
are excluded from the basic shares outstanding calculation and
added back for dilutive
57
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
shares outstanding. At December 31, 2004, the trust had
purchased approximately 0.1 million shares on the open
market.
Comprehensive Income (Loss)
The Companys other comprehensive income (loss) consists of
the changes in the cumulative foreign currency translation gains
and losses, the change in the fair value of derivative financial
instruments which qualify for hedge accounting, net of tax and
the minimum pension liability adjustment, net of tax. The
Company does not provide for U.S. income taxes on foreign
currency translation adjustments since it does not provide for
such taxes on undistributed earnings of foreign subsidiaries.
Employee Benefit Plans
Pension and postretirement health care and life insurance
benefits earned during the year as well as interest on projected
benefit obligations are accrued currently. Prior service costs
and credits resulting from changes in plan benefits are
amortized over the average remaining service period of employees
expected to receive benefits. Curtailment gains and losses are
recognized as incurred. Settlement gains and losses are
recognized when significant pension obligations are settled and
the gain or loss is determinable. The Companys policy is
to fund, at a minimum, amounts as are necessary to provide
assets sufficient to meet the benefits to be paid to plan
members in accordance with the relevant regulatory requirements
governing such plans.
Business and Credit Concentrations
A significant portion of sales of the treatment products segment
(approximately 17%) is dependent upon two customers, one of
which accounts for a significant portion of the sales of the HTH
water products business and the other of which accounts for a
significant portion of the sales of the personal care and
industrial biocides businesses. Sales to these two customers are
individually less than 10% of the Companys 2004
consolidated sales. However, the loss of either of these
customers could have a material adverse effect on the sales and
operating results of the respective segment and businesses if
such customer were not replaced.
Sales of the HTH water products segment are seasonal in nature
as its products are primarily used in the U.S. residential
pool market. Historically, approximately 40%-50% of the sales in
the HTH water products business occur in the second quarter of
the fiscal year, as retail sales in the U.S. residential
pool market are concentrated between Memorial Day and the Fourth
of July. Therefore, interim results for this segment are not
necessarily indicative of the results to be expected for the
entire fiscal year.
|
|
2. |
Accounts Receivable/ Short-Term Investment |
Accounts receivable at December 31, 2004 and 2003 include
the following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Accounts receivable, trade
|
|
$ |
110.6 |
|
|
$ |
83.7 |
|
Accounts receivable, other
|
|
|
20.0 |
|
|
|
19.8 |
|
|
|
|
|
|
|
|
|
|
|
130.6 |
|
|
|
103.5 |
|
Less allowance for doubtful accounts
|
|
|
(5.0 |
) |
|
|
(3.2 |
) |
|
|
|
|
|
|
|
Accounts receivable, net
|
|
$ |
125.6 |
|
|
$ |
100.3 |
|
|
|
|
|
|
|
|
58
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Included in other accounts receivable at December 31, 2003
are an insurance receivable for storm damage of
$3.3 million, which was received in 2004. In addition,
accounts receivable other includes a receivable for a
post-closing working capital adjustment related to the sale of
the Hickson organics business of $4.3 million. In November
2004, the Company received approximately $2.1 million
related to this receivable. As a result of significant
uncertainty of the collectibility of the balance in 2004, the
Company provided a reserve for the remaining balance.
Changes in the allowance for doubtful accounts for the years
ended December 31, 2004, 2003 and 2002 are as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended | |
|
Year Ended | |
|
Year Ended | |
|
|
December 31, | |
|
December 31, | |
|
December 31, | |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Beginning balance
|
|
$ |
(3.2 |
) |
|
$ |
(2.8 |
) |
|
$ |
(5.8 |
) |
Provision for doubtful accounts
|
|
|
(2.1 |
) |
|
|
(3.5 |
) |
|
|
(3.1 |
) |
Bad debt write-offs, net of recoveries
|
|
|
1.7 |
|
|
|
3.8 |
|
|
|
2.7 |
|
Foreign exchange and other
|
|
|
(0.2 |
) |
|
|
(0.5 |
) |
|
|
(0.3 |
) |
Reclassification to short-term investment
|
|
|
(1.2 |
) |
|
|
(0.2 |
) |
|
|
3.7 |
|
|
|
|
|
|
|
|
|
|
|
Ending balance
|
|
$ |
(5.0 |
) |
|
$ |
(3.2 |
) |
|
$ |
(2.8 |
) |
|
|
|
|
|
|
|
|
|
|
In March 2002, the Company completed arrangements to sell,
without recourse, certain accounts receivable through its
wholly-owned subsidiary, Arch Chemicals Receivables Corp., a
special-purpose corporation. Arch Chemicals Receivables Corp.
entered into a trade accounts receivable securitization
agreement with an independent financial institution whereby it
can sell, on an ongoing basis, participation interests in
accounts receivable for a maximum purchase price of up to
$80.0 million. Such agreement is renewable annually. The
Company has agreed to provide servicing for accounts receivable
collections. The proceeds from the sale of participation
interests under this arrangement are subject to change based on
the level of eligible receivables. The accounts receivable sold
have been reflected as a sale of accounts receivable in
accordance with SFAS 140.
As of December 31, 2004 and 2003, the Company had not sold
any participation interests in such accounts receivables. The
fair value of the retained undivided interest of
$53.3 million and $43.3 million at December 31,
2004 and 2003, respectively, is classified as a held-to-maturity
debt security and is reflected as Short-Term Investment on the
accompanying Consolidated Balance Sheets. During the year,
proceeds from the sales are used to reduce borrowings. The costs
of the program, including certain one-time fees, for the years
ended December 31, 2004, 2003 and 2002 of
$1.1 million, $0.8 million and $1.6 million,
respectively, are included in Selling and Administration
expenses in the accompanying Consolidated Statements of Income.
The costs of the accounts receivable securitization program are
a percentage of the fair market value of the participation
interests sold. The percentage is variable and was approximately
equivalent to the one-month LIBOR rate plus 0.45% (1.9%, 1.7%
and 2.2% in 2004, 2003 and 2002, respectively). Fair value of
the retained undivided interest includes a reserve for credit
losses ($2.3 million and $3.5 million at
December 31, 2004 and 2003, respectively) and has not been
discounted due to the short-term nature of the underlying
financial assets. The Company has not recorded an asset or
liability related to the servicing responsibility retained as
the fees earned for servicing are estimated to approximate fair
value.
59
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Inventories at December 31, 2004 and 2003 include the
following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Raw materials and supplies
|
|
$ |
45.4 |
|
|
$ |
35.6 |
|
Work-in-progress
|
|
|
8.1 |
|
|
|
7.9 |
|
Finished goods
|
|
|
142.0 |
|
|
|
106.7 |
|
|
|
|
|
|
|
|
Inventories, gross
|
|
|
195.5 |
|
|
|
150.2 |
|
LIFO reserves
|
|
|
(44.4 |
) |
|
|
(39.3 |
) |
|
|
|
|
|
|
|
Inventories, net
|
|
$ |
151.1 |
|
|
$ |
110.9 |
|
|
|
|
|
|
|
|
Inventory valued using the LIFO method comprised approximately
45% of the total inventory at December 31, 2004 and 2003.
Gross inventory values approximate replacement cost.
Other current assets at December 31, 2004 and 2003 include
the following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Deferred income taxes
|
|
$ |
28.0 |
|
|
$ |
19.1 |
|
Other
|
|
|
9.9 |
|
|
|
7.6 |
|
|
|
|
|
|
|
|
Other current assets
|
|
$ |
37.9 |
|
|
$ |
26.7 |
|
|
|
|
|
|
|
|
|
|
5. |
Assets Held for Sale/Discontinued Operations |
Microelectronic Materials Business
On November 30, 2004, the Company completed the sale of the
majority of the operations of its microelectronic materials
business to Fuji Photo Film Co., Ltd. (Fuji) for
$160.5 million inclusive of a working capital adjustment of
$1.1 million. The estimated proceeds from the divestiture
were principally used to pay down debt. The after-tax loss on
the sale is reflected in Gain (Loss) on Sales of Discontinued
Operations, as follows:
|
|
|
|
|
|
|
|
|
($ in millions) | |
Cash Proceeds
|
|
$ |
161.6 |
|
Working Capital Payment
|
|
|
(1.1 |
) |
|
|
|
|
Adjusted Cash Proceeds
|
|
|
160.5 |
|
Net Assets Sold
|
|
|
149.4 |
|
Transaction Costs Incurred
|
|
|
7.5 |
|
|
|
|
|
|
|
Subtotal
|
|
|
3.6 |
|
Foreign Exchange Realized
|
|
|
(3.0 |
) |
|
|
|
|
Pre-tax Gain
|
|
|
0.6 |
|
Tax Expense
|
|
|
2.2 |
|
|
|
|
|
|
Net Loss
|
|
$ |
(1.6 |
) |
|
|
|
|
60
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Included in the net assets sold is $26.8 million of
goodwill related to the microelectronic materials businesses.
The transaction costs include $0.9 million related to
curtailment losses for the pension and postretirement plans that
occurred as a result of the sale of majority of the
microelectronic materials businesses. All employees were vested
at the date of the sale.
The transaction includes the Companys microelectronics
manufacturing facilities and research and development facilities
located in North America, Europe and Asia, and its
49 percent ownership of FUJIFILM Arch Co., Ltd., the
Companys joint venture with Fuji Photo Film Co., Ltd. in
Japan. These facilities manufacture and supply a wide range of
products, which includes photoresists, formulated products,
polyimides and thin film systems to semiconductor manufacturers
and to flat panel display manufacturers throughout the world.
The Company retained its 50 percent interest in Planar
Solutions, LLC, the Companys joint venture with Wacker
Chemical Corporation for the production and sale of CMP
slurries, the microelectronics-dedicated manufacturing facility
in Brandenburg, Kentucky and CMS. The Company will pursue all
strategic options for its CMS business, including its sale. The
Company will continue to supply certain products for a
transition period to the purchaser of the microelectronic
materials businesses from its Brandenburg, Kentucky facility.
The results of its CMP joint venture has been included in
Corporate Expenses (Unallocated).
The CMS business, which essentially services the customers of
the businesses sold, no longer has any connections to any of the
Companys other businesses; therefore the Company began an
active program to dispose of the business. As a result and in
accordance with the accounting requirements of SFAS 144,
the CMS business is reported as an asset held for sale and the
results of operations are included in discontinued operations in
the consolidated financial statements. The amounts actually
realized (including future operating results) by the Company
could differ materially from the amounts estimated in the
financial statements. Factors that could influence the ultimate
outcome include, but are not limited to, general economic
conditions, the Companys ability to dispose of the
business within the time, price and manner originally estimated
and the retention of key customers during the divestiture period.
The fully-dedicated manufacturing assets that the Company
continues to own of the microelectronic materials business
located in Brandenburg, Kentucky will be utilized by the Company
solely to supply certain raw materials to Fuji for a transition
period of up to two years. Based upon the Companys current
operations, these assets will have limited use, if any, after
such transition period. As a result, the Company was required to
review these long-lived assets for recoverability. Based upon an
undiscounted cash-flow analysis, including an estimate of
salvage value, these assets were determined to be impaired (not
recoverable) as the carrying value of the assets was greater
than the expected cash flows. Therefore, during the fourth
quarter of 2004, the Company recorded an impairment charge of
$2.9 million to write-down such assets to fair value. Fair
value was determined based upon estimated discounted cash flows
directly related to the assets, including an estimate of salvage
value.
In accordance with the SFAS 144, the Company has restated
its prior year results to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations.
Hickson Organics Division
On August 11, 2003, the Company completed the sale of the
Hickson organics operations in Castleford, England. Total
proceeds from the sale were £12.5 million
($20.1 million), subject to a post-closing working capital
adjustment. Proceeds consist of cash of £11.0 million
($17.7 million) and two notes for £1.5 million
($2.4 million), of which one note for
£1.0 million ($1.6 million) is contingent on
future operating results from January 1, 2003 through
December 31, 2005. The Company has placed a valuation
reserve against the note of
61
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
£1.0 million ($1.6 million). As a result of the
sale, the Company recorded an after-tax loss of
$2.0 million, which includes $3.9 million of deferred
gains related to foreign currency translation adjustments that
were realized at the time of the sale. Included in the loss on
the sale is a curtailment loss of $0.5 million, after tax,
related to the pension plan of the former Hickson employees due
to the sale of the business.
On October 26, 2004, the Company received a final
determination of the working capital adjustment from an
independent third party appointed by the Company and the
purchaser. The independent third party ruled in favor of the
Company in an amount of $2.8 million related to the
disputed amount of $3.4 million. As a result, the
difference of $0.6 million was recorded as a component of
loss from the sale of discontinued operations during the third
quarter, along with $0.3 million of legal fees associated
with the arbitration. On November 3, 2004, the Company
received approximately $2.1 million of the post-closing
working capital adjustment. During the fourth quarter of 2004,
there was significant uncertainty concerning the viability of
the purchaser, and as a result, the Company provided a reserve
for the remaining portion of the working capital payment and the
outstanding note. In addition, the Company recorded a charge of
$4.0 million related to probable future commitments as a
result of the significant uncertainty concerning the viability
of the purchaser.
In March 2002, the Company completed the sale of its DanChem
operations in Danville, Virginia, which was part of the Hickson
organics division, for approximately $25 million and
recorded a loss on the disposal of $1.5 million, net of a
tax benefit of $0.9 million. Proceeds from the sale of
these assets were used to pay down debt.
Sulfuric Acid Business
On July 2, 2003, the Company completed the sale of
substantially all of the net assets of its sulfuric acid
business to Peak Sulfur, Inc. Net proceeds from the sale were
$47.6 million, after a post-closing working capital
payment. The gain on the sale of $16.5 million, net of
taxes of $10.5 million, is reflected in Gain (Loss) on
Sales of Discontinued Operations.
In accordance with SFAS 144, the Company has restated its
prior year results to include the results of the sulfuric acid
business as an asset held for sale and a component of
discontinued operations.
62
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Balance Sheet
Assets held for sale at December 31, 2004 and 2003 relate
to the microelectronic materials business and the major classes
of assets and liabilities classified as assets held for sale of
the microelectronic materials business at December 31, 2004
and 2003 are as follows:
|
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Accounts receivable, net
|
|
$ |
9.5 |
|
|
$ |
24.6 |
|
Inventory
|
|
|
5.5 |
|
|
|
30.7 |
|
Other current assets
|
|
|
0.2 |
|
|
|
1.2 |
|
Investments and advances affiliated companies at
equity
|
|
|
|
|
|
|
22.2 |
|
Property, plant and equipment, net
|
|
|
0.6 |
|
|
|
73.5 |
|
Goodwill and intangibles
|
|
|
|
|
|
|
27.4 |
|
Other assets
|
|
|
0.1 |
|
|
|
0.3 |
|
|
|
|
|
|
|
|
|
Total assets associated with assets held for sale
|
|
|
15.9 |
|
|
|
179.9 |
|
Accounts payable and accrued liabilities
|
|
|
12.2 |
|
|
|
26.5 |
|
|
|
|
|
|
|
|
|
Total liabilities associated with assets held for sale
|
|
|
12.2 |
|
|
|
26.5 |
|
|
|
|
|
|
|
|
Net assets held for sale
|
|
$ |
3.7 |
|
|
$ |
153.4 |
|
|
|
|
|
|
|
|
63
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Income (Loss) From Discontinued Operations
Income (Loss) from Discontinued Operations until the date of the
applicable sale for the year ended December 31, 2004, 2003
and 2002 include the following:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Year Ended | |
|
Year Ended | |
|
Year Ended | |
|
|
December 31, | |
|
December 31, | |
|
December 31, | |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Sales microelectronic materials business
|
|
$ |
147.9 |
|
|
$ |
145.6 |
|
|
$ |
142.6 |
|
Sales Hickson organics Castleford business
|
|
|
|
|
|
|
33.8 |
|
|
|
59.0 |
|
Sales DanChem business
|
|
|
|
|
|
|
|
|
|
|
2.9 |
|
Sales sulfuric acid business
|
|
|
|
|
|
|
17.5 |
|
|
|
33.8 |
|
|
|
|
|
|
|
|
|
|
|
|
Total sales of discontinued operations
|
|
$ |
147.9 |
|
|
$ |
196.9 |
|
|
$ |
238.3 |
|
|
|
|
|
|
|
|
|
|
|
Earnings before interest, taxes and restructuring
microelectronic materials business
|
|
$ |
12.7 |
|
|
$ |
6.0 |
|
|
$ |
1.8 |
|
Earnings before interest, taxes, restructuring and
impairment Hickson organics Castleford business
|
|
|
|
|
|
|
1.5 |
|
|
|
0.1 |
|
Earnings before interest and taxes DanChem business
|
|
|
|
|
|
|
|
|
|
|
0.1 |
|
Earnings before interest and taxes sulfuric acid
business
|
|
|
|
|
|
|
1.7 |
|
|
|
2.3 |
|
Impairment charge Hickson organics Castleford
business
|
|
|
|
|
|
|
(4.0 |
) |
|
|
|
|
Restructuring income (expense) microelectronic
materials business
|
|
|
|
|
|
|
1.0 |
|
|
|
(1.9 |
) |
Restructuring income (expense) Hickson organics
Castleford business
|
|
|
|
|
|
|
0.1 |
|
|
|
(1.9 |
) |
Interest expense allocated Hickson organics
Castleford business
|
|
|
|
|
|
|
(0.8 |
) |
|
|
(1.8 |
) |
Interest expense allocated DanChem business
|
|
|
|
|
|
|
|
|
|
|
(0.2 |
) |
Tax expense
|
|
|
(2.7 |
) |
|
|
(2.3 |
) |
|
|
(0.4 |
) |
|
|
|
|
|
|
|
|
|
|
|
Income (loss) from discontinued operations
|
|
$ |
10.0 |
|
|
$ |
3.2 |
|
|
$ |
(1.9 |
) |
|
|
|
|
|
|
|
|
|
|
Operating results for the Hickson organics Castleford operations
for the year ended December 31, 2002 include a
$1.9 million restructuring charge, which related to
headcount reductions of approximately 40 employees.
|
|
6. |
Investments and Advances Affiliated Companies at
Equity |
The Companys investments and advances to affiliated
companies at December 31, 2004 include its
50% investment in Nordesclor S.A., its 49% investment in
Koppers Arch (Koppers) and its 50% investment in
Planar Solutions LLC (Planar). Nordesclor produces
and packages calcium hypochlorite, and is located in Brazil.
Koppers manufactures CCA-based and other wood preservatives, and
is located in Australia. Planar produces and markets chemical
mechanical planarization slurry products, and is located in the
United States of America.
64
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The amount of cumulative unremitted earnings of joint ventures
included in consolidated retained earnings at December 31,
2004 was $0.5 million. During the years ended
December 31, 2004, 2003 and 2002, distributions of
$5.6 million, $4.7 million and $2.9 million
respectively, were received from joint ventures.
Summarized unaudited financial information for Nordesclor and
Koppers joint ventures is as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nordesclor | |
|
Koppers | |
|
|
| |
|
| |
|
|
2004 | |
|
2003 | |
|
2004 | |
|
2003 | |
December 31, |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Financial Position:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Current assets
|
|
$ |
15.5 |
|
|
$ |
13.4 |
|
|
$ |
21.8 |
|
|
$ |
16.1 |
|
|
Current liabilities
|
|
|
2.4 |
|
|
|
1.9 |
|
|
|
11.8 |
|
|
|
6.8 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net working capital
|
|
|
13.1 |
|
|
|
11.5 |
|
|
|
10.0 |
|
|
|
9.3 |
|
|
Noncurrent assets
|
|
|
5.9 |
|
|
|
6.1 |
|
|
|
6.5 |
|
|
|
6.2 |
|
|
Noncurrent liabilities
|
|
|
0.1 |
|
|
|
0.1 |
|
|
|
7.2 |
|
|
|
3.0 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Equity
|
|
$ |
18.9 |
|
|
$ |
17.5 |
|
|
$ |
9.3 |
|
|
$ |
12.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Nordesclor | |
|
Koppers | |
|
|
| |
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
2004 | |
|
2003 | |
|
2002 | |
For the Year Ended December 31: |
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Results of Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sales
|
|
$ |
24.6 |
|
|
$ |
22.6 |
|
|
$ |
20.2 |
|
|
$ |
50.8 |
|
|
$ |
42.2 |
|
|
$ |
31.1 |
|
|
Income from operations before tax
|
|
|
5.5 |
|
|
|
6.8 |
|
|
|
5.5 |
|
|
|
5.3 |
|
|
|
5.0 |
|
|
|
2.8 |
|
|
Net income
|
|
|
4.6 |
|
|
|
5.7 |
|
|
|
5.2 |
|
|
|
3.3 |
|
|
|
3.5 |
|
|
|
1.8 |
|
|
|
7. |
Property, Plant and Equipment |
Property, plant and equipment at December 31, 2004 and 2003
include the following:
|
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Land and improvements to land
|
|
$ |
27.1 |
|
|
$ |
26.1 |
|
Buildings and building equipment
|
|
|
97.9 |
|
|
|
94.2 |
|
Machinery and equipment
|
|
|
616.5 |
|
|
|
580.8 |
|
Leasehold improvements
|
|
|
8.0 |
|
|
|
7.4 |
|
Construction-in-progress
|
|
|
8.5 |
|
|
|
12.5 |
|
|
|
|
|
|
|
|
|
Property, plant and equipment
|
|
|
758.0 |
|
|
|
721.0 |
|
Less accumulated depreciation
|
|
|
(546.4 |
) |
|
|
(513.1 |
) |
|
|
|
|
|
|
|
|
Property, plant and equipment, net
|
|
$ |
211.6 |
|
|
$ |
207.9 |
|
|
|
|
|
|
|
|
Leased assets capitalized and included in the previous table are
not significant. Maintenance and repairs charged to operations
amounted to $22.1 million, $20.6 million and
$22.2 million in 2004, 2003 and 2002, respectively.
65
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
|
|
8. |
Goodwill and Other Intangibles |
Goodwill
The changes in the carrying amount of goodwill for the years
ended December 31, 2004 and 2003 are as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Wood | |
|
|
|
|
|
|
|
|
|
|
Personal | |
|
Protection | |
|
|
|
|
|
|
|
|
HTH | |
|
Care and | |
|
and | |
|
|
|
|
|
|
|
|
Water | |
|
Industrial | |
|
Industrial | |
|
Total | |
|
Performance | |
|
|
|
|
Products | |
|
Biocides | |
|
Coatings | |
|
Treatment | |
|
Urethanes | |
|
Total | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Balance, December 31, 2002
|
|
$ |
2.2 |
|
|
$ |
30.3 |
|
|
$ |
72.2 |
|
|
$ |
104.7 |
|
|
$ |
4.4 |
|
|
$ |
109.1 |
|
Foreign exchange & other
|
|
|
0.2 |
|
|
|
|
|
|
|
1.1 |
|
|
|
1.3 |
|
|
|
|
|
|
|
1.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2003
|
|
|
2.4 |
|
|
|
30.3 |
|
|
|
73.3 |
|
|
|
106.0 |
|
|
|
4.4 |
|
|
|
110.4 |
|
Acquisitions
|
|
|
24.0 |
|
|
|
53.5 |
|
|
|
|
|
|
|
77.5 |
|
|
|
|
|
|
|
77.5 |
|
Post acquisition adjustment
|
|
|
2.5 |
|
|
|
2.3 |
|
|
|
(2.7 |
) |
|
|
2.1 |
|
|
|
|
|
|
|
2.1 |
|
Foreign exchange & other
|
|
|
0.1 |
|
|
|
2.0 |
|
|
|
0.3 |
|
|
|
2.4 |
|
|
|
|
|
|
|
2.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2004
|
|
$ |
29.0 |
|
|
$ |
88.1 |
|
|
$ |
70.9 |
|
|
$ |
188.0 |
|
|
$ |
4.4 |
|
|
$ |
192.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The post acquisition adjustments for HTH water products and
personal care and industrial biocides businesses reflect the
interim contingent payments that are due to Avecia (see
Note 19 for more information).
Other Intangibles
The gross carrying amount and accumulated amortization for other
intangible assets as of December 31, 2004 and 2003 are as
follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
December 31, 2004 | |
|
December 31, 2003 | |
|
|
| |
|
| |
|
|
Gross | |
|
|
|
Net | |
|
Gross | |
|
|
|
Net | |
|
|
Carrying | |
|
Accumulated | |
|
Carrying | |
|
Carrying | |
|
Accumulated | |
|
Carrying | |
|
|
Amount | |
|
Amortization | |
|
Amount | |
|
Amount | |
|
Amortization | |
|
Amount | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Patents
|
|
$ |
0.2 |
|
|
$ |
0.2 |
|
|
$ |
|
|
|
$ |
0.2 |
|
|
$ |
0.2 |
|
|
$ |
|
|
Customer lists
|
|
|
70.8 |
|
|
|
7.7 |
|
|
|
63.1 |
|
|
|
23.8 |
|
|
|
3.9 |
|
|
|
19.9 |
|
Toxicology database
|
|
|
17.4 |
|
|
|
0.9 |
|
|
|
16.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Developed technology
|
|
|
14.7 |
|
|
|
0.2 |
|
|
|
14.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Other
|
|
|
10.5 |
|
|
|
3.7 |
|
|
|
6.8 |
|
|
|
12.1 |
|
|
|
2.5 |
|
|
|
9.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total amortizable other intangibles
|
|
|
113.6 |
|
|
|
12.7 |
|
|
|
100.9 |
|
|
|
36.1 |
|
|
|
6.6 |
|
|
|
29.5 |
|
Total non-amortizable other Intangibles Trademarks
|
|
|
50.7 |
|
|
|
0.4 |
|
|
|
50.3 |
|
|
|
31.5 |
|
|
|
0.4 |
|
|
|
31.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total other intangibles
|
|
$ |
164.3 |
|
|
$ |
13.1 |
|
|
$ |
151.2 |
|
|
$ |
67.6 |
|
|
$ |
7.0 |
|
|
$ |
60.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31, 2003, the Company had an intangible
asset of $2.1 related to the Companys minimum pension
liability adjustment. In addition, the Company recorded
$0.4 million of deferred financing fees in 2004 related to
the debt amendments (see Note 11) and $1.4 of deferred
financing fees related to the renewal of the Companys
three-year credit facility in 2003.
66
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The Company has obtained a final third party valuation for
intangible assets and is in the process of finalizing the
third-party valuation of tangible assets; thus, goodwill is
preliminary and subject to refinement (see Note 19).
Amortization
Amortization expense for the years ended December 31, 2004,
2003 and 2002 was $5.2 million, $1.9 million and
$2.0 million, respectively. Estimated amortization expense
is $7.3 million for the year ended December 31, 2005,
$8.3 million for each of the years ended December 31,
2006 through 2008, and $7.3 million for the year ended
December 31, 2009.
Included in other assets at December 31, 2004 and 2003 are
the following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Deferred taxes
|
|
$ |
57.8 |
|
|
$ |
44.2 |
|
Other
|
|
|
13.1 |
|
|
|
11.4 |
|
|
|
|
|
|
|
|
Other assets
|
|
$ |
70.9 |
|
|
$ |
55.6 |
|
|
|
|
|
|
|
|
Included in accrued liabilities at December 31, 2004 and
2003 are the following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Accrued compensation
|
|
$ |
25.8 |
|
|
$ |
18.9 |
|
Accrued litigation
|
|
|
13.1 |
|
|
|
11.6 |
|
Restructuring reserves
|
|
|
2.3 |
|
|
|
1.8 |
|
Environmental reserves
|
|
|
3.3 |
|
|
|
3.3 |
|
Other
|
|
|
63.6 |
|
|
|
44.6 |
|
|
|
|
|
|
|
|
Accrued liabilities
|
|
$ |
108.1 |
|
|
$ |
80.2 |
|
|
|
|
|
|
|
|
Included in short-term borrowings and long-term debt at
December 31, 2004 and 2003 are the following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Unsecured senior notes
|
|
$ |
213.6 |
|
|
$ |
216.2 |
|
Other borrowings
|
|
|
10.7 |
|
|
|
3.0 |
|
|
|
|
|
|
|
|
Total debt
|
|
|
224.3 |
|
|
|
219.2 |
|
Less: short-term borrowings
|
|
|
(9.1 |
) |
|
|
(0.7 |
) |
|
|
|
|
|
|
|
Long-term debt
|
|
$ |
215.2 |
|
|
$ |
218.5 |
|
|
|
|
|
|
|
|
67
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Senior Notes
In March 2002, the Company issued $211.0 million of
unsecured senior notes to certain institutional investors in two
series. The Series A notes of $149.0 million are due
in March 2007 and the Series B notes of $62.0 million
are due in March 2009 and bear fixed interest rates of 7.94% and
8.24%, respectively.
In May 2003, the Company terminated its interest rate swap
agreements that were entered into in April 2002. As a result,
the Company received cash proceeds of $7.1 million, which
represented the market value of the contracts on the date of
termination. The Company utilized the proceeds to pay down debt.
In accordance with SFAS 133, the basis adjustment of
$7.1 million has been recorded as an increase to the
carrying amount of the senior notes and is being amortized as a
reduction of interest expense over the remaining life of the
senior notes (through March 2007) using the effective-interest
yield method ($4.2 million and $6.0 million as of
December 31, 2004 and 2003, respectively).
Simultaneous with the termination of the interest rate swap
agreements, the Company entered into new interest rate swap
agreements, under which it swapped its 7.94% fixed interest rate
on $80.0 million principal amount of unsecured senior notes
for floating rate interest based upon six-month LIBOR plus
5.4539%. The counter parties to these agreements are major
financial institutions. The agreements expire in March 2007. The
Company has designated the swap agreements as fair value hedges
of the risk of changes in the value of fixed rate debt due to
changes in interest rates for a portion of its fixed rate
borrowings under SFAS 133. Accordingly, the swap agreements
have been recorded at their fair market value of
$1.6 million and are included in Other Liabilities on the
accompanying Consolidated Balance Sheets at December 31,
2004, with a corresponding decrease in the carrying amount of
the related debt. No gain or loss has been recorded as the
contracts meet the criteria of SFAS 133 to qualify for
hedge accounting treatment with no ineffectiveness.
In connection with the acquisition of Avecias
pool & spa and protection & hygiene
businesses, the Company amended its quarterly leverage ratio
(debt/ EBITDA) covenants and the debt to total capitalization
ratio requirement for its senior notes. The amendment was put in
place to take into account the fact that the acquisition would
occur during the Companys seasonal build of receivables
and inventory. The quarterly leverage ratio was amended to 4.00
as of the last day of the quarter ending June 30, 2004,
returning to 3.50 thereafter. The debt to total capitalization
ratio was amended to 65% beginning on April 2, 2004 to and
including June 30, 2004, 60% beginning on July 1, 2004
to and including September 30, 2004, returning to 55%
beginning on October 1, 2004. Such amendments became
effective on April 2, 2004, the date the Company completed
the acquisition of Avecias pool & spa and
protection & hygiene businesses. In addition, the notes
contain a fixed coverage ratio covenant of 2.25 and a covenant
that restricts the payment of dividends and repurchases of stock
to $65.0 million less cumulative dividends and repurchases
of stock plus 50% of cumulative net income (loss) subject to
certain adjustments beginning January 1, 2002
($37.6 million at December 31, 2004).
Credit Facility
In June 2003, the Company entered into a new unsecured
$210.0 million senior revolving credit facility
(credit facility), which expires in June 2006. In
connection with the acquisition of Avecias pool &
spa and protection & hygiene businesses, the Company
amended its quarterly leverage ratio (debt/ EBITDA) for its
revolving credit facility. The amendment was put in place to
take into account the fact that the acquisition would occur
during the Companys seasonal build of receivables and
inventory. The quarterly leverage ratio was amended to 4.25 for
the quarter ending March 31, 2004, 4.00 for the quarter
ending June 30, 2004, returning to 3.50 thereafter. Such
amendments became effective on April 2, 2004, the date the
Company completed the acquisition of Avecias
pool & spa and protection & hygiene
businesses. The credit facility also contains an interest
coverage ratio (EBITDA/ total interest expense) covenant not to
be less than 3.0. Additionally, the credit facility restricts
the payment of dividends and repurchase of stock to
$65.0 million plus 50% of cumulative net income (loss)
subject to certain limitations beginning June 20, 2003
($48.7 million at
68
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
December 31, 2004). As of December 31, 2004, facility
fees payable on the credit facility are 0.35%. The facility fees
can range from 0.2% to 0.4% depending on the Companys
quarterly leverage ratios. The Company may select various
floating rate borrowing options, including, but not limited to,
LIBOR plus a spread that can range from 0.55% to 1.35% depending
on the Companys quarterly leverage ratios. There were no
outstanding borrowings under the credit facility at
December 31, 2004.
Other Borrowings
Other borrowings at December 31, 2004 and 2003 have
interest rates ranging from 2% to 15%.
At December 31, 2004, the Company had $22.3 million of
outstanding letters of credit. In addition, the Company had a
$6.0 million letter of guarantee outstanding for borrowings
of its Planar Solutions joint venture. As of December 31,
2004, the Company has agreed to guarantee 50% or up to
$8.5 million of Planar Solutions line of credit,
which is provided by the Companys joint venture partner.
The guarantee expires in May 2005. The Company would be required
to perform under the above guarantee in the case of nonpayment
by Planar Solutions.
Fair Value of Long-term Debt
The fair value of the Companys long-term debt at
December 31, 2004 was approximately $231.9 million.
The fair value of the Companys short-term debt at
December 31, 2004 approximated the book value of
$9.1 million due to the floating interest rate terms and
the short maturity of the instruments.
Included in other non-current liabilities at December 31,
2004 and 2003 are the following:
|
|
|
|
|
|
|
|
|
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Pensions and other postretirement employee benefit obligations
|
|
$ |
194.4 |
|
|
$ |
163.7 |
|
Environmental reserves
|
|
|
5.0 |
|
|
|
5.3 |
|
Other
|
|
|
36.0 |
|
|
|
22.1 |
|
|
|
|
|
|
|
|
Other liabilities
|
|
$ |
235.4 |
|
|
$ |
191.1 |
|
|
|
|
|
|
|
|
Included in pensions and other postretirement employee benefit
obligations as of December 31, 2004 and 2003 are minimum
pension liability adjustments of $155.1 million and
$127.6 million, respectively.
|
|
13. |
Derivative Financial Instruments |
Foreign Currency
The Company uses foreign currency forward sale and purchase
contracts and currency options as a means of hedging exposure to
foreign currency risk. It is the Companys policy to hedge
up to 80% of its anticipated purchase and sales commitments
denominated or expected to be denominated in a foreign currency
(principally the euro, British pound, Canadian dollar and
Japanese yen). All of the currency derivatives expire within one
year. During 2004 and 2003, the majority of the Companys
foreign currency forward contracts qualified as effective cash
flow hedges under the criteria of SFAS 133. The accounting
for gains and losses associated with changes in the fair value
of the derivative and the effect on the consolidated financial
statements will depend on its hedge designation and whether the
hedge is highly effective in achieving offsetting changes in
fair value of cash flows of the asset or liability hedged.
69
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
During 2004 and 2003, the Company recorded net gains (losses) of
$(0.2) million and $0, respectively in Other Comprehensive
Income (Loss) related to the change in the fair market value of
the derivatives designated as effective cash flow hedges of
which, $0 and $0.3 million, respectively, were subsequently
reclassified into current earnings during the year. The Company
records expense in Selling and Administration expense related to
the change in the time value of the forward contracts, which has
been excluded from the assessment of hedge effectiveness.
At December 31, 2004 and 2003, the Company had no
outstanding option contracts to sell or buy foreign currencies.
At December 31, 2004, the Company had forward contracts to
sell foreign currencies with notional amounts of
$13.8 million. The fair value of these forward contracts is
included in Accrued Liabilities. At December 31, 2003, the
Company had no forward contracts to sell or buy foreign
currencies. The counterparties to the contracts are major
financial institutions. The risk of loss to the Company in the
event of nonperformance by a counterparty is not significant.
The Company does not use financial instruments for speculative
or trading purposes nor is the Company a party to leveraged
derivatives.
Foreign currency exchange gains (losses), net of taxes, were
$(0.2) million in 2004, $0.4 million in 2003 and
$(0.3) million in 2002.
Debt and Interest
In April 2002, the Company entered into interest rate swap
agreements under which the Company swapped the 7.94% fixed
interest rate on $80.0 million principal amount of
unsecured senior notes for floating rate interest based on
six-month LIBOR plus 3.045%. The counter parties to these
agreements were major financial institutions. The agreements
were to expire in March 2007. The Company had designated the
swap agreements as fair value hedges of the risk of changes in
the value of fixed rate debt due to changes in interest rates
for a portion of its fixed rate borrowings under SFAS 133.
In May 2003, the Company terminated these interest rate swap
agreements and received cash proceeds of $7.1 million. The
Company utilized the proceeds to pay down debt. In accordance
with SFAS 133, the basis adjustment of $7.1 million
has been recorded as an increase to the carrying amount of the
senior notes and is being amortized as a reduction of interest
expense over the remaining life of the senior notes (through
March 2007) using the effective-interest yield method
($4.2 million and $6.0 million as of December 31,
2004 and 2003, respectively).
Simultaneous with the termination of the interest rate swap
agreements, the Company entered into new interest rate swap
agreements, under which it swapped its 7.94% fixed interest rate
on $80.0 million principal amount of unsecured senior notes
for floating rate interest based upon six-month LIBOR plus
5.4539%. The counter parties to these agreements are major
financial institutions. The agreements expire in March 2007. The
Company has designated the swap agreements as fair value hedges
of the risk of changes in the value of fixed rate debt due to
changes in interest rates for a portion of its fixed rate
borrowings under SFAS 133. Accordingly, the swap agreements
have been recorded at their fair market value of
$1.6 million and $0.8 million as of December 31,
2004 and 2003, respectively, and are included in Other
Liabilities on the accompanying Consolidated Balance Sheets at
December 31, 2003, with a corresponding decrease in the
carrying amount of the related debt. No gain or loss has been
recorded as the contracts meet the criteria of SFAS 133 to
qualify for hedge accounting treatment with no ineffectiveness.
As of December 31, 2001, a portion of the Companys
outstanding short-term borrowings was denominated in British
pounds and had been designated since its inception as a hedge of
the British pound net investment in the Hickson organics
division. Foreign currency translation adjustments during the
year ended December 31, 2002 include $(0.7) million,
respectively, related to this debt instrument. In March 2002,
the portion of the Companys outstanding borrowings that
was denominated in British pounds and that had been designated
since its inception as a hedge of the British pound net
investment in the Hickson organics division was paid-off with
the expiration of the credit facility used to acquire Hickson.
The cumulative foreign currency
70
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
translation gain adjustments related to this debt instrument of
$1.0 million was recognized upon the sale of the Hickson
organics Castleford, England operation in 2003.
Components of Pretax Income from Continuing Operations
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Domestic
|
|
$ |
(12.8 |
) |
|
$ |
(9.0 |
) |
|
$ |
(11.1 |
) |
Foreign
|
|
|
37.1 |
|
|
|
24.6 |
|
|
|
20.2 |
|
|
|
|
|
|
|
|
|
|
|
Pretax income
|
|
$ |
24.3 |
|
|
$ |
15.6 |
|
|
$ |
9.1 |
|
|
|
|
|
|
|
|
|
|
|
Components of Income Tax Expense (Benefit)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Current:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Federal
|
|
$ |
(1.8 |
) |
|
$ |
(2.1 |
) |
|
$ |
(0.5 |
) |
|
State
|
|
|
2.0 |
|
|
|
0.7 |
|
|
|
|
|
|
Foreign
|
|
|
9.2 |
|
|
|
6.3 |
|
|
|
4.6 |
|
Deferred
|
|
|
(2.4 |
) |
|
|
0.6 |
|
|
|
(1.4 |
) |
|
|
|
|
|
|
|
|
|
|
Income tax expense
|
|
$ |
7.0 |
|
|
$ |
5.5 |
|
|
$ |
2.7 |
|
|
|
|
|
|
|
|
|
|
|
The following table accounts for the difference between the
actual tax provision and the amounts obtained by applying the
statutory U.S. federal income tax rate of 35% to the income
before taxes.
Effective Tax Rate Reconciliation
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
Income tax provision at U.S. federal income tax rate
|
|
|
35.0 |
% |
|
|
35.0 |
% |
|
|
35.0 |
% |
Foreign income tax
|
|
|
(4.3 |
) |
|
|
2.1 |
|
|
|
(0.6 |
) |
State income taxes, net
|
|
|
1.1 |
|
|
|
3.9 |
|
|
|
4.4 |
|
Equity in income of affiliates
|
|
|
(1.3 |
) |
|
|
(6.3 |
) |
|
|
(9.4 |
) |
Research and development credit
|
|
|
(2.0 |
) |
|
|
(2.2 |
) |
|
|
|
|
Other, net
|
|
|
0.3 |
|
|
|
2.8 |
|
|
|
0.3 |
|
|
|
|
|
|
|
|
|
|
|
Income tax provision
|
|
|
28.8 |
% |
|
|
35.3 |
% |
|
|
29.7 |
% |
|
|
|
|
|
|
|
|
|
|
71
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Components of Deferred Tax Assets and Liabilities
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended | |
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Deferred tax assets:
|
|
|
|
|
|
|
|
|
|
Postretirement benefits
|
|
$ |
18.5 |
|
|
$ |
15.7 |
|
|
Non-deductible reserves and accrued expenses
|
|
|
28.7 |
|
|
|
13.7 |
|
|
Net operating losses and tax credit carryforwards
|
|
|
23.7 |
|
|
|
16.9 |
|
|
Minimum pension liability
|
|
|
50.8 |
|
|
|
40.7 |
|
|
Other miscellaneous items
|
|
|
9.1 |
|
|
|
7.3 |
|
|
Valuation allowance
|
|
|
(10.2 |
) |
|
|
(10.1 |
) |
|
|
|
|
|
|
|
|
|
Total deferred tax assets
|
|
|
120.6 |
|
|
|
84.2 |
|
|
|
|
|
|
|
|
Deferred tax liabilities:
|
|
|
|
|
|
|
|
|
|
Property, plant and equipment
|
|
|
23.2 |
|
|
|
20.6 |
|
|
Other miscellaneous items
|
|
|
13.7 |
|
|
|
1.0 |
|
|
|
|
|
|
|
|
|
|
Total deferred tax liabilities
|
|
|
36.9 |
|
|
|
21.6 |
|
|
|
|
|
|
|
|
Net deferred tax asset
|
|
$ |
83.7 |
|
|
$ |
62.6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended | |
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Deferred tax asset current
|
|
$ |
28.0 |
|
|
$ |
19.1 |
|
Deferred tax asset non-current
|
|
|
57.8 |
|
|
|
44.2 |
|
Deferred tax liability non-current
|
|
|
(2.1 |
) |
|
|
(0.7 |
) |
|
|
|
|
|
|
|
Net deferred tax asset
|
|
$ |
83.7 |
|
|
$ |
62.6 |
|
|
|
|
|
|
|
|
In 2004, the Company reduced its valuation allowance
$2.7 million with a corresponding decrease to goodwill
related to a tax asset of an acquired business which became
realizable.
The valuation allowance of $10.2 million, relates to state
tax credits and net operating losses and certain tax assets of
foreign entities for which management believes are not likely to
be realized. Taxable income is expected to be sufficient to
recover the remaining net tax benefit within the period in which
these differences are expected to reverse, or expire and,
therefore, no other valuation allowance was established.
Management believes it is more likely than not that the results
of future operations will generate sufficient taxable income to
realize the net deferred tax assets.
The Company has federal net operating loss carryforwards of
approximately $22.5 million, which are available to offset
future taxable income through 2023. The company also has net tax
assets of $5.5 million related to state and foreign net
operating loss carryforwards. The Company has alternative
minimum tax credit carryforwards of approximately
$0.3 million, which are available to reduce regular income
taxes, if any, over an indefinite period. The Company has
research and development credit carryforwards of
$4.6 million which expire beginning in 2019.
The Company provides for deferred taxes on temporary differences
between the financial statement and tax bases of assets using
the enacted tax rates that are expected to apply to taxable
income when the
72
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
temporary differences are expected to reverse. At
December 31, 2004, the Companys share of the
cumulative undistributed earnings of foreign subsidiaries was
approximately $165 million. No provision has been made for
U.S. or additional foreign taxes on the undistributed
earnings of foreign subsidiaries since the Company intends to
continue to reinvest these earnings. Foreign tax credits would
be available to substantially reduce or eliminate any amount of
additional U.S. tax that might be payable on these foreign
earnings in the event of distributions or sale. The Company has
evaluated the repatriation provisions of the American Jobs
Creation Act of 2004 (the Act) and does not plan to repatriate
any earnings as a result of such legislation.
|
|
15. |
Employee Benefit Plans |
Pension Plans and Retirement Benefits
Effective February 8, 1999, the Company established the
Arch Pension Benefit Plan, a defined benefit pension plan
covering most U.S. employees. The Company also maintains
two nonqualified supplemental pension plans. These plans were
established to provide additional retirement benefits for
certain key employees. Prior to the Distribution, these
employees were participants in one of several Olin pension
benefit plans covering employees of other Olin businesses. The
Arch pension benefit plan provides benefits based on service
with Olin and with the Company. The Company is liable for the
payment of all pension plan benefits earned by Company employees
prior to and following the Distribution. Olin transferred assets
to the Companys pension plan. The amount of the assets
transferred was calculated in accordance with Section 4044
of the Employee Retirement Income Security Act of 1974, as
amended. The assets of the Arch plan consist primarily of
investments in commingled funds administered by independent
investment advisors. The Companys policy is to fund, at a
minimum, amounts as are necessary on an actuarial basis to
provide assets sufficient to meet the benefits to be paid to
plan members in accordance with the requirements of the Employee
Retirement Income Security Act of 1974.
Subsequent to the Distribution, the Company adopted a retiree
medical and death benefits plan that covers most domestic
employees. The Company is liable for the payment of all retiree
medical and death benefits earned by Company employees prior to
and following the Distribution who retire after the
Distribution. The Arch plan is an unfunded plan.
As part of the acquisition of Avecias
U.S. pool & spa and protection & hygiene
businesses, the Company assumed the liabilities and received
assets related to pension benefits for the employees that
transferred into the Arch Pension Benefit Plan.
73
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The following tables provide a reconciliation of the changes in
the plans projected benefit obligations, fair value of
plan assets and funded status of the Arch retirement plans.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Other | |
|
|
|
|
Postretirement | |
|
|
Pension Benefits | |
|
Benefits | |
|
|
| |
|
| |
|
|
2004 | |
|
2003 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Reconciliation of Projected Benefit Obligation:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Projected benefit obligation at beginning of year
|
|
$ |
205.4 |
|
|
$ |
178.7 |
|
|
$ |
12.9 |
|
|
$ |
11.9 |
|
Service cost (benefits earned during the period)
|
|
|
6.9 |
|
|
|
6.5 |
|
|
|
0.6 |
|
|
|
0.6 |
|
Interest cost on the projected benefit obligation
|
|
|
13.0 |
|
|
|
12.1 |
|
|
|
0.9 |
|
|
|
0.8 |
|
Plan amendments
|
|
|
(4.2 |
) |
|
|
|
|
|
|
|
|
|
|
(0.6 |
) |
Actuarial loss
|
|
|
13.5 |
|
|
|
14.0 |
|
|
|
2.7 |
|
|
|
1.6 |
|
Curtailment (gain)/loss
|
|
|
(1.6 |
) |
|
|
|
|
|
|
0.4 |
|
|
|
|
|
Business acquisition
|
|
|
6.2 |
|
|
|
|
|
|
|
1.4 |
|
|
|
|
|
Benefits paid
|
|
|
(6.8 |
) |
|
|
(5.9 |
) |
|
|
(1.8 |
) |
|
|
(1.4 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Projected benefit obligation at end of year
|
|
$ |
232.4 |
|
|
$ |
205.4 |
|
|
$ |
17.1 |
|
|
$ |
12.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Reconciliation of Fair Value of Plan Assets:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fair value of plan assets at beginning of year
|
|
$ |
114.0 |
|
|
$ |
101.7 |
|
|
$ |
|
|
|
$ |
|
|
Employer contributions
|
|
|
7.8 |
|
|
|
1.0 |
|
|
|
1.8 |
|
|
|
1.4 |
|
Benefits paid
|
|
|
(6.8 |
) |
|
|
(5.9 |
) |
|
|
(1.8 |
) |
|
|
(1.4 |
) |
Business acquisition
|
|
|
2.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
Actual return on plan assets (net of expenses)
|
|
|
9.5 |
|
|
|
17.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Fair value of plan assets at end of year
|
|
$ |
127.4 |
|
|
$ |
114.0 |
|
|
$ |
|
|
|
$ |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Funded Status
|
|
$ |
(105.0 |
) |
|
$ |
(91.4 |
) |
|
$ |
(17.1 |
) |
|
$ |
(12.9 |
) |
Unrecognized net actuarial (gain)/loss
|
|
|
71.1 |
|
|
|
59.9 |
|
|
|
5.0 |
|
|
|
2.5 |
|
Unamortized prior service cost
|
|
|
(2.1 |
) |
|
|
2.0 |
|
|
|
(0.4 |
) |
|
|
(0.5 |
) |
Unamortized transition obligation
|
|
|
0.1 |
|
|
|
0.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued benefit cost
|
|
$ |
(35.9 |
) |
|
$ |
(29.4 |
) |
|
$ |
(12.5 |
) |
|
$ |
(10.9 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Amounts Recognized in the Statement of Financial Position
Consist of:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total accrued benefit cost
|
|
$ |
(83.8 |
) |
|
$ |
(65.7 |
) |
|
|
|
|
|
|
|
|
Intangible Asset
|
|
|
|
|
|
|
2.1 |
|
|
|
|
|
|
|
|
|
Minimum pension liability adjustment
|
|
|
47.9 |
|
|
|
34.2 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Accrued benefit cost
|
|
$ |
(35.9 |
) |
|
$ |
(29.4 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The Companys qualified pension plan has an accumulated
benefit obligation in excess of plan assets as of
December 31, 2004 and 2003. The accumulated benefit
obligation of this plan was $196.6 million and
$169.4 million as of December 31, 2004 and 2003,
respectively. The projected benefit obligation relating to the
qualified plan was $215.5 million and $192.4 million,
as of December 31, 2004 and 2003, respectively. The
Companys nonqualified pension plans are unfunded. The
accumulated benefit obligation relating to these plans, included
in the tables above, was $14.6 million and
$10.3 million, as of December 31, 2004 and 2003,
74
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
respectively. The projected benefit obligation related to these
plans was $16.9 million and $13.0 million as of
December 31, 2004 and 2003, respectively.
The Plan amendments in 2004 represent an amendment to harmonize
pension benefits for the former-Avecia employees and an
amendment to eliminate Long Term Disability Payments from the
Pension Plan.
Required cash funding is expected to be $2.0 million lower
in 2005 and pension expense is expected to be approximately
$4.0 million higher in 2005.
Benefit costs presented below were determined based on actuarial
methods and include the following components:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension Benefits | |
|
Postretirement Benefits | |
|
|
| |
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Net Periodic Benefit Expense:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Service cost including expenses (benefits earned during the
period)
|
|
$ |
7.1 |
|
|
$ |
6.7 |
|
|
$ |
5.5 |
|
|
$ |
0.6 |
|
|
$ |
0.6 |
|
|
$ |
0.5 |
|
Interest cost on the projected benefit obligation
|
|
|
13.0 |
|
|
|
12.1 |
|
|
|
11.0 |
|
|
|
0.9 |
|
|
|
0.8 |
|
|
|
0.8 |
|
Expected return on plan assets
|
|
|
(11.5 |
) |
|
|
(11.9 |
) |
|
|
(12.5 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
Amortization of prior service cost
|
|
|
0.3 |
|
|
|
0.6 |
|
|
|
0.6 |
|
|
|
(0.1 |
) |
|
|
(0.2 |
) |
|
|
|
|
Amortization of transition obligation
|
|
|
|
|
|
|
0.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Curtailment (gain)/loss
|
|
|
(0.1 |
) |
|
|
|
|
|
|
0.4 |
|
|
|
1.5 |
|
|
|
|
|
|
|
0.2 |
|
Recognized actuarial (gain)/loss
|
|
|
1.9 |
|
|
|
0.3 |
|
|
|
(0.2 |
) |
|
|
0.3 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net periodic benefit cost
|
|
$ |
10.7 |
|
|
$ |
7.9 |
|
|
$ |
4.8 |
|
|
$ |
3.2 |
|
|
$ |
1.2 |
|
|
$ |
1.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
The 2004 curtailment gain for the pension plan includes
$(0.3) million which is included as a component of the sale
of the microelectronic materials business and $0.2 million
is included in Restructuring in the accompanying Consolidated
Statements of Income related to the hydrazine business. The
curtailment loss related to the postretirement benefit plan
includes $1.2 million which is included as a component of
the sale of the microelectronic materials business and
$0.3 million is included in Restructuring in the
accompanying Consolidated Statements of Income related to the
hydrazine business.
The principal assumptions used to determine the pension and
other postretirement expense and the actuarial value of the
projected benefit obligation for the pension and the
postretirement plans were:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pension Benefits | |
|
Postretirement Benefits | |
|
|
| |
|
| |
|
|
2004 | |
|
2003 | |
|
2002 | |
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
| |
Weighted Average Rate Assumptions
as of December 31:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Discount rate
|
|
|
6.00 |
% |
|
|
6.25 |
% |
|
|
6.75 |
% |
|
|
6.00 |
% |
|
|
6.25 |
% |
|
|
6.75 |
% |
Rate of compensation increase
|
|
|
4.50 |
% |
|
|
4.50 |
% |
|
|
4.50 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
Long-term rate of return on assets
|
|
|
8.50 |
% |
|
|
8.75 |
% |
|
|
9.00 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
For 2004, the Companys expected long-term rate of return
on assets assumption was 8.50%. As defined in FAS 87, this
assumption represents the rate of return on plan assets
reflecting the average rate of earnings expected on the funds
invested or to be invested to provide for the benefits included
in the benefit obligation. The assumption has been determined by
reflecting expectations regarding future rates of return for the
investment portfolio, with consideration given to the
distribution of investments by asset class and historical rates
of return for each individual asset class.
75
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The Companys pension plan asset allocation at
December 31, 2004 and 2003 were:
|
|
|
|
|
|
|
|
|
|
|
|
Pension | |
|
|
Benefits | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
Asset Category:
|
|
|
|
|
|
|
|
|
Equity Funds
|
|
|
69 |
% |
|
|
64 |
% |
Fixed Income Funds
|
|
|
31 |
% |
|
|
36 |
% |
|
|
|
|
|
|
|
|
Total
|
|
|
100 |
% |
|
|
100 |
% |
|
|
|
|
|
|
|
The Companys target allocation of the pension plan assets
is 70% in equity funds and 30% fixed income funds. The
Companys investment strategy includes meeting the plan
objectives, generating competitive investment returns and
investing in a diversified portfolio consisting of an array of
asset classes that attempt to maximize returns while minimizing
volatility. These asset classes currently include
U.S. equities and fixed income, in the future it may
include other asset classes including non-U.S. equities and
real estate.
The benefits expected to be paid for the qualified and the
nonqualified plans in each year from 2005 through 2009 are
$7.2 million, $7.8 million, $8.3 million,
$8.9 million and $9.7 million, respectively. The
aggregate benefits expected to be paid in the five years from
2010 to 2014 are $65.2 million. The expected benefits to be
paid are based on the same assumptions used to measure the
Companys benefit obligation at December 31, 2004 and
include estimated future employee service.
The benefits expected to be paid for the other postretirement
benefit plans in each year from 2005 through 2009 are
$1.5 million, $1.6 million, $1.7 million,
$1.7 million and $1.6 million, respectively. The
aggregate benefits expected to be paid in the five years from
2010 to 2014 are $7.8 million. The expected benefits to be
paid are based on the same assumptions used to measure the
Companys benefit obligation at December 31, 2004 and
include estimated future employee service.
The annual measurement date is January 1 for the pension
benefits and other postretirement benefits. For measurement
purposes, the assumed health care cost trend rate used for
pre-65 non-HMO plans was 10.25% and 11.0% in 2004 and 2003,
respectively, decreasing to an ultimate trend rate of 4.5% in
2012. The trend rate for pre-65 HMO plans was 10.25% and 11.0%
in 2004 and 2003, respectively, decreasing to an ultimate trend
rate of 4.5% in 2012. For non-bargained participants,
Archs subsidy for pre-65 coverage is limited to
$10,000/retiree with all future cost increases to be paid by the
retiree. For post-65 retirees, the Company provides a fixed
dollar benefit that is not subject to escalation.
The assumed health care cost trend rate assumptions can have a
significant impact on the amounts reported. A one percent
increase or decrease each year in the health care cost trend
rate utilized would have resulted in a $0.1 million
increase or decrease, respectively, in the aggregate service and
interest cost components of expense for the year 2004, and a
$0.6 million increase or $0.5 million decrease in the
accumulated postretirement benefit obligation at
December 31, 2004.
In May 2004, the FASB issued Staff Position 106-2,
Accounting and Disclosure Requirements Related to the
Medicare Prescription Drug Improvement and Modernization Act of
2003 which provides guidance on the accounting for the
effects of the Medicare Act. FASB Staff Position 106-2 is
effective for interim or annual periods beginning after
June 15, 2004. Management has been advised by its actuaries
that the provisions of the Medicare Act will not have any effect
on the Companys consolidated financial statements as the
postretirement medical programs as currently offered by the
Company will not be entitled to any reimbursement from the
government as a result of this Act.
76
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
As part of the acquisition of Hickson, the Company acquired the
liability for the Hickson U.K. and the Hickson U.K. Senior
Executive retirement plan. The following tables provide a
reconciliation of the changes in the plans projected
benefit obligations, fair value of plan assets, funded status,
certain assumptions and components of net periodic pension
expense of the Hickson U.K. and the Hickson U.K. Senior
Executive retirement plan for the years ended December 31,
2004 and 2003.
|
|
|
|
|
|
|
|
|
|
|
Pension Benefits | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Reconciliation of Projected Benefit Obligation:
|
|
|
|
|
|
|
|
|
Projected benefit obligation at beginning of year
|
|
$ |
301.3 |
|
|
$ |
251.7 |
|
Service cost (benefits earned during the period)
|
|
|
0.5 |
|
|
|
1.2 |
|
Interest cost on the projected benefit obligation
|
|
|
17.6 |
|
|
|
15.5 |
|
Participant contributions
|
|
|
0.2 |
|
|
|
0.6 |
|
Actuarial loss
|
|
|
12.8 |
|
|
|
13.9 |
|
Benefits paid
|
|
|
(11.7 |
) |
|
|
(11.0 |
) |
Curtailment loss
|
|
|
|
|
|
|
0.7 |
|
Foreign exchange impact
|
|
|
30.0 |
|
|
|
28.7 |
|
|
|
|
|
|
|
|
Projected benefit obligation at end of year
|
|
$ |
350.7 |
|
|
$ |
301.3 |
|
|
|
|
|
|
|
|
Reconciliation of Fair Value of Plan Assets:
|
|
|
|
|
|
|
|
|
Fair value of plan assets at beginning of year
|
|
$ |
218.7 |
|
|
$ |
177.2 |
|
Employer contributions
|
|
|
10.7 |
|
|
|
11.2 |
|
Benefits paid
|
|
|
(11.7 |
) |
|
|
(11.0 |
) |
Participant contributions
|
|
|
0.2 |
|
|
|
0.6 |
|
Actual return on plan assets (net of expenses)
|
|
|
20.8 |
|
|
|
20.0 |
|
Foreign exchange impact
|
|
|
22.1 |
|
|
|
20.7 |
|
|
|
|
|
|
|
|
Fair value of plan assets at end of year
|
|
$ |
260.8 |
|
|
$ |
218.7 |
|
|
|
|
|
|
|
|
Funded Status
|
|
$ |
(89.9 |
) |
|
$ |
(82.6 |
) |
Unrecognized net actuarial loss
|
|
|
111.4 |
|
|
|
95.0 |
|
|
|
|
|
|
|
|
Prepaid benefit cost
|
|
$ |
21.5 |
|
|
$ |
12.4 |
|
|
|
|
|
|
|
|
Amounts Recognized in the Statement of Financial Position
Consist of:
|
|
|
|
|
|
|
|
|
Total accrued benefit cost
|
|
$ |
(85.7 |
) |
|
$ |
(78.9 |
) |
Minimum pension liability adjustment
|
|
|
107.2 |
|
|
|
91.3 |
|
|
|
|
|
|
|
|
Prepaid benefit cost
|
|
$ |
21.5 |
|
|
$ |
12.4 |
|
|
|
|
|
|
|
|
The Companys Hickson U.K. plan has an accumulated benefit
obligation in excess of plan assets as of December 31, 2004
and 2003. The accumulated benefit obligation of this plan was
$334.8 million and $287.2 million as of
December 31, 2004 and 2003, respectively. The projected
benefit obligation relating to the Hickson U.K. plan was
$339.0 million and $290.9 million, as of
December 31, 2004 and 2003, respectively. The accumulated
benefit obligation relating to the Hickson U.K. Senior Executive
plan, included above, was $11.7 million and
$10.4 million, as of December 31, 2004 and 2003,
respectively. The projected benefit obligation related to this
plan was $11.7 million and $10.4 million as of
December 31, 2004 and 2003, respectively. In the fourth
quarter of 2003, the Company recorded a pre-tax curtailment loss
of $0.7 million
77
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
related to the pension plan of former Hickson organics employees
due to the sale of the business and is included in the loss on
the sale of the business.
The principal assumptions used to determine the pension and
other postretirement expense and the actuarial value of the
projected benefit obligation for the pension and the
postretirement plans were:
|
|
|
|
|
|
|
|
|
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
Weighted Average Rate Assumptions as of December 31:
|
|
|
|
|
|
|
|
|
Discount rate
|
|
|
5.50 |
% |
|
|
5.75 |
% |
Rate of compensation increase
|
|
|
4.00 |
% |
|
|
3.90 |
% |
Long-term rate of return on assets
|
|
|
7.00 |
% |
|
|
7.25 |
% |
For 2004, the Companys expected long-term rate of return
on assets assumption was 7.25%, which was reduced by 0.25% to
allow for administration expenses of administering the plan,
which have been removed from the service cost. As defined in
FAS 87, this assumption represents the rate of return on
plan assets reflecting the average rate of earnings expected on
the funds invested or to be invested to provide for the benefits
included in the benefit obligation. The assumption has been
determined by reflecting expectations regarding future rates of
return for the investment portfolio, with consideration given to
the distribution of investments by asset class and historical
rates of return for each individual asset class.
Benefit costs presented below were determined based on actuarial
methods and include the following components:
|
|
|
|
|
|
|
|
|
|
|
($ in millions) | |
|
|
| |
Net Periodic Benefit Expense:
|
|
|
|
|
|
|
|
|
Service cost (benefits earned during the period)
|
|
$ |
0.5 |
|
|
$ |
1.2 |
|
Interest cost on the projected benefit obligation
|
|
|
17.6 |
|
|
|
15.5 |
|
Expected return on plan assets
|
|
|
(17.9 |
) |
|
|
(16.3 |
) |
Curtailment loss
|
|
|
|
|
|
|
0.7 |
|
Realized actuarial loss
|
|
|
2.6 |
|
|
|
1.3 |
|
|
|
|
|
|
|
|
Net periodic benefit cost
|
|
$ |
2.8 |
|
|
$ |
2.4 |
|
|
|
|
|
|
|
|
The Companys policy is to fund, at a minimum, amounts as
are necessary to provide assets sufficient to meet the benefits
to be paid to plan members in accordance with the requirements
of the United Kingdom Pensions Act of 1995. Cash funding in 2005
is expected to be comparable to 2004 and pension expense is
expected to be approximately $2.0 million higher in 2005.
The Companys pension plan asset allocation at
December 31, 2004 and 2003 were:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Hickson | |
|
|
Hickson | |
|
U.K. Senior | |
|
|
U.K. Pension | |
|
Executive | |
|
|
Plan | |
|
Plan | |
|
|
| |
|
| |
|
|
2004 | |
|
2003 | |
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
| |
|
| |
Asset Category:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Equity Funds
|
|
|
44 |
% |
|
|
44 |
% |
|
|
32 |
% |
|
|
34 |
% |
Fixed Income Funds
|
|
|
56 |
% |
|
|
56 |
% |
|
|
68 |
% |
|
|
66 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Total
|
|
|
100 |
% |
|
|
100 |
% |
|
|
100 |
% |
|
|
100 |
% |
|
|
|
|
|
|
|
|
|
|
|
|
|
The Companys target allocation of the pension plan assets
is 43% in equity funds and 57% fixed income funds for the
Hickson U.K. plan and 32% in equity funds and 68% fixed income
funds for the Hickson U.K.
78
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Senior Executive plan. The Companys investment strategy
includes meeting the plan objectives, generating competitive
investment returns and investing in a diversified portfolio
consisting of an array of asset classes that attempts to
maximize returns while minimizing volatility. These asset
classes currently include U.S. domestic equities and fixed
income, in the future it may include non-U.S. equities and
real estate.
The benefits expected to be paid in each year from 2005 through
2009 are £8.1 million, £7.5 million,
£7.9 million, £8.3 million and
£8.7 million, respectively. The aggregate benefits
expected to be paid in the five years from 2010 to 2014 are
£50.6 million. The expected benefits to be paid are
based on the same assumptions used to measure the Companys
benefit obligation at December 31, 2004 and include
estimated future employee service.
As part of the acquisition of Avecias pool & spa
and protection & hygiene businesses, the Company
acquired certain liabilities for prior service associated with
its UK defined benefit pension plan. As of December 31,
2004, the projected benefit obligation was
£10.5 million ($20.4 million), the accumulated
benefit obligation was £6.4 million
($12.5 million), net assets of £6.9 million
($13.4 million) and the accrued benefit was
£3.0 million ($5.8 million). The assumptions for
the valuation are consistent with that of the Companys
other UK plans. Subsequent to the acquisition, a defined
contribution plan was established for the transferred employees
and no further future service benefit will be accrued in the
defined benefit plan. During 2004, the Company incurred
£0.3 million related to this plan ($0.5 million).
The Companys other foreign subsidiaries maintain pension
and other benefit plans that are consistent with statutory
practices and are not significant to the consolidated financial
statements.
Deferred Compensation Plans
The Board of Directors of the Company had previously adopted
three deferred compensation plans, namely, the 1999 Stock Plan
for Non-employee Directors (the Directors Plan), the
Supplemental Contributing Employee Ownership Plan and the
Employee Deferral Plan. The non-employee Directors participate
only in the Directors Plan while officers and certain other key
employees are eligible to participate in the other two plans.
These plans permit or require their participants to defer a
portion of their compensation. The participants
compensation deferrals are adjusted for changes in value of
phantom shares of common stock of the Company and in other
phantom investment vehicles. The Company established a rabbi
trust for each of these plans (collectively, the Rabbi
Trust).
The Rabbi Trust invests its assets in shares of Arch common
stock, marketable securities and a cash surrender life insurance
policy, which generally are expected to generate returns
consistent with those credited to the participants. The assets
of the Rabbi Trust are available to satisfy the claims of the
Companys creditors in the event of bankruptcy or
insolvency of the Company. The Companys stock held in the
Rabbi Trust is treated in a manner similar to treasury stock,
with no subsequent changes in fair value and recorded as a
reduction of shareholders equity ($2.4 million at
December 31, 2004), with an offsetting amount reflected as
a deferred compensation liability of the Company. The carrying
value of the deferred compensation liability related to the
Companys stock is adjusted to fair market value each
reporting period by a charge or credit to operations in Selling
and Administration on the Companys Consolidated Statements
of Income. The other assets of the Rabbi Trust are reported at
fair market value in Other assets in the Consolidated Balance
Sheets ($2.4 million at December 31, 2004). The
deferred compensation liability in Other liabilities in the
Consolidated Balance Sheets reflects the fair market value of
the plan participants compensation deferrals
($5.0 million at December 31, 2004). Changes in the
market value of the marketable securities and the deferred
compensation liability are adjusted to fair market value each
reporting period by a charge or credit to operations in Selling
and Administration on the Companys Consolidated Statements
of Income.
79
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Contributing Employee Ownership Plan
Effective March 1, 2001, the Company established the Arch
Chemicals, Inc. Contributing Employee Ownership Plan (Arch
CEOP) which is a defined contribution plan available to
all domestic employees. As of that date, the Company ended its
participation in the Olin Corporation Contributing Employee
Ownership Plan (Olin CEOP) and all Company employee
balances were transferred to the Arch CEOP. The matching
contribution allocable to Company employees under both plans has
been included in costs and expenses in the accompanying
Consolidated Statements of Income and was $3.4 million,
$3.6 million and $4.0 million in 2004, 2003 and 2002,
respectively.
|
|
16. |
Stock Option and Shareholder Rights Plans |
Stock Option Plans
As of December 31, 2004, the Company had four stock-based
compensation plans, which are described below.
At the time of the Distribution, stock options issued by Olin
were converted into both an option to purchase Company common
stock (Company Options) and an option to purchase
Olin common stock (New Olin Options) with the same
aggregate intrinsic value at the time of the
Distribution as the old award. The conversion of the options did
not result in a charge to earnings as no new measurement date
was created. The Company is responsible for delivering shares of
Company common stock upon exercise of Company Options, and Olin
is responsible for the delivery of shares of Olin Common stock
upon exercise of New Olin Options. Options granted under the
Olin 1980 Stock Option Plan terminated during 2001. Options
granted to such employees under the Olin 1988 Stock Option Plan
or the Olin 1996 Stock Option Plan retained the original term of
the option. Options granted to such employees under the Olin
1996 Stock Option Plan, which were not vested at the time of the
Distribution, continue to vest in accordance with their vesting
schedule so long as the optionee remains employed at the
Company. No additional Company options will be granted under the
1988 and 1996 Olin Stock Option Plans.
In 1999, the Company adopted the 1999 Long Term Incentive Plan,
a long-term incentive plan to encourage selected salaried
employees to acquire a proprietary interest in the
Companys growth and performance and to attract and retain
qualified individuals. The plan will provide for the ability to
issue stock options, restricted stock and restricted stock
units, and performance awards. In addition, in 1999, the Company
adopted the 1999 Stock Plan for Nonemployee Directors pursuant
to which stock options and other stock awards may be granted to
nonemployee directors. The Companys policy is to grant
options to purchase common stock at an exercise price
representing the fair market value of the common stock on the
grant date. In general, the employee options vest and become
exercisable within one to three years and the directors
options are exercisable upon grant. In general, all options are
exercisable up to ten years from the date of grant. At
December 31, 2004, total shares authorized for grant under
plans established subsequent to the Distribution Date were
2,298,000.
80
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The following table summarizes stock option activity during
2004, 2003 and 2002 (number of options in thousands):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Weighted | |
|
|
|
|
Stock | |
|
Average | |
|
|
|
|
Options | |
|
Price | |
|
Range of Prices | |
|
|
| |
|
| |
|
| |
Balance, December 31, 2001
|
|
|
2,392 |
|
|
$ |
23.74 |
|
|
$ |
15.68 $31.92 |
|
|
Options granted
|
|
|
146 |
|
|
|
21.04 |
|
|
|
20.85 23.00 |
|
|
Options exercised
|
|
|
188 |
|
|
|
19.20 |
|
|
|
15.68 20.16 |
|
|
Options cancelled or forfeited
|
|
|
66 |
|
|
|
23.41 |
|
|
|
17.38 31.92 |
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2002
|
|
|
2,284 |
|
|
|
23.95 |
|
|
|
15.68 31.92 |
|
|
|
|
|
|
|
|
|
|
|
|
Options granted
|
|
|
184 |
|
|
|
18.50 |
|
|
|
16.53 18.56 |
|
|
Options exercised
|
|
|
77 |
|
|
|
16.99 |
|
|
|
15.68 20.85 |
|
|
Options cancelled or forfeited
|
|
|
32 |
|
|
|
20.03 |
|
|
|
17.38 31.92 |
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2003
|
|
|
2,359 |
|
|
|
23.81 |
|
|
|
16.53 31.92 |
|
|
|
|
|
|
|
|
|
|
|
|
Options exercised
|
|
|
352 |
|
|
|
19.27 |
|
|
|
17.38 23.48 |
|
|
Options cancelled or forfeited
|
|
|
4 |
|
|
|
25.40 |
|
|
|
17.38 31.92 |
|
|
|
|
|
|
|
|
|
|
|
Balance, December 31, 2004
|
|
|
2,003 |
|
|
$ |
24.60 |
|
|
$ |
16.53 $31.92 |
|
|
|
|
|
|
|
|
|
|
|
At December 31, 2004 and 2003, options covering 2,002,966
and 2,119,566 shares, respectively, were exercisable at
weighted average exercise prices of $24.60 and $24.41,
respectively. The average remaining contractual life was
approximately four years.
The following table summarizes information about stock options
outstanding at December 31, 2004 (number of options in
thousands):
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Number | |
|
|
|
|
|
|
Outstanding | |
|
Weighted Average | |
|
Weighted Average | |
Range of | |
|
and | |
|
Remaining | |
|
Option Exercise Price | |
Exercise Prices | |
|
Exercisable | |
|
Contractual Life | |
|
Outstanding and Exercisable | |
| |
|
| |
|
| |
|
| |
|
$16.53 $23.00 |
|
|
|
1,003 |
|
|
|
5 years |
|
|
$ |
19.35 |
|
|
$28.58 $31.92 |
|
|
|
1,000 |
|
|
|
2 years |
|
|
$ |
29.87 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2,003 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Pursuant to APB No. 25, compensation cost is recorded when
the fair market value of the Companys stock at the date of
grant for fixed options exceeds the exercise price of the stock
option. The Companys policy is to grant stock options with
an exercise price equal to its common stock fair value on the
date of grant. Accordingly, there are no charges reflected in
the accompanying consolidated financial statements for stock
options granted to employees. Compensation cost for restricted
stock units is accrued over the life of the award based on the
quoted market price of the Companys stock at the date of
the award. Compensation cost for performance share units are
estimated based on the number of shares to be earned. The
ultimate cost will be based on the market price of the
Companys stock at the settlement date. The Company did not
grant any stock options in 2004 and currently does not have any
plans to grant options in 2005 (see Note 1 for accounting
policy).
81
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The fair value of each Arch option granted during 2003 and 2002
was estimated on the date of grant using the Black-Scholes
option pricing model. Assumptions used, weighted average fair
values and pro forma net income for 2003 and 2002 are listed
below:
|
|
|
|
|
|
|
|
|
|
|
|
Years Ended December 31, | |
|
|
| |
|
|
2003 | |
|
2002 | |
|
|
| |
|
| |
Black-Scholes weighted-average assumptions:
|
|
|
|
|
|
|
|
|
Risk-free interest rate
|
|
|
3.62 |
% |
|
|
4.80 |
% |
Dividend yield
|
|
|
4.3 |
% |
|
|
3.8 |
% |
Expected volatility
|
|
|
45 |
% |
|
|
44 |
% |
Term
|
|
|
10 years |
|
|
|
10 years |
|
Expected life
|
|
|
7 years |
|
|
|
7 years |
|
Option weighted average fair value
|
|
$ |
5.98 |
|
|
$ |
7.37 |
|
Net income, as reported
|
|
$ |
27.4 |
|
|
$ |
3.0 |
|
Stock-based employee compensation expense, net of tax
|
|
|
(0.8 |
) |
|
|
(0.9 |
) |
|
|
|
|
|
|
|
Pro forma net income
|
|
$ |
26.6 |
|
|
$ |
2.1 |
|
|
|
|
|
|
|
|
Earnings per share:
|
|
|
|
|
|
|
|
|
|
Basic and diluted as reported
|
|
$ |
1.21 |
|
|
$ |
0.13 |
|
|
Basic and diluted pro forma
|
|
$ |
1.18 |
|
|
$ |
0.09 |
|
Shareholder Rights Plan
The Board of Directors adopted a Shareholder Rights Plan in
1999. This plan is designed to prevent a potential acquirer from
gaining control of the Company without offering a fair price to
all shareholders. Each right entitles a shareholder (other than
the potential acquirer) to buy one one-thousandth share of
Series A Participating Cumulative Preferred Stock at a
purchase price of $125 per share. The rights are
exercisable only if a person (or group of affiliated persons)
acquires more than 15% of the Companys common stock or if
the Board of Directors so determines following the commencement
of a tender or exchange offer to acquire more than 15% of the
Companys common stock. If any person acquires more than
15% of the Companys common stock and effects a subsequent
merger or combination with the Company, each right will entitle
the holder (other than the acquirer) to purchase stock or other
property of the acquirer having a market value of twice the
purchase price. The Company can redeem the rights at one cent
per right for a certain period of time. The rights will expire
on January 29, 2009 unless redeemed earlier by the Company.
Common Stock
On February 8, 1999, Olin, the sole shareholder of the
Company, distributed (on a 1-for-2 basis) all the issued and
outstanding shares of common stock, par value $1 per share,
of the Company, to the shareholders of record of Olins
common stock as of February 1, 1999, upon which the Company
became a separate, independent company. The total number of
shares distributed was approximately 22,980,000.
At December 31, 2004, the Company has reserved
2,475,624 shares of its authorized but unissued common
stock for possible future issuance in connection with the
exercise of stock options, restricted stock, and performance
share units.
In 2004, the Company established a Rabbi Trust for several
deferred compensation plans (see Note 15 for more
information), that permit or require their participants to defer
a portion of their compensation. The
82
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Companys stock held in the Rabbi Trust is treated in a
manner similar to treasury stock, with no subsequent changes in
fair value and recorded as a reduction of shareholders
equity.
On October 28, 1999, the Companys Board of Directors
approved a stock repurchase program whereby the Company is
authorized to buy back up to 1.2 million shares of its
common stock, representing approximately five percent of
outstanding shares. The program was suspended in 2000. In
October 2003, the Board of Directors unanimously agreed to
continue the previous suspension of its stock repurchase
program. The Company had previously repurchased
893,000 shares of the 1.2 million shares authorized,
or approximately 75 percent, at a cost of approximately
$16 million. In connection with the acquisition of the
Avecia pool & spa and protection & hygiene
businesses, the Company reissued 669,750 shares with a
value of $15.7 million.
Series A Participating Cumulative Preferred Stock
The Company has 40,000 authorized shares of $1 par value
Series A Participating Cumulative Preferred Stock, of which
none is outstanding.
Retained Earnings
Retained earnings as of December 31, 2004 and 2003 include
earnings (losses) since the Distribution.
Accumulated Other Comprehensive Loss
Accumulated other comprehensive loss includes cumulative foreign
currency translation adjustments, additional minimum pension
liability adjustments, net of tax and accumulated net unrealized
gain (loss) on derivative instruments, net of tax.
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Change in Fair | |
|
|
|
|
Foreign Currency | |
|
Minimum Pension | |
|
Value of | |
|
|
|
|
Translation | |
|
Liability | |
|
Derivative | |
|
Accumulated Other | |
|
|
Adjustments | |
|
Adjustments | |
|
Contracts | |
|
Comprehensive Loss | |
|
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Balance at December 31, 2001
|
|
$ |
(45.7 |
) |
|
$ |
(0.9 |
) |
|
$ |
|
|
|
$ |
(46.6 |
) |
2002 activity
|
|
|
13.6 |
|
|
|
(60.4 |
) |
|
|
0.3 |
|
|
|
(46.5 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2002
|
|
|
(32.1 |
) |
|
|
(61.3 |
) |
|
|
0.3 |
|
|
|
(93.1 |
) |
2003 activity
|
|
|
20.5 |
|
|
|
(23.5 |
) |
|
|
(0.3 |
) |
|
|
(3.3 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2003
|
|
|
(11.6 |
) |
|
|
(84.8 |
) |
|
|
|
|
|
|
(96.4 |
) |
2004 activity
|
|
|
19.5 |
|
|
|
(19.5 |
) |
|
|
(0.2 |
) |
|
|
(0.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2004
|
|
$ |
7.9 |
|
|
$ |
(104.3 |
) |
|
$ |
(0.2 |
) |
|
$ |
(96.6 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
The additional minimum pension liability adjustments recorded
were principally the result of depressed market values of the
Companys pension plan assets in 2002 and 2001, combined
with a decrease in the discount rate due to declining market
interest rates in recent years.
83
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Accumulated Net Unrealized Gain (Loss) on Derivative
Instruments
Changes in the accumulated net unrealized gain (loss) on
derivative instruments for the years ended December 31,
2004 and 2003 are as follows:
|
|
|
|
|
|
|
|
|
|
|
Year Ended | |
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Beginning balance of accumulated net unrealized gain on
derivative instruments
|
|
$ |
|
|
|
$ |
0.3 |
|
Net gain (loss) on cash flow hedges
|
|
|
(0.2 |
) |
|
|
|
|
Reclassification into earnings
|
|
|
|
|
|
|
(0.3 |
) |
|
|
|
|
|
|
|
Ending balance of accumulated net unrealized gain (loss) on
derivative instruments
|
|
$ |
(0.2 |
) |
|
$ |
|
|
|
|
|
|
|
|
|
As a result of the sale of the majority of the microelectronic
materials businesses, the Company has restated its prior year
financial statements to include the results of the
microelectronic materials businesses sold and the loss on the
disposition as a component of discontinued operations in
accordance with the SFAS 144. The Company has retained its
50 percent interest in Planar Solutions LLC, its joint
venture with Wacker Chemical Corporation for the production and
sale of CMP slurries, the microelectronics-dedicated
manufacturing facility in Brandenburg, Kentucky and its
CMS business. The Company will pursue all strategic options
for the CMS business, including its sale. As a result, and in
accordance with the accounting requirements of SFAS 144,
the CMS business is reported as an asset held for sale and the
results of operations are included in discontinued operation in
the consolidated financial statements. The Company will continue
to supply certain products for a transition period to the
purchaser of the microelectronic materials businesses from its
Brandenburg, Kentucky facility. The Company now reports the
results of its CMP joint venture in Corporate Expenses
(Unallocated) and the microelectronics-dedicated manufacturing
assets retained in Brandenburg, Kentucky as a component of the
performance products business. In addition, as a result of the
sale the Company has reallocated certain centralized service
costs to the Companys segments that were previously
allocated to the microelectronic materials business.
The Company has organized its business portfolio into two
operating segments to reflect the Companys business
strategy. The two segments are treatment products and
performance products. The treatment products segment includes
three reportable business units: the HTH water products
business, the personal care and industrial biocides business,
and the wood protection and industrial coatings business. The
recently acquired Avecia pool & spa business is
included in the results of the HTH water products business and
the Avecia protection & hygiene business is included in
the results of the personal care and industrial biocides
business. Segment operating income includes the equity in
earnings of affiliated companies and excludes restructuring
(income) expense, impairment expense and certain unallocated
expenses of the corporate headquarters.
84
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Segment results for the three years ended December 31 were
as follows:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Sales:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
366.0 |
|
|
$ |
289.7 |
|
|
$ |
243.1 |
|
|
|
Personal Care and Industrial Biocides
|
|
|
234.6 |
|
|
|
149.3 |
|
|
|
124.5 |
|
|
|
Wood Protection and Industrial Coatings
|
|
|
351.1 |
|
|
|
268.3 |
|
|
|
233.2 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
951.7 |
|
|
|
707.3 |
|
|
|
600.8 |
|
|
Performance Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
|
145.0 |
|
|
|
122.2 |
|
|
|
120.2 |
|
|
|
Hydrazine
|
|
|
24.2 |
|
|
|
34.0 |
|
|
|
42.0 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Performance Products
|
|
|
169.2 |
|
|
|
156.2 |
|
|
|
162.2 |
|
|
|
|
|
|
|
|
|
|
|
Total Sales
|
|
$ |
1,120.9 |
|
|
$ |
863.5 |
|
|
$ |
763.0 |
|
|
|
|
|
|
|
|
|
|
|
Segment Operating Income (Loss), including Equity Income in
Affiliated Companies:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
7.2 |
|
|
$ |
7.6 |
|
|
$ |
(2.3 |
) |
|
|
Personal Care and Industrial Biocides
|
|
|
50.1 |
|
|
|
28.3 |
|
|
|
28.0 |
|
|
|
Wood Protection and Industrial Coatings
|
|
|
24.1 |
|
|
|
13.9 |
|
|
|
15.9 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
81.4 |
|
|
|
49.8 |
|
|
|
41.6 |
|
|
Performance Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
|
(5.2 |
) |
|
|
(6.0 |
) |
|
|
(1.4 |
) |
|
|
Hydrazine
|
|
|
(2.6 |
) |
|
|
1.9 |
|
|
|
5.5 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Performance Products
|
|
|
(7.8 |
) |
|
|
(4.1 |
) |
|
|
4.1 |
|
|
Corporate Unallocated
|
|
|
(26.1 |
) |
|
|
(13.1 |
) |
|
|
(14.9 |
) |
|
|
|
|
|
|
|
|
|
|
Total Segment Operating Income, including Equity Income in
Affiliated Companies
|
|
|
47.5 |
|
|
|
32.6 |
|
|
|
30.8 |
|
|
Restructuring Expense
|
|
|
(1.7 |
) |
|
|
(0.4 |
) |
|
|
(5.7 |
) |
|
Impairment Expense
|
|
|
(2.9 |
) |
|
|
|
|
|
|
|
|
|
Equity in Earnings of Affiliated Companies
|
|
|
(4.0 |
) |
|
|
(5.6 |
) |
|
|
(3.1 |
) |
|
|
|
|
|
|
|
|
|
|
Total Operating Income
|
|
|
38.9 |
|
|
|
26.6 |
|
|
|
22.0 |
|
|
Interest expense, net
|
|
|
(18.6 |
) |
|
|
(16.6 |
) |
|
|
(16.0 |
) |
|
|
|
|
|
|
|
|
|
|
Total Income from Continuing Operations before Taxes, Equity
Income in Affiliated Companies and Cumulative Effect of
Accounting Change
|
|
$ |
20.3 |
|
|
$ |
10.0 |
|
|
$ |
6.0 |
|
|
|
|
|
|
|
|
|
|
|
85
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Equity Income (Loss) in Affiliated Companies:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
2.3 |
|
|
$ |
2.9 |
|
|
$ |
2.6 |
|
|
|
|
Wood Protection and Industrial Coatings
|
|
|
2.2 |
|
|
|
2.2 |
|
|
|
1.2 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
4.5 |
|
|
|
5.1 |
|
|
|
3.8 |
|
|
|
|
General Corporate Unallocated
|
|
|
(0.5 |
) |
|
|
0.5 |
|
|
|
(0.7 |
) |
|
|
|
|
|
|
|
|
|
|
Total Equity Income in Affiliated Companies
|
|
$ |
4.0 |
|
|
$ |
5.6 |
|
|
$ |
3.1 |
|
|
|
|
|
|
|
|
|
|
|
Depreciation Expense:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
13.4 |
|
|
$ |
12.6 |
|
|
$ |
12.3 |
|
|
|
|
Personal Care and Industrial Biocides
|
|
|
11.7 |
|
|
|
8.6 |
|
|
|
8.5 |
|
|
|
|
Wood Protection and Industrial Coatings
|
|
|
7.4 |
|
|
|
6.8 |
|
|
|
6.0 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
32.5 |
|
|
|
28.0 |
|
|
|
26.8 |
|
|
Performance Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
|
4.5 |
|
|
|
4.7 |
|
|
|
6.3 |
|
|
|
Hydrazine
|
|
|
4.7 |
|
|
|
4.8 |
|
|
|
4.3 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Performance Products
|
|
|
9.2 |
|
|
|
9.5 |
|
|
|
10.6 |
|
|
|
|
|
|
|
|
|
|
|
Total Depreciation Expense
|
|
$ |
41.7 |
|
|
$ |
37.5 |
|
|
$ |
37.4 |
|
|
|
|
|
|
|
|
|
|
|
Amortization Expense:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
0.3 |
|
|
$ |
|
|
|
$ |
|
|
|
|
|
Personal Care and Industrial Biocides
|
|
|
3.0 |
|
|
|
0.1 |
|
|
|
0.1 |
|
|
|
|
Wood Protection and Industrial Coatings
|
|
|
1.7 |
|
|
|
1.6 |
|
|
|
1.7 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
5.0 |
|
|
|
1.7 |
|
|
|
1.8 |
|
|
Performance Products
|
|
|
0.2 |
|
|
|
0.2 |
|
|
|
0.2 |
|
|
|
|
|
|
|
|
|
|
|
Total Amortization Expense
|
|
$ |
5.2 |
|
|
$ |
1.9 |
|
|
$ |
2.0 |
|
|
|
|
|
|
|
|
|
|
|
Capital Spending:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
6.0 |
|
|
$ |
4.1 |
|
|
$ |
8.5 |
|
|
|
|
Personal Care and Industrial Biocides
|
|
|
4.3 |
|
|
|
4.5 |
|
|
|
7.2 |
|
|
|
|
Wood Protection and Industrial Coatings
|
|
|
6.0 |
|
|
|
3.9 |
|
|
|
3.8 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
16.3 |
|
|
|
12.5 |
|
|
|
19.5 |
|
|
Performance Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
|
1.1 |
|
|
|
2.9 |
|
|
|
4.1 |
|
|
|
|
Hydrazine
|
|
|
0.9 |
|
|
|
1.6 |
|
|
|
4.6 |
|
|
|
|
|
|
|
|
|
|
|
|
Performance Products
|
|
|
2.0 |
|
|
|
4.5 |
|
|
|
8.7 |
|
|
|
|
|
|
|
|
|
|
|
Total Capital Spending
|
|
$ |
18.3 |
|
|
$ |
17.0 |
|
|
$ |
28.2 |
|
|
|
|
|
|
|
|
|
|
|
86
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Total Assets:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
217.3 |
|
|
$ |
148.1 |
|
|
$ |
130.1 |
|
|
|
Personal Care and Industrial Biocides
|
|
|
296.1 |
|
|
|
115.2 |
|
|
|
111.1 |
|
|
|
Wood Protection and Industrial Coatings
|
|
|
359.7 |
|
|
|
303.5 |
|
|
|
262.5 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
873.1 |
|
|
|
566.8 |
|
|
|
503.7 |
|
|
Performance Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Performance Urethanes
|
|
|
73.6 |
|
|
|
87.0 |
|
|
|
94.4 |
|
|
|
Hydrazine
|
|
|
16.9 |
|
|
|
23.3 |
|
|
|
26.4 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Performance Products
|
|
|
90.5 |
|
|
|
110.3 |
|
|
|
120.8 |
|
|
Other
|
|
|
136.4 |
|
|
|
299.3 |
|
|
|
314.6 |
|
|
|
|
|
|
|
|
|
|
|
Total Assets
|
|
$ |
1,100.0 |
|
|
$ |
976.4 |
|
|
$ |
939.1 |
|
|
|
|
|
|
|
|
|
|
|
Investment & Advances Affiliated
Companies at Equity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Treatment Products:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HTH Water Products
|
|
$ |
9.4 |
|
|
$ |
8.7 |
|
|
$ |
6.8 |
|
|
|
Wood Protection and Industrial Coatings
|
|
|
6.1 |
|
|
|
7.3 |
|
|
|
5.8 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Treatment Products
|
|
|
15.5 |
|
|
|
16.0 |
|
|
|
12.6 |
|
|
|
|
|
|
|
|
|
|
|
Total Investment & Advances Affiliated
Companies at Equity
|
|
$ |
15.5 |
|
|
$ |
16.0 |
|
|
$ |
12.6 |
|
|
|
|
|
|
|
|
|
|
|
Segment operating income includes the equity in earnings of
affiliated companies and excludes restructuring (income)
expense, impairment expense and certain unallocated expenses of
the corporate headquarters. The Company includes the equity
income (loss) of affiliates in its segment operating results as
it believes it to be relevant and useful information for
investors as these affiliates are the means by which certain
segments participate in certain geographic regions. Furthermore,
the Company includes equity income (loss) as a component of
segment operating results because the Company includes it to
measure the performance of the segment. Other gains and (losses)
that are directly related to the segments are included in
segment operating results. The 2003 corporate unallocated
expense includes the gain on sale of land of $2.5 million.
The Company believes the exclusion of restructuring and
impairment expenses from segment operating income provides
additional perspective on the Companys underlying business
trends and provides useful information to investors by excluding
amounts from the Companys results that the Company
believes are not indicative of ongoing operating results.
Segment assets include only those assets that are directly
identifiable to a segment and do not include such items as cash,
deferred taxes, LIFO reserves, assets held for sale, and certain
other assets. Sales by reportable business unit substantially
represent sales for the major product lines of the Company.
87
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Geographic area information for the periods ended
December 31, were as follows:
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2004 | |
|
2003 | |
|
2002 | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Sales
|
|
|
|
|
|
|
|
|
|
|
|
|
United States
|
|
$ |
557.8 |
|
|
$ |
419.5 |
|
|
$ |
391.5 |
|
Europe, Africa and the Middle East
|
|
|
373.4 |
|
|
|
297.4 |
|
|
|
233.7 |
|
Latin America and Canada
|
|
|
101.9 |
|
|
|
83.6 |
|
|
|
84.9 |
|
Pacific Rim
|
|
|
87.8 |
|
|
|
63.0 |
|
|
|
52.9 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Sales
|
|
$ |
1,120.9 |
|
|
$ |
863.5 |
|
|
$ |
763.0 |
|
|
|
|
|
|
|
|
|
|
|
Long-lived Assets (excludes Goodwill)
|
|
|
|
|
|
|
|
|
|
|
|
|
United States
|
|
$ |
211.4 |
|
|
$ |
198.2 |
|
|
$ |
218.1 |
|
Canada
|
|
|
1.3 |
|
|
|
1.6 |
|
|
|
1.1 |
|
Italy
|
|
|
51.4 |
|
|
|
52.0 |
|
|
|
51.4 |
|
England
|
|
|
145.5 |
|
|
|
47.4 |
|
|
|
42.4 |
|
Europe (remaining), Africa and the Middle East
|
|
|
19.1 |
|
|
|
21.1 |
|
|
|
16.9 |
|
Latin America
|
|
|
8.1 |
|
|
|
11.9 |
|
|
|
11.3 |
|
Pacific Rim
|
|
|
12.4 |
|
|
|
7.9 |
|
|
|
7.3 |
|
|
|
|
|
|
|
|
|
|
|
|
Total Long-lived Assets
|
|
$ |
449.2 |
|
|
$ |
340.1 |
|
|
$ |
348.5 |
|
|
|
|
|
|
|
|
|
|
|
Sales to external customers are attributed to geographic areas
based on country of destination. Transfers between geographic
areas are priced generally at prevailing market prices. Export
sales from the United States to unaffiliated customers were
$76.2 million, $68.6 million and $66.7 million in
2004, 2003 and 2002, respectively.
On April 2, 2004, the Company completed the acquisition of
Avecias pool & spa and protection &
hygiene businesses. The results of these operations have been
included in the Companys consolidated financial statements
since that date. The total purchase price, net of cash acquired,
was approximately $230.8 million, inclusive of expenses and
a final working capital payment of $7.4 million. The
payment consisted of cash and 669,750 shares of Arch common
stock which was valued at $15.7 million. The fair value of
the common stock issued was determined based on the average
market price of Archs common stock over the 2-day period
before and after the terms of the acquisition were agreed to and
announced, including a discount due to the fact that the shares
contain certain restrictions that limit their immediate
marketability. The shares issued may not be transferred without
being registered under the Securities Act of 1933, as amended,
or pursuant to an exemption from such registration. Generally
speaking, the Company has granted Avecia, Inc. and its
affiliates piggyback registration rights in certain
circumstances in connection with the shares if the Company were
to file a registration statement for the issuance of shares. The
purchase price is further subject to a contingent payment of up
to $5.0 million in cash based upon earnings attributable to
North American sales of certain products. An interim payment is
to be made based on 2004 results and as of December 31,
2004, the Company has accrued $2.5 million with a
corresponding increase to goodwill. In addition, to the extent
that the unfunded pension liability in the U.K. pension plan was
less than $10.0 million, the purchase price was adjusted
upwards by the difference between $10.0 million and the
unfunded liability, with the consideration split equally between
a contingent cash payment and up to 223,250 additional shares of
Arch common stock. The share component of this adjustment was
74,788 shares of common stock, which were issued in January
2005 with a value of $1.7 million which was accrued as of
December 31, 2004, with a
88
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
corresponding increase to goodwill. The contingent cash payment
will be earned, to a maximum of $1.7 million, based upon
cumulative global net sales of certain products through 2005. An
interim payment will be made in 2005, based on 2004 results and
the Company has accrued $0.5 million as of
December 31, 2004, with a corresponding increase to
goodwill. The acquisition was financed principally from
borrowings under the Companys revolving credit facility.
The following table summarizes the estimated fair value of the
assets acquired and liabilities assumed at the date of
acquisition, including the contingent payments earned during
2004. The Company has obtained a final third party valuation for
intangible assets and is in the process of finalizing the
third-party valuations of tangible assets; thus, the allocation
of the purchase price is preliminary and subject to refinement.
|
|
|
|
|
|
|
|
|
($ in millions) | |
Current Assets
|
|
$ |
59.4 |
|
Property and equipment
|
|
|
28.1 |
|
Intangible Assets
|
|
|
95.4 |
|
Deferred Tax Asset
|
|
|
4.8 |
|
Goodwill
|
|
|
82.0 |
|
|
|
|
|
|
Total assets acquired
|
|
|
269.7 |
|
Current Liabilities
|
|
|
29.8 |
|
Long-term liabilities
|
|
|
9.1 |
|
|
|
|
|
|
|
Total liabilities assumed
|
|
|
38.9 |
|
|
|
|
|
|
|
Net assets acquired
|
|
$ |
230.8 |
|
|
|
|
|
Included in the current liabilities in the opening balance sheet
is an accrual for $4.6 million for headcount reductions at
the U.S. and U.K. locations and office closure costs in the
U.S. As of December 31, 2004, $3.2 million in
payments have been made. The major actions of these plans should
be completed by the end of the first quarter of 2005.
Of the $95.4 million of acquired intangible assets,
$18.7 million was assigned to tradenames, which is not
subject to amortization as it has an indefinite life. The
remaining $76.7 million of acquired intangible assets have
a preliminary weighted average useful life of approximately
14 years. The intangible assets that make up that amount
include customer lists of $45.4 million (14-year
weighted-average useful life), a toxicology database of
$16.7 million (15-year life), $14.2 million was
assigned to developed technology (15-year life) and a
non-compete agreement of $0.4 million (5-year life).
The Company has also provided deferred taxes on the opening
balance sheet, which has resulted in a $4.8 million
reduction in goodwill.
The $82.0 million of goodwill was assigned to
pool & spa and protection & hygiene businesses
in the amounts of $26.2 million and $55.8 million,
respectively.
Supplemental Pro Forma Information
The table below presents unaudited pro forma financial
information in connection with the Avecia acquisition as if it
had occurred on January 1, 2003 and 2004.
The unaudited pro forma information below reflects pro forma
adjustments which are based upon currently available information
and certain estimates and assumptions, and therefore the actual
results may differ from the pro forma results. However,
management believes that the assumptions provide a reasonable
basis for presenting the significant effects of the transaction,
and that the pro forma adjustments give appropriate effect to
those assumptions and are properly applied in the pro forma
financial information. This
89
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
information should be read in conjunction with the
Form 8-K/A, filed by the Company on June 16, 2004, in
connection with the Avecia acquisition, which contains unaudited
pro forma combined condensed financial statements and the
Form 8-K/A, filed by the Company on December 6, 2004,
in connection with the sale of the majority of the
microelectronic materials businesses.
The unaudited pro forma financial information is presented for
illustrative purposes only and is not necessarily indicative of
the operating results or financial position that would have
occurred if the acquisition had been completed at the dates
indicated. The information does not necessarily indicate the
future operating results or financial position of the
Company. The Avecia pool & spa business is
seasonal in nature as its products are primarily used in the
U.S. residential pool market.
|
|
|
|
|
|
|
|
|
|
|
|
Twelve Months Ended | |
|
|
December 31, | |
|
|
| |
|
|
2004 | |
|
2003 | |
|
|
| |
|
| |
|
|
($ in millions) | |
Sales
|
|
$ |
1,160.0 |
|
|
$ |
1,001.4 |
|
Income from continuing operations before cumulative effect of
accounting change
|
|
|
20.0 |
|
|
|
13.3 |
|
Net Income
|
|
|
22.6 |
|
|
|
30.6 |
|
Basic income per common share
|
|
|
|
|
|
|
|
|
|
Continuing operations before cumulative effect of accounting
change
|
|
$ |
0.85 |
|
|
$ |
0.57 |
|
|
Net Income
|
|
$ |
0.96 |
|
|
$ |
1.31 |
|
Diluted income per common share
|
|
|
|
|
|
|
|
|
|
Continuing operations before cumulative effect of accounting
change
|
|
$ |
0.84 |
|
|
$ |
0.57 |
|
|
Net Income
|
|
$ |
0.95 |
|
|
$ |
1.31 |
|
On August 1, 2003, the Company completed the purchase of
the remaining 50 percent share of Aquachlor (Proprietary)
Limited in South Africa from its joint venture partner
Sentrachem Limited for $2.5 million in cash. Aquachlor
produces calcium hypochlorite, which is marketed under the
HTH® brand, for use in residential and
commercial swimming pools in South Africa. Annual sales for
Aquachlor for the year ended December 31, 2002 were
approximately $26 million. This acquisition was accounted
for as a purchase business combination and the results of
operations have been included in the consolidated financial
statements from the date of purchase in the HTH water products
segment and were not material in 2002. In the fourth quarter of
2003, the Company adjusted the opening balance sheet of
Aquachlor to include a liability for its post-employment health
care plan of $0.8 million. No goodwill was recognized as
part of the transaction. The supplemental cash flow information
on the business acquired is as follows (in millions of $):
|
|
|
|
|
|
Working Capital
|
|
$ |
4.3 |
|
Property, plant and equipment, net
|
|
|
3.6 |
|
Non-Current Liabilities
|
|
|
(0.8 |
) |
Payable to Arch Chemicals, Inc.
|
|
|
(4.6 |
) |
|
|
|
|
|
Cash paid
|
|
$ |
2.5 |
|
|
|
|
|
|
|
20. |
Commitments and Contingencies |
Leases
The Company leases certain properties, such as manufacturing,
warehousing and office space and data processing and office
equipment. Leases covering these properties may contain
escalation clauses based on increased costs of the lessor,
primarily property taxes, maintenance and insurance and have
renewal or
90
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
purchase options. Total rent expense charged to operations
amounted to $14.8 million in 2004, $13.8 million in
2003 and $12.3 million in 2002 (sublease income and
contingent rent expense is not significant).
Future minimum rent payments under operating leases having
initial or remaining noncancelable lease terms in excess of one
year at December 31, 2004 are as follows: $9.3 million
in 2005; $5.4 million in 2006; $4.9 million in 2007;
$4.5 million in 2008; $4.2 million in 2009 and
$9.2 million thereafter.
Litigation
In connection with the acquisition of Hickson, the Company
assumed certain legal obligations, including a trial court
judgment, in favor of a railroad, of approximately
$8.5 million plus interest in a lawsuit associated with a
wood preservative spillage in 1994. In 2002, a new trial
resulted in a judgment of $2.6 million plus interest. The
railroad has appealed the judgment, and in February 2005 the
court of appeals affirmed the judgment. The judgment and related
interest is included in Accrued Liabilities in the accompanying
Consolidated Balance Sheets. The Company does not expect any
final resolution of this case to have a material adverse effect
on the results of operations or the financial position of the
Company.
The Company is a co-defendant in consolidated litigation arising
from a fire in August 2000, which destroyed a warehouse in which
the Companys water treatment products were stored. The
parties have reached an agreement to settle a portion of the
litigation that involves claims by plaintiffs who are
individuals. This agreement has received court approval and the
settlement amount has been paid by the Company. The balance of
the litigation primarily involves claims by a number of
businesses for property damage. The Company has provided for its
exposure in this litigation, $3.0 million, including the
amount of its participation in the settlement, and does not
expect any final resolution of these cases, net of an expected
insurance recovery, to have a material adverse effect on results
of operations or financial position of the Company. Given that
the Companys applicable insurance policies provide
coverage on a reimbursement basis, there may be a lag between
any payment ultimately paid to the remaining plaintiffs by the
Company and reimbursement of such payment from the
Companys insurers.
The Company and/or its CCA-formulating subsidiary Arch Wood
Protection, Inc. were named, along with several other chromated
copper arsenate (CCA) manufacturers, several CCA
customers and various retailers, in five putative class action
lawsuits filed in various state and federal courts regarding the
marketing and use of CCA-treated wood. Three of these cases have
been dismissed without prejudice. In the fourth case
(Jacobs v. Osmose, Inc. et. al.), the federal
district court has ruled that the requirements for a class
action have not been met and has denied class action status in
this case. Subsequently, the court entered an order granting
plaintiffs motion for voluntary dismissal of their claims
against the Company, its subsidiaries and several other
defendants.
In March 2004, in the fifth putative class action lawsuit
(Ardoin v. Stine Lumber Company et. al.), the
federal district court ruled that the requirements for a class
action were not met and denied class action status to the case.
The parties entered an agreement to settle the claims of the
individual plaintiffs for a nominal amount, and the case was
dismissed with prejudice.
In addition, there are fewer than ten other CCA-related lawsuits
in which the Company and/or one or more of the Companys
subsidiaries is involved. These additional cases are not
putative class actions. They are actions by individual claimants
alleging various personal injuries allegedly due to exposure to
CCA-treated wood.
The Company and its subsidiaries deny the material allegations
of all the various CCA-related claims and have vigorously
defended and will continue to vigorously defend them. As a
result, legal defense and related costs associated with these
cases were significant in 2004, 2003 and 2002, and may be
significant in the future.
91
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
All CCA-related cases are subject to a number of uncertainties.
As a result, their impact, if any, is difficult to assess. Based
on the information currently available to the Company, however,
the Company does not believe the resolution of these cases is
likely to have a material adverse effect on its consolidated
financial condition, cash flow or results of operations.
In March 2004, a jury in the U.S. District Court for the
District of New Jersey awarded Arch Personal Care Products, a
wholly-owned subsidiary of the Company, approximately
$7.0 million in damages after finding, among other things,
one of the defendants had breached his non-compete obligations
to Arch Personal Care Products. In July 2004, the parties
reached agreement to settle $6.6 million of the judgment
for $6.1 million, which has been recognized in the results
for the twelve months ended December 31, 2004.
In April 2004, the Company was served with a complaint by two
parents, their minor child and the parents acting as personal
representatives of the estates of their two other children. In
the complaint, which was initially filed in Oregon state court
against the Company, two of its subsidiaries, and others,
plaintiffs allege that a fire caused by a spontaneous exothermic
chemical reaction of the Companys pool chlorination
products with other common household products erupted in the
parents vehicle while occupied by the family. Plaintiffs
ask for damages, including non-economic damages of
$40.0 million per plaintiff. The Company is effectively
self-insured for the first $3.0 million in this case,
regardless of the number of plaintiffs. The case has been
removed to the U.S. district court in Oregon by the Company
and plaintiffs have moved to return the case to state court. The
court denied the motion, and plaintiffs have moved to reargue.
During the second quarter, the Company recorded
$3.0 million of self-insurance reserves related to its
potential exposure in this case and does not expect any final
resolution of these cases, net of an expected insurance
recovery, to have a material adverse effect on results of
operations or financial position of the Company. Given that the
Companys applicable insurance policies provide coverage on
a reimbursement basis, there may be a lag between any payment
ultimately paid by the Company and reimbursement of such payment
from the Companys insurers.
In Brazil, the Company uses a third-party agent to process and
pay certain state import duties. In July 2004, the Company was
notified of a claim for unpaid state import duties, including
interest and potential penalties. The Company accrued
$2.1 million for the estimated taxes and related interest
for this claim. As of December 31, 2004, the Company had
estimated contingent liabilities related to this claim up to
$1.8 million.
In May 2004, the U.S. Department of Commerce and the
U.S. International Trade Commission initiated antidumping
duty investigations of Chinese and Spanish suppliers of
chlorinated isocyanurates and related chemicals as a result of
petitions filed by domestic producers who asserted that these
products were being imported and sold in the U.S.A. at prices
below normal value. One of the suppliers being investigated is a
major supplier of chlorinated isocyanurates to the Company. In
December 2004, the Department of Commerce issued a preliminary
determination and estimated antidumping duties margins ranging
from approximately 126% to 180% for Chinese producers and 12%
for Spanish producers. In February 2005, the rate for the
Chinese producer who currently supplies the Company was reduced
to 87%. As the importer of record, the Company is obliged to
post a bond or cash deposit of these preliminary duties until
the investigation is concluded. If the final finding is that no
dumping occurred or that those imports did not injure the
domestic industry, the duties will terminate and be refunded if
paid. The final results of the investigations, and the order if
issued, are expected in June 2005. The producers may annually
request a review of the final results which may result in a
further adjustment of the duties.
Koppers Arch Wood Protection (NZ) Limited
(KANZ), a New Zealand joint venture company in which
the Company owns indirectly a 49% interest, is the subject of an
on-going investigation by the New Zealand Commerce Commission
(NZ Commerce Commission) regarding industry
competitive practices. KANZ manufactures and markets wood
preservative products throughout New Zealand. The NZ Commerce
Commission has the authority to assess fines equal to the higher
of (i) NZ$10 million (approximately
US$7 million), (ii) three times the commercial gain
from any contravention or (iii) 10% of the sales of
92
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
KANZ (approximately US$2 million). Penalties, if assessed
against KANZ, could have a material adverse effect on the joint
ventures business, financial condition, cash flows and
results of operations.
Similarly, Koppers Arch Wood Protection (Aust) Pty Ltd
(KAWP), an Australian joint venture company in which
the Company owns indirectly a 49% interest and the majority
shareholder of KANZ, has made an application for leniency under
the Australian Competition and Consumer Commissions
(ACCC) policy for cartel conduct. The ACCC has
granted immunity to KAWP, subject to fulfillment of certain
conditions. If conditions are not fulfilled, the ACCC may
penalize KAWP for any violations of the competition laws of
Australia. Such penalties, if assessed against KAWP, could have
a material adverse effect on KAWPs business, financial
condition, cash flows and results of operations.
As a result of the Companys ownership in such entities, an
unfavorable resolution, could have a material adverse effect on
equity in earnings of affiliated companies and dividends
received.
There are a variety of non-environmental legal proceedings
pending or threatened against the Company. Those matters that
are probable have been accrued for in the accompanying
Consolidated Financial Statements. Any contingent amounts in
excess of amounts accrued are not expected to have a material
adverse effect on results of operations, financial position or
liquidity of the Company.
Environmental
Olin and the Company have entered into an agreement, which
specifies that the Company is only responsible for certain
environmental liabilities at the Companys current
operating plant sites and certain offsite locations. Olin
retained the liability for all former Olin plant sites and
former waste disposal sites. In connection with the acquisition
of Hickson, the Company acquired certain environmental exposures
and potential liabilities of current and past operating sites
all of which have been accrued for in the accompanying
Consolidated Financial Statements.
In connection with the disposition of the majority of the
microelectronic materials business on November 30, 2004,
the Company provided indemnification for environmental concerns.
For identified environmental liabilities as of the transition
date, there is no limit to the liability retained by the
Company. The Company estimates such potential liability to be
less then $1.0 million. For other pre-closing environmental
liabilities the purchaser will be liable for the first
$3.0 million of any such liabilities and the parties will
share equally the next $6.0 million of any such liabilities
with the Companys total exposure thus limited to
$3.0 million over a five-year period from the closing date.
In connection with the disposition of the sulfuric acid business
on July 2, 2003, the Company provided environmental
covenants to the purchaser in which the Company is solely liable
for the costs of any environmental claim for remediation of any
hazardous substances that was generated, managed, treated,
stored or disposed of prior to the closing date of the sale. The
Company will be released, under the sales agreement, from its
obligation, which cannot exceed $22.5 million,
20 years from the closing date. Additionally, as part of
its environmental indemnifications, the Company will be
responsible for damages directly related to the process sewer
system at the Beaumont, Texas plant during the first five years
from the closing date.
As part of the Hickson organics disposition, the Company will
continue to be responsible for known environmental matters. Such
matters have previously been accrued for in its environmental
reserve included in the Consolidated Financial Statements.
Additionally, regarding any unknown environmental matters that
are identified subsequent to the sale, the Company has agreed to
share responsibility with the purchaser over a seven-year
period, with the Companys share decreasing to zero over
the seven-year period. The Companys maximum aggregate
liability for such unknown environmental matters is
£5.0 million.
93
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
The Company does not anticipate any material exposure related to
the environmental indemnifications for the microelectronic
materials, sulfuric acid and the Hickson organics dispositions,
aside from what has all ready been provided for by the Company
for the microelectronic materials and Hickson organics
Castleford location. The Company has estimated that the fair
value of any such additional exposure would be immaterial.
The Companys Consolidated Balance Sheets included
liabilities for future environmental expenditures to investigate
and remediate known sites amounting to $8.3 million and
$8.6 million at December 31, 2004 and 2003,
respectively. The Companys estimated environmental
liability relates to seven sites, six of which are in the United
States and none of which are on the U.S. National Priority
List. These amounts did not take into account any discounting of
future expenditures, any consideration of insurance recoveries
or any advances in technology. These liabilities are reassessed
periodically to determine if environmental circumstances have
changed or if the costs of remediation efforts can be better
estimated. As a result of these reassessments, future charges to
income may be made for additional liabilities.
Environmental exposures are difficult to assess for numerous
reasons, including the identification of new sites, developments
at sites resulting from investigatory studies and remedial
activities, advances in technology, changes in environmental
laws and regulations and their application, the scarcity of
reliable data pertaining to identified sites, the difficulty in
assessing the involvement and financial capability of other
potentially responsible parties and the Companys ability
to obtain contributions from other parties and the length of
time over which site remediation occurs. It is possible that
some of these matters (the outcomes of which are subject to
various uncertainties) may be resolved unfavorably against the
Company. At December 31, 2004, the Company had estimated
additional contingent environmental liabilities of
$7.3 million.
|
|
21. |
U.S. Government Contract |
The Company was notified by the U.S. Defense Energy Support
Center (DESC), on April 30, 2004, that it had
not been awarded the 10-year hydrazine propellant supply
contract which the Company had anticipated receiving. The
Company had a debriefing with the DESC and submitted a formal
protest of the award. In July 2004, the U.S. Government
Accountability Office (GAO) informed Arch and the
DESC that the GAO will sustain the Companys formal protest
of the DESCs recent decision to award the
governments next 10-year hydrazine propellant supply
contract to a competing firm. As a result of the GAOs
decision, the DESC notified the Company that it has taken
corrective action by re-opening the bidding process. The Company
submitted its new bid on January 20, 2005. Final revised
bids are currently due March 15, 2005. The DESC has
notified the Company that it anticipates completing its
contract-award decision in the first quarter or early in the
second quarter of 2005.
The hydrazine business as a whole is not core to the
Companys portfolio, is not a growth business and has been
managed for cash for several years. As of December 31, the
Company reassessed the potential impairment of its entire
hydrazine business, which consists of a hydrazine propellant and
a hydrazine hydrate product line, as a result of the original
DESC decision. This assessment was based upon a weighted average
probability of cash flows, which included an estimate of
obtaining the new contract. As a result of such reassessments at
December 31, 2004, the Company did not incur an impairment
charge but has incurred severance costs in connection with
headcount reductions at the Lake Charles, Louisiana
manufacturing facility.
If the Company ultimately does not win the contract after the
re-opening the bidding process, the Company estimates the
potential one-time pre-tax charge related to these decisions to
be the following (unaudited):
The Company may incur a non-cash impairment charge for the
long-lived assets of the hydrazine business. As of
December 31, 2004, the estimate of the amount of the
impairment would be approximately $13 million, including
the assets associated with the propellants product line. In
addition, the Company may
94
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
incur cash costs for shutdown and the present value of certain
presumed contractual obligations that are assumed to no longer
have any benefit to the Company. (Such annual contractual
payments are approximately $2.3 million through 2011.) The
estimated amount of the pre-tax cash charge resulting from these
costs is approximately $15 million. These one-time cash
costs are expected to be more than offset by payments to be
received from the U.S. Government upon the shut down of the
Lake Charles, LA and McIntosh, AL propellants facilities. The
present values of such payments are approximately
$19 million. The projected annual cash flows relating to
these decisions are estimated to be the following over the next
three years and beyond:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
2005 | |
|
2006 | |
|
2007 | |
|
Thereafter | |
|
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Cash Inflow (Outflow)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Contractual obligations
|
|
$ |
(2.3 |
) |
|
$ |
(2.3 |
) |
|
$ |
(2.3 |
) |
|
$ |
(9.2 |
) |
Shutdown costs
|
|
|
(1.0 |
) |
|
|
|
|
|
|
(2.0 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Sub-total
|
|
|
(3.3 |
) |
|
|
(2.3 |
) |
|
|
(4.3 |
) |
|
|
(9.2 |
) |
U.S. government receipts
|
|
|
8.5 |
|
|
|
|
|
|
|
13.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Net Cash Flows
|
|
$ |
5.2 |
|
|
$ |
(2.3 |
) |
|
$ |
9.2 |
|
|
$ |
(9.2 |
) |
|
|
|
|
|
|
|
|
|
|
|
|
|
The net aggregate pre-tax charge for one-time items is expected
to be approximately $9 million, net of the payments to be
received from the U.S. Government.
The 35-month contract secured in November 2003 for storage and
distribution services of the DESCs hydrazine-based
propellants products, valued at $4.3 million, is not
affected by its decision nor is the award in February 2004 to
the Company of the $11.9 million Ultra
Puretm
hydrazine 25-month supply contract. Although the Company does
not currently manufacture hydrazine, it will continue to
manufacture and sell Ultra
Puretm
hydrazine from existing hydrazine inventory. The Company also
provides proprietary blends using hydrazine sourced through
third party producers.
In February 2004, the Company was awarded a twenty-five month
contract valued at $11.9 million, with the Department of
Defense for Ultra
Puretm
Hydrazine. This contract began January 1, 2005 and will
provide fuel for future satellite programs.
In 2004, 2003, and 2002, the Companys performance products
segment sales include $12.4 million, $23.9 million and
$26.4 million, respectively, related to these agreements.
|
|
22. |
Restructuring and Other Gains (Losses) |
Restructuring
Results for 2004, 2003 and 2002 include restructuring (income)
expense totaling $1.7 million, $0.4 million and
$5.7 million, respectively. In addition, included within
the results of the microelectronic materials business which have
been reclassified into discontinued operations for 2003 and 2002
is restructuring (income) expense of $(1.0) million and
$1.9 million, respectively.
Restructuring expense of $1.7 million in 2004 includes
$2.1 million for severance costs related to headcount
reductions in the hydrazine business due to the expiration of
the government contract, offset by a reduction of
$0.4 million of prior year restructuring reserves for
revisions to previous plans estimates.
The 2003 restructuring expense consists of $1.4 million for
headcount reductions of approximately 30 employees in the
performance products segment. The headcount reductions are due
to the reorganization
95
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
related to the sale of the sulfuric acid business and the
temporary idling of the Companys hydrazine hydrate plant
in Lake Charles, Louisiana. It also includes a charge of
$1.1 million, for additional headcount reductions
associated with a revision to the 2002 organizational
restructuring program, offset by a reduction in the prior
years restructuring reserves of $2.1 million for
revisions to previous plans estimates. In addition, there
is $1.0 million reduction in the prior years
restructuring reserves for revisions to previous plans
estimates included in discontinued operations for the
microelectronic materials business.
The 2002 restructuring charge of $5.7 million included
$4.7 million related to headcount reductions of
approximately 140 employees in the performance urethanes and HTH
water products businesses, as well as a charge related to the
consolidation of several treatment products segment operations.
The non-cash portion of the restructuring charge was
approximately $1.0 million. In addition, there is
$1.9 million restructuring charge related to headcount
reductions in the microelectronic materials business which is
included in discontinued operations.
The 2001 restructuring of $1.5 million includes a
restructuring charge of $2.4 million for headcount
reductions at corporate and at the performance urethanes
business offset by a $1.5 million reduction of the 2000
restructuring reserve to its estimated remaining liability as of
December 31, 2001. In addition, the Company recorded
restructuring income of $0.2 million for the reimbursement
of certain severance costs which were previously recorded in the
fourth quarter of 2000, and a charge of $0.8 million
consisting of retention payments made to employees as a result
of the Companys restructuring of the process chemicals
business. The 2001 headcount reductions affected approximately
30 individuals. As a result of the sale of the microelectronic
materials business, the $0.8 million has been included in
discontinued operations.
The 2000 restructuring charge of $34.0 million included
$8.9 million of costs associated with headcount reductions
and contractual vendor obligations of the process chemicals
business, $14.1 million related to the biocides business
for the write-off of certain costs associated with the
abandonment of construction of a facility in China, the
completion of a consolidation study, and additional headcount
reductions, and $11.0 million related to headcount
reductions at other businesses and corporate. Total headcount
reductions affected approximately 450 individuals. The non-cash
portion of the restructuring charges was approximately
$13 million. As a result of the sale of the microelectronic
materials business, $8.9 million of restructuring costs and
the $31.0 million impairment charge has been reclassified
to be included in discontinued operations.
The following table summarizes activity related to restructuring
costs:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Severance | |
|
Asset | |
|
|
|
|
|
|
Costs | |
|
Write-downs | |
|
Other Items | |
|
Total | |
|
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Provision
|
|
$ |
18.0 |
|
|
$ |
11.0 |
|
|
$ |
5.0 |
|
|
$ |
34.0 |
|
2000 Activity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments
|
|
|
1.4 |
|
|
|
|
|
|
|
|
|
|
|
1.4 |
|
|
Utilized
|
|
|
|
|
|
|
11.0 |
|
|
|
|
|
|
|
11.0 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2000
|
|
|
16.6 |
|
|
|
|
|
|
|
5.0 |
|
|
|
21.6 |
|
2001 Activity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Provision
|
|
|
2.4 |
|
|
|
|
|
|
|
|
|
|
|
2.4 |
|
|
Payments
|
|
|
11.0 |
|
|
|
|
|
|
|
1.6 |
|
|
|
12.6 |
|
|
Reclass postemployment liability
|
|
|
2.5 |
|
|
|
|
|
|
|
|
|
|
|
2.5 |
|
|
Reserve reduction
|
|
|
0.3 |
|
|
|
|
|
|
|
1.2 |
|
|
|
1.5 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
96
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Severance | |
|
Asset |
|
|
|
|
|
|
Costs | |
|
Write-downs |
|
Other Items | |
|
Total | |
|
|
| |
|
|
|
| |
|
| |
|
|
($ in millions) | |
Balance at December 31, 2001
|
|
|
5.2 |
|
|
|
|
|
|
|
2.2 |
|
|
|
7.4 |
|
2002 Activity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Provision
|
|
|
6.6 |
|
|
|
|
|
|
|
1.0 |
|
|
|
7.6 |
|
|
Payments
|
|
|
6.1 |
|
|
|
|
|
|
|
0.5 |
|
|
|
6.6 |
|
|
Reclass postemployment liability
|
|
|
0.5 |
|
|
|
|
|
|
|
|
|
|
|
0.5 |
|
|
Utilized
|
|
|
|
|
|
|
|
|
|
|
0.4 |
|
|
|
0.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2002
|
|
|
5.2 |
|
|
|
|
|
|
|
2.3 |
|
|
|
7.5 |
|
2003 Activity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Provision
|
|
|
2.5 |
|
|
|
|
|
|
|
|
|
|
|
2.5 |
|
|
Payments
|
|
|
3.8 |
|
|
|
|
|
|
|
0.7 |
|
|
|
4.5 |
|
|
Utilized
|
|
|
0.6 |
|
|
|
|
|
|
|
|
|
|
|
0.6 |
|
|
Reserve reduction
|
|
|
1.9 |
|
|
|
|
|
|
|
1.2 |
|
|
|
3.1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2003
|
|
|
1.4 |
|
|
|
|
|
|
|
0.4 |
|
|
|
1.8 |
|
2004 Activity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Provision
|
|
|
2.1 |
|
|
|
|
|
|
|
|
|
|
|
2.1 |
|
|
Payments
|
|
|
1.5 |
|
|
|
|
|
|
|
0.1 |
|
|
|
1.6 |
|
|
Utilized
|
|
|
1.0 |
|
|
|
|
|
|
|
|
|
|
|
1.0 |
|
|
Reserve reduction
|
|
|
0.2 |
|
|
|
|
|
|
|
0.2 |
|
|
|
0.4 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2004
|
|
$ |
0.8 |
|
|
$ |
|
|
|
$ |
0.1 |
|
|
$ |
0.9 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
As of December 31, 2004, 2003 and 2002, $42.7 million,
$40.1 million and $35.0 million, respectively, had
been charged against restructuring reserves. As of
December 31, 2004, all employees from each restructuring
program have been terminated with a portion still receiving
benefits under the 2004 program. At December 31, 2004 and
2003, $0.9 million and $1.8 million, respectively, of
restructuring reserves were included in Accrued Liabilities in
the accompanying Consolidated Balance Sheets. All of the costs
related to the 2000, 2001 and 2003 programs have been incurred
and no accrual relates to these restructuring programs. An
accrual remains for the 2002 program related to office
consolidation space.
As a result of the acquisition of the Avecia pool and spa and
protection and hygiene businesses, the Company incurred
$4.6 million for headcount reductions at the U.S. and U.K.
locations and office closure costs in the U.S. which has been
included as a component of goodwill. The following table
summarizes activity related to this plan:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Severance and | |
|
|
|
|
|
|
Relocation | |
|
|
|
|
|
|
Costs | |
|
Other Items | |
|
Total | |
|
|
| |
|
| |
|
| |
|
|
($ in millions) | |
Provision
|
|
$ |
4.1 |
|
|
$ |
0.5 |
|
|
$ |
4.6 |
|
2004 Activity:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Payments
|
|
|
3.2 |
|
|
|
|
|
|
|
3.2 |
|
|
|
|
|
|
|
|
|
|
|
Balance at December 31, 2004
|
|
$ |
0.9 |
|
|
$ |
0.5 |
|
|
$ |
1.4 |
|
|
|
|
|
|
|
|
|
|
|
97
ARCH CHEMICALS, INC. and SUBSIDIARIES
NOTES TO CONSOLIDATED FINANCIAL
STATEMENTS (Continued)
Other (gains) and losses in 2004 principally includes a
charge for a Brazilian state import tax claim of
$2.1 million in the performance urethanes, HTH water
products and hydrazine businesses, offset by the pre-tax gain of
$0.6 million on the sale of a building in the personal care
business.
Other gains and losses in 2003 include the pre-tax gain on the
sales of two warehouses of $0.5 million and the sale of
excess land of $2.5 million. Total proceeds of the sale of
excess land were $6.5 million. Proceeds consist of cash of
$2.0 million and a note of $4.5 million. The note is
payable in two installments, $0.5 million is due by
March 31, 2005 and $4.0 million is due by
September 30, 2006. The note is collateralized by the
property. The note bears interest per the ten-year constant
maturity treasury index.
2002 other gains and losses include the pre-tax gain on sales of
excess land of $1.8 million.
|
|
23. |
Quarterly Financial Data (Unaudited) |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
First | |
|
Second | |
|
Third | |
|
Fourth | |
|
|
2004 |
|
Quarter | |
|
Quarter | |
|
Quarter | |
|
Quarter | |
|
Year | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
|
|
($ in millions, except per share amounts) | |
Sales
|
|
$ |
240.3 |
|
|
$ |
362.0 |
|
|
$ |
276.8 |
|
|
$ |
241.8 |
|
|
$ |
1,120.9 |
|
Gross margin
|
|
|
65.1 |
|
|
|
113.9 |
|
|
|
73.9 |
|
|
|
60.0 |
|
|
|
312.9 |
|
Net income (loss)
|
|
|
3.0 |
|
|
|
25.2 |
|
|
|
5.6 |
|
|
|
(13.9 |
) |
|
|
19.9 |
|
Diluted income (loss) per share from continuing operations
before cumulative effect of accounting change
|
|
|
0.10 |
|
|
|
0.93 |
|
|
|
0.07 |
|
|
|
(0.36 |
) |
|
|
0.74 |
|
Diluted income (loss) per share
|
|
|
0.13 |
|
|
|
1.07 |
|
|
|
0.24 |
|
|
|
(0.59 |
) |
|
|
0.84 |
|
Stock market price:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High
|
|
|
28.60 |
|
|
|
30.18 |
|
|
|
29.49 |
|
|
|
30.87 |
|
|
|
30.87 |
|
|
Low
|
|
|
23.41 |
|
|
|
24.70 |
|
|
|
25.04 |
|
|
|
26.76 |
|
|
|
23.41 |
|
|
Close (at end of quarter)
|
|
|
28.23 |
|
|
|
28.82 |
|
|
|
28.50 |
|
|
|
28.78 |
|
|
|
28.78 |
|
Common dividend paid per share
|
|
|
0.20 |
|
|
|
0.20 |
|
|
|
0.20 |
|
|
|
0.20 |
|
|
|
0.80 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
First | |
|
Second | |
|
Third | |
|
Fourth | |
|
|
2003 |
|
Quarter | |
|
Quarter | |
|
Quarter | |
|
Quarter | |
|
Year | |
|
|
| |
|
| |
|
| |
|
| |
|
| |
Sales
|
|
$ |
189.4 |
|
|
$ |
270.9 |
|
|
$ |
219.7 |
|
|
$ |
183.5 |
|
|
$ |
863.5 |
|
Gross margin
|
|
|
54.1 |
|
|
|
80.6 |
|
|
|
62.4 |
|
|
|
48.3 |
|
|
|
245.4 |
|
Net income (loss)
|
|
|
1.4 |
|
|
|
10.9 |
|
|
|
17.7 |
|
|
|
(2.6 |
) |
|
|
27.4 |
|
Diluted income (loss) per share from continuing operations
before cumulative effect of accounting change
|
|
|
0.07 |
|
|
|
0.53 |
|
|
|
0.04 |
|
|
|
(0.19 |
) |
|
|
0.45 |
|
Diluted income (loss) per share
|
|
|
0.06 |
|
|
|
0.48 |
|
|
|
0.78 |
|
|
|
(0.11 |
) |
|
|
1.21 |
|
Stock market price:
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
High
|
|
|
20.25 |
|
|
|
21.82 |
|
|
|
22.93 |
|
|
|
25.80 |
|
|
|
25.80 |
|
|
Low
|
|
|
15.15 |
|
|
|
18.00 |
|
|
|
18.42 |
|
|
|
19.97 |
|
|
|
15.15 |
|
|
Close (at end of quarter)
|
|
|
18.70 |
|
|
|
19.10 |
|
|
|
20.80 |
|
|
|
25.66 |
|
|
|
25.66 |
|
Common dividend paid per share
|
|
|
0.20 |
|
|
|
0.20 |
|
|
|
0.20 |
|
|
|
0.20 |
|
|
|
0.80 |
|
98
|
|
Item 9. |
Changes in and Disagreements with Accountants on
Accounting and Financial Disclosure |
Not Applicable.
|
|
Item 9A. |
Controls and Procedures |
As of December 31, 2004 (Evaluation Date), the
Company conducted an evaluation, under the supervision and with
the participation of the Companys chief executive officer
and chief financial officer, pursuant to Rule 13a-15
promulgated under the Securities Exchange Act of 1934, as
amended (Exchange Act) of the effectiveness of the
design and operation of the Companys disclosure controls
and procedures. Based on this evaluation, the Companys
chief executive officer and chief financial officer concluded
that as of the Evaluation Date such disclosure controls and
procedures were effective to provide reasonable assurance that
information required to be disclosed by the Company in reports
it files or submits under the Exchange Act is recorded,
processed, summarized and reported within the time period
specified in the rules and forms of the Securities and Exchange
Commission. As permitted by the SEC, the Company has excluded
the former Avecia entities acquired by the Company in 2004 from
its evaluation of the effectiveness of internal control over
financial reporting. The Companys consolidated sales for
the year ended December 31, 2004 were $1.1 billion, of
which the former Avecia entities represented $102 million. The
Companys total consolidated assets as of December 31,
2004, were $1.1 billion, of which the former Avecia entities
represented $238 million (approximately $179 million consists of
goodwill and other intangibles). The Company also has
investments in certain unconsolidated entities. As the Company
does not control or manage these entities, its disclosure
controls and procedures with respect to such entities are
necessarily more limited than those it maintains with respect to
its consolidated subsidiaries.
There were no changes in the Companys internal control
over financial reporting (as defined in Rule 13a-15(f)
promulgated under the Exchange Act) during the fourth quarter of
2004 that materially affected, or are reasonably likely to
materially affect, the Companys internal control over
financial reporting.
MANAGEMENT REPORT
Management is responsible for the preparation and integrity of
the Consolidated Financial Statements appearing in this Annual
Report. The Consolidated Financial Statements were prepared in
conformity with accounting principles generally accepted in the
United States and include amounts based on managements
estimates and judgments. All other financial information in this
report has been presented on a basis consistent with the
information included in the Consolidated Financial Statements.
Management is also responsible for establishing and maintaining
an adequate system of internal control over financial reporting
as defined in Rules 13a-15(f) and 15d-l5(f) promulgated
under the Securities Exchange Act of 1934. We maintain a system
of internal controls that is designed to provide reasonable
assurance as to the fair and reliable preparation and
presentation of the Consolidated Financial Statements in
accordance with generally accepted accounting principles, as
well as to safeguard assets from unauthorized use or disposition.
Our control environment is the foundation for our system of
internal control over financial reporting and is embodied in our
Code of Ethics. Our internal control over financial reporting
includes written policies and procedures that:
|
|
|
|
|
pertain to the maintenance of records that, in reasonable
detail, accurately and fairly reflect the transactions of the
Company; |
|
|
|
provide reasonable assurance that transactions are recorded as
necessary to permit preparation of financial statements in
accordance with generally accepted accounting principles; |
|
|
|
provide reasonable assurance that receipts and expenditures of
the Company are made in accordance with the appropriate
authorization of management and the directors of the Company; and |
99
|
|
|
|
|
provide reasonable assurance regarding prevention or timely
detection of unauthorized acquisition, use or disposition of
assets that could have a material effect on the consolidated
financial statements. Internal control over financial reporting
includes the controls themselves, monitoring and internal
auditing practices and remedial actions to correct deficiencies
as they are identified. |
Management evaluated the effectiveness of the Companys
internal control over financial reporting as of
December 31, 2004. Management based such assessment upon
the criteria set forth in Internal Control
Integrated Framework issued by the Committee of Sponsoring
Organizations of the Treadway Commission. This evaluation
included review of the documentation of controls, evaluation of
the design effectiveness of controls, testing of the operating
effectiveness of controls and a conclusion on this evaluation.
Although there are inherent limitations in the effectiveness of
any system of internal controls over financial reporting, based
on our evaluation, we have concluded that our internal controls
over financial reporting were effective as of December 31,
2004. As permitted by the U.S. Securities and Exchange
Commission, the Company has excluded the former Avecia entities
acquired by the Company in 2004 from its evaluation of the
effectiveness of internal control over financial reporting. The
Companys consolidated sales for the year ended
December 31, 2004 were $1.1 billion, of which the
former Avecia entities represented $102 million. The
Companys total consolidated assets as of December 31,
2004, were $1.1 billion, of which the former Avecia
entities represented $238 million (approximately
$179 million consists of goodwill and other intangibles).
KPMG LLP, an independent registered public accounting firm, has
issued an attestation report on managements assessment of
internal control over financial reporting, which is included on
the following page.
|
|
|
Michael E. Campbell
|
|
Louis S. Massimo
|
Chairman of the Board, President
|
|
Executive Vice President and Chief Financial Officer |
and Chief Executive Officer
|
|
|
100
REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
The Board of Directors and Shareholders
Arch Chemicals, Inc.
We have audited managements assessment, included in the
accompanying Management Report, that Arch Chemicals, Inc. and
subsidiaries maintained effective internal control over
financial reporting as of December 31, 2004, based on
criteria established in Internal
Control Integrated Framework issued by the
Committee of Sponsoring Organizations of the Treadway Commission
(COSO). The Companys management is responsible for
maintaining effective internal control over financial reporting
and for its assessment of the effectiveness of internal control
over financial reporting. Our responsibility is to express an
opinion on managements assessment and an opinion on the
effectiveness of the Companys 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, evaluating
managements assessment, testing and evaluating the design
and operating effectiveness of internal control, 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 companys internal control over financial reporting is a
process designed 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 companys
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
companys assets that could have a material effect on the
financial statements.
Because of its inherent limitations, internal control over
financial reporting may not prevent or detect misstatements.
Also, projections of any evaluation of effectiveness to future
periods are subject to the risk that 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, managements assessment that Arch
Chemicals, Inc. and subsidiaries maintained effective internal
control over financial reporting as of December 31, 2004,
is fairly stated, in all material respects, based on criteria
established in COSO. Also, in our opinion, Arch Chemicals, Inc.
and subsidiaries maintained, in all material respects, effective
internal control over financial reporting as of
December 31, 2004, based on criteria established in COSO.
As permitted by the U.S. Securities and Exchange Commission, the
Company has excluded the former Avecia entities acquired by the
Company in 2004 from its evaluation of the effectiveness of
internal controls over financial reporting. The Companys
consolidated sales for the year ended December 31, 2004 were
$1.1 billion, of which the former Avecia entities
represented $102 million. The Companys total
consolidated assets as of December 31, 2004, were $l.l
billion, of which the former Avecia entities represented
$238 million (approximately $179 million consists of
goodwill and other intangibles). Our audit of internal control
over financial reporting of Arch Chemicals, Inc. also excluded
an evaluation of the internal control over financial reporting
of the former Avecia entities acquired.
We also have audited, in accordance with the standards of the
Public Company Accounting Oversight Board (United States), the
consolidated balance sheets of Arch Chemicals, Inc. and
subsidiaries as of
101
December 31, 2004 and 2003, and the related consolidated
statements of income, shareholders equity and cash flows
for each of the years in the three-year period ended
December 31, 2004, and our report dated March 14, 2005
expressed an unqualified opinion on those consolidated financial
statements.
Stamford, CT
March 14, 2005
|
|
Item 9B. |
Other Information |
Not applicable.
PART III
|
|
Item 10. |
Directors and Executive Officers of the Registrant |
The information relating to the Companys Directors under
the paragraphs entitled Who are the persons nominated by
the Board in this election to serve as directors? and
Who are the other remaining directors and when are their
terms scheduled to end? under the heading
Item 1 Election of Directors in the
Proxy Statement relating to the Companys 2005 Annual
Meeting of Shareholders (the Proxy Statement) is
incorporated by reference in this Report. See also the list of
executive officers following Item 4 of this Report. The
information regarding compliance with Section 16 of the
Securities Exchange Act of 1934, as amended, contained in the
paragraph entitled Section 16(a) Beneficial Ownership
Reporting Compliance under the heading Security
Ownership of Directors and Officers in the Proxy Statement
is incorporated by reference in this Report.
The Company has a code of conduct that applies to all officers
and employees, including the Companys principal executive
officer, principal financial officer and principal accounting
officer. The Companys code of conduct is on its website
at: http://www.archchemicals.com in the Investor
Relations section under Corporate Governance. The Company will
post any amendments to the code of conduct, as well as any
waivers that are required to be disclosed by the rules of either
the Securities and Exchange Commission or the New York Stock
Exchange, on its website.
The Board of Directors has adopted Principles of Corporate
Governance and charters for the Audit, Compensation and
Corporate Governance Committees of the Board of Directors. These
documents can be found on the Companys website by going to
the following address: http://www.archchemicals.com in
the Investor Relations section under Corporate Governance. A
printed copy of such code and such principles and charters can
be obtained by contacting Investor Relations, Arch Chemicals,
Inc., 501 Merritt 7, P.O. Box 5204, Norwalk, CT
06856-5204 or calling (203) 229-2654.
The Audit Committee of the Board of Directors is an audit
committee for purposes of Section 3(a)(58) of the
Securities Exchange Act of 1934. As of March 1, 2005, the
members of the Committee are: John P. Schaefer (chair), Michael
O. Magdol and Janice J. Teal. The information under the heading
Who is the Audit Committee expert? in the Proxy
Statement is incorporated by reference in the Report.
|
|
Item 11. |
Executive Compensation |
The information under the heading Executive
Compensation in the Proxy Statement (but excluding the
Report of the Compensation Committee on Executive Compensation
contained in the Proxy Statement and the performance graph
contained in the Proxy Statement) is incorporated by reference
in this Report. The information under the heading
Additional Information Regarding the Board of
Directors What are the directors paid for their
services? in the Proxy Statement is incorporated by
reference in this Report.
102
|
|
Item 12. |
Security Ownership of Certain Beneficial Owners and
Management and Related Stockholder Matters |
The information concerning holdings of Company stock by certain
beneficial owners contained under the heading Certain
Beneficial Owners in the Proxy Statement and the
information concerning beneficial ownership of Common Stock by
directors and officers of the Company under the heading
Security Ownership of Directors and Officers in the
Proxy Statement are incorporated by reference in this Report.
The equity plan information contained under the heading
Equity Plan Information in
Item 3 Approval of the 1999 Long
Term Incentive Plan of the Proxy Statement is incorporated
herein by reference.
|
|
Item 13. |
Certain Relationships and Related Transactions |
Not applicable.
|
|
Item 14. |
Principal Accountant Fees and Services |
The information contained under the headings What were
KPMG fees in 2003 and 2004? and Pre-Approval Policy
and Provisions in the Proxy Statement is incorporated by
reference in this Report.
103
PART IV
|
|
Item 15. |
Exhibits and Financial Statement Schedules |
(a) 1. Financial
Statements
The following is a list of the Financial Statements included in
Item 8 of this Report:
2. Financial Statement
Schedules
Except as noted below, schedules not included herein are omitted
because they are inapplicable or not required or because the
required information is given in the consolidated financial
statements and notes thereto.
The financial statements of the Companys Nordesclor joint
venture and Koppers Arch joint venture have been summarized
within the Notes to the Consolidated Financial Statements due to
the significance of their results to the consolidated Company.
Separate financial statements of the remaining 50% or less owned
companies accounted for by the equity method are not summarized
herein and have been omitted because they would not constitute a
significant subsidiary.
Due to the significance of the Companys former FUJIFILM
Arch joint venture as of December 31, 2003, the Company
filed audited financial statements of the joint venture for the
fiscal year ended March 31, 2004 and certain unaudited
financial information for the fiscal years ended March 31,
2003 and 2002, pursuant to SEC Rule 3-09 of
Regulation S-X. The Company filed the financial statements
as an amendment to its December 31, 2003 10-K on
July 22, 2004.
In February 2005, the SEC staff asked the Company to amend its
2003 10-K filing to include audited financial statements for the
fiscal year ended March 31, 2003 and unaudited financial
statements for the fiscal year ended March 31, 2002 for
this joint venture. Under its interpretation, the Company was
required to perform the test of significance in 2003, of the
prior year, utilizing the restated financial information for
2002 that resulted from a business being treated as discontinued
operations. As a result, the joint venture was a significant
subsidiary in 2002 as well as 2003. The Company is appealing the
staffs position. If such appeal is unsuccessful, the
Company will be required to file audited financial statements
for the fiscal year ended March 31, 2003 and unaudited
financial statements for the fiscal year ended March 31,
2002 for this joint venture which was sold in connection with
the sale of the majority of its microelectronic materials
business in 2004 and which along with the other microelectronic
materials businesses sold are reflected as discontinued
operations in the Companys financial statements for all
periods contained in this Report.
Currently, the Company is evaluating its ability to obtain
audited financial statements for the fiscal year ended
March 31, 2003.
In light of the particular factors and circumstances regarding
this matter, the Company has modified its detailed procedures in
preparation of its 10-K to add a specific reference that
Rule 1-02(w) be reviewed in light of the staffs
position in the event of a restatement.
104
3. Exhibits
Management contracts and compensatory plans and arrangements are
listed as Exhibits 10.7 through 10.19 below.
|
|
|
|
|
|
2 |
.1 |
|
Share Purchase Agreement, dated August 11, 2003, among
Hickson Limited, Greentag (8) Limited, Hickson International
Limited, Arch Chemicals, Inc. and Hickson & Welch
Chemical Products Limited Exhibit 2 to the
Companys Current Report on Form 8-K, filed August 18,
2003.* |
|
2 |
.2 |
|
Restated Sale and Purchase Agreement dated as of 8th March 2004,
restating an agreement made between the parties on
4th March 2004 Exhibit 2.1 to the
Companys Current Report on Form 8-K, filed March 9,
2004.* |
|
2 |
.3 |
|
Stock and Asset Purchase Agreement dated as of October 24,
2004 between Arch Chemicals, Inc. and Fuji Photo Film Co.,
Ltd. Exhibit 2 to the Companys Current
Report on Form 8-K, filed October 24, 2004.* |
|
2 |
.4 |
|
First Amendment dated as of November 30, 2004 to the Stock
and Asset Purchase Agreement dated as of October 24, 2004
between Arch Chemicals, Inc. and Fuji Photo Film Co.,
Ltd. Exhibit 2 to the Companys Current
Report on Form 8-K, filed December 6, 2004.* |
|
3 |
.1 |
|
Amended and Restated Articles of Incorporation of the
Company Exhibit 3.1 to the Companys
Current Report on Form 8-K, filed February 17, 1999.* |
|
3 |
.2 |
|
Bylaws of the Company as amended July 22, 2004
Exhibit 3 to the Companys Quarterly Report on Form
10-Q for the period ending June 30, 2004.* |
|
4 |
.1 |
|
Specimen Common Share certificate Exhibit 4.1
to the Companys Registration Statement on Form 10, as
amended.* |
|
4 |
.2 |
|
Amended and Restated Articles of Incorporation of the Company
(filed as Exhibit 3.1 hereto).* |
|
4 |
.3 |
|
Bylaws of the Company (filed as Exhibit 3.2 hereto).* |
|
4 |
.4(a) |
|
Rights Agreement dated as of January 29, 1999 between the
Company and ChaseMellon Shareholder Services, L.L.C., as Rights
Agent Exhibit 4.1 to the Companys Current
Report on Form 8-K, filed February 17, 1999.* |
|
4 |
.4(b) |
|
Amendment No. 1, dated July 25, 1999, to Rights
Agreement, dated as of January 29, 1999
Exhibit 4 to the Companys Quarterly Report on Form
10-Q, for the period ending June 30, 1999.* |
|
4 |
.4(c) |
|
Amendment No. 2, dated April 26, 2002, to Rights
Agreement, dated as of January 29, 1999
Exhibit 4 to the Companys Quarterly Report on Form
10-Q for the period ending March 31, 2002.* |
|
4 |
.5 |
|
Form of Rights Certificate (attached as Exhibit B to the
Rights Agreement filed as Exhibit 4.4(a) hereto).* |
|
4 |
.6(a) |
|
Revolving Credit Agreement, dated as of June 20, 2003 among
Arch Chemicals, Inc., The Lenders Party hereto, JPMorgan Chase
Bank, as Administrative Agent, J.P. Morgan Securities Inc.,
as Joint Lead Arranger and Joint Book Manager, Banc of America
Securities, L.L.C., as Joint Lead Arranger and Joint Book
Manager, Bank of America, National Association, as Documentation
Agent, and Fleet National Bank, as Syndication
Agent, Exhibit 4 to the Companys
Quarterly Report on Form 10-Q for the period ending
June 30, 2003.* |
|
|
* |
Previously filed as indicated and incorporated herein by
reference. Exhibits incorporated by reference are located in SEC
File No. 1-14601 unless otherwise indicated. |
105
|
|
|
|
|
|
4 |
.6(b) |
|
First Amendment entered into as of February 20, 2004
relating to the Revolving Credit Agreement dated as of
June 30, 2003 among the Company, The Lenders Party hereto,
JPMorgan Chase Bank, as administrative agent, JPMorgan
Securities Inc., as Joint Lead Arranger and Joint Book Manager,
Banc of America Securities, L.L.C., as Joint Lead Arranger and
Joint Book Manager, Bank of America, National Association, as
Documentation Agent, and Fleet National Bank, as Syndication
Agent Exhibit 4.1 to the Companys Current
Report on Form 8-K, filed March 9, 2004.* |
|
4 |
.7(a) |
|
Note Purchase Agreement, dated as of March 20, 2002, among
the Company and the purchasers named therein, relating to the
Companys $149,000,000 Senior Notes, Series A, due
March 20, 2007 and $62,000,000 Senior Notes, Series B,
due March 20, 2009 Exhibit 4.8 to the
Companys Annual Report on Form 10-K for the period ending
December 31, 2001.* |
|
4 |
.7(b) |
|
First Amendment entered into as of February 27, 2004
relating to the Note Purchase Agreement dated as of
March 20, 2002 among the Company and the purchasers named
therein, relating to the Companys $149,000,000 Senior
Notes, Series A, due March 20, 2007 and $62,000,000
Senior Notes, Series B, due March 20, 2009
Exhibit 4.2 to the Companys Current Report on Form
8-K, filed March 8, 2004.* |
|
10 |
.1 |
|
Distribution Agreement, dated as of February 1, 1999,
between the Company and Olin Exhibit 2 to the
Companys Current Report on Form 8-K, filed
February 17, 1999.* |
|
10 |
.2 |
|
Form of Employee Benefits Allocation Agreement between the
Company and Olin Exhibit 10.4 to the
Companys Annual Report on Form 10-K for the period ending
December 31, 1998.* |
|
10 |
.3 |
|
Form of Intellectual Property Transfer and License Agreement
between the Company and Olin Exhibit 10.9 to
the Companys Registration Statement on Form 10, as
amended.* |
|
10 |
.4 |
|
Form of Sublease between the Company and Olin
Exhibit 10.5 to the Companys Registration Statement
on Form 10, as amended.* |
|
10 |
.5 |
|
Tax Sharing Agreement, dated as of February 8, 1999,
between the Company and Olin Exhibit 10.9 to
the Companys Annual Report on Form 10-K for the period
ending December 31, 1998.* |
|
10 |
.6 |
|
Charleston Services Agreement, dated as of February 8,
1999, between the Company and Olin
Exhibit 10.10 to the Companys Annual Report on Form
10-K for the period ending December 31, 1998.* |
|
10 |
.7(a) |
|
Form of Executive Agreement Exhibit 10.1 to the
Companys Current Report on Form 8-K, filed January 5,
2005.* |
|
10 |
.7(b) |
|
Form of Change in Control Agreement
Exhibit 10.2 to the Companys Current Report on
Form 8-K, filed January 5, 2005.* |
|
10 |
.8 |
|
1999 Stock Plan for Non-employee Directors, as amended
October 28, 2004 Exhibit 10 to the
Companys Quarterly Report on Form 10-Q for the period
ending September 30, 2004.* |
|
10 |
.9 |
|
1999 Long Term Incentive Plan, as amended through
February 9, 2005. |
|
10 |
.10 |
|
Supplemental Contributing Employee Ownership Plan, as amended
and restated January 30, 2003 Exhibit 10.10 to
the Companys Annual Report on Form 10-K for the
period ending December 31, 2003.* |
|
10 |
.11 |
|
Supplementary and Deferral Benefit Pension Plan, as amended
July 29, 1999 Exhibit 10.16 to the
Companys Annual Report on Form 10-K for the period ending
December 31, 1999.* |
|
10 |
.12 |
|
Senior Executive Pension Plan, as amended and restated as of
October 23, 2003 Exhibit 10.12 to the
Companys Annual Report on Form 10-K for the period ending
December 31, 2003.* |
|
|
* |
Previously filed as indicated and incorporated herein by
reference. Exhibits incorporated by reference are located in SEC
File No. 1-14601 unless otherwise indicated. |
106
|
|
|
|
|
|
10 |
.13 |
|
Employee Deferral Plan, as amended and restated January 30,
2003 Exhibit 10.13 to the Companys Annual
Report on Form 10-K for the period ending December 31,
2003.* |
|
10 |
.14 |
|
Key Executive Death Benefits Exhibit 10.19 to
the Companys Registration Statement on Form 10, as
amended.* |
|
10 |
.15 |
|
Form of Endorsement Split Dollar Agreement
Exhibit 10.20 to the Companys Registration Statement
on Form 10, as amended.* |
|
10 |
.16 |
|
Arch Chemicals, Inc. Annual Incentive Plan, as amended
December 9, 1999 and April 27, 2000
Exhibit 10.21 to the Companys Annual Report on Form
10-K for the period ending December 31, 2000.* |
|
10 |
.17 |
|
Senior Management Incentive Compensation Plan, as amended
through February 9, 2005. |
|
10 |
.18 |
|
Form of Award Description and Agreement for Performance Share
Awards granted under Arch Chemicals, Inc. 1999 Long Term
Incentive Plan. |
|
10 |
.19 |
|
Form of Award Description and Agreement for Performance
Retention Share Awards granted under Arch Chemicals, Inc. 1999
Long Term Incentive Plan. |
|
10 |
.20(a) |
|
Receivables Sale Agreement, dated as of March 19, 2002,
between the Company, Arch Specialty Chemicals, Inc., Arch
Chemicals Specialty Products, Inc., Arch Electronic Chemicals,
Inc., Arch Wood Protection, Inc., Arch Personal Care Products,
L.P., and Arch Chemicals Receivables Corp.
Exhibit 10.25(a) to the Companys Annual Report on
Form 10-K for the period ending December 31, 2001.* |
|
10 |
.20(b) |
|
First Amendment to Receivables Sale Agreement, dated as of
March 18, 2003, among Arch Chemicals, Inc. and certain
affiliates and Arch Chemicals Receivables Corp. |
|
10 |
.20(c) |
|
Receivables Purchase Agreement, dated as of March 19, 2002,
between Arch Chemicals Receivables Corp., the Company, Blue
Ridge Asset Funding Corporation and Wachovia Bank, N.A., as
agent Exhibit 10.25(b) to the Companys
Annual Report on Form 10-K for the period ending
December 31, 2001.* |
|
10 |
.20(d) |
|
First Amendment, dated as of April 10, 2002, to Receivables
Purchase Agreement, dated as of March 19, 2002, among Arch
Chemicals Receivables Corp., Arch Chemicals, Inc., Blue Ridge
Asset Funding Corporation, and Wachovia Bank, National
Association Exhibit 10.1 to the Companys
Quarterly Report on Form 10-Q for the period ending
March 31, 2002.* |
|
10 |
.20(e) |
|
Second Amendment, dated as of May 15, 2002, to Receivables
Purchase Agreement, dated as of March 19, 2002, among Arch
Chemicals Receivables Corp., Arch Chemicals, Inc., Blue Ridge
Asset Funding Corporation and Wachovia Bank, National
Association Exhibit 10.1 to the Companys
Quarterly Report on Form 10-Q for the period ending
June 30, 2002.* |
|
10 |
.20(f) |
|
Third Amendment, dated as of March 18, 2003, to Receivables
Purchase Agreement, dated as of March 19, 2002, among Arch
Chemicals Receivables Corp., Arch Chemicals, Inc., Blue Ridge
Asset Funding Corporation and Wachovia Bank, National
Association Exhibit 10.18(e) to the
Companys Annual Report on Form 10-K for the period ending
December 31, 2003.* |
|
|
|
|
|
|
10 |
.20(g) |
|
Fourth Amendment to Receivables Purchase Agreement, dated as of
December 10, 2003, entered into by and among Arch Chemicals
Receivables Corp., as seller, Arch Chemicals, Inc., as the
servicer, Blue Ridge Asset Funding Corporation, as a purchaser
and Wachovia Bank, National Association, as the
Agent Exhibit 10.1 to the Companys
Quarterly Report on Form 10-Q for the period ending
March 31, 2004.* |
|
|
* |
Previously filed as indicated and incorporated herein by
reference. Exhibits incorporated by reference are located in SEC
File No. 1-14601 unless otherwise indicated. |
107
|
|
|
|
|
|
10 |
.20(h) |
|
Fifth Amendment to Receivables Purchase Agreement, dated as of
January 9, 2004, entered into by and among Arch Chemicals
Receivables Corp., as seller, Arch Chemicals, Inc., as the
servicer, Blue Ridge Asset Funding Corporation, as a purchaser
and Wachovia Bank, National Association, as the
Agent Exhibit 10.2 to the Companys
Quarterly Report on Form 10-Q for the period ending
March 31, 2004.* |
|
10 |
.20(i) |
|
Sixth Amendment to Receivables Purchase Agreement, dated as of
March 31, 2004, entered into by and among Arch Chemicals
Receivables Corp., as seller, Arch Chemicals, Inc., as the
servicer, Blue Ridge Asset Funding Corporation, as a purchaser
and Wachovia Bank, National Association, as the
Agent Exhibit 10.3 to the Companys
Quarterly Report on Form 10-Q for the period ending
March 31, 2004.* |
|
10 |
.20(j) |
|
Omnibus Amendment No. 1 to Receivables Sale Agreement and
Receivables Purchase Agreement (Arch Chemicals Receivables
Corp.) entered into as of June 25, 2003, by and among Arch
Chemicals Receivables Corp., Arch Chemicals, Inc. and certain
affiliates, Arch Chemicals Receivables Corp., Blue Ridge Asset
Funding Corporation, the liquidity banks and Wachovia Bank,
National Association. |
|
10 |
.20(k) |
|
Omnibus Amendment No. 2 to Receivables Sale Agreement and
Receivables Purchase Agreement (Arch Chemicals Receivables
Corp.) entered into as of November 12, 2004, by and among
Arch Chemicals Receivables Corp., Arch Chemicals, Inc. and
certain affiliates, Arch Chemicals Receivables Corp., Blue Ridge
Asset Funding Corporation, the liquidity banks and Wachovia
Bank, National Association. |
|
21 |
. |
|
List of Subsidiaries. |
|
23 |
. |
|
Consent of KPMG LLP. |
|
31 |
.1 |
|
Certification of Chief Executive Officer pursuant to
Rule 13a-14(a). |
|
31 |
.2 |
|
Certification of Chief Financial Officer pursuant to
Rule 13a-14(a). |
|
32 |
|
|
Certification of Chief Executive Officer and Chief Financial
Officer pursuant to 18 U.S.C. 1350. |
|
|
* |
Previously filed as indicated and incorporated herein by
reference. Exhibits incorporated by reference are located in SEC
File No. 1-14601 unless otherwise indicated. |
108
SIGNATURES
Pursuant to the requirements of Section 13 or 15(d) of the
Securities Exchange Act of 1934, the registrant has duly caused
this report to be signed on its behalf by the undersigned,
thereunto duly authorized.
|
|
|
|
By |
/s/ Michael E. Campbell
|
|
|
|
|
|
Michael E. Campbell |
|
Chairman of the Board, President and |
|
Chief Executive Officer |
Date: March 14, 2005
Pursuant to the requirements of the Securities Exchange Act of
1934, this report has been signed below by the following persons
on behalf of the registrant and in the capacities and on the
date indicated.
|
|
|
|
|
Signature |
|
Title |
|
|
|
|
/s/ Michael E. Campbell
Michael
E. Campbell |
|
Chairman Of The Board, President, Chief Executive Officer and
Director (Principal Executive Officer) |
|
/s/ Richard E. Cavanagh
Richard
E. Cavanagh |
|
Director |
|
/s/ John W.
Johnstone, Jr.
John
W. Johnstone, Jr. |
|
Director |
|
/s/ H. William
Lichtenberger
H.
William Lichtenberger |
|
Director |
|
/s/ Michael O. Magdol
Michael
O. Magdol |
|
Director |
|
/s/ Daniel S. Sanders
Daniel
S. Sanders |
|
Director |
|
/s/ John P. Schaefer
John
P. Schaefer |
|
Director |
|
/s/ Janice J. Teal
Janice
J. Teal |
|
Director |
|
/s/ Louis S. Massimo
Louis
S. Massimo |
|
Executive Vice President and Chief Financial Officer (Principal
Financial Officer) |
|
/s/ Steven C. Giuliano
Steven
C. Giuliano |
|
Controller (Principal Accounting Officer) |
Date: March 14, 2005
109