SECURITIES AND EXCHANGE COMMISSION
Form 10-K
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ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 | |
For the fiscal year ended December 31, 2003 | ||
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TRANSITION REPORT PURSUANT TO SECTION 13 or 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 |
Commission file no. 0-28178
Carbo Ceramics Inc.
Delaware | 72-1100013 | |
(State or other jurisdiction of incorporation or organization) |
(I.R.S. Employer Identification Number) |
6565 MacArthur Boulevard
(972) 401-0090
Securities registered pursuant to Section 12(b) of the Act: None
Securities registered pursuant to Section 12(g) of the Act:
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
The aggregate market value of the Common Stock held by non-affiliates of the Registrant, based upon the closing sale price of the Common Stock on June 30, 2003, as reported on the New York Stock Exchange, was approximately $447,769,473. Shares of Common Stock held by each officer and director and by each person who owns 10% or more of the outstanding Common Stock have been excluded in that such persons may be deemed to be affiliates. This determination of affiliate status is not necessarily a conclusive determination for other purposes.
As of February 26, 2004, Registrant had outstanding 15,880,407 shares of Common Stock.
DOCUMENTS INCORPORATED BY REFERENCE
Portions of the Proxy Statement for Registrants Annual Meeting of Shareholders to be held April 13, 2004 are incorporated by reference in Parts II and III.
PART I
Item 1. Business
General
Since its founding in 1987, CARBO Ceramics Inc. (the Company) has become the worlds largest producer and supplier of ceramic proppant for use in the hydraulic fracturing of natural gas and oil wells. Demand for ceramic proppant depends primarily upon the demand for natural gas and oil and on the number of natural gas and oil wells drilled, completed or recompleted worldwide. More specifically, the demand for ceramic proppant is dependent on the number of oil and gas wells that are hydraulically fractured to stimulate production.
Hydraulic fracturing is the most widely used method of increasing production from oil and gas wells. The hydraulic fracturing process consists of pumping fluids down a natural gas or oil well at pressures sufficient to create fractures in the hydrocarbon-bearing rock formation. A granular material, called proppant, is suspended and transported in the fluid and fills the fracture, propping it open once high-pressure pumping stops. The proppant-filled fracture creates a permeable channel through which the hydrocarbons can flow more freely from the formation to the well and then to the surface.
There are three primary types of proppant that can be utilized in the hydraulic fracturing process: sand, resin-coated sand and ceramic. Sand is the least expensive proppant, resin-coated sand is more expensive and ceramic proppant is typically the highest cost. The higher initial cost of ceramic proppant is justified by the fact that the use of these proppants in certain well conditions results in increased production of oil and gas and increased cash flow for the operators of oil and gas wells. The increased production rates are primarily attributable to the higher strength and more uniform size and shape of ceramic proppant versus alternative materials.
Based on the Companys internally generated market information and information contained in the United States Geological Survey Minerals Yearbook, the Company estimates that it supplies approximately 52% of the ceramic proppant and 11% of all proppant used worldwide. During the year ended December 31, 2003, the Company generated approximately 64% of its revenues in the U.S. and 36% in international markets.
In 2002, the Company expanded its business through the acquisition of Pinnacle Technologies, Inc. (Pinnacle). Pinnacle provides fracture diagnostic and mapping services, sells fracture simulation software and provides fracture design services to oil and gas companies worldwide. The acquisition was made to expand the Companys ability to provide production-enhancing solutions to oil and gas exploration and production companies worldwide and to provide a catalyst for accelerating the growth of ceramic proppant sales. Pinnacle is the worlds leading provider of fracture mapping services, and its fracture simulation software FracproPT® is the most widely used model in the world. For the year ended December 31, 2003, Pinnacle accounted for less than 10% of the Companys total revenues, net income and operating assets.
Products
The Company manufactures four distinct ceramic proppants. CARBOHSPTM and CARBOPROP® are premium priced, high strength proppants designed primarily for use in deep gas wells. CARBOHSPTM was the original ceramic proppant and was introduced in 1979. The Company continues to manufacture and sell an improved version of this original product. CARBOHSPTM has the highest strength of any of the ceramic proppants manufactured by CARBO Ceramics and is used primarily in the fracturing of deep gas wells. CARBOPROP®, which was introduced by the Company in 1982, is slightly lower in weight and strength than CARBOHSPTM and was developed for use in deep gas wells that do not require the strength of CARBOHSPTM.
CARBOLITE® and CARBOECONOPROP® are lightweight proppants designed for use in gas wells of moderate depth and shallower oil wells. CARBOLITE®, introduced in 1984, is used in medium depth oil and gas wells, where the additional strength of ceramic proppant may not be essential, but where higher production rates can be achieved due to the products uniform size and spherical shape. CARBOECONOPROP®,
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Competition
The Companys chief worldwide competitor is Norton Proppants (Norton). Norton is owned by Compagnie de Saint-Gobain, a large French glass and materials company. Norton manufactures ceramic proppants that directly compete with each of the Companys products. In addition, Mineracao Curimbaba (Curimbaba), based in Brazil, manufactures a sintered bauxite product similar to the Companys CARBOHSPTM, which is marketed in the United States under the name Sinterball. Curimbaba has notified the Company that it intends to introduce an intermediate strength ceramic proppant similar to the Companys CARBOPROP® although the Company believes that it would be difficult for Curimbaba to introduce such a product without infringing patents held by the Company and Norton. The Company believes that Curimbaba has not expanded its U.S. product line to include a lightweight ceramic proppant and is unlikely to do so in light of patents held by the Company. Borovichi Refractories (Borovichi) is a manufacturer of ceramic proppant located in Russia. While the Company has limited information about Borovichi, the Company believes that Borovichi currently manufactures only an intermediate strength ceramic proppant and markets that product exclusively within Russia.
Competition for CARBOHSPTM and CARBOPROP® principally includes ceramic proppant manufactured by Norton, Curimbaba and Borovichi. The Companys CARBOLITE® and CARBOECONOPROP® products compete with ceramic proppant produced by Norton and with sand-based proppant for use in the hydraulic fracturing of medium depth natural gas and oil wells. The leading suppliers of mined sand are Unimin Corp., Badger Mining Corp., Fairmount Minerals Limited, Inc. and Ogelbay-Norton Company. The leading suppliers of resin-coated sand are Borden Chemical, Inc. Oilfield Products Group and Santrol, a subsidiary of Fairmount Minerals.
The Company believes that the most significant factors that influence a customers decision to purchase the Companys products are (i) price/performance ratio, (ii) on-time delivery performance, (iii) technical support and (iv) proppant availability. The Company believes that its products are competitively priced and that its delivery performance is excellent. The Company also believes that its superior technical support has enabled it to persuade customers to use ceramic proppant in an increasingly broad range of applications and thus increased the overall market for the Companys products. Since 1993, the Company has consistently expanded its manufacturing capacity and plans to continue its strategy of adding capacity to meet anticipated future increases in sales demand.
The Company continually conducts testing and development activities with respect to alternative raw materials to be used in the Companys existing and alternative production methods. The Company is not aware of the development of alternative products for use as proppant in the hydraulic fracturing process. The Company believes that the main barriers to entry for additional competitors are the patent rights held by the Company and certain of its current competitors, the know-how and trade secrets necessary to manufacture a competitive product and the capital costs involved in building production facilities of sufficient size to be operated efficiently.
Customers and Marketing
The Companys largest customers are, in alphabetical order, BJ Services Company, Halliburton Energy Services, Inc. and Schlumberger, the three largest participants in the worldwide petroleum pressure pumping industry. These companies collectively accounted for approximately 71% of the Companys 2003 revenues and
* | CARBOHSPTM, CARBOPROP®, CARBOLITE®, and CARBOECONOPROP® are registered |
marks of CARBO Ceramics Inc.
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The Company recognizes the importance of a technical marketing program when selling a product that offers financial benefits over time but is initially more costly than alternative products. The Company markets its products both to its direct customers and to owners and operators of natural gas and oil wells. The Companys sales and marketing staff regularly calls on and keeps close contact with the people who are influential in the proppant purchasing decision: production companies, regional offices of oilfield service companies that offer pressure pumping services and various completion engineering consultants. Beginning in 1999, the Company increased its marketing efforts to production companies and has continued to expand its relationships with production companies. The Company increased the size of its technical sales force in recent years and plans to continue to increase its efforts to educate end users on the benefits of using ceramic proppant. While the Companys products have historically been used in very deep wells that require high-strength proppant, the Company believes that there is economic benefit to well operators of using ceramic proppant in shallower wells that do not necessarily require a high-strength proppant. The Company believes that its education-based technical marketing efforts will allow it to capture a greater portion of the large market for sand-based proppant over time.
The Company provides a variety of technical support services and has developed computer software that models the return on investment achievable by using the Companys ceramic proppant versus other proppant in the hydraulic fracturing of a natural gas or oil well. In addition to the increased technical marketing effort, the Company has engaged in large-scale field trials to demonstrate the economic benefits of its products and validate the findings of its computer simulations. Occasionally, the Company will sell its products on a discounted basis in exchange for a production companys agreement to provide production data for direct comparison of the results of fracturing with ceramic proppant as compared to alternative proppants. During 2003, the Company initiated eight such field trials, principally in markets that had not previously used ceramic proppant.
The Companys worldwide sales and marketing activities are coordinated by its North American and International Marketing Managers. The Companys international marketing efforts in 2003 were conducted through its sales office in Aberdeen, Scotland, and through commissioned sales agents located in South America, China and Australia.
The Companys products and services are used worldwide by U.S. customers operating domestically and abroad, and by foreign customers. Sales outside the United States accounted for 36%, 30% and 27% of the Companys sales for 2003, 2002 and 2001, respectively. The distribution of the Companys international and domestic revenues is shown below, based upon the region in which the customer used the products and services:
Location | 2003 | 2002 | 2001 | ||||||||||
($ in millions) | |||||||||||||
United States
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$ | 108.0 | $ | 88.0 | $ | 100.4 | |||||||
International
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61.9 | 38.3 | 36.8 | ||||||||||
Total
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$ | 169.9 | $ | 126.3 | $ | 137.2 | |||||||
Distribution
The Company maintains finished goods inventories at its plants in New Iberia, Louisiana; Eufaula, Alabama; McIntyre, Georgia; and Luoyang, China; and at 11 remote stocking facilities located in Rock Springs, Wyoming; Oklahoma City, Oklahoma; San Antonio, Texas; Fairbanks, Alaska; Edmonton, Alberta,
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Raw Materials
Ceramic proppant is made from alumina-bearing ores (commonly referred to as bauxite, bauxitic clay or kaolin, depending on the alumina content), that are readily available on the world market. Bauxite is largely used in the production of aluminum metal, refractory material and abrasives. The main deposits of alumina-bearing ores in the United States are in Arkansas, Alabama and Georgia; other economically mineable deposits are located in Australia, Brazil, China, Jamaica, Russia and Surinam.
For the production of CARBOHSPTM in the Companys New Iberia, Louisiana, and McIntyre, Georgia, facilities, the Company uses calcined, abrasive-grade bauxite imported from Australia, and typically purchases its annual requirements at the sellers current prices. The Company has entered into an agreement with a foreign supplier to supply its anticipated need for this ore at a fixed price through 2005. While prices for the material are fixed through 2005, the Company has seen recent increases in the cost (which is borne by the Company) of transporting this material to the U.S. For the production of CARBOPROP®, also produced in both New Iberia and McIntyre, the Company uses a variety of materials that meet specific chemical and mineralogical requirements. Raw material for the production of CARBOPROP® may be either as-mined bauxitic clays or a blend of bauxite and kaolin, either of which is readily available to the Company at sellers current prices or through long-term contracts.
The Companys Eufaula facility uses primarily locally mined kaolin for the production of CARBOLITE® and CARBOECONOPROP®. The Company has entered into a contract that requires a supplier to sell to the Company up to 200,000 net tons of kaolin per year and the Company to purchase from the supplier 70% of the Eufaula facilitys annual kaolin requirements through 2010.
The Companys production facility in McIntyre, Georgia, uses locally mined uncalcined kaolin for the production of CARBOECONOPROP®. During 2002 and 2003, the Company acquired on both a fee simple and leasehold basis, acreage in Wilkinson County, Georgia, which contains approximately 12 million tons of raw material suitable for production of CARBOLITE® and CARBOECONOPROP®. At current production rates, the acquired raw material would supply the needs of the McIntyre facility for a period in excess of 80 years. Based on maximum production capacity after the planned construction of a second plant in the area, these raw material reserves would supply the needs of both plants for a period in excess of 40 years. The Company has entered into a long-term agreement with a third party to mine and transport this material at a fixed price subject to annual adjustment. The agreement requires the Company to utilize the third party to mine and transport at least 80% of the McIntyre facilitys annual kaolin requirement.
The Companys production facility in Luoyang, China, uses locally mined kaolin and bauxite for the production of CARBOPROP® and CARBOLITE®. Each of these materials is purchased under long-term contracts with a minimum term of five years. The contracts stipulate a fixed price subject to annual adjustment. Under the terms of the agreements, the Company has an obligation to purchase, in total, a minimum of 10,000 metric tons of bauxite per year or 100% of its annual requirements for bauxite if it purchases less than 10,000 metric tons per year.
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Production Process
Ceramic proppants are made by grinding or dispersing ore to a fine powder, combining the powder into small, green (i.e., unfired) pellets and sintering the pellets at 2,500F to 3,000F in a rotary kiln.
The Company uses two different methods to produce ceramic proppant. The Companys plants in New Iberia, Louisiana; McIntyre, Georgia; and Luoyang, China, use a dry process (the Dry Process) which starts with bauxite, bauxitic clay or kaolin that has been dried to remove both free water and water which was chemically bound within the ore. This drying process is referred to as calcining. The Company has calcining facilities at its McIntyre, Georgia, and Luoyang, China, plants. Once the raw material is calcined, the ore is ground to a very fine powder. Pellets are then formed by combining the powder with water and binders and introducing the mixture into high-shear mixers. The process is completed once these pellets are sintered in a rotary kiln. The Company believes its competitors also use the Dry Process to produce ceramic proppant.
The Companys plant in Eufaula, Alabama, uses a wet process (the Wet Process), which starts with moist, uncalcined kaolin from local mines. The kaolin is dispersed with chemicals in a water slurry. With an atomizer, the slurry is sprayed into a dryer that causes the slurry to harden into green pellets. These green pellets are then sintered in rotary kilns. The Company believes that the Wet Process is unique to its plant in Eufaula, Alabama.
Patent Protection
The Company makes ceramic proppant by processes and techniques that involve a high degree of proprietary technology, some of which are protected by patents.
The Company owns six U.S. patents and three foreign patents. Two of these U.S. patents and two of these foreign patents relate to the CARBOPROP® product. One of these U.S. patents and one of these foreign patents relate to the CARBOLITE® and CARBOECONOPROP® products. The Companys U.S. patents relating to the CARBOPROP® product expire in 2006. The Companys U.S. patent relating to the CARBOLITE® and CARBOECONOPROP® products expires in 2009. The three foreign patents cover various products in Canada, Mexico and Argentina and do not have a significant effect on the Companys business.
The Company believes that its patents have been and will continue to be important in enabling the Company to compete in the market to supply proppant to the natural gas and oil industry. The Company intends to enforce, and has in the past vigorously enforced, its patents. The Company may be involved from time to time in the future, as it has been in the past, in litigation to determine the enforceability, scope and validity of its patent rights. Past disputes with its main competitor have been resolved in settlements that permit the Company to continue to benefit fully from its patent rights. The Company and this competitor have cross-licensed certain of their respective patents relating to intermediate and low density proppant on both a royalty-free and royalty-bearing basis. Royalties under these licenses are not material to the Companys financial results. As a result of these cross licensing arrangements, the Company is able to produce a broad range of ceramic proppant while third parties are unlikely to be able to produce certain of these ceramic proppant without infringing on the patent rights held by the Company, its main competitor or both.
Pinnacle owns one U.S. patent application (together with a number of counterparts to that application in numerous foreign jurisdictions) that covers certain of its proprietary systems. The patent application is in the early stages of the patent prosecution process, and a patent may not issue on such application in any jurisdiction for some time, if it issues at all. Pinnacle also licenses several patents from third parties for use in its business. In addition to patent rights, Pinnacle uses a significant amount of Know-how and other proprietary technology in the conduct of its business, and a substantial portion of this Know-how and technology is licensed by Pinnacle from third parties.
Production Capacity
The Company believes that constructing adequate capacity ahead of demand while incorporating new technology to reduce manufacturing costs are important competitive strategies to increase its overall share of
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In June 1999, the Company substantially completed construction of a new manufacturing facility in McIntyre, Georgia. Design capacity of the plant is 200 million pounds per year and the total initial cost of the plant was approximately $60 million. The plant consists of two distinct production lines housed in a single building. Initial production was generated from the first production line in June 1999 and full design throughput was achieved on that line in November 1999. Initial production from the second production line began in December 1999 and the plant operated at approximately 61% of its design capacity in 2000 and 88% in 2001. During 2002 and 2003, the Company spent approximately $17.2 million to expand the capacity of the McIntyre facility. Upon completion of this expansion project in early 2003, total annual capacity at the McIntyre facility was increased to 275 million pounds.
In late 2002, the Company completed construction of a new manufacturing facility in Luoyang, China, at a cost of approximately $10 million. The plant began operation on schedule in the fourth quarter of 2002 and the first commercial shipments were made from the plant in January 2003. Since mid-2003, the plant has consistently demonstrated the ability to operate at rates in excess of its original design capacity and the plants annual capacity has been demonstrated to be 45 million pounds instead of the 40 million pounds initially projected.
The Company has announced plans to add a second production line to its facility in Luoyang, China, at a projected cost of $6.6 million. The second line is expected to double the capacity of the facility and is expected to be operational in mid-2004. The Company has also announced plans to construct a new manufacturing facility in Wilkinson County, Georgia. This facility is expected to cost $62 million, have annual capacity of 250 million pounds, and be completed at the end of 2005.
The following table sets forth the current capacity of each of the Companys existing manufacturing facilities:
Annual | |||||||
Location | Capacity | Products | |||||
(Millions of | |||||||
pounds) | |||||||
New Iberia, Louisiana
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120 | CARBOHSPTM and CARBOPROP® | |||||
Eufaula, Alabama
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250 | CARBOLITE® and CARBOECONOPROP® | |||||
McIntyre, Georgia
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275 | CARBOLITE®, CARBOECONOPROP® CARBOHSPTM and CARBOPROP® | |||||
Luoyang, China
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45 | CARBOPROP® and CARBOLITE® | |||||
Total current capacity
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690 |
The Company generally supplies its customers with products on a just-in-time basis and operates without any material backlog.
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Environmental and Other Governmental Regulations
The Company believes that its operations are in substantial compliance with applicable federal, state and local environmental and safety laws and regulations. The Company does not anticipate any significant expenditures in order to continue to comply with such laws and regulations.
Employees
At December 31, 2003, the Company had 360 full-time employees. In addition to the services of its employees, the Company employs the services of consultants as required. The Companys employees are not represented by labor unions. There have been no work stoppages or strikes during the last three years that have resulted in the loss of production or production delays. The Company believes its relations with its employees are satisfactory.
Forward-Looking Information
The Private Securities Litigation Reform Act of 1995 provides a safe harbor for forward-looking statements. This Form 10-K, the Companys Annual Report to Shareholders, any Form 10-Q or any Form 8-K of the Company or any other written or oral statements made by or on behalf of the Company may include forward-looking statements which reflect the Companys current views with respect to future events and financial performance. The words believe, expect, anticipate, project and similar expressions identify forward-looking statements. Readers are cautioned not to place undue reliance on these forward-looking statements, each of which speaks only as of the date the statement was made. The Company undertakes no obligation to publicly update or revise any forward-looking statements, whether as a result of new information, future events or otherwise. The Companys forward-looking statements are based on assumptions that we believe to be reasonable but that may not prove to be accurate. All of the Companys forward-looking information is subject to risks and uncertainties that could cause actual results to differ materially from the results expected. Although it is not possible to identify all factors, these risks and uncertainties include the risk factors discussed below.
The Companys results of operations could be adversely affected if its business assumptions do not prove to be accurate or if adverse changes occur in the Companys business environment, including but not limited to:
| a potential decline in the demand for oil and natural gas; | |
| potential declines or increased volatility in oil and natural gas prices that would adversely affect our customers, the energy industry or our production costs; | |
| potential reductions in spending on exploration and development drilling in the oil and natural gas industry that would reduce demand for our products and services; | |
| the development of alternative stimulation techniques; | |
| the development of alternative proppants for use in hydraulic fracturing; | |
| general global economic and business conditions; | |
| fluctuations in foreign currency exchange rates; and | |
| the potential expropriation of assets by foreign governments. |
The Companys results of operations could also be adversely affected as a result of worldwide economic, political and military events, including war, terrorist activity or initiatives by the Organization of the Petroleum Exporting Countries.
Available Information
The Companys annual reports on Form 10-K, quarterly reports on Form 10-Q, current reports on Form 8-K and amendments to those reports filed or furnished pursuant to Section 13(a) or 15(d) of the
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Item 2. | Properties |
The Company maintains its corporate headquarters (approximately 8,000 square feet of leased office space) in Irving, Texas, owns its manufacturing facilities, land and substantially all of the related production equipment in New Iberia, Louisiana, and Eufaula, Alabama, and leases its McIntyre, Georgia, facility through 2016, at which time title will be conveyed to the Company. The Company owns the buildings and production equipment at its facility in Luoyang, China, and has been granted use of the land on which the facility is located through 2051 under the terms of a land use agreement with the Peoples Republic of China. The Company maintains a sales office in Houston, Texas (approximately 2,100 square feet of leased office space).
The facility in New Iberia, Louisiana, located on 24 acres of land owned by the Company, consists of two production units (approximately 85,000 square feet), a laboratory (approximately 4,000 square feet) and an office building (approximately 3,000 square feet). The Company also owns an 80,000 square foot warehouse on the plant grounds in New Iberia, Louisiana.
The facility in Eufaula, Alabama, located on 14 acres of land owned by the Company, consists of one production unit (approximately 111,000 square feet), a laboratory (approximately 2,000 square feet) and an office (approximately 1,700 square feet).
The facility in McIntyre, Georgia, includes real property, consisting of approximately 36 acres, plant and equipment that are leased by the Company from the Development Authority of Wilkinson County. The term of the lease commenced on September 1, 1997 and terminates on December 1, 2016. Under the terms of the lease, as amended in 2003, the Company was responsible for all costs incurred in connection with the premises, including costs of construction of the plant and equipment. As an inducement to locate the facility in Wilkinson County, Georgia, the Company received certain ad-valorem property tax incentives. The lease and a related memorandum of understanding define a negotiated value of the Companys leasehold interest during the term of the lease. The lease also calls for annual payments of rent to the Development Authority of Wilkinson County. The total additional rent payments are immaterial in relation to the cost of the facility borne by the Company. At the termination of the lease, title to all of the real property, plant and equipment will be conveyed to the Company in exchange for nominal consideration. The Company has the right to purchase the property, plant and equipment at any time during the term of the lease for a nominal price plus payment of any rent due to the Development Authority of Wilkinson County through the remaining lease term.
The facility in Luoyang, China, is located on approximately 9 acres and consists of various production and support buildings (approximately 106,000 square feet), a laboratory (approximately 6,000 square feet) and an office building (approximately 6,000 square feet).
The Companys customer service and distribution operations are located at the New Iberia facility, while its quality control, testing and development functions operate at the New Iberia, Eufaula and McIntyre facilities. The Company owns distribution facilities in San Antonio, Texas; Rock Springs, Wyoming; Edmonton and Grande Prairie, Alberta, Canada.
During 2002 and 2003, the Company completed the acquisition of approximately 1,500 acres of land and leasehold interests in Wilkinson County, Georgia, near its plant in McIntyre, Georgia. The land contains approximately 12 million tons of raw material for use in the production of the Companys lightweight ceramic proppants. The Company has contracted with a third party to mine and haul the reserves and bear the responsibility for subsequent reclamation of the mined areas.
The Companys wholly-owned subsidiary, Pinnacle Technologies, Inc., leases its corporate headquarters in San Francisco, California (approximately 6,800 square feet), and maintains leased offices totaling approximately 23,000 square feet in Houston, Texas; Centennial, Colorado; Delft, The Netherlands; and
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Item 3. | Legal Proceedings |
In November 2002, a $993,000 judgment was entered against the Company in Texas state court in a lawsuit commenced by Proppant Technology, Inc. In December 2003, the Company settled the claim for an amount that did not differ materially from the amount of the judgment. The Company paid the settlement amount in January 2004.
From time to time, the Company is the subject of legal proceedings arising in the ordinary course of business. The Company does not believe that any of these proceedings will have a material adverse effect on its business or its results of operations.
Item 4. | Submission of Matters to a Vote of Security Holders |
No matters were submitted to a vote of security holders during the fourth quarter of fiscal year 2003.
Executive Officers of the Registrant
Dr. C. Mark Pearson (age 48) has served as President and Chief Executive Officer since April 2001. Prior to assuming these positions, Dr. Pearson served as the Companys Senior Vice President of Marketing & Technology from March 1997 to 2001. Prior to joining the Company, Dr. Pearson was an Associate Professor of Petroleum Engineering at the Colorado School of Mines from 1995 to March 1997. Dr. Pearson held various positions with Atlantic Richfield Company from 1984 to 1995.
Paul G. Vitek (age 45) has been the Senior Vice President of Finance and Administration and Chief Financial Officer since January 2000. Prior to serving in his current capacity, Mr. Vitek served as Vice President of Finance from February 1996 and has served as Treasurer and Secretary of the Company since 1988.
Mark L. Edmunds (age 48) has been the Vice President, Operations since April 2002. From 2000 until joining the Company, Mr. Edmunds served as Business Unit Manager and Plant Manager for FMC Corporation. Prior to 2000, Mr. Edmunds served Union Carbide Corporation and The Dow Chemical Company in a variety of management positions including Director of Operations, Director of Internal Consulting and Manufacturing Operations Manager.
Christopher A. Wright (age 39) has been a Vice President of the Company since May 2002. Mr. Wright has been President of Pinnacle Technologies, Inc., a provider of fracture diagnostic products and services, and subsidiary of the Company, since its founding in 1992.
All officers are elected at the Annual Meeting of the Board of Directors for one-year terms or until their successors are duly elected. There are no arrangements between any officer and any other person pursuant to which he was selected as an officer. There is no family relationship between any of the named executive officers or between any of them and the Companys directors.
PART II
Item 5. Market for Registrants Common Equity and Related Stockholder Matters
Common Stock Market Prices and Dividends
The Companys Common Stock is traded on the New York Stock Exchange (ticker symbol CRR). The approximate number of holders, including both record holders and individual participants in security position listings, of the Companys Common Stock at February 13, 2004 was 9,100.
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High and low stock prices and dividends for the last two fiscal years were:
2003 | 2002 | |||||||||||||||||||||||
Sales Price | Cash | Sales Price | Cash | |||||||||||||||||||||
Dividends | Dividends | |||||||||||||||||||||||
Quarter Ended | High | Low | Declared | High | Low | Declared | ||||||||||||||||||
March 31
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$ | 35.90 | $ | 30.72 | $ | 0.09 | $ | 41.15 | $ | 31.00 | $ | 0.09 | ||||||||||||
June 30
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39.97 | 32.65 | 0.09 | 42.00 | 32.70 | 0.09 | ||||||||||||||||||
September 30
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39.25 | 35.29 | 0.10 | 37.00 | 29.60 | 0.09 | ||||||||||||||||||
December 31
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53.65 | 36.14 | 0.10 | 36.29 | 31.30 | 0.09 |
The Company currently expects to continue its policy of paying quarterly cash dividends, although there can be no assurance as to future dividends because they depend on future earnings, capital requirements and financial condition.
Item 6. Selected Financial Data
The following selected financial data are derived from the audited consolidated financial statements of the Company. The data should be read in conjunction with Managements Discussion and Analysis of Financial Condition and Results of Operations and the financial statements and notes thereto included elsewhere in this Report.
Years Ended December 31, | ||||||||||||||||||||||
2003 | 2002 | 2001 | 2000 | 1999 | ||||||||||||||||||
($ in thousands, except per share data) | ||||||||||||||||||||||
Statement of Income Data:
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Revenues
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$ | 169,936 | $ | 126,308 | $ | 137,226 | $ | 93,324 | $ | 69,738 | ||||||||||||
Cost of sales
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97,002 | 74,672 | 78,975 | 57,763 | 41,718 | |||||||||||||||||
Gross profit
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72,934 | 51,636 | 58,251 | 35,561 | 28,020 | |||||||||||||||||
Selling, general and administrative expenses(1)
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25,920 | 20,956 | 18,676 | 12,404 | 11,761 | |||||||||||||||||
Operating profit
|
47,014 | 30,680 | 39,575 | 23,157 | 16,259 | |||||||||||||||||
Other, net
|
73 | 563 | 1,106 | 268 | (288 | ) | ||||||||||||||||
Income before income taxes
|
47,087 | 31,243 | 40,681 | 23,425 | 15,971 | |||||||||||||||||
Income taxes
|
17,518 | 11,529 | 14,483 | 8,595 | 5,459 | |||||||||||||||||
Net income
|
$ | 29,569 | $ | 19,714 | $ | 26,198 | $ | 14,830 | $ | 10,512 | ||||||||||||
Earnings per share
|
||||||||||||||||||||||
Basic
|
$ | 1.90 | $ | 1.29 | $ | 1.76 | $ | 1.01 | $ | 0.72 | ||||||||||||
Diluted
|
$ | 1.88 | $ | 1.28 | $ | 1.74 | $ | 1.00 | $ | 0.71 | ||||||||||||
10
December 31, | |||||||||||||||||||||
2003 | 2002 | 2001 | 2000 | 1999 | |||||||||||||||||
($ in thousands, except per share data) | |||||||||||||||||||||
Balance Sheet Data:
|
|||||||||||||||||||||
Current assets
|
$ | 92,709 | $ | 64,867 | $ | 76,502 | $ | 47,415 | $ | 23,809 | |||||||||||
Current liabilities excluding bank borrowings
|
16,432 | 17,940 | 11,127 | 9,415 | 5,648 | ||||||||||||||||
Bank borrowings-current
|
| | | | 1,809 | ||||||||||||||||
Property, plant and equipment, net
|
116,664 | 111,797 | 82,527 | 78,007 | 83,171 | ||||||||||||||||
Total assets
|
235,124 | 199,610 | 159,029 | 125,422 | 106,980 | ||||||||||||||||
Total shareholders equity
|
200,139 | 168,585 | 136,942 | 106,140 | 93,400 | ||||||||||||||||
Cash dividends per share
|
$ | 0.380 | $ | 0.360 | $ | 0.345 | $ | 0.300 | $ | 0.300 |
(1) | Selling, general and administrative (SG&A) expenses for 2003, 2002, 2001, 2000 and 1999 include costs of start-up activities of $80,000, $1,099,000, $35,000, $27,000 and $1,464,000, respectively. Start-up costs for 2003 are related to expansion of the McIntyre and New Iberia facilities and initial operation of the new China facility. Start-up costs for 2002 and 2001 are related to the new production facility in China, including organizational and administrative costs associated with plant construction plus labor, materials and utilities expended to bring installed equipment to operating condition. Start-up costs prior to 2001 consist of labor, materials and utilities expended in bringing installed equipment to normal operating conditions at the Companys plant in McIntyre, Georgia. SG&A expenses in 2002 also include the accrual of a $993,000 reserve related to a legal judgment against the Company. SG&A expenses in 2003 also include a loss of $717,000 associated with the disposal of certain equipment. |
Item 7. Managements Discussion and Analysis of Financial Condition and Results of Operations
Executive Level Overview
CARBO Ceramics Inc. generates revenue through the sale of products and services to the oil and gas industry. The Companys principal business consists of manufacturing and selling ceramic proppant for use in the hydraulic fracturing of oil and natural gas wells. The Companys products and services help oil and gas producers increase production and recovery rates from their wells, thereby lowering overall reservoir development costs. As a result, the Companys business is dependent to a large extent on the level of drilling activity in the oil and gas industry worldwide. However, the Company has increased its revenues and income over an extended period and across various industry business cycles by increasing its market share of worldwide proppant sales. While the Companys ceramic proppants are more expensive than alternative products, the Company has been able to demonstrate the cost-effectiveness of its products to numerous operators of oil and gas wells through increased technical marketing activity in recent years. The Company believes its future prospects will benefit from both an expected increase in drilling activity worldwide and the desire of industry participants to lower their overall development costs.
Recently, the Company has expanded its operations outside the United States. International revenues represented 36%, 30% and 27% of total revenues, respectively, over the past three years. In 2002 the Company constructed a manufacturing plant in China, its first plant located outside the United States, and currently is constructing a second production line that will double the capacity of this plant. The Company recently established a subsidiary company and opened two sales offices in Russia, and by mid-2004 expects to establish a warehouse there. The Company believes international operations will represent an increasingly important role in its future growth.
Revenue growth in recent years has been driven primarily by increases in sales volume. Because the Companys products compete in part against lower-cost alternatives, price increases for the Companys products have been minimal in recent years and the Company expects future growth will continue to be dependent on increasing sales volume. As a result, the Company has initiated construction of significant new manufacturing capacity to meet anticipated future demand.
11
The Companys gross profit margins are principally impacted by natural gas costs and the Companys production levels as a percentage of its capacity. While most direct production expenses have been relatively stable or predictable over time, natural gas, which is the fuel used to fire the kilns in which ceramic proppant is made, has varied from approximately 14% to 24% of total direct production costs over the last two years due to the price volatility of this fuel source. The Companys practice had been to purchase its estimated annual natural gas requirement in the spring of each year. However, beginning in 2003, the Company has initiated a program to purchase its natural gas requirement at various times during the year, in order to average the cost and reduce exposure to short-term spikes in commodity prices. Despite the efforts to reduce exposure to changes in natural gas prices, it is possible that, given the significant portion of manufacturing costs represented by this fuel, future changes in net income may not be proportionate to changes in revenue.
Over the past five years, the Company has expanded its production capacity by 97%. While the Company has operated near full capacity for much of this period, the addition of significant new capacity in the future could adversely impact gross profit and operating margins if the timing of this new capacity does not match increases in demand for the Companys products. However, the Company believes that the addition of this capacity is a key component to continuing long-term growth in sales volume and revenue.
As the Companys sales volume has increased, there has also been an increase in activities and expenses related to marketing, distribution, research and development, and finance and administration. As a result, selling, general and administrative expenses have increased as a percentage of revenue in recent years. In the future, the Company expects to continue to actively pursue new business opportunities by:
| increasing marketing activities, | |
| improving and expanding its distribution capabilities, | |
| focusing on new product development, and | |
| increasing international activities. |
The Company expects that these activities will generate increased revenue and that selling, general and administrative expenses as a percentage of revenue will not change significantly.
General Business Conditions
The Companys business is significantly impacted by the number of natural gas wells drilled in North America, where the majority of wells are hydraulically fractured. In markets outside North America, sales of the Companys products are less dependent on natural gas markets but are influenced by the overall level of drilling and hydraulic fracturing activity. Furthermore, because the decision to use ceramic proppant is based on comparing the higher cost of ceramic proppant to the future value derived from increased production rates, the Companys business is influenced by the current and expected prices of natural gas and oil.
Natural gas prices and drilling activity in the North American market have been highly variable over the past three years. The North American natural gas market remained very strong through the first half of 2001. As a result of the strong market conditions in North America, the Company established new annual records for sales volume, average selling price, revenues and net income in 2001 despite a downturn in North American natural gas drilling activity in the second half of the year. This decline in North American drilling activity continued through much of 2002. In 2002, the average natural gas rig count declined by 26% in the U.S. and 24% in Canada compared to 2001. In 2003, activity levels in North America rebounded and the Company established new sales volume records in a number of regions including the U.S. Rocky Mountains, Canada and East Texas. In addition, the Company experienced significant sales growth in overseas markets due to an increase in drilling and fracturing activity in Europe and Asia.
Critical Accounting Policies
The consolidated financial statements are prepared in accordance with accounting principles generally accepted in the U.S., which require the Company to make estimates and assumptions (see Note 1 to the
12
Revenue is recognized when title passes to the customer upon delivery. The Company generates a significant portion of its revenues and corresponding accounts receivable from sales to the petroleum pressure pumping industry. In addition, the Company generates a significant portion of its revenues and corresponding accounts receivable from sales to three major customers, all of which are in the petroleum pressure pumping industry. As of December 31, 2003, approximately 68% of the balance in accounts receivable was attributable to those three customers. As stated in Note 1 to the consolidated financial statements, credit losses historically have been insignificant. Therefore, except in circumstances in which management is aware of a specific customers inability to meet its financial obligations (e.g., bankruptcy filings), the Company generally does not record a reserve for bad debts. If a prolonged economic downturn in the petroleum pressure pumping industry were to occur or, for some other reason, any of the Companys primary customers were to experience significant adverse conditions, its estimates of the recoverability of accounts receivable could be reduced by a material amount.
Inventory is stated at the lower of cost or market. Obsolete or unmarketable inventory historically has been insignificant and generally written off when identified. Assessing the ultimate realization of inventories requires judgments about future demand and market conditions, and management believes that current inventories are properly valued at cost. Accordingly, no reserve to write-down inventories has been recorded. If actual market conditions are less favorable than those projected by management, inventory write-downs may be required.
Income taxes are provided for in accordance with Statement of Financial Accounting Standards (SFAS) No. 109, Accounting for Income Taxes. This standard takes into account the differences between financial statement treatment and tax treatment of certain transactions. Deferred tax assets and liabilities are recognized for the future tax consequences attributable to differences between the financial statement carrying amounts of existing assets and liabilities and their respective tax bases. Deferred tax assets and liabilities are measured using enacted tax rates expected to apply to taxable income in the years in which those temporary differences are expected to be recovered or settled. The effect of a change in tax rates is recognized as income or expense in the period that includes the enactment date. This calculation requires the Company to make certain estimates about its future operations. Changes in state, federal and foreign tax laws, as well as changes in the Companys financial condition, could affect these estimates.
Long-lived assets, which include property, plant and equipment, goodwill and other intangibles, and other assets comprise a significant amount of the Companys total assets. The Company makes judgments and estimates in conjunction with the carrying value of these assets, including amounts to be capitalized, depreciation and amortization methods and useful lives. Additionally, the carrying values of these assets are periodically reviewed for impairment or whenever events or changes in circumstances indicate that the carrying amounts may not be recoverable. An impairment loss is recorded in the period in which it is determined that the carrying amount is not recoverable. This requires the Company to make long-term forecasts of its future revenues and costs related to the assets subject to review. These forecasts require assumptions about demand for the Companys products and services, future market conditions and technological developments. Significant and unanticipated changes to these assumptions could require a provision for impairment in a future period.
Purchase accounting requires extensive use of estimates and judgments to allocate the cost of an acquired enterprise to the assets acquired and liabilities assumed. The cost of an acquired enterprise is allocated to the assets acquired and liabilities assumed based on their estimated fair values. If necessary, these estimates can be revised during an allocation period when information becomes available to further define and quantify the value of assets acquired and liabilities assumed. The allocation period does not exceed a period of one-year from the date of acquisition. To the extent additional information to refine the original allocation becomes available during the allocation period, the purchase price allocation would be adjusted accordingly. Should information become available after the allocation period, the effects would be reflected in operating results.
13
Results of Operations
Percent | Percent | |||||||||||||||||||
2003 | Change | 2002 | Change | 2001 | ||||||||||||||||
($ in thousands) | ||||||||||||||||||||
Net Income
|
$ | 29,569 | 50 | % | $ | 19,714 | (25 | )% | $ | 26,198 |
The Companys net income for 2003 was 50% higher than the previous year. A strong North American natural gas market and increased demand for proppants in Russia and China were the driving forces behind a significant increase in net income for the year. The U.S. natural gas rig count increased steadily throughout 2003, ending the year 39% above the 2002 year-end rig count. While activity in the traditionally strong ceramic proppant markets in South Texas and the Gulf of Mexico remained relatively flat compared to 2002, the Company saw increasing demand in the Rockies, Canada and East Texas. In addition to increased revenues, improved operating efficiency in its manufacturing facilities contributed to the increase in net income.
The Company reported net income for 2002 that was 25% lower than the previous year. The primary factor contributing to the reduction in net income was a significant decrease in North American gas drilling activity that began in the second half of 2001 and continued into 2002. The average domestic natural gas rig count for 2002 was 26% lower than 2001, while the average price of natural gas in the U.S. decreased by 11% from the previous year. The reduction in revenues, increased manufacturing costs and increased selling, general and administrative expenses contributed to the decline in net income.
Individual components of operating results are discussed below.
Revenues
Percent | Percent | |||||||||||||||||||
2003 | Change | 2002 | Change | 2001 | ||||||||||||||||
($ in thousands) | ||||||||||||||||||||
Revenues
|
$ | 169,936 | 35 | % | $ | 126,308 | (8 | )% | $ | 137,226 |
Revenues in 2003 of $169.9 million were 35% higher than 2002. The increase was driven primarily by a 32% increase in sales volume, with domestic sales volume up 19% and international sales volume up 64%. Worldwide sales volume of 578 million pounds during 2003 established a new annual record. Sales volume in Canada increased by 41% and sales volume outside of North America increased by 100% compared to 2002. Significant increases in overseas sales volume occurred in Russia and China. The worldwide sales increase is largely attributable to a 19% increase in the average worldwide rig count from 2002 to 2003, the addition of the plant in Luoyang, China, which commenced operations in January 2003, and continued success with the Companys technical marketing efforts. The average selling price per pound of ceramic proppant for 2003 was $0.270 compared to $0.274 for 2002. The decline in average selling price was due to an increase in sales of lower-priced, light-weight ceramic proppant products. Revenues for 2003 also included a full year of Pinnacle operations compared to only seven months in 2002. The Company acquired Pinnacle on May 31, 2002 and has consolidated its results since that date.
The Companys revenues in 2002 of $126.3 million were 8% lower than 2001 revenues. Revenues in 2002 included $6.0 million from Pinnacle. Total proppant sales volume decreased by 13%, with domestic volume down 17% and export volume down by 2%, despite a 28% drop in the U.S. rig count and a 20% decline in the average worldwide rig count compared to 2001. The Company believes that these relatively strong results in a weak market indicate that the Companys ceramic proppants continued to gain market share due to the success of the Companys technical marketing program and expanded distribution network. The decreased domestic volume was due to a 23% drop in sales in South Texas, while decreased export sales were attributable to reduced sales into South America, Australia, and Mexico. Increased sales in Russia and Canada offset some of the export declines. The average selling price of $0.274 per pound in 2002 improved slightly versus $0.271 per pound in 2001.
14
Gross Profit
Percent | Percent | |||||||||||||||||||
2003 | Change | 2002 | Change | 2001 | ||||||||||||||||
($ in thousands) | ||||||||||||||||||||
Gross Profit
|
$ | 72,934 | 41 | % | $ | 51,636 | (11 | )% | $ | 58,251 | ||||||||||
Gross Profit %
|
43 | % | 41 | % | 42 | % |
The Companys cost of sales consists of manufacturing costs and packaging and transportation expenses associated with the delivery of the Companys products to its customers. Variable manufacturing expenses include raw materials, labor, utilities and repair and maintenance supplies. Fixed manufacturing expenses include depreciation, property taxes on production facilities, insurance and factory overhead. Certain handling costs related to maintaining finished goods inventory and operating the Companys remote stocking facilities are charged to selling, general and administrative expenses. Those costs amounted to $4.8 million, $3.7 million and $3.6 million in 2003, 2002 and 2001, respectively.
Gross profit increased by 41% from 2002 to 2003. Gross profit as a percentage of sales was 43% for 2003, compared to 41% for 2002. The improvement in gross profit was the result of both the significant increase in sales volume as well as increases in sales of higher margin products. Improved efficiency in manufacturing and distribution operations contributed to increased gross profit margins. Manufacturing facilities operated at 90% of capacity in 2003 versus 82% of capacity in 2002. Partially offsetting this improvement was the effect of higher natural gas costs in manufacturing operations. Continued improvement in distribution performance resulted in lower freight cost to transport finished goods from plants to remote storage locations.
Gross profit decreased by 11% from 2001 to 2002. Gross profit as a percentage of sales was 41% for 2002, compared to 42% for 2001. The decrease in gross profit was due primarily to reduced sales volume. The reduction in gross profit margins was directly related to the Companys manufacturing facilities operating at approximately 82% of capacity in 2002 versus 95% of capacity in 2001. This was caused by both reduced sales volumes and unscheduled downtime at the McIntyre production facility due to unanticipated maintenance requirements. The impact of this was partially offset by the lower cost of natural gas used at the manufacturing facilities during 2002 and reduced freight costs in transporting finished goods from the plants to remote storage locations.
Selling, General & Administrative Expenses and Other Operating Expenses
Percent | Percent | |||||||||||||||||||
2003 | Change | 2002 | Change | 2001 | ||||||||||||||||
($ in thousands) | ||||||||||||||||||||
SG&A
|
$ | 25,920 | 24 | % | $ | 20,956 | 12 | % | $ | 18,676 | ||||||||||
SG&A as a % of Revenues
|
15 | % | 17 | % | 14 | % |
Selling, general and administrative expenses and other operating expenses increased by $5.0 million in 2003 over 2002 and, as a percentage of sales, decreased from 17% in 2002 to 15% in 2003. The increase was due to the consolidation of expenses of Pinnacle Technologies, Inc. for the full year in 2003 and increased spending related to distribution, marketing, business development and research activities. Other operating expenses in 2003 also include a $0.7 million write-off for equipment disposed of during the expansion of the McIntyre facility and $0.1 million start-up costs related to production expansions. The decrease in SG&A as a percentage of revenue is due primarily to start-up costs and a legal reserve incurred during 2002, which represented 2% of 2002 sales.
Selling, general and administrative expenses and other operating expenses increased by $2.3 million in 2002 over 2001. SG&A and start-up expenses increased as a percentage of sales to 17% in 2002 from 14% in 2001. The most significant items were start-up costs related to the new manufacturing facility in China and a $993,000 reserve related to a judgment against the Company in a lawsuit alleging tortious interference with a contract. Excluding the China start-up expenses and legal judgment reserve in 2002 and a $3.5 million non-recurring, non-cash stock-based compensation charge related to the modification of the expiration date of fully vested stock options in connection with the retirement of the companys former president in 2001, SG&A
15
Liquidity and Capital Resources
Cash and cash equivalents as of December 31, 2003 were $38.7 million compared to $24.4 million at the beginning of the year. The Company generated cash from operations of $38.3 million and realized proceeds of $4.8 million from the issuance of common stock for exercises of employee stock options. Total capital expenditures for the year were $22.0 million, cash dividends paid totaled $5.9 million, and $0.9 million was paid to former Pinnacle shareholders in respect of amounts withheld at the time of the Pinnacle acquisition pursuant to the Pinnacle acquisition agreement. Major capital spending items during 2003 included spending on improvements at the McIntyre manufacturing facility to debottleneck the current production process and improve equipment reliability in order to increase production capacity, equipment for Pinnacle operations, partial construction of a second production line at the manufacturing plant in China and various improvements and additions to other manufacturing facilities.
The Companys current intention, subject to its financial condition, the amount of funds generated from operations and the level of capital expenditures, is to continue to pay quarterly dividends to holders of its Common Stock.
The Company maintains an unsecured line of credit of $10.0 million. As of December 31, 2003, there was no outstanding debt under the credit agreement. The Company anticipates that cash provided by operating activities and funds available under its line of credit will be sufficient to meet planned operating expenses, tax obligations and capital expenditures through 2004. Also, based on the strength of its balance sheet, the Company believes that it could acquire additional debt financing, if necessary. Based on these assumptions, the Company believes that its fixed costs could be met even with a moderate decrease in demand for the Companys products.
Off-Balance Sheet Arrangements
The Company had no off-balance sheet arrangements as of December 31, 2003.
Contractual Obligations
The following table summarizes the Companys contractual obligations as of December 31, 2003:
Payments Due in Period | |||||||||||||||||||||
Less than | 1-3 | 4-5 | More than | ||||||||||||||||||
Total | 1 Year | Years | Years | 5 Years | |||||||||||||||||
($ in thousands) | |||||||||||||||||||||
Long-term debt
|
$ | | $ | | $ | | $ | | $ | | |||||||||||
Capital lease obligations
|
| | | | | ||||||||||||||||
Operating lease obligations:
|
|||||||||||||||||||||
Primarily railroad equipment
|
5,364 | 1,414 | 2,342 | 1,251 | 357 | ||||||||||||||||
Purchase obligations:
|
|||||||||||||||||||||
Natural gas contracts
|
3,020 | 3,020 | | | | ||||||||||||||||
Raw materials contracts
|
12,960 | 6,480 | 6,480 | | | ||||||||||||||||
Other long-term obligations
|
| | | | | ||||||||||||||||
Total contractual obligations
|
$ | 21,344 | $ | 10,914 | $ | 8,822 | $ | 1,251 | $ | 357 | |||||||||||
Operating lease obligations relate primarily to railroad equipment leases and include leases of other property, plant and equipment. See Note 5 and Note 14 to the Notes to the Consolidated Financial Statements.
16
The Company uses natural gas to power its domestic manufacturing plants. From time to time the Company enters into contracts to purchase a portion of the anticipated natural gas requirements. The contracts are at specified prices and are typically short-term in duration. As of December 31, 2003, the last contract was due to expire October 1, 2004.
The Company has entered into contracts to supply raw materials, primarily kaolin and bauxite, to each of its manufacturing plants. Each of the contracts is described in Note 14 to the Notes to the Consolidated Financial Statements. Three of the contracts do not require annual minimum purchase commitments, but do require the purchase of minimum percentages of annual raw material requirements, ranging from 70% to 100% of the respective plants total raw materials purchases. One of the contracts requires annual minimum purchase commitments, which are included in the above table.
Item 7A. | Quantitative and Qualitative Disclosures about Market Risk |
The Companys major market risk exposure is to foreign currency fluctuations that could impact its investment in China. When necessary, the Company may enter into forward foreign exchange contracts to hedge the impact of foreign currency fluctuations. There were no such foreign exchange contracts outstanding at December 31, 2003.
The Company has a $10.0 million line of credit with its primary commercial bank. Under the terms of the revolving credit agreement, the Company may elect to pay interest at either a fluctuating base rate established by the bank from time to time or at a rate based on the rate established in the London inter-bank market. The Company does not believe that it has any material exposure to market risk associated with interest rates.
Item 8. | Financial Statements and Supplementary Data |
The information required by this Item is contained in pages F-1 through F-18 of this Report.
Item 9. | Changes in and Disagreements with Accountants on Accounting and Financial Disclosure |
Not applicable.
Item 9A. | Controls and Procedures |
(a) Evaluation of Disclosure Controls and Procedures
Disclosure controls and procedures are designed to ensure that information required to be disclosed in the reports filed or submitted under the Securities Exchange Act of 1934 (the Exchange Act) is recorded, processed, summarized and reported, within the time periods specified in the SECs rules and forms. Disclosure controls and procedures include, without limitation, controls and procedures designed to ensure that information required to be disclosed in the reports filed under the Exchange Act is accumulated and communicated to management, including the Chief Executive Officer and Chief Financial Officer, as appropriate to allow timely decisions regarding required disclosure.
As of December 31, 2003, management carried out an evaluation, under the supervision and with the participation of the Chief Executive Officer and Chief Financial Officer, of the effectiveness of the design and operation of the Companys disclosure controls and procedures. There are inherent limitations to the effectiveness of any system of disclosure controls and procedures, including the possibility of human error and the circumvention of the controls and procedures. Accordingly, even effective disclosure controls and procedures can only provide reasonable assurance of achieving their control objectives. Based upon and as of the date of that evaluation, the Chief Executive Officer and Chief Financial Officer concluded that the Companys disclosure controls and procedures are effective to provide reasonable assurance that information required to be disclosed in the reports the Company files and submits under the Exchange Act is recorded, processed, summarized and reported as and when required.
(b) Changes in Internal Controls
17
There were no changes in the Companys internal control over financial reporting during the fiscal year ended December 31, 2003 that materially affected, or are reasonably likely to materially affect, those controls.
PART III
Certain information required by Part III is omitted from this Report. The Company will file a definitive proxy statement pursuant to Regulation 14A (the Proxy Statement) not later than 120 days after the end of the fiscal year covered by this Report and certain information included therein is incorporated herein by reference. Only those sections of the Proxy Statement that specifically address the items set forth herein are incorporated by reference. Such incorporation does not include the Compensation Committee Report or the Performance Graph included in the Proxy Statement.
Item 10. | Directors and Executive Officers of the Registrant |
Information concerning executive officers under Item 401 of Regulation S-K is set forth in Part I of this Form 10-K. The other information required by this Item is incorporated by reference to the Companys Proxy Statement.
Item 11. | Executive Compensation |
The information required by this Item is incorporated by reference to the Companys Proxy Statement.
Item 12. | Security Ownership of Certain Beneficial Owners and Management |
The information required by this Item is incorporated by reference to the Companys Proxy Statement.
Item 13. | Certain Relationships and Related Transactions |
The information required by this Item is incorporated by reference to the Companys Proxy Statement.
Item 14. | Principal Accounting Fees and Services |
The information required by this Item is incorporated by reference to the Companys Proxy Statement.
PART IV
Item 15. | Exhibits, Financial Statement Schedules, and Reports on Form 8-K |
(a) Exhibits, Financial Statements and Financial Statement Schedules:
1. Financial Statements
The consolidated financial statements of CARBO Ceramics Inc. listed below are contained in pages F-1 through F-18 of this Report:
Report of Independent Auditors | |
Consolidated Balance Sheets at December 31, 2003 and 2002 | |
Consolidated Statements of Income for each of the three years ended December 31, 2003, 2002 and 2001 | |
Consolidated Statements of Shareholders Equity for each of the three years ended December 31, 2003, 2002 and 2001 | |
Consolidated Statements of Cash Flows for each of the three years ended December 31, 2003, 2002 and 2001 |
2. Financial Statement Schedules
All schedules have been omitted since they are either not required or not applicable.
18
(b) Reports on Form 8-K:
On October 20, 2003, the company furnished a report on Form 8-K concerning its press release announcing third quarter 2003 results.
3. Exhibits
The exhibits listed on the accompanying Exhibit Index are filed as part of, or incorporated by reference into, this Report.
19
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.
CARBO CERAMICS INC. |
By: | /s/ C. MARK PEARSON |
|
|
C. Mark Pearson | |
President and Chief Executive Officer |
By: | /s/ PAUL G. VITEK |
|
|
Paul G. Vitek | |
Sr. Vice President, Finance and | |
Chief Financial Officer |
POWER OF ATTORNEY
KNOW ALL PERSONS BY THESE PRESENTS, that each person whose signature appears below constitutes and appoints C. Mark Pearson and Paul G. Vitek, jointly and severally, his attorneys-in-fact, each with the power of substitution, for him in any and all capacities, to sign any amendments to this Report on Form 10-K, and to file the same, with exhibits thereto and other documents in connection therewith, with the Securities and Exchange Commission, hereby ratifying and confirming all that each of said attorneys-in-fact, or his substitute or substitutes, may do or cause to be done by virtue hereof.
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 dates indicated.
Signature | Title | Date | ||||
/s/ WILLIAM C. MORRIS William C. Morris |
Chairman of the Board | March 3, 2004 | ||||
/s/ C. MARK PEARSON C. Mark Pearson |
President, Chief Executive Officer and Director (Principal Executive Officer) | March 3, 2004 | ||||
/s/ PAUL G. VITEK Paul G. Vitek |
Sr. Vice President, Finance and Chief Financial Officer (Principal Financial and Accounting Officer) | March 3, 2004 | ||||
/s/ CLAUDE E. COOKE, JR. Claude E. Cooke, Jr. |
Director | March 3, 2004 | ||||
/s/ H.E. LENTZ, JR. H.E. Lentz, Jr. |
Director | March 3, 2004 | ||||
/s/ JOHN J. MURPHY John J. Murphy |
Director | March 3, 2004 | ||||
/s/ ROBERT S. RUBIN Robert S. Rubin |
Director | March 3, 2004 |
20
REPORT OF INDEPENDENT AUDITORS
The Board of Directors and Shareholders
We have audited the accompanying consolidated balance sheets of CARBO Ceramics Inc. as of December 31, 2003 and 2002, and the related consolidated statements of income, shareholders equity, and cash flows for each of the three years in the period ended December 31, 2003. These financial statements are the responsibility of the Companys management. Our responsibility is to express an opinion on these financial statements based on our audits.
We conducted our audits in accordance with auditing standards generally accepted in the 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 financial statements referred to above present fairly, in all material respects, the consolidated financial position of CARBO Ceramics Inc. at December 31, 2003 and 2002, and the consolidated results of its operations and its cash flows for each of the three years in the period ended December 31, 2003, in conformity with accounting principles generally accepted in the United States.
ERNST & YOUNG LLP |
New Orleans, Louisiana
F-1
CARBO CERAMICS INC.
CONSOLIDATED BALANCE SHEETS
December 31, | |||||||||||
2003 | 2002 | ||||||||||
($ in thousands) | |||||||||||
ASSETS | |||||||||||
Current assets:
|
|||||||||||
Cash and cash equivalents
|
$ | 38,714 | $ | 24,447 | |||||||
Trade accounts receivable
|
30,395 | 22,967 | |||||||||
Inventories:
|
|||||||||||
Finished goods
|
14,004 | 10,535 | |||||||||
Raw materials and supplies
|
6,433 | 5,295 | |||||||||
Total inventories
|
20,437 | 15,830 | |||||||||
Prepaid expenses and other current assets
|
1,086 | 600 | |||||||||
Deferred income taxes
|
2,077 | 1,023 | |||||||||
Total current assets
|
92,709 | 64,867 | |||||||||
Property, plant and equipment:
|
|||||||||||
Land and land improvements
|
1,958 | 1,866 | |||||||||
Land-use and mineral rights
|
5,052 | 5,050 | |||||||||
Buildings
|
12,826 | 12,058 | |||||||||
Machinery and equipment
|
132,973 | 105,052 | |||||||||
Construction in progress
|
11,011 | 25,425 | |||||||||
Total
|
163,820 | 149,451 | |||||||||
Less accumulated depreciation
|
47,156 | 37,654 | |||||||||
Net property, plant and equipment
|
116,664 | 111,797 | |||||||||
Goodwill
|
21,840 | 19,449 | |||||||||
Intangible assets, net
|
3,911 | 3,497 | |||||||||
Total assets
|
$ | 235,124 | $ | 199,610 | |||||||
LIABILITIES AND SHAREHOLDERS EQUITY | |||||||||||
Current liabilities:
|
|||||||||||
Accounts payable
|
$ | 5,599 | $ | 8,074 | |||||||
Accrued payroll and benefits
|
4,680 | 2,981 | |||||||||
Accrued freight
|
1,076 | 754 | |||||||||
Accrued utilities
|
1,645 | 1,061 | |||||||||
Accrued income taxes
|
38 | 1,563 | |||||||||
Retainage related to construction in progress
|
265 | 1,494 | |||||||||
Provision for legal judgment
|
975 | 993 | |||||||||
Other accrued expenses
|
2,154 | 1,020 | |||||||||
Total current liabilities
|
16,432 | 17,940 | |||||||||
Deferred income taxes
|
18,553 | 13,085 | |||||||||
Shareholders equity:
|
|||||||||||
Preferred stock, par value $0.01 per share, 5,000
shares authorized, none outstanding
|
| | |||||||||
Common stock, par value $0.01 per share,
40,000,000 shares authorized; 15,733,432 and 15,482,436 shares
issued and outstanding at December 31, 2003 and 2002,
respectively
|
157 | 155 | |||||||||
Additional paid-in capital
|
80,534 | 72,925 | |||||||||
Unearned stock compensation
|
(253 | ) | (557 | ) | |||||||
Retained earnings
|
119,743 | 96,078 | |||||||||
Accumulated other comprehensive income (loss)
|
(42 | ) | (16 | ) | |||||||
Total shareholders equity
|
200,139 | 168,585 | |||||||||
Total liabilities and shareholders equity
|
$ | 235,124 | $ | 199,610 | |||||||
F-2
CARBO CERAMICS INC.
CONSOLIDATED STATEMENTS OF INCOME
Years Ended December 31, | |||||||||||||
2003 | 2002 | 2001 | |||||||||||
($ in thousands, except per share data) | |||||||||||||
Revenues
|
$ | 169,936 | $ | 126,308 | $ | 137,226 | |||||||
Cost of sales
|
97,002 | 74,672 | 78,975 | ||||||||||
Gross profit
|
72,934 | 51,636 | 58,251 | ||||||||||
Selling, general and administrative expenses
|
25,141 | 18,864 | 18,641 | ||||||||||
Start-up costs
|
80 | 1,099 | 35 | ||||||||||
Provision for legal judgment
|
(18 | ) | 993 | | |||||||||
Loss on disposal of equipment
|
717 | | | ||||||||||
Operating profit
|
47,014 | 30,680 | 39,575 | ||||||||||
Other income (expense):
|
|||||||||||||
Interest income
|
204 | 500 | 891 | ||||||||||
Interest expense
|
(13 | ) | (14 | ) | (1 | ) | |||||||
Other, net
|
(118 | ) | 77 | 216 | |||||||||
73 | 563 | 1,106 | |||||||||||
Income before income taxes
|
47,087 | 31,243 | 40,681 | ||||||||||
Income taxes
|
17,518 | 11,529 | 14,483 | ||||||||||
Net income
|
$ | 29,569 | $ | 19,714 | $ | 26,198 | |||||||
Earnings per share:
|
|||||||||||||
Basic
|
$ | 1.90 | $ | 1.29 | $ | 1.76 | |||||||
Diluted
|
$ | 1.88 | $ | 1.28 | $ | 1.74 | |||||||
F-3
CARBO CERAMICS INC.
CONSOLIDATED STATEMENTS OF SHAREHOLDERS EQUITY
Accumulated | |||||||||||||||||||||||||
Unearned | Other | ||||||||||||||||||||||||
Additional | Stock | Comprehensive | |||||||||||||||||||||||
Common | Paid-In | Compen- | Retained | Income | |||||||||||||||||||||
Stock | Capital | sation | Earnings | (Loss) | Total | ||||||||||||||||||||
($ in thousands) | |||||||||||||||||||||||||
Balances at January 1, 2001
|
$ | 147 | $ | 45,225 | $ | | $ | 60,768 | $ | | $ | 106,140 | |||||||||||||
Net income
|
| | | 26,198 | | 26,198 | |||||||||||||||||||
Foreign currency translation adjustment
|
| | | | (8 | ) | (8 | ) | |||||||||||||||||
Comprehensive income
|
26,190 | ||||||||||||||||||||||||
Exercise of stock options
|
2 | 4,333 | | | | 4,335 | |||||||||||||||||||
Tax benefit from exercise of options
|
| 1,905 | | | | 1,905 | |||||||||||||||||||
Modification of fixed stock option award
|
| 3,504 | | | | 3,504 | |||||||||||||||||||
Cash dividends ($0.345 per share)
|
| | | (5,132 | ) | | (5,132 | ) | |||||||||||||||||
Balances at December 31, 2001
|
149 | 54,967 | | 81,834 | (8 | ) | 136,942 | ||||||||||||||||||
Net income
|
| | | 19,714 | | 19,714 | |||||||||||||||||||
Foreign currency translation adjustment
|
| | | | (8 | ) | (8 | ) | |||||||||||||||||
Comprehensive income
|
19,706 | ||||||||||||||||||||||||
Exercise of stock options
|
3 | 4,480 | | | | 4,483 | |||||||||||||||||||
Tax benefit from exercise of options
|
| 382 | | | | 382 | |||||||||||||||||||
Shares issued in acquisition
|
3 | 9,677 | | | | 9,680 | |||||||||||||||||||
Vested options assumed in acquisition
|
| 2,630 | | | | 2,630 | |||||||||||||||||||
Unvested options assumed in acquisition
|
| 789 | (789 | ) | | | | ||||||||||||||||||
Amortization of unearned compensation
|
| | 232 | | | 232 | |||||||||||||||||||
Cash dividends ($0.36 per share)
|
| | | (5,470 | ) | | (5,470 | ) | |||||||||||||||||
Balances at December 31, 2002
|
155 | 72,925 | (557 | ) | 96,078 | (16 | ) | 168,585 | |||||||||||||||||
Net income
|
| | | 29,569 | | 29,569 | |||||||||||||||||||
Foreign currency translation adjustment
|
| | | | (26 | ) | (26 | ) | |||||||||||||||||
Comprehensive income
|
29,543 | ||||||||||||||||||||||||
Exercise of stock options
|
2 | 4,796 | | | | 4,798 | |||||||||||||||||||
Tax benefit from exercise of options
|
| 1,308 | | | | 1,308 | |||||||||||||||||||
Shares issued in acquisition
|
| 1,505 | | | | 1,505 | |||||||||||||||||||
Amortization of unearned compensation
|
| | 304 | | | 304 | |||||||||||||||||||
Cash dividends ($0.38 per share)
|
| | | (5,904 | ) | | (5,904 | ) | |||||||||||||||||
Balances at December 31, 2003
|
$ | 157 | $ | 80,534 | $ | (253 | ) | $ | 119,743 | $ | (42 | ) | $ | 200,139 | |||||||||||
F-4
CARBO CERAMICS INC.
CONSOLIDATED STATEMENTS OF CASH FLOWS
Years Ended December 31, | ||||||||||||||
2003 | 2002 | 2001 | ||||||||||||
($ in thousands) | ||||||||||||||
Operating activities
|
||||||||||||||
Net income
|
$ | 29,569 | $ | 19,714 | $ | 26,198 | ||||||||
Adjustments to reconcile net income to net cash
provided by operating activities:
|
||||||||||||||
Depreciation
|
9,921 | 7,592 | 6,776 | |||||||||||
Amortization
|
472 | 223 | | |||||||||||
Deferred income taxes
|
4,414 | 1,977 | 1,049 | |||||||||||
Loss on disposal of equipment
|
717 | | | |||||||||||
Non-cash stock option expense
|
304 | 232 | 3,504 | |||||||||||
Changes in operating assets and liabilities:
|
||||||||||||||
Trade accounts receivable
|
(7,428 | ) | 651 | (4,374 | ) | |||||||||
Inventories
|
(4,607 | ) | (421 | ) | (2,935 | ) | ||||||||
Prepaid expenses and other current assets
|
(486 | ) | 92 | 56 | ||||||||||
Accounts payable
|
1,880 | (1,222 | ) | 2,279 | ||||||||||
Accrued payroll and benefits
|
1,699 | 159 | 546 | |||||||||||
Accrued freight
|
322 | (385 | ) | (677 | ) | |||||||||
Accrued utilities
|
584 | 213 | (89 | ) | ||||||||||
Accrued income taxes
|
(194 | ) | (359 | ) | 1,628 | |||||||||
Provision for legal judgment
|
(18 | ) | 993 | | ||||||||||
Other accrued expenses
|
1,134 | 12 | (70 | ) | ||||||||||
Net cash provided by operating activities
|
38,283 | 29,471 | 33,891 | |||||||||||
Investing activities
|
||||||||||||||
Maturities of investment securities
|
| 6,000 | 1,000 | |||||||||||
Purchases of investment securities
|
| | (6,000 | ) | ||||||||||
Capital expenditures, net
|
(21,975 | ) | (27,356 | ) | (11,296 | ) | ||||||||
Purchase of Pinnacle Technologies,
Inc.
|
(909 | ) | (12,022 | ) | | |||||||||
Net cash used in investing activities
|
(22,884 | ) | (33,378 | ) | (16,296 | ) | ||||||||
Financing activities
|
||||||||||||||
Repayments on bank borrowings
|
| (2,198 | ) | | ||||||||||
Proceeds from exercise of stock options
|
4,798 | 4,483 | 4,335 | |||||||||||
Dividends paid
|
(5,904 | ) | (5,470 | ) | (5,132 | ) | ||||||||
Net cash used in financing activities
|
(1,106 | ) | (3,185 | ) | (797 | ) | ||||||||
Net increase (decrease) in cash and cash
equivalents
|
14,293 | (7,092 | ) | 16,798 | ||||||||||
Effect of exchange rate changes on cash
|
(26 | ) | (8 | ) | (8 | ) | ||||||||
Cash and cash equivalents at beginning of year
|
24,447 | 31,547 | 14,757 | |||||||||||
Cash and cash equivalents at end of year
|
$ | 38,714 | $ | 24,447 | $ | 31,547 | ||||||||
Supplemental cash flow information
|
||||||||||||||
Interest paid
|
$ | 13 | $ | 14 | $ | 1 | ||||||||
Income taxes paid
|
$ | 13,298 | $ | 9,764 | $ | 11,806 | ||||||||
Capital expenditures through accounts payable and
retainage
|
$ | 265 | $ | 5,849 | $ | | ||||||||
F-5
CARBO CERAMICS INC.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS
1. Significant Accounting Policies
Description of Business |
CARBO Ceramics Inc. (the Company) was formed in 1987 and is a manufacturer of ceramic proppants. The Company has four production plants operating in New Iberia, Louisiana; Eufaula, Alabama; McIntyre, Georgia; and Luoyang, China. The Company predominantly markets its proppant products through pumping service companies that perform hydraulic fracturing for major oil and gas companies. Finished goods inventories are stored at the plant sites and eleven remote distribution facilities located in: Rock Springs, Wyoming; Oklahoma City, Oklahoma; San Antonio, Texas; Fairbanks, Alaska; Edmonton, Alberta, Canada; Grande Prairie, Alberta, Canada; Rotterdam, The Netherlands; Tianjin, China; Adelaide, Australia; Singapore; and Jebel Ali, United Arab Emirates. The Company also provides fracture diagnostic and mapping services, sells fracture simulation software and provides fracture design services to oil and gas companies worldwide through its wholly-owned subsidiary, Pinnacle Technologies, Inc., which is headquartered in San Francisco, California (see Note 2).
Principles of Consolidation |
The consolidated financial statements include the accounts of CARBO Ceramics Inc. and its wholly owned subsidiaries: CARBO Ceramics (UK) Limited, CARBO Ceramics (Mauritius) Inc., CARBO Ceramics (China) Company Limited, CARBO Ceramics Cyprus Limited and Pinnacle Technologies, Inc. All significant intercompany transactions have been eliminated.
Concentration of Credit Risk |
The Company performs periodic credit evaluations of its customers financial condition and generally does not require collateral. Receivables are generally due within 30 days. The majority of the Companys receivables are from customers in the petroleum pressure pumping industry. Credit losses historically have been insignificant.
Cash Equivalents |
The Company considers all highly liquid investments with a maturity of three months or less when purchased to be cash equivalents. The carrying amounts reported in the balance sheet for cash equivalents approximate fair value.
Inventories |
Inventories are stated at the lower of cost (first-in, first-out method) or market. Finished goods inventories include costs of materials, plant labor and overhead incurred in the production of the Companys products.
Property, Plant and Equipment |
Property, plant and equipment are stated at cost. Repair and maintenance costs are expensed as incurred. Depreciation is computed on the straight-line method for financial reporting purposes using the following estimated useful lives:
Buildings and improvements
|
15 to 30 years | |||
Machinery and equipment
|
3 to 30 years | |||
Land-use rights
|
30 years |
F-6
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
Land-use rights represent capitalized costs to acquire rights to the land for the Companys China plant site. The Companys rights to use of the property are for a 50-year period expiring in 2051. Depreciation in 2002 was based on a 50-year life. In 2003, the Company decided it was more appropriate to recover the cost of the land-use rights over the 30-year life of its business license in China, which expires in 2031. The effect of the change in estimated useful life did not have a material impact on 2003 net income or related per share amounts.
During 2002 and 2003, the Company completed the acquisition of approximately 1,500 acres of land and leasehold interests in Wilkinson County, Georgia, near its plant in McIntyre, Georgia. The Company estimates the land has 12 million tons of kaolin reserves for use as raw material in production of its lightweight ceramic proppant. The capitalized costs of land and mineral rights as well as costs incurred to develop such property are amortized using the units-of-production method based on estimated total tons of kaolin reserves.
Impairment of Long-Lived Assets and Intangible Assets |
When events or circumstances indicate that the carrying amount of long-lived assets to be held and used or intangible assets might not be recoverable, the expected future undiscounted cash flows from the assets is estimated and compared with the carrying amount of the assets. If the sum of the estimated undiscounted cash flows is less than the carrying amount of the assets, an impairment loss is recorded. The impairment loss is measured by comparing the fair value of the assets with their carrying amounts. Fair value is determined based on discounted cash flow or appraised values, as appropriate. Long-lived assets that are held for disposal are reported at the lower of the assets carrying amount or fair value less costs related to the assets disposition. During 2003, the Company recognized a $717,000 loss on the disposal of certain equipment during expansion of the McIntyre plant.
Goodwill |
Goodwill represents the excess of the cost of companies acquired over the fair value of their net assets at the date of acquisition. Realization of goodwill is assessed periodically by management based on the expected future profitability and undiscounted future cash flows of acquired entities and their contribution to the overall operations of the Company. The Company has performed a goodwill impairment review at the reporting unit level based on a fair value concept. Should a review indicate that the carrying value was not recoverable, the excess of the carrying value over the undiscounted cash flow would be recognized as an impairment loss.
Revenue Recognition |
Revenue is recognized when title passes to the customer. Title passes to the customer upon delivery.
Shipping and Handling Costs |
Shipping costs, which consist of transportation costs associated with the delivery of the Companys products to customers, are classified as cost of sales. Handling costs are charged to selling, general and administrative expenses and include labor and overhead costs related to maintaining finished goods inventory and operating the Companys distribution facilities. Handling costs incurred in 2003, 2002 and 2001 were $4,808,000, $3,676,000 and $3,555,000, respectively.
Cost of Start-Up Activities |
Start-up activities, including organization costs, are expensed as incurred. Start-up costs for 2003 are related to expansion of the McIntyre and New Iberia facilities and initial operation of the China facility. Start-up costs for 2002 and 2001 are related to the China facility, including organizational and administrative costs
F-7
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
associated with plant construction plus labor, materials and utilities expended in the fourth quarter of 2002 to bring installed equipment to operating condition.
Use of Estimates |
The preparation of financial statements in conformity with accounting principles generally accepted in the United States requires management to make estimates and assumptions that affect the amounts reported in the financial statements and accompanying notes. Actual results could differ from those estimates.
Research and Development Costs |
Research and development costs are charged to operations when incurred and are included in selling, general and administrative expenses. The amounts incurred in 2003, 2002 and 2001 were $2,578,000, $2,124,000 and $784,000, respectively.
Stock Based Compensation |
The Company applies APB Opinion No. 25, Accounting for Stock Issued to Employees (APB 25) and related Interpretations in accounting for its employee stock options because, as discussed below, the alternative fair value accounting provided for under FASB Statement No. 123, Accounting for Stock-Based Compensation (Statement 123), requires use of option valuation models that were not developed for use in valuing employee stock options. Under APB 25, generally no compensation expense is recognized because the exercise price of the Companys employee stock options equals the market price of the underlying stock on the date of grant. However, certain transactions involving fixed stock option awards may result in the recognition of compensation expense under APB 25. Compensation expense of $304,000 and $232,000 was charged to operations in 2003 and 2002, respectively, for amortization of unearned stock compensation related to unvested stock options assumed in a business acquisition (see Note 2). In 2001, $3,504,000 compensation expense was charged to operations, resulting from the modification of outstanding options of the Companys former president at the time of his retirement in April 2001. As of December 31, 2002, those options had been fully exercised by the former president.
F-8
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
The following table illustrates the effect on net income and earnings per share if the Company had applied the fair value recognition provisions of Statement 123 to stock-based employee compensation for the years ended December 31:
2003 | 2002 | 2001 | |||||||||||
($ in thousands, except | |||||||||||||
per share data) | |||||||||||||
Net income, as reported
|
$ | 29,569 | $ | 19,714 | $ | 26,198 | |||||||
Add: stock-based employee compensation expense
included in reported net income, net of related tax effects
|
191 | 146 | 2,207 | ||||||||||
Deduct: total stock-based compensation expense
determined under fair value based method for all awards, net of
related tax effects
|
(1,145 | ) | (976 | ) | (2,584 | ) | |||||||
Pro forma net income
|
$ | 28,615 | $ | 18,884 | $ | 25,821 | |||||||
Earnings per share:
|
|||||||||||||
Basic as reported
|
$ | 1.90 | $ | 1.29 | $ | 1.76 | |||||||
Basic pro forma
|
$ | 1.84 | $ | 1.24 | $ | 1.73 | |||||||
Diluted as reported
|
$ | 1.88 | $ | 1.28 | $ | 1.74 | |||||||
Diluted pro forma
|
$ | 1.82 | $ | 1.23 | $ | 1.72 | |||||||
Foreign Subsidiaries |
Financial statements of the Companys foreign subsidiaries are translated using current exchange rates for assets and liabilities; average exchange rates for the period for revenues, expenses, gains and losses; and historical exchange rates for paid-in capital accounts. Resulting translation adjustments are included in accumulated other comprehensive income (loss).
New Pronouncement |
In January 2003, the FASB issued FIN 46, Consolidation of Variable Interest Entities, which clarifies the application of Accounting Research Bulletin 51 (ARB 51), Consolidated Financial Statements, to certain entities (called variable interest entities) in which equity investors do not have the characteristics of a controlling financial interest or do not have sufficient equity at risk for the entity to finance its activities without additional subordinated financial support from other parties. The disclosure requirements of this interpretation are effective for all financial statements issued after January 31, 2003. The consolidation requirements apply to all variable interest entities created after January 31, 2003. In addition, public companies must apply the consolidation requirements to variable interest entities that existed prior to February 1, 2003, and remain in existence as of the beginning of annual or interim periods beginning after March 15, 2004. The Company adopted FIN 46 in the fourth quarter 2003. As the Company has no arrangements that meet the definition of a variable interest entity, the adoption had no impact on the Companys consolidated financial statements.
2. Acquisition of Business
On May 31, 2002, the Company purchased 100 percent of the outstanding shares of Pinnacle Technologies, Inc. (Pinnacle). Results of operations for Pinnacle are included in the consolidated financial statements since that date. Pinnacle provides fracture diagnostic and mapping services, sells fracture simulation software and provides fracture design services to oil and gas companies worldwide. The acquisition
F-9
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
was made to expand the Companys ability to provide production-enhancing solutions to oil and gas exploration and production companies worldwide and to provide a catalyst for accelerating the growth of ceramic proppant sales in the future. The acquisition was accounted for using the purchase method of accounting provided for under FASB Statement No. 141, Business Combinations.
The aggregate cost of the acquisition was approximately $26.7 million, including $12.4 million cash; 324,207 shares of common stock valued at $11.2 million; 158,300 stock options valued at $2.5 million granted in exchange for outstanding Pinnacle options; and $0.6 million direct costs of the acquisition. Goodwill was recorded because the aggregate cost of the transaction exceeded the fair value of the assets acquired of $9.0 million net of liabilities assumed of $4.1 million. Goodwill is fully deductible for tax purposes. The value of the common shares was determined based on the closing market price of the Companys common stock on the date of acquisition. The value of stock options was determined using the Black-Scholes option valuation model based on the closing market price of the Companys common stock on the date of acquisition. The fair value of options granted was reduced by $0.8 million allocated to unearned stock compensation, which represents the intrinsic value of options exchanged for unvested Pinnacle options. Unearned stock compensation is being amortized to expense on a straight-line basis over the remaining vesting period. Under the terms of the acquisition agreement, the Company withheld $2.3 million of the aggregate purchase price in the form of $0.8 million cash and 43,621 common shares valued at $1.5 million using the closing market price on the date of acquisition. The final installment was paid on June 1, 2003, and recorded as goodwill.
Following are pro forma amounts assuming the acquisition was made on January 1, 2001 ($ in thousands, except per share data):
Year Ended December 31, | |||||||||
2002 | 2001 | ||||||||
Pro forma revenue
|
$ | 129,808 | $ | 146,580 | |||||
Pro forma net income
|
$ | 19,213 | $ | 26,174 | |||||
Pro forma earnings per share:
|
|||||||||
Basic
|
$ | 1.25 | $ | 1.72 | |||||
Diluted
|
$ | 1.24 | $ | 1.70 | |||||
The following table summarizes the fair values of the assets acquired and liabilities assumed in the acquisition ($ in thousands):
Current assets
|
$ | 1,639 | ||
Property, plant and equipment
|
3,942 | |||
Intangible assets
|
3,434 | |||
Goodwill arising in the transaction
|
21,840 | |||
30,855 | ||||
Current liabilities
|
(3,212 | ) | ||
Long-term debt
|
(921 | ) | ||
Net assets acquired
|
$ | 26,722 | ||
F-10
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
3. Intangible Assets
Following is a summary of intangible assets as of December 31:
2003 | 2002 | ||||||||||||||||
Gross | Accumulated | Gross | Accumulated | ||||||||||||||
Amount | Amortization | Amount | Amortization | ||||||||||||||
($ in thousands) | |||||||||||||||||
Intangibles subject to amortization:
|
|||||||||||||||||
Patents and licenses
|
$ | 2,547 | $ | 412 | $ | 2,526 | $ | 152 | |||||||||
Hardware designs
|
683 | 193 | 545 | 71 | |||||||||||||
Other
|
369 | 90 | 132 | | |||||||||||||
Other intangibles not subject to amortization
|
1,007 | | 517 | | |||||||||||||
$ | 4,606 | $ | 695 | $ | 3,720 | $ | 223 | ||||||||||
Certain amounts in the December 31, 2002 summary have been reclassified to conform to the December 31, 2003 presentation.
Amortization expense for 2003 and 2002 was $472,000 and $223,000, respectively. Estimated amortization expense for each of the ensuing years through December 31, 2008 is, respectively, $479,000, $449,000, $393,000, $356,000, and $264,000.
4. Bank Borrowings
Under the terms of an unsecured revolving credit agreement with a bank, dated December 31, 2000, and amended December 23, 2003, the Company may borrow up to $10.0 million through December 31, 2006, with the option of choosing either the banks fluctuating Base Rate or LIBOR Fixed Rate (as defined in the credit agreement). At December 31, 2003 the unused portion of the credit facility was $10.0 million. The terms of the credit agreement provide for certain affirmative and negative covenants and require the Company to maintain certain financial ratios. Commitment fees are payable quarterly at the annual rate of three-eighths of one percent of the unused line of credit. Commitment fees were $38,000 in each of the years 2003, 2002 and 2001.
5. Leases
The Company leases certain property, plant and equipment under operating leases, primarily consisting of railroad equipment leases. Minimum future rental payments due under non-cancelable operating leases with remaining terms in excess of one year as of December 31, 2003 are as follows ($ in thousands):
2004
|
$ | 1,414 | ||
2005
|
1,309 | |||
2006
|
1,033 | |||
2007
|
751 | |||
2008
|
500 | |||
Thereafter
|
357 | |||
Total
|
$ | 5,364 | ||
Leases of railroad equipment generally provide for renewal options for periods from one to five years at their fair rental value at the time of renewal. In the normal course of business, operating leases for railroad equipment are generally renewed or replaced by other leases. Rent expense for all operating leases was $2,625,000 in 2003, $1,900,000 in 2002 and $1,723,000 in 2001.
F-11
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
6. Income Taxes
Deferred income taxes reflect the net tax effects of temporary differences between the carrying amounts of assets and liabilities for financial reporting purposes and the amounts used for income tax purposes. Significant components of the Companys deferred tax assets and liabilities as of December 31 are as follows:
2003 | 2002 | ||||||||
($ in thousands) | |||||||||
Deferred tax assets:
|
|||||||||
Employee benefits
|
$ | 734 | $ | 356 | |||||
Inventories
|
953 | 575 | |||||||
Other
|
390 | 92 | |||||||
Total deferred tax assets
|
2,077 | 1,023 | |||||||
Deferred tax liabilities:
|
|||||||||
Depreciation
|
17,087 | 13,085 | |||||||
Goodwill
|
815 | | |||||||
Foreign earnings
|
651 | | |||||||
Total deferred tax liabilities
|
18,553 | 13,085 | |||||||
Net deferred tax liabilities
|
$ | 16,476 | $ | 12,062 | |||||
Significant components of the provision for income taxes for the years ended December 31 are as follows:
2003 | 2002 | 2001 | ||||||||||||
($ in thousands) | ||||||||||||||
Current:
|
||||||||||||||
Federal
|
$ | 11,211 | $ | 8,620 | $ | 12,302 | ||||||||
State
|
1,893 | 932 | 1,132 | |||||||||||
Total current
|
13,104 | 9,552 | 13,434 | |||||||||||
Deferred:
|
||||||||||||||
Federal
|
3,829 | 1,784 | 961 | |||||||||||
State
|
585 | 193 | 88 | |||||||||||
Total deferred
|
4,414 | 1,977 | 1,049 | |||||||||||
$ | 17,518 | $ | 11,529 | $ | 14,483 | |||||||||
The reconciliation of income taxes computed at the U.S. statutory tax rate to the Companys income tax expense for the years ended December 31 is as follows:
2003 | 2002 | 2001 | ||||||||||||||||||||||
Amount | Percent | Amount | Percent | Amount | Percent | |||||||||||||||||||
($ in thousands) | ||||||||||||||||||||||||
U.S. statutory rate
|
$ | 16,480 | 35.0 | % | $ | 10,935 | 35.0 | % | $ | 14,238 | 35.0 | % | ||||||||||||
State income taxes, net of federal tax benefit
|
1,611 | 3.4 | 1,125 | 3.6 | 1,220 | 3.0 | ||||||||||||||||||
Extraterritorial Income Exclusion and other
|
(573 | ) | (1.2 | ) | (531 | ) | (1.7 | ) | (975 | ) | (2.4 | ) | ||||||||||||
$ | 17,518 | 37.2 | % | $ | 11,529 | 36.9 | % | $ | 14,483 | 35.6 | % | |||||||||||||
F-12
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
7. Shareholders Equity
Common Stock
Holders of Common Stock are entitled to one vote per share on all matters to be voted on by shareholders and do not have cumulative voting rights. Subject to preferences of any Preferred Stock, the holders of Common Stock are entitled to receive ratably such dividends, if any, as may be declared from time to time by the Board of Directors out of funds legally available for that purpose. In the event of liquidation, dissolution or winding up of the Company, holders of Common Stock are entitled to share ratably in all assets remaining after payment of liabilities, subject to prior distribution rights of any Preferred Stock then outstanding. The Common Stock has no preemptive or conversion rights or other subscription rights. There are no redemption or sinking fund provisions applicable to the Common Stock. All outstanding shares of Common Stock are fully paid and nonassessable.
On January 14, 2004, the Board of Directors declared a cash dividend of $0.10 per share. The dividend is payable on February 16, 2004 to shareholders of record on January 30, 2004.
Preferred Stock |
The Companys charter authorizes 5,000 shares of Preferred Stock. The Board of Directors has the authority to issue Preferred Stock in one or more series and to fix the rights, preferences, privileges and restrictions thereof, including dividend rights, conversion rights, voting rights, terms of redemption, redemption prices, liquidation preferences and the number of shares constituting any series or the designation of such series, without further vote or action by the Companys shareholders. In connection with adoption of a shareholder rights plan on February 13, 2002, the Company created the Series A Preferred Stock and authorized 2,000 shares of the Series A Preferred Stock.
Shareholder Rights Plan |
On February 13, 2002, the Company adopted a shareholder rights plan and declared a dividend of one right for each outstanding share of Common Stock to shareholders of record on February 25, 2002. With certain exceptions, the rights become exercisable if a tender offer for the Company is announced or any person or group acquires beneficial ownership of at least 15 percent of the Companys Common Stock. If exercisable, each right entitles the holder to purchase one ten-thousandth of a share of Series A Preferred Stock at an exercise price of $200 and, if any person or group acquires beneficial ownership of at least 15 percent of the Companys Common Stock, to acquire a number of shares of Common Stock having a market value of two times the $200 exercise price. The Company may redeem the rights for $0.01 per right at any time before any person or group acquires beneficial ownership of at least 15 percent of the Common Stock. The rights expire on February 13, 2012.
8. Stock Option Plans
The Company has two fixed stock-based compensation plans: 1996 Stock Option Plan for Key Employees (CARBO Plan) and 1996 Stock Option Plan of Pinnacle Technologies, Inc. as Amended and Restated May 31, 2002 (Pinnacle Plan). The plans provide for granting options to purchase shares of the Companys Common Stock primarily to key employees, officers and directors. Under the CARBO Plan, the Company may grant options for up to 1,250,000 shares of Common Stock. The exercise price of each option is equal to the market price of the Companys Common Stock on the date of grant, no individual employee may be granted options to purchase more than an aggregate of 500,000 shares of Common Stock, options have maximum terms of ten years and vest annually over four years. Under the Pinnacle Plan, the Company may grant options for up to 200,000 shares of Common Stock. The exercise price of each option may not be less
F-13
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
than 85 percent of the market price of the Companys Common Stock on the date of grant, options have maximum terms of ten years and vesting is determined for each grant (generally 3 to 5 years).
Pro forma information regarding net income and earnings per share is required by FASB Statement No. 123 (see note 1), and has been determined as if the Company had accounted for its employee stock options under the fair value method of that statement. The fair value for these options was estimated at the date of grant using a Black-Scholes option pricing model with the following weighted-average assumptions for 2003, 2002 and 2001, respectively: risk-free interest rates of 3.15%, 4.59% and 4.45%; a dividend yield of 1.0%; volatility factors of the expected market price of the Companys Common Stock of .458, .498 and .507; and a weighted-average expected life of the option of 5 years.
The Black-Scholes option valuation model was developed for use in estimating the fair value of traded options that have no vesting restrictions and are fully transferable. In addition, option valuation models require the input of highly subjective assumptions including the expected stock price volatility. Because the Companys employee stock options have characteristics significantly different from those of traded options, and because changes in the subjective input assumptions can materially affect the fair value estimate, in managements opinion, the existing models do not necessarily provide a reliable single measure of the fair value of its employee stock options.
A summary of stock option activity and related information for the years ended December 31 follows:
2003 | 2002 | 2001 | ||||||||||||||||||||||
Options | Weighted-Average | Options | Weighted-Average | Options | Weighted-Average | |||||||||||||||||||
(000) | Exercise Price | (000) | Exercise Price | (000) | Exercise Price | |||||||||||||||||||
Outstanding-beginning of year
|
778 | $ | 28 | 757 | $ | 25 | 818 | $ | 21 | |||||||||||||||
Granted
|
34 | 35 | 279 | 26 | 209 | 34 | ||||||||||||||||||
Exercised
|
207 | 23 | 252 | 18 | 250 | 17 | ||||||||||||||||||
Forfeited
|
12 | 26 | 6 | 32 | 20 | 35 | ||||||||||||||||||
Outstanding-end of year
|
593 | $ | 30 | 778 | $ | 28 | 757 | $ | 25 | |||||||||||||||
Exercisable at end of year
|
341 | $ | 27 | 443 | $ | 24 | 534 | $ | 22 | |||||||||||||||
Weighted-average fair value of options granted
during the year
|
$ | 14.00 | $ | 19.30 | $ | 15.55 |
Following is a summary of the status of fixed options outstanding at December 31, 2003:
Outstanding Options | Exercisable Options | |||||||||||||||||||||
Weighted | ||||||||||||||||||||||
Average | Weighted | Weighted | ||||||||||||||||||||
Exercise | Remaining | Average | Average | |||||||||||||||||||
Price | Number | Contractual | Exercise | Number | Exercise | |||||||||||||||||
Range | (000) | Life | Price | (000) | Price | |||||||||||||||||
$ | 8 24 | 156 | 4 years | $ | 17 | 141 | $ | 18 | ||||||||||||||
30 42 | 437 | 7 years | 34 | 200 | 33 | |||||||||||||||||
593 | 30 | 341 | 27 | |||||||||||||||||||
F-14
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
9. Earnings Per Share
The following table sets forth the computation of basic and diluted earnings per share:
2003 | 2002 | 2001 | ||||||||||||
($ in thousands, except per share data) | ||||||||||||||
Numerator for basic and diluted earnings per
share:
|
||||||||||||||
Net income
|
$ | 29,569 | $ | 19,714 | $ | 26,198 | ||||||||
Denominator:
|
||||||||||||||
Denominator for basic earnings per
share weighted average shares
|
15,559,785 | 15,233,096 | 14,897,175 | |||||||||||
Effect of dilutive securities:
|
||||||||||||||
Employee stock options (See Note 8)
|
111,530 | 116,454 | 144,903 | |||||||||||
Contingent stock acquisition
|
18,046 | 25,706 | | |||||||||||
Dilutive potential common shares
|
129,576 | 142,160 | 144,903 | |||||||||||
Denominator for diluted earnings per
share adjusted weighted-average shares
|
15,689,361 | 15,375,256 | 15,042,078 | |||||||||||
Basic earnings per share
|
$ | 1.90 | $ | 1.29 | $ | 1.76 | ||||||||
Diluted earnings per share
|
$ | 1.88 | $ | 1.28 | $ | 1.74 | ||||||||
10. Quarterly Operating Results (Unaudited)
Quarterly results of operations for the years ended December 31, 2003 and 2002 were as follows:
Three Months Ended, | |||||||||||||||||
March 31 | June 30 | September 30 | December 31 | ||||||||||||||
($ in thousands, except per share data) | |||||||||||||||||
2003
|
|||||||||||||||||
Revenues
|
$ | 38,538 | $ | 39,423 | $ | 43,260 | $ | 48,715 | |||||||||
Gross profit
|
15,079 | 16,938 | 19,075 | 21,842 | |||||||||||||
Net income
|
5,710 | 6,444 | 8,114 | 9,301 | |||||||||||||
Earnings per share:
|
|||||||||||||||||
Basic
|
$ | 0.37 | $ | 0.42 | $ | 0.52 | $ | 0.59 | |||||||||
Diluted
|
$ | 0.37 | $ | 0.41 | $ | 0.52 | $ | 0.59 | |||||||||
2002
|
|||||||||||||||||
Revenues
|
$ | 29,311 | $ | 29,651 | $ | 35,484 | $ | 31,862 | |||||||||
Gross profit
|
11,678 | 11,970 | 15,000 | 12,988 | |||||||||||||
Net income
|
5,029 | 4,976 | 5,814 | 3,895 | |||||||||||||
Earnings per share:
|
|||||||||||||||||
Basic
|
$ | 0.34 | $ | 0.33 | $ | 0.38 | $ | 0.25 | |||||||||
Diluted
|
$ | 0.33 | $ | 0.33 | $ | 0.37 | $ | 0.25 |
Quarterly data may not sum to full year data reported in the consolidated financial statements due to rounding.
F-15
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
11. Sales to Customers
The following schedule presents the percentages of total revenues related to the Companys three major customers for the three-year period ended December 31, 2003:
Major Customers | ||||||||||||||||||||
A | B | C | Others | Total | ||||||||||||||||
2003
|
30.1 | % | 16.5 | % | 24.3 | % | 29.1 | % | 100 | % | ||||||||||
2002
|
35.0 | % | 20.0 | % | 23.6 | % | 21.4 | % | 100 | % | ||||||||||
2001
|
33.8 | % | 22.8 | % | 24.4 | % | 19.0 | % | 100 | % |
12. Geographic Information
Long-lived assets, consisting of net property, plant and equipment and goodwill, as of December 31 in the United States and other countries are as follows:
2003 | 2002 | 2001 | ||||||||||||
($ in millions) | ||||||||||||||
Long-lived assets:
|
||||||||||||||
United States
|
$ | 124.1 | $ | 119.4 | $ | 76.5 | ||||||||
International (primarily China)
|
14.4 | 11.8 | 6.0 | |||||||||||
Total
|
$ | 138.5 | $ | 131.2 | $ | 82.5 | ||||||||
Revenues outside the United States accounted for 36%, 30% and 27% of the Companys revenues for 2003, 2002, and 2001, respectively. Revenues for the years ended December 31 in the United States, Canada and other countries are as follows:
2003 | 2002 | 2001 | ||||||||||||
($ in millions) | ||||||||||||||
Revenues:
|
||||||||||||||
United States
|
$ | 108.0 | $ | 88.0 | $ | 100.4 | ||||||||
Canada
|
18.1 | 13.0 | 11.1 | |||||||||||
Other international
|
43.8 | 25.3 | 25.7 | |||||||||||
Total
|
$ | 169.9 | $ | 126.3 | $ | 137.2 | ||||||||
13. Benefit Plans
The Company has defined contribution savings and profit sharing plans pursuant to Section 401(k) of the Internal Revenue Code. The increase in savings contributions beginning in 2002 is due to additional employment related to expansions and the acquisition of Pinnacle Technologies, Inc. on May 31, 2002. Benefit costs recognized as expense under these plans consisted of the following for the years ended December 31:
2003 | 2002 | 2001 | |||||||||||
($ in thousands) | |||||||||||||
Contributions:
|
|||||||||||||
Profit sharing
|
$ | 719 | $ | 425 | $ | 500 | |||||||
Savings
|
431 | 338 | 201 | ||||||||||
$ | 1,150 | $ | 763 | $ | 701 | ||||||||
F-16
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
14. Commitments
In 1995, the Company entered into an agreement with a supplier to purchase kaolin for its Eufaula, Alabama, plant at a specified contract price. The term of the agreement was eight years commencing January 1, 1996. Beginning January 1, 1997, the agreement required the Company to purchase from the supplier at least 80 percent of the Companys estimated annual requirements of kaolin for its Eufaula plant. For the years ended December 31, 2003, 2002 and 2001, the Company purchased from the supplier $2.6 million, $2.2 million and $3.7 million, respectively, of kaolin under the agreement. In June 2003, the Company entered into a new agreement with the supplier. The new agreement supercedes and replaces the 1995 agreement. The term of the agreement is seven years commencing January 1, 2004 and requires the Company to purchase from the supplier at least 70 percent of its annual kaolin requirements for its Eufaula, Alabama, plant at specified contract prices.
In January 2003, the Company entered into a mining agreement with a contractor to provide kaolin for the Companys McIntyre plant at specified contract prices, from lands owned or leased by either the Company or the contractor. The term of the agreement is twenty years commencing on January 1, 2003 and requires the Company to accept delivery from the contractor of at least 80% of the McIntyre plants annual kaolin requirements. Under the agreement, the contractor bears responsibility for reclaiming property owned by the Company and indemnifies the Company from all claims. For the year ended December 31, 2003, the Company purchased $0.5 million of kaolin under the agreement.
In January 2003, the Company entered into an agreement with a supplier to purchase bauxite for production at its plants in New Iberia, Louisiana, and McIntyre, Georgia. The term of the agreement is three years commencing January 1, 2003 and requires the Company to purchase 60,000 metric tons of material annually at specified contract prices. The contract also has provisions to allow the Company to commit to purchase up to an additional 45,000 metric tons in any contract year. For the year ended December 31, 2003, the Company purchased $7.5 million of bauxite under the agreement.
In 2002, the Company entered into a five-year agreement and a ten-year agreement with two different suppliers to purchase bauxite and hard clays for its China plant at specified contract prices. The agreements require the Company to purchase a minimum of 10,000 metric tons of material annually, or 100 percent of its annual requirements for bauxite if less than 10,000 metric tons. For the year ended December 31, 2003, the Company purchased approximately $0.4 million of material under the agreements.
The Company has entered into a lease agreement with the Development Authority of Wilkinson County (the Development Authority) in the State of Georgia. Pursuant to this agreement, the Development Authority holds the title to the real and personal property of the Companys McIntyre manufacturing facility and leases the facility to the Company for an annual rental fee of $35,000 per year through the year 2016. At any time prior to the scheduled termination of the lease, the Company has the option to terminate the lease and purchase the property for a nominal fee plus the payment of any rent payable through the balance of the lease term. Furthermore, the Company has a security interest in the title held by the Development Authority. The Company has also entered into a Memorandum of Understanding (the MOU) with the Development Authority and other local agencies, under which the Company receives tax incentives in exchange for its commitment to invest in the county and increase employment. The Company is required to achieve certain employment levels in order to retain its tax incentive. In the event the Company does not meet the agreed-upon employment targets or the MOU is otherwise terminated, the Company would be subjected to additional property taxes annually. The property subject to the lease agreement is included in Property, Plant and Equipment (net book value of $71.4 million at December 31, 2003) in the accompanying financial statements.
The Company was in compliance with the terms of all agreements in existence at December 31, 2003.
F-17
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Continued)
15. Employment Agreements
The Company has an employment agreement with its President through December 31, 2004 that extends automatically for successive one-year periods without prior written notice. The agreement provides for an annual base salary and incentive bonus. If the President is terminated early without cause, the Company will be obligated to pay two years base salary and a prorated incentive bonus, and all outstanding stock options granted to the President will become fully exercisable. The agreement also contains a two-year non-competition covenant that would become effective upon termination for any reason.
The Company has an employment agreement with the President of Pinnacle Technologies, Inc. through May 31, 2007. The agreement provides for an annual base salary and incentive bonus. The term of the agreement may be terminated by the Company or the President of Pinnacle Technologies, Inc. for any reason. The agreement contains a non-competition covenant that is effective for one year beyond the term of the agreement.
16. Legal Proceedings and Judgment
In November 2002, a judgment was entered in a lawsuit in which a state court jury in Texas found the Company liable for tortious interference with a contract between Proppant Technology, Inc. and its supplier. The Company believes that it did not act improperly in this matter but appealed only the amount of the judgment. In December 2003 the Company dropped its appeal of the amount of the judgment and settled the claim for an amount that was not significantly different than the $993,000 reserve established in 2002. The Company paid the settlement amount in January 2004.
The Company is subject to legal proceedings, claims and litigation arising in the ordinary course of business. While the outcome of these matters is currently not determinable, management does not expect that the ultimate costs to resolve these matters will have a material adverse effect on the Companys consolidated financial position, results of operations, or cash flows.
F-18
EXHIBIT INDEX
3.1 | Certificate of Incorporation of CARBO Ceramics Inc. (incorporated by reference to exhibit 3.1 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
3.2 | Bylaws of CARBO Ceramics Inc. (incorporated by reference to exhibit 3.2 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
4.1 | Form of Common Stock Certificate of CARBO Ceramics Inc. (incorporated by reference to exhibit 4.1 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
4.2 | Certificate of Designations of Series A Preferred Stock (incorporated by reference to exhibit 2 to registrants Form 8-A Registration Statement No. 001-15903) | |||
10.1 | Second Amended and Restated Credit Agreement dated as of December 31, 2000, between Brown Brothers Harriman & Co. and CARBO Ceramics Inc. (incorporated by reference to exhibit 10.1 to the registrants Form 10-K Annual Report for the year ended December 31, 2000) | |||
10.2 | Form of Tax Indemnification Agreement between CARBO Ceramics Inc. and William C. Morris, Robert S. Rubin, Lewis C. Glucksman, George A. Wiegers, William A. Griffin, and Jesse P. Orsini (incorporated by reference to exhibit 10.2 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
10.3 | Purchase and Sale Agreement dated as of March 31, 1995, between CARBO Ceramics Inc. and GEO Specialty Chemicals, Inc., as amended (incorporated by reference to exhibit 10.5 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
10.4 | Raw Material Requirements Agreement dated as of June 1, 2003, between CARBO Ceramics Inc. and C-E Minerals Inc.* | |||
10.5 | Incentive Compensation Plan (incorporated by reference to exhibit 10.8 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
10.6 | CARBO Ceramics Inc. 1996 Stock Option Plan for Key Employees (incorporated by reference to exhibit 10.9 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
10.7 | Form of Stock Option Award Agreement (incorporated by reference to exhibit 10.10 to the registrants Form S-1 Registration Statement No. 333-1884) | |||
10.8 | Mining Agreement dated as of January 1, 2003 between CARBO Ceramics Inc. and Arcilla Mining and Land Co. (incorporated by reference to exhibit 10.8 to the registrants Form 10-K Annual Report for the year ended December 31, 2002) | |||
10.9 | Form of Employment Agreement between CARBO Ceramics Inc. and C. Mark Pearson | |||
10.10 | Form of Employment Agreement between CARBO Ceramics Inc. and Christopher A. Wright (incorporated by reference to the registrants Form 10-K Annual Report for the year ended December 31, 2002) | |||
10.11 | 1996 Stock Option Plan of Pinnacle Technologies, Inc., as amended and restated May 31, 2002 (incorporated by reference to exhibit 4.1 to registrants Form S-8 Registration Statement No. 333-91252) | |||
10.12 | Lease Agreement dated as of November 1, 2003, between the Development Authority of Wilkinson Count and CARBO Ceramics Inc. | |||
14 | Code of ethics | |||
23.1 | Consent of Ernst & Young LLP | |||
31.1 | Rule 13a-14(a)/15d-14(a) Certification by C. Mark Pearson. | |||
31.2 | Rule 13a-14(a)/15d-14(a) Certification by Paul G. Vitek. | |||
32 | Certification pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002 |
* | Certain portions of Exhibit 10.4 have been omitted based upon a request for confidential treatment. These portions have been filed separately with the Securities and Exchange Commission. |