SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
FORM 10-Q
QUARTERLY REPORT UNDER SECTION 13 OR 15(d) OF THE SECURITIES
EXCHANGE ACT OF 1934
For the quarter ended June 30, 2010 | Commission file number 1-3919 |
Keystone Consolidated Industries, Inc. |
(Exact name of Registrant as specified in its charter) |
Delaware | | 37-0364250 |
(State or other jurisdiction of Incorporation or organization) | | (IRS Employer Identification No.) |
5430 LBJ Freeway, Suite 1740, Three Lincoln Centre, Dallas, Texas | | 75240-2697 |
(Address of principal executive offices) | | (Zip Code) |
Registrant’s telephone number, including area code: | (972) 458-0028 |
| |
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 S No £
Whether the registrant has submitted electronically and posted on its corporate Web site, if any, every Interactive Data File required to be submitted and posted pursuant to Rule 405 of Regulation S-T during the preceding 12 months (or for such shorter period that the registrant was required to submit and post such files).* Yes___ No ____
| * | The registrant has not yet been phased into the interactive data requirements. |
Whether the registrant is a large accelerated filer, an accelerated filer, a non-accelerated filer or a smaller reporting company (as defined in Rule 12b-2 of the Act). Large accelerated filer £ Accelerated filer £ Non-accelerated filer S Smaller reporting company £.
Whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act). Yes £ No S
Whether the registrant has filed all documents and reports required to be filed by Section 12, 13 or 15(d) of the Securities Exchange Act of 1934 subsequent to the distribution of securities under a plan confirmed by a court. Yes S No £.
Number of shares of common stock outstanding on August 6, 2010: 12,101,932
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
INDEX
Part I. | FINANCIAL INFORMATION | Page |
| | |
Item 1. | Financial Statements | |
| | |
| Condensed Consolidated Balance Sheets – December 31, 2009; June 30, 2010 (unaudited) | 3 |
| | |
| Condensed Consolidated Statements of Operations (unaudited) – Three months and six months ended June 30, 2009 and 2010 | 5 |
| | |
| Condensed Consolidated Statements of Cash Flows (unaudited) – Six months ended June 30, 2009 and 2010 | 6 |
| | |
| Condensed Consolidated Statement of Stockholders' Equity and Comprehensive Income (unaudited) – Six months ended June 30, 2010 | 7 |
| | |
| Notes to Condensed Consolidated Financial Statements (unaudited) | 8 |
| | |
Item 2. | Management's Discussion and Analysis of Financial Condition and Results of Operations | 16 |
| | |
Item 3. | Quantitative and Qualitative Disclosures About Market Risk | 29 |
| | |
Item 4. | Controls and Procedures | 29 |
| | |
PART II. | OTHER INFORMATION | |
| | |
Item 1. | Legal Proceedings | 31 |
| | |
Item 1A. | Risk Factors | 31 |
| | |
Item 6. | Exhibits | 31 |
| | |
Items 2, 3 and 5 of Part II are omitted because there is no information to report. |
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
CONDENSED CONSOLIDATED BALANCE SHEETS
(In thousands)
| | December 31, | | | June 30, | |
ASSETS | | 2009 | | | 2010 | |
| | | | | (unaudited) | |
| | | | | | |
Current assets: | | | | | | |
Accounts receivable, net | | $ | 41,231 | | | $ | 58,508 | |
Inventories | | | 41,225 | | | | 70,549 | |
Deferred income taxes | | | 4,434 | | | | 4,434 | |
Income taxes receivable | | | 4,206 | | | | 4,695 | |
Prepaid expenses and other | | | 2,626 | | | | 1,475 | |
| | | | | | | | |
Total current assets | | | 93,722 | | | | 139,661 | |
| | | | | | | | |
Property, plant and equipment: | | | | | | | | |
Land | | | 1,468 | | | | 1,468 | |
Buildings and improvements | | | 61,207 | | | | 61,828 | |
Machinery and equipment | | | 328,497 | | | | 329,175 | |
Construction in progress | | | 2,583 | | | | 3,793 | |
| | | 393,755 | | | | 396,264 | |
Less accumulated depreciation | | | 308,586 | | | | 314,322 | |
| | | | | | | | |
Net property, plant and equipment | | | 85,169 | | | | 81,942 | |
| | | | | | | | |
Other assets: | | | | | | | | |
Pension asset | | | 84,806 | | | | 95,171 | |
Other, net | | | 1,387 | | | | 1,255 | |
| | | | | | | | |
Total other assets | | | 86,193 | | | | 96,426 | |
| | | | | | | | |
| | | | | | | | |
Total assets | | $ | 265,084 | | | $ | 318,029 | |
| | | | | | | | |
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
CONDENSED CONSOLIDATED BALANCE SHEETS (CONTINUED)
(In thousands)
LIABILITIES AND STOCKHOLDERS' EQUITY | | December 31, | | | June 30, | |
| | 2009 | | | 2010 | |
| | | | | (unaudited) | |
| | | | | | |
Current liabilities: | | | | | | |
Notes payable and current maturities of long-term debt | | $ | 19,396 | | | $ | 43,082 | |
Accounts payable | | | 5,577 | | | | 11,531 | |
Accrued OPEB cost | | | 1,357 | | | | 1,357 | |
Other accrued liabilities | | | 18,329 | | | | 23,362 | |
| | | | | | | | |
Total current liabilities | | | 44,659 | | | | 79,332 | |
| | | | | | | | |
Noncurrent liabilities: | | | | | | | | |
Long-term debt | | | 5,974 | | | | 5,346 | |
Accrued OPEB cost | | | 44,244 | | | | 45,052 | |
Deferred income taxes | | | 19,569 | | | | 25,003 | |
Other accrued liabilities | | | 2,868 | | | | 1,943 | |
| | | | | | | | |
Total noncurrent liabilities | | | 72,655 | | | | 77,344 | |
| | | | | | | | |
| | | | | | | | |
Stockholders' equity: | | | | | | | | |
Common stock | | | 125 | | | | 125 | |
Additional paid-in capital | | | 100,111 | | | | 100,111 | |
Accumulated other comprehensive loss | | | (132,530 | ) | | | (130,071 | ) |
Retained earnings | | | 180,860 | | | | 191,984 | |
Treasury stock | | | (796 | ) | | | (796 | ) |
| | | | | | | | |
Total stockholders' equity | | | 147,770 | | | | 161,353 | |
| | | | | | | | |
Total liabilities and stockholders’ equity | | $ | 265,084 | | | $ | 318,029 | |
| | | | | | | | |
Commitments and contingencies (Note 5)
See accompanying Notes to Condensed Consolidated Financial Statements.
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
CONDENSED CONSOLIDATED STATEMENTS OF OPERATIONS
(In thousands, except per share data)
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | (unaudited) | |
| | | | | | | | | | | | |
Net sales | | $ | 70,511 | | | $ | 134,970 | | | $ | 130,986 | | | $ | 234,713 | |
Cost of goods sold | | | (65,272 | ) | | | (120,246 | ) | | | (127,546 | ) | | | (209,484 | ) |
| | | | | | | | | | | | | | | | |
Gross margin | | | 5,239 | | | | 14,724 | | | | 3,440 | | | | 25,229 | |
| | | | | | | | | | | | | | | | |
Other operating income (expense): | | | | | | | | | | | | | | | | |
Selling expense | | | (1,672 | ) | | | (1,792 | ) | | | (3,278 | ) | | | (3,501 | ) |
General and administrative expense | | | (803 | ) | | | (4,006 | ) | | | (3,861 | ) | | | (7,881 | ) |
Defined benefit pension credit (expense) | | | (1,513 | ) | | | 1,209 | | | | (3,028 | ) | | | 2,421 | |
Other postretirement benefit credit | | | 1,260 | | | | 1,345 | | | | 2,520 | | | | 2,687 | |
| | | | | | | | | | | | | | | | |
Total other operating expense | | | (2,728 | ) | | | (3,244 | ) | | | (7,647 | ) | | | (6,274 | ) |
| | | | | | | | | | | | | | | | |
Operating income (loss) | | | 2,511 | | | | 11,480 | | | | (4,207 | ) | | | 18,955 | |
| | | | | | | | | | | | | | | | |
Nonoperating income (expense): | | | | | | | | | | | | | | | | |
Interest expense | | | (408 | ) | | | (622 | ) | | | (740 | ) | | | (1,065 | ) |
Other income, net | | | 104 | | | | 83 | | | | 102 | | | | 147 | |
| | | | | | | | | | | | | | | | |
Total nonoperating expense | | | (304 | ) | | | (539 | ) | | | (638 | ) | | | (918 | ) |
| | | | | | | | | | | | | | | | |
Income (loss) before income taxes | | | 2,207 | | | | 10,941 | | | | (4,845 | ) | | | 18,037 | |
| | | | | | | | | | | | | | | | |
Income tax benefit (expense) | | | (1,207 | ) | | | (4,192 | ) | | | 1,471 | | | | (6,913 | ) |
| | | | | | | | | | | | | | | | |
Net income (loss) | | $ | 1,000 | | | $ | 6,749 | | | $ | (3,374 | ) | | $ | 11,124 | |
| | | | | | | | | | | | | | | | |
Basic and diluted income (loss) per share | | $ | 0.08 | | | $ | 0.56 | | | $ | (0.28 | ) | | $ | 0.92 | |
| | | | | | | | | | | | | | | | |
Basic and diluted weighted average shares outstanding | | | 12,102 | | | | 12,102 | | | | 12,102 | | | | 12,102 | |
| | | | | | | | | | | | | | | | |
See accompanying Notes to Condensed Consolidated Financial Statements.
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
CONDENSED CONSOLIDATED STATEMENTS OF CASH FLOWS
(In thousands)
| | Six months ended June 30, | |
| | 2009 | | | 2010 | |
| | (unaudited) | |
| | | | | | |
Cash flows from operating activities: | | | | | | |
Net income (loss) | | $ | (3,374 | ) | | $ | 11,124 | |
Depreciation and amortization | | | 7,249 | | | | 6,546 | |
Deferred income taxes | | | 2,171 | | | | 3,912 | |
Defined benefit pension expense (credit) | | | 3,028 | | | | (2,421 | ) |
OPEB credit | | | (2,520 | ) | | | (2,687 | ) |
OPEB payments | | | (675 | ) | | | (467 | ) |
Bad debt expense (credit) | | | 2,530 | | | | (16 | ) |
Inventory impairment | | | 2,345 | | | | 147 | |
Other, net | | | 246 | | | | 154 | |
Change in assets and liabilities: | | | | | | | | |
Accounts receivable | | | (12,332 | ) | | | (17,261 | ) |
Inventories | | | 16,978 | | | | (29,471 | ) |
Accounts payable | | | (740 | ) | | | 5,954 | |
Accrued environmental costs | | | (4,250 | ) | | | (18 | ) |
Accrued liabilities | | | (13,192 | ) | | | 4,126 | |
Income taxes | | | (4,603 | ) | | | (489 | ) |
Other, net | | | 975 | | | | 1,151 | |
| | | | | | | | |
Net cash used in operating activities | | | (6,164 | ) | | | (19,716 | ) |
| | | | | | | | |
Cash flows from investing activities: | | | | | | | | |
Capital expenditures | | | (3,933 | ) | | | (3,341 | ) |
Other, net | | | 55 | | | | 36 | |
| | | | | | | | |
Net cash used in investing activities | | | (3,878 | ) | | | (3,305 | ) |
| | | | | | | | |
Cash flows from financing activities: | | | | | | | | |
Revolving credit facility, net | | | 22,394 | | | | 26,307 | |
Principal payments on other notes payable and long-term debt | | | (12,337 | ) | | | (3,271 | ) |
Deferred financing costs paid | | | (15 | ) | | | (15 | ) |
| | | | | | | | |
Net cash provided by financing activities | | | 10,042 | | | | 23,021 | |
| | | | | | | | |
Net change in cash and cash equivalents | | | - | | | | - | |
| | | | | | | | |
Cash and cash equivalents, beginning of period | | | - | | | | - | |
| | | | | | | | |
Cash and cash equivalents, end of period | | $ | - | | | $ | - | |
| | | | | | | | |
Supplemental disclosures: Cash paid for: | | | | | | | | |
Interest, net of amount capitalized | | $ | 617 | | | $ | 899 | |
Income taxes, net | | | 961 | | | | 3,490 | |
| | | | | | | | |
See accompanying Notes to Condensed Consolidated Financial Statements.
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
CONDENSED CONSOLIDATED STATEMENT OF STOCKHOLDERS' EQUITY
AND COMPREHENSIVE INCOME
Six months ended June 30, 2010
(In thousands)
| | Common | | | Additional paid-in | | | Accumulated other comprehensive income (loss) | | | Retained | | | Treasury | | | | | | Comprehensive | |
| | stock | | | capital | | | Pensions | | | OPEB | | | earnings | | | stock | | | Total | | | income (loss) | |
| | (unaudited) | |
| | | | | | | | | | | | | | | | | | | | | | | | |
Balance – December 31, 2009 | | $ | 125 | | | $ | 100,111 | | | $ | (158,401 | ) | | $ | 25,871 | | | $ | 180,860 | | | $ | (796 | ) | | $ | 147,770 | | | | |
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Net income | | | - | | | | - | | | | - | | | | - | | | | 11,124 | | | | - | | | | 11,124 | | | $ | 11,124 | |
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Amortization of prior service cost (credit) | | | - | | | | - | | | | 373 | | | | (4,901 | ) | | | - | | | | - | | | | (4,528 | ) | | | (4,528 | ) |
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Amortization of actuarial losses | | | - | | | | - | | | | 4,534 | | | | 2,453 | | | | - | | | | - | | | | 6,987 | | | | 6,987 | |
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Balance – June 30, 2010 | | $ | 125 | | | $ | 100,111 | | | $ | (153,494 | ) | | $ | 23,423 | | | $ | 191,984 | | | $ | (796 | ) | | $ | 161,353 | | | | | |
| | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | |
Comprehensive income | | | | | | | | | | | | | | | | | | | | | | | | | | | | | | $ | 13,583 | |
See accompanying Notes to Condensed Consolidated Financial Statements.
KEYSTONE CONSOLIDATED INDUSTRIES, INC.
AND SUBSIDIARIES
NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS
June 30, 2010
(unaudited)
Note 1 – Organization and basis of presentation:
The unaudited Condensed Consolidated Financial Statements contained in this Quarterly Report have been prepared on the same basis as the audited Consolidated Financial Statements included in our Annual Report on Form 10-K for the year ended December 31, 2009 that we filed with the Securities and Exchange Commission (“SEC”) on March 11, 2010 (the “2009 Annual Report”). In our opinion, we have made all necessary adjustments (which include only normal recurring adjustments) in order to state fairly, in all material respects, our consolidated financial position, results of operations and cash flows as of the dates and for the periods presented. Certain reclassifications have been made to conform the prior year’s Condensed Consolidated Financial Statements to the current year’s clas sifications. As compared to the 2009 Annual Report, we have omitted certain information and footnote disclosures from this Quarterly Report that are normally included in financial statements prepared in accordance with accounting principles generally accepted in the United States of America (“GAAP”). Our results of operations for the interim periods ended June 30, 2010 may not be indicative of our operating results for the full year. The Condensed Consolidated Financial Statements contained in this Quarterly Report should be read in conjunction with the 2009 Consolidated Financial Statements contained in the 2009 Annual Report.
At June 30, 2010, Contran Corporation (“Contran”) owned approximately 62% of our outstanding common stock. Substantially all of Contran's outstanding voting stock is held by trusts established for the benefit of certain children and grandchildren of Harold C. Simmons (for which Mr. Simmons is the sole trustee) or is held directly by Mr. Simmons or other persons or companies related to Mr. Simmons. Consequently, Mr. Simmons may be deemed to control Contran and us.
Unless otherwise indicated, references in this report to “we”, “us” or “our” refer to Keystone Consolidated Industries, Inc. (“KCI”) and its subsidiaries, taken as a whole.
Note 2 – Business segment information:
Our operating segments are organized by our manufacturing facilities and include three reportable segments:
· | Keystone Steel & Wire (“KSW”), located in Peoria, Illinois, operates an electric arc furnace mini-mill and manufactures and sells wire rod, coiled rebar, industrial wire, fabricated wire and other products to agricultural, industrial, construction, commercial, original equipment manufacturers and retail consumer markets; |
· | Engineered Wire Products, Inc. (“EWP”), located in Upper Sandusky, Ohio, manufactures and sells wire mesh in both roll and sheet form that is utilized in concrete construction products including pipe, pre-cast boxes and applications for use in roadways, buildings and bridges; and |
· | Keystone-Calumet, Inc. (“Calumet”), located in Chicago Heights, Illinois, manufactures and sells merchant and special bar quality products and special sections in carbon and alloy steel grades for use in agricultural, cold drawn, construction, industrial chain, service centers and transportation applications as well as in the production of a wide variety of products by original equipment manufacturers. |
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | (In thousands) | | | (In thousands) | |
| | | | | | | | | | | | |
Net sales: | | | | | | | | | | | | |
KSW | | $ | 67,090 | | | $ | 130,892 | | | $ | 121,083 | | | $ | 233,382 | |
EWP | | | 11,563 | | | | 12,991 | | | | 18,724 | | | | 20,367 | |
Calumet | | | 2,438 | | | | 5,735 | | | | 4,356 | | | | 9,986 | |
Elimination of intersegment sales | | | (10,580 | ) | | | (14,648 | ) | | | (13,177 | ) | | | (29,022 | ) |
| | | | | | | | | | | | | | | | |
Total net sales | | $ | 70,511 | | | $ | 134,970 | | | $ | 130,986 | | | $ | 234,713 | |
| | | | | | | | | | | | | | | | |
Operating income (loss): | | | | | | | | | | | | | | | | |
KSW | | $ | 3,765 | | | $ | 8,533 | | | $ | (685 | ) | | $ | 15,518 | |
EWP | | | 240 | | | | 873 | | | | (86 | ) | | | 510 | |
Calumet | | | (720 | ) | | | 499 | | | | (3,191 | ) | | | 646 | |
Pension credit (expense) | | | (1,513 | ) | | | 1,209 | | | | (3,028 | ) | | | 2,421 | |
OPEB credit | | | 1,260 | | | | 1,345 | | | | 2,520 | | | | 2,687 | |
Other (1) | | | (521 | ) | | | (979 | ) | | | 263 | | | | (2,827 | ) |
| | | | | | | | | | | | | | | | |
Total operating income (loss) | | | 2,511 | | | | 11,480 | | | | (4,207 | ) | | | 18,955 | |
| | | | | | | | | | | | | | | | |
Nonoperating income (expense): | | | | | | | | | | | | | | | | |
Interest expense | | | (408 | ) | | | (622 | ) | | | (740 | ) | | | (1,065 | ) |
Other income, net | | | 104 | | | | 83 | | | | 102 | | | | 147 | |
| | | | | | | | | | | | | | | | |
Income (loss) before income taxes | | $ | 2,207 | | | $ | 10,941 | | | $ | (4,845 | ) | | $ | 18,037 | |
(1) Other items primarily consist of the elimination of intercompany profit or loss on ending inventory balances and general corporate expenses.
During the second quarter and first six months of 2009, Calumet determined it was probable it would not recover the cost of certain inventory items in future selling prices and recognized impairment charges of $849,000 and $2.3 million, respectively, to reduce these inventory items to their estimated net realizable values. During 2010, most of Calumet’s product lines were profitable, resulting in only nominal impairment charges in 2010. These impairment charges are included in Calumet’s cost of goods sold.
On a quarterly basis, we estimate our LIFO reserve balances that would be required at the end of the year based on projections of year-end inventory quantities and costs, and we record a pro-rated, year-to-date change in our LIFO reserve balances from the prior year-end based on these projections. Changes in LIFO reserves are reflected in cost of goods sold. The changes in KSW’s and EWP’s LIFO inventory reserve balances for the 2009 and 2010 periods are presented in the table below.
| | Increase (decrease) in LIFO reserve | |
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | (In thousands) | | | (In thousands) | |
| | | | | | |
KSW | | $ | (3,320 | ) | | $ | (328 | ) | | $ | (6,737 | ) | | $ | (22 | ) |
| | | | | | | | | | | | | | | | |
EWP | | | (2,147 | ) | | | 63 | | | | (3,217 | ) | | | 157 | |
| | | | | | | | | | | | | | | | |
Total | | $ | (5,467 | ) | | $ | (265 | ) | | $ | (9,954 | ) | | $ | 135 | |
During the second quarter and first six months of 2009, KSW recorded bad debt expense of $1.6 million and $2.5 million, respectively, due primarily to a Chapter 11 filing by one of its customers. Bad debt expense is included in general and administrative expense.
On July 2, 2009, the Illinois Environmental Protection Agency approved the completion of the soil portion of the remediation plan of certain waste management units at KSW which resulted in a $4.2 million decrease (recorded as a credit to general administrative expense) in KSW’s environmental reserves as of June 30, 2009.
Note 3 – Inventories, net:
| | December 31, | | | June 30, | |
| | 2009 | | | 2010 | |
| | (In thousands) | |
| | | | | | |
Raw materials | | $ | 3,222 | | | $ | 5,696 | |
Billet | | | 4,917 | | | | 9,874 | |
Wire rod | | | 5,282 | | | | 15,855 | |
Work in process | | | 4,645 | | | | 6,958 | |
Finished product | | | 19,747 | | | | 26,269 | |
Supplies | | | 22,646 | | | | 25,266 | |
| | | | | | | | |
Inventory at FIFO | | | 60,459 | | | | 89,918 | |
Less LIFO reserve | | | 19,234 | | | | 19,369 | |
| | | | | | | | |
Total | | $ | 41,225 | | | $ | 70,549 | |
| | | | | | | | |
We believe our LIFO reserve represents the excess of replacement or current cost over the stated LIFO value of our inventories. See also Note 2.
Note 4 - Notes payable and long-term debt:
| | December 31, | | | June 30, | |
| | 2009 | | | 2010 | |
| | (In thousands) | |
| | | | | | |
Wells Fargo revolving credit facility | | $ | 12,546 | | | $ | 38,853 | |
Term loans: | | | | | | | | |
Wells Fargo | | | 5,620 | | | | 2,953 | |
County | | | 6,302 | | | | 5,701 | |
Other | | | 902 | | | | 921 | |
| | | | | | | | |
Total debt | | | 25,370 | | | | 48,428 | |
Less current maturities | | | 19,396 | | | | 43,082 | |
| | | | | | | | |
Total long-term debt | | $ | 5,974 | | | $ | 5,346 | |
Our Wells Fargo credit facility expires on August 31, 2010. Based on a term sheet provided to us by Wells Fargo, we believe we will amend the existing credit facility upon its maturity to, among other things, lower the interest rate on outstanding borrowings, decrease the aggregate size of the facility from $100 million to $70 million and extend the term of the facility for an additional five years.
While we have agreed to the terms in the term sheet with Wells Fargo, the final agreement incorporating those terms is subject to definitive documentation, and we can make no assurance that the parties will agree on the terms and conditions set forth in the definitive documentation until such documentation is fully negotiated and signed.
Note 5 – Environmental matters and other commitments and contingencies:
We have been named as a defendant for certain environmental sites pursuant to laws in governmental and private actions associated with environmental matters, including waste disposal sites and facilities currently or previously owned, operated or used by us. These proceedings seek cleanup costs, damages for personal injury or property damage and/or damages for injury to natural resources. Certain of these proceedings involve claims for substantial amounts.
On a quarterly basis, we evaluate the potential range of our liability at sites where we have been named a defendant by analyzing and estimating the range of reasonably possible costs to us. At June 30, 2010, the upper end of the range of reasonably possible costs to us for sites where we have been named a defendant is approximately $2.0 million, including our recorded accrual of $.7 million. Our cost estimates have not been discounted to present value due to the uncertainty of the timing of the pay out. At each balance sheet date, we make an estimate of the amount of our accrued environmental costs that will be paid out over the subsequent twelve months, and we classify such amount as a current liability. We classify the remainder of the accrued environmental costs as noncurrent liabilities . See Note 6.
It is possible our actual costs could differ materially from the amounts we have accrued or the upper end of the range for the sites where we have been named a defendant. Our ultimate liability may be affected by a number of factors, including the imposition of more stringent standards or requirements under environmental laws or regulations, new developments or changes in remedial alternatives and costs or a determination that we are potentially responsible for the release of hazardous substances at other sites. Although we believe our comprehensive general liability insurance policies provide indemnification for certain costs that we incur with respect to our environmental remediation obligations, we do not currently have receivables recorded for any such recoveries.
Prior to one of our subsidiaries’ 1996 acquisition of DeSoto, Inc. (“DeSoto”), DeSoto was notified by the Texas Natural Resource Conservation Commission (now called the Texas Commission on Environmental Quality or “TCEQ”) that there were certain deficiencies in prior reports to the TCEQ relative to one of DeSoto’s non-operating facilities located in Gainesville, Texas. During 1999, that subsidiary entered into the TCEQ's Voluntary Cleanup Program as it relates to that facility. Remediation activities at this site are expected to continue for another two to three years and total future remediation costs are presently estimated to be between $.5 million and $1.7 million.
In February 2009, we received a Notice of Violation from the U.S. EPA regarding alleged air permit issues at KSW. The U.S. EPA alleges KSW (i) is exceeding its sulfur dioxide emission limits set forth in its permits, (ii) failed to apply for a permit that would be issued under the U.S. Clean Air Act and the Illinois Environmental Protection Act in connection with the installation of certain equipment in its melt shop, and (iii) failed to monitor pH readings of an air scrubber in the wire galvanizing area of the plant. We disagree with the U.S. EPA’s assertions and we were in discussions with the U.S. EPA throughout 2009. On December 31, 2009, we were notified the case had been referred to the Department of Justice (the “DOJ”) for review and follow-up. During the first quart er of 2010, we submitted letters regarding our perspective on the matter to the DOJ and we are awaiting their response. During the second quarter of 2010, the U.S. EPA requested additional information regarding the alleged permit issues and we submitted such information in May 2010. We can make no assurance our efforts will be successful or that we can avoid any enforcement action or resulting fines from these alleged violations.
Other current litigation
From time-to-time, we are involved in various environmental, contractual, product liability, patent (or intellectual property), employment and other claims and disputes incidental to our operations. In certain cases, we have insurance coverage for these items. We currently believe the disposition of all claims and disputes, individually or in the aggregate, should not have a material adverse effect on our consolidated financial position, results of operations or liquidity beyond the accruals we have already provided.
Please refer to our 2009 Annual Report for a discussion of certain other legal proceedings to which we are a party.
Note 6 - Other accrued liabilities:
| | December 31, | | | June 30, | |
| | 2009 | | | 2010 | |
| | (In thousands) | |
Current: | | | | | | |
Employee benefits | | $ | 10,456 | | | $ | 14,976 | |
Self insurance | | | 4,431 | | | | 4,518 | |
Environmental | | | 430 | | | | 447 | |
Other | | | 3,012 | | | | 3,421 | |
| | | | | | | | |
Total | | $ | 18,329 | | | $ | 23,362 | |
| | | | | | | | |
Noncurrent: | | | | | | | | |
Workers compensation payments | | $ | 2,315 | | | $ | 1,418 | |
Environmental | | | 300 | | | | 265 | |
Other | | | 253 | | | | 260 | |
| | | | | | | | |
Total | | $ | 2,868 | | | $ | 1,943 | |
Note 7 – Employee benefit plans:
We currently expect to record a defined benefit pension credit of $4.9 million during 2010 and we anticipate no cash contributions to our defined benefit pension plans will be required during 2010. The components of our net periodic defined benefit pension expense (credit) for the second quarter and first six months of 2009 and 2010 are presented in the table below.
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | (In thousands) | |
Service cost | | $ | 813 | | | $ | 832 | | | $ | 1,627 | | | $ | 1,664 | |
Interest cost | | | 5,410 | | | | 4,937 | | | | 10,820 | | | | 9,873 | |
Expected return on plan assets | | | (9,720 | ) | | | (10,951 | ) | | | (19,440 | ) | | | (21,902 | ) |
Amortization of accumulated other comprehensive income: | | | | | | | | | | | | | | | | |
Prior service cost | | | 308 | | | | 303 | | | | 616 | | | | 605 | |
Actuarial losses | | | 4,702 | | | | 3,670 | | | | 9,405 | | | | 7,339 | |
| | | | | | | | | | | | | | | | |
Total expense (credit) | | $ | 1,513 | | | $ | (1,209 | ) | | $ | 3,028 | | | $ | (2,421 | ) |
We currently expect our 2010 other postretirement benefit (“OPEB”) credit will be $5.5 million. As allowed under one of our amended benefit plans, we exercised our right to create supplemental pension benefits in lieu of certain 2010 benefit payments due under that OPEB plan. As such, we anticipate contributing an aggregate of $1.4 million to our OPEB plans during 2010. The components of our net periodic credit related to OPEB for the second quarter and first six months of 2009 and 2010 are presented in the table below.
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | (In thousands) | |
Service cost | | $ | 24 | | | $ | 27 | | | $ | 48 | | | $ | 55 | |
Interest cost | | | 672 | | | | 609 | | | | 1,344 | | | | 1,220 | |
Amortization of accumulated other comprehensive income: | | | | | | | | | | | | | | | | |
Prior service credit | | | (4,044 | ) | | | (3,966 | ) | | | (8,088 | ) | | | (7,932 | ) |
Actuarial losses | | | 2,088 | | | | 1,985 | | | | 4,176 | | | | 3,970 | |
| | | | | | | | | | | | | | | | |
Total credit | | $ | (1,260 | ) | | $ | (1,345 | ) | | $ | (2,520 | ) | | $ | (2,687 | ) |
Future variances from assumed actuarial rates, including the rate of return on our defined benefit pension plans’ assets, as well as changes in the discount rate used to determine projected benefit obligations, may result in increases or decreases to pension and postretirement benefit assets and liabilities, pension expense or credits, OPEB expense or credits and pension and OPEB funding requirements in future periods.
Note 8 – Income taxes:
| | Six months ended | |
| | June 30, | |
| | 2009 | | | 2010 | |
| | (In thousands) | |
| | | |
| | | | | | |
Expected income tax expense (benefit), at statutory rate | | $ | (1,695 | ) | | $ | 6,313 | |
U.S. state income tax expense (benefit), net | | | (17 | ) | | | 574 | |
Other, net | | | 241 | | | | 26 | |
| | | | | | | | |
Income tax expense (benefit) | | $ | (1,471 | ) | | $ | 6,913 | |
Tax authorities are examining certain of our U.S. tax returns and may propose tax deficiencies, including penalties and interest. We cannot guarantee that any adjustments, if proposed, will be resolved in our favor due to the inherent uncertainties involved in settlement initiatives and court and tax proceedings. We believe the ultimate disposition of such tax examinations should not have a material adverse effect on our consolidated financial position, results of operations or liquidity.
Note 9 – Financial instruments:
The following table presents the carrying value and estimated fair value of our financial instruments:
| | | | | | |
| | December 31, 2009 | | | June 30, 2010 | |
| | Carrying amount | | | Fair value | | | Carrying amount | | | Fair value | |
| | (In thousands) | |
| | | | | | | | | | | | |
Restricted cash equivalents | | $ | 249 | | | $ | 249 | | | $ | 251 | | | $ | 251 | |
Accounts receivable, net | | | 41,231 | | | | 41,231 | | | | 58,508 | | | | 58,508 | |
Accounts payable | | | 5,577 | | | | 5,577 | | | | 11,531 | | | | 11,531 | |
| | | | | | | | | | | | | | | | |
Long-term debt (excluding capitalized leases): | | | | | | | | | | | | | | | | |
Variable-rate debt | | | 18,166 | | | | 18,166 | | | | 41,806 | | | | 41,806 | |
Fixed-rate debt | | | 7,195 | | | | 6,680 | | | | 6,615 | | | | 6,236 | |
| | | | | | | | | | | | | | | | |
Due to their nature, the carrying amounts of our restricted cash equivalents and variable rate indebtedness are considered equivalent to fair value. Additionally, due to their near-term maturities, the carrying amounts of accounts receivable and accounts payable are considered equivalent to fair value. The fair value of our fixed-rate indebtedness was based on the net present value of our remaining debt payments at an interest rate commensurate with our variable-rate debt which represents Level 3 inputs as defined in ASC Topic 820-10-35.
ITEM 2. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS
This report contains forward-looking statements within the meaning of the Private Securities Litigation Reform Act of 1995. Statements in this Quarterly Report on Form 10-Q that are not historical in nature are forward-looking and are not statements of fact. Some statements found in this report including, but not limited to, statements found in Item 2 - "Management’s Discussion and Analysis of Financial Condition and Results of Operations," are forward-looking statements that represent our beliefs and assumptions based on currently available information. In some cases you can identify these forward-looking statements by the use of words such as "believes," "intends," "may," "should," "could," "anticipates," "expected" or comparable terminology, or by discussions of strategies or trends. 0;Although we believe the expectations reflected in forward-looking statements are reasonable, we do not know if these expectations will be correct. Forward-looking statements by their nature involve substantial risks and uncertainties that could significantly impact expected results. Actual future results could differ materially from those predicted. While it is not possible to identify all factors, we continue to face many risks and uncertainties. Among the factors that could cause our actual future results to differ materially from those described herein are the risks and uncertainties discussed in this Quarterly Report and those described from time to time in our other filings with the Securities and Exchange Commission including, but not limited to, the following:
· | Future supply and demand for our products (including cyclicality thereof), |
· | Customer inventory levels, |
· | Changes in raw material and other operating costs (such as ferrous scrap and energy), |
· | The possibility of labor disruptions, |
· | General global economic and political conditions, |
· | Competitive products (including low-priced imports) and substitute products, |
· | Customer and competitor strategies, |
· | The impact of pricing and production decisions, |
· | Environmental matters (such as those requiring emission and discharge limits for existing and new facilities), |
· | Government regulations and possible changes thereof, |
· | Significant increases in the cost of providing medical coverage to employees, |
· | The ultimate resolution of pending litigation, U.S. EPA investigations and audits conducted by the Internal Revenue Service, |
· | International trade policies of the United States and certain foreign countries, |
· | Operating interruptions (including, but not limited to, labor disputes, fires, explosions, unscheduled or unplanned downtime, supply disruptions and transportation interruptions), |
· | Our ability to renew or refinance credit facilities, |
· | The ability of our customers to obtain adequate credit, |
· | Any possible future litigation, and |
· | Other risks and uncertainties as discussed in this Quarterly Report and the 2009 Annual Report, including, without limitation, the section referenced above. |
Should one or more of these risks materialize, if the consequences worsen, or if the underlying assumptions prove incorrect, actual results could differ materially from those forecasted or expected. We disclaim any intention or obligation to update or revise any forward-looking statement whether as a result of changes in information, future events or otherwise.
RESULTS OF OPERATIONS
Business Overview
We are a leading domestic producer of steel fabricated wire products, industrial wire and wire rod. We also manufacture wire mesh, coiled rebar, steel bar and other products. Our products are used in the agricultural, industrial, cold drawn, construction, transportation, original equipment manufacturer and retail consumer markets. We are vertically integrated, converting substantially all of our products from billets produced in our steel mini-mill. Historically, our vertical integration has allowed us to benefit from the higher and more stable margins associated with fabricated wire products and wire mesh as compared to wire rod, as well as from lower costs of billets and wire rod as compared to bar manufacturers and wire fabricators that purchase billet and wire rod in the open market. 0; Moreover, we believe our downstream fabricated wire products, wire mesh, coiled rebar and industrial wire businesses are better insulated from the effects of wire rod imports as compared to non-integrated wire rod producers.
Recent Developments
Sales volume increased significantly during the first half of 2010 which resulted in a return to more normal production schedules. However, customer orders have started to decline as the economic recovery has slowed and we anticipate increased foreign competition throughout the remainder of 2010. We currently anticipate adjusting operating schedules according to demand.
Ferrous scrap costs increased during the first five months of 2010 and we implemented selling price increases to compensate for our higher costs. Ferrous scrap costs decreased during June 2010 and we currently expect scrap costs to generally decline throughout the remainder of the year, resulting in downward pressure on our product selling prices. However, we currently believe we will be able to maintain positive overall margins on our products throughout 2010, as any lower selling prices would be offset by our lower scrap costs.
Our Wells Fargo credit facility expires on August 31, 2010. Based on a term sheet provided to us by Wells Fargo, we believe we will amend the existing credit facility upon its maturity to, among other things, lower the interest rate on outstanding borrowings, decrease the aggregate size of the facility from $100 million to $70 million and extend the term of the facility for an additional five years. We believe $70 million will be sufficient to finance our operations for the foreseeable future.
While we have agreed to the terms in the term sheet with Wells Fargo, the final agreement incorporating those terms is subject to definitive documentation, and we can make no assurance that the parties will agree on the terms and conditions set forth in the definitive documentation until such documentation is fully negotiated and signed.
Results of Operations
Our profitability is primarily dependent on sales volume, selling prices, ferrous scrap costs and energy costs. Additionally, because pension and OPEB expense or credits are unrelated to the operating activities of our businesses, we measure and evaluate the performance of our businesses using operating income (loss) before pension and OPEB credit or expense. As such, we believe the presentation of operating income (loss) before pension and OPEB credit or expense provides more useful information to investors. Operating income (loss) before pension and OPEB credit or expense is a non-GAAP measure of profitability that is not in accordance with accounting principles generally accepted in the United States of America (“GAAP”) and it should not be considered in isolation or as a substitute for a measure prepared in accordance with GAAP. A reconciliation of operating income (loss) as reported to operating income (loss) adjusted for pension and OPEB expense or credit is set forth in the following table.
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | (In thousands) | | | (In thousands) | |
| | | | | | | | | | | | |
Operating income (loss) as reported | | $ | 2,511 | | | $ | 11,480 | | | $ | (4,207 | ) | | $ | 18,955 | |
Defined benefit pension expense (credit) | | | 1,513 | | | | (1,209 | ) | | | 3,028 | | | | (2,421 | ) |
OPEB credit | | | (1,260 | ) | | | (1,345 | ) | | | (2,520 | ) | | | (2,687 | ) |
Operating income (loss) before pension and OPEB | | $ | 2,764 | | | $ | 8,926 | | | $ | (3,699 | ) | | $ | 13,847 | |
Operating performance before pension and OPEB for the second quarter and first six months of 2010 was significantly better than the same periods of 2009 primarily due to a substantial increase in shipment volumes and production levels as discussed above. During 2009, economic conditions resulted in a sharp reduction of customer orders and we operated on an extremely reduced production schedule, which resulted in a much higher percentage of fixed costs included in cost of goods sold as these costs could not be capitalized into inventory.
Our consolidated sales volume and average per-ton selling prices for the second quarter and first six months of 2009 and 2010 are as follows:
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | | | | | | | | | | | |
Sales volume (000 tons): | | | | | | | | | | | | |
Wire rod | | | 36 | | | | 108 | | | | 58 | | | | 189 | |
Fabricated wire products | | | 20 | | | | 23 | | | | 40 | | | | 45 | |
Industrial wire | | | 9 | | | | 15 | | | | 16 | | | | 27 | |
Wire mesh | | | 13 | | | | 15 | | | | 20 | | | | 23 | |
Bar | | | 3 | | | | 6 | | | | 5 | | | | 11 | |
Coiled rebar | | | 2 | | | | 2 | | | | 2 | | | | 3 | |
Other | | | 1 | | | | 4 | | | | 1 | | | | 6 | |
| | | | | | | | | | | | | | | | |
Total | | | 84 | | | | 173 | | | | 142 | | | | 304 | |
| | | | | | | | | | | | | | | | |
| | | | | | | | | | | | | | | | |
Average per-ton selling prices: | | | | | | | | | | | | | | | | |
Wire rod | | $ | 546 | | | $ | 629 | | | $ | 592 | | | $ | 614 | |
Fabricated wire products | | | 1,364 | | | | 1,315 | | | | 1,410 | | | | 1,301 | |
Industrial wire | | | 892 | | | | 927 | | | | 967 | | | | 907 | |
Wire mesh | | | 910 | | | | 884 | | | | 968 | | | | 874 | |
Bar | | | 752 | | | | 906 | | | | 812 | | | | 886 | |
Coiled rebar | | | 522 | | | | 641 | | | | 544 | | | | 636 | |
All products | | | 838 | | | | 773 | | | | 920 | | | | 765 | |
Other items affecting the comparability of our operating performance before pension and OPEB include:
· | increased cost of raw material included in cost of goods sold during the second quarter of 2010 due to increased ferrous scrap market prices as discussed above; but lower cost of raw material included in cost of goods sold during the first half of 2010 because products sold during the first half of 2009 were produced with ferrous scrap purchased during the last half of 2008 when market prices were at unprecedented high levels; |
· | increased utility costs at our largest manufacturing facility during 2010 primarily due to extreme weather conditions; |
· | impairment charges to reduce certain inventories to net realizable value of $849,000 and $2.3 million during the second quarter and first six months of 2009, respectively, as compared to nominal impairment charges during the second quarter and first six months of 2010; |
· | bad debt expense of $1.6 million and $2.5 million during the second quarter and first six months of 2009, respectively, primarily due to the Chapter 11 proceedings of one of our customers as compared to insignificant amounts during the 2010 periods; |
· | higher incentive compensation expense during 2010 due to increased profitability; |
· | significant decreases in our LIFO reserve and cost of goods sold during the second quarter and first six months of 2009 as compared to insignificant changes in our LIFO reserve and cost of goods sold during the second quarter and first six months of 2010 as discussed in Note 2 to our Condensed Consolidated Financial Statements; and |
· | a $4.2 million credit to general and administrative expense during 2009 related to the release of accrued environmental costs for certain inactive waste management units. |
Segment Operating Results:
Our operating segments are organized by our manufacturing facilities and include three reportable segments:
· | Keystone Steel & Wire (“KSW”), located in Peoria, Illinois, operates an electric arc furnace mini-mill and manufactures and sells wire rod, coiled rebar, industrial wire, fabricated wire and other products to agricultural, industrial, construction, commercial, original equipment manufacturers and retail consumer markets; |
· | Engineered Wire Products, Inc. (“EWP”), located in Upper Sandusky, Ohio, manufactures and sells wire mesh in both roll and sheet form that is utilized in concrete construction products including pipe, pre-cast boxes and applications for use in roadways, buildings and bridges; and |
· | Keystone-Calumet, Inc. (“Calumet”), located in Chicago Heights, Illinois, manufactures and sells merchant and special bar quality products and special sections in carbon and alloy steel grades for use in agricultural, cold drawn, construction, industrial chain, service centers and transportation applications as well as in the production of a wide variety of products by original equipment manufacturers. |
Our consolidated net sales, cost of goods sold, operating costs and operating performance before pension and OPEB credit or expense by segment are set forth in the following table:
| | KSW | | | EWP | | | Calumet | | | Other (1) | | | Total | |
| | (In thousands) | |
Three months ended June 30, 2009: | |
| | | | | | | | | | | | | | | |
Net sales | | $ | 67,090 | | | $ | 11,563 | | | $ | 2,438 | | | $ | (10,580 | ) | | $ | 70,511 | |
Cost of goods sold | | | (62,601 | ) | | | (10,575 | ) | | | (3,001 | ) | | | 10,905 | | | | (65,272 | ) |
Gross margin (loss) | | | 4,489 | | | | 988 | | | | (563 | ) | | | 325 | | | | 5,239 | |
| | | | | | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (724 | ) | | | (748 | ) | | | (157 | ) | | | (846 | ) | | | (2,475 | ) |
Operating income (loss) before pension/OPEB | | $ | 3,765 | | | $ | 240 | | | $ | (720 | ) | | $ | (521 | ) | | $ | 2,764 | |
| | | | | | | | | | | | | | | | | | | | |
Three months ended June 30, 2010: | |
| |
Net sales | | $ | 130,892 | | | $ | 12,991 | | | $ | 5,735 | | | $ | (14,648 | ) | | $ | 134,970 | |
Cost of goods sold | | | (118,228 | ) | | | (11,585 | ) | | | (5,087 | ) | | | 14,654 | | | | (120,246 | ) |
Gross margin | | | 12,664 | | | | 1,406 | | | | 648 | | | | 6 | | | | 14,724 | |
| | | | | | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (4,131 | ) | | | (533 | ) | | | (149 | ) | | | (985 | ) | | | (5,798 | ) |
Operating income before pension/OPEB | | $ | 8,533 | | | $ | 873 | | | $ | 499 | | | $ | (979 | ) | | $ | 8,926 | |
Six months ended June 30, 2009: | |
| | | | | | | | | | | | | | | |
Net sales | | $ | 121,083 | | | $ | 18,724 | | | $ | 4,356 | | | $ | (13,177 | ) | | $ | 130,986 | |
Cost of goods sold | | | (117,525 | ) | | | (17,409 | ) | | | (7,330 | ) | | | 14,718 | | | | (127,546 | ) |
Gross margin (loss) | | | 3,558 | | | | 1,315 | | | | (2,974 | ) | | | 1,541 | | | | 3,440 | |
| | | | | | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (4,243 | ) | | | (1,401 | ) | | | (217 | ) | | | (1,278 | ) | | | (7,139 | ) |
Operating income (loss) before pension/OPEB | | $ | (685 | ) | | $ | (86 | ) | | $ | (3,191 | ) | | $ | 263 | | | $ | (3,699 | ) |
| | | | | | | | | | | | | | | | | | | | |
Six months ended June 30, 2010: | |
| |
Net sales | | $ | 233,382 | | | $ | 20,367 | | | $ | 9,986 | | | $ | (29,022 | ) | | $ | 234,713 | |
Cost of goods sold | | | (209,995 | ) | | | (18,757 | ) | | | (8,985 | ) | | | 28,253 | | | | (209,484 | ) |
Gross margin | | | 23,387 | | | | 1,610 | | | | 1,001 | | | | (769 | ) | | | 25,229 | |
| | | | | | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (7,869 | ) | | | (1,100 | ) | | | (355 | ) | | | (2,058 | ) | | | (11,382 | ) |
Operating income before pension/OPEB | | $ | 15,518 | | | $ | 510 | | | $ | 646 | | | $ | (2,827 | ) | | $ | 13,847 | |
(1) Other items primarily consist of the elimination of intercompany sales, the elimination of intercompany profit or loss on ending inventory balances and general corporate expenses.
Keystone Steel & Wire
| | Three months ended June 30, | |
| | 2009 | | | % of sales | | | 2010 | | | % of sales | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Net sales | | $ | 67,090 | | | | 100.0 | % | | $ | 130,892 | | | | 100.0 | % |
Cost of goods sold | | | (62,601 | ) | | | (93.3 | ) | | | (118,228 | ) | | | (90.3 | ) |
Gross margin | | | 4,489 | | | | 6.7 | | | | 12,664 | | | | 9.7 | |
| | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (724 | ) | | | (1.1 | ) | | | (4,131 | ) | | | (3.2 | ) |
Operating income before pension/OPEB | | $ | 3,765 | | | | 5.6 | % | | $ | 8,533 | | | | 6.5 | % |
| | Six months ended June 30, | |
| | 2009 | | | % of sales | | | 2010 | | | % of sales | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Net sales | | $ | 121,083 | | | | 100.0 | % | | $ | 233,382 | | | | 100.0 | % |
Cost of goods sold | | | (117,525 | ) | | | (97.1 | ) | | | (209,995 | ) | | | (90.0 | ) |
Gross margin | | | 3,558 | | | | 2.9 | | | | 23,387 | | | | 10.0 | |
| | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (4,243 | ) | | | (3.5 | ) | | | (7,869 | ) | | | (3.4 | ) |
Operating income (loss) before pension/OPEB | | $ | (685 | ) | | | (0.6 | )% | | $ | 15,518 | | | | 6.6 | % |
The primary drivers of KSW’s sales, cost of goods sold and the resulting gross margin are as follows:
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | | | | | | | | | | | |
Sales volume (000 tons): | | | | | | | | | | | | |
Wire rod | | | 53 | | | | 124 | | | | 78 | | | | 222 | |
Fabricated wire products | | | 20 | | | | 23 | | | | 40 | | | | 45 | |
Industrial wire | | | 9 | | | | 15 | | | | 16 | | | | 27 | |
Billet | | | 2 | | | | 12 | | | | 4 | | | | 24 | |
Coiled rebar | | | 2 | | | | 2 | | | | 2 | | | | 3 | |
Total | | | 86 | | | | 176 | | | | 140 | | | | 321 | |
| | | | | | | | | | | | | | | | |
Average per-ton selling prices: | | | | | | | | | | | | | | | | |
Wire rod | | $ | 563 | | | $ | 630 | | | $ | 596 | | | $ | 614 | |
Fabricated wire products | | | 1,364 | | | | 1,315 | | | | 1,410 | | | | 1,301 | |
Industrial wire | | | 892 | | | | 927 | | | | 967 | | | | 907 | |
Billet | | | 345 | | | | 457 | | | | 423 | | | | 443 | |
Coiled rebar | | | 522 | | | | 641 | | | | 544 | | | | 636 | |
All products | | | 780 | | | | 734 | | | | 867 | | | | 723 | |
| | | | | | | | | | | | | | | | |
Average per-ton ferrous scrap cost of goods sold | | $ | 274 | | | $ | 311 | | | $ | 299 | | | $ | 283 | |
| | | | | | | | | | | | | | | | |
Decrease in LIFO reserve and cost of goods sold | | $ | (3,320 | ) | | $ | (328 | ) | | $ | (6,737 | ) | | $ | (22 | ) |
| | | | | | | | | | | | | | | | |
Average electricity cost per kilowatt hour | | $ | 0.03 | | | $ | 0.04 | | | $ | 0.03 | | | $ | 0.04 | |
| | | | | | | | | | | | | | | | |
Kilowatt hours consumed (000 hrs) | | | 89,621 | | | | 138,913 | | | | 131,748 | | | | 267,355 | |
| | | | | | | | | | | | | | | | |
Average natural gas cost per therm | | $ | 0.37 | | | $ | 0.46 | | | $ | 0.59 | | | $ | 0.53 | |
| | | | | | | | | | | | | | | | |
Natural gas therms consumed (000 therms) | | | 3,267 | | | | 4,638 | | | | 6,665 | | | | 10,561 | |
KSW’s operating performance during the second quarter and first six months of 2009 was also impacted by:
· | substantially reduced production volumes which resulted in a much higher percentage of fixed costs included in cost of goods sold; |
· | increased variable costs of production as idle production facilities were difficult to re-start given cold winter temperatures; |
· | an increase in KSW’s allowance for bad debt of $1.6 million and $2.5 million, respectively, primarily due to the Chapter 11 proceedings of one of KSW’s customers; |
· | decreased employee incentive compensation accruals during 2009 due to decreased profitability; and |
· | a $4.2 million credit related to the release of accrued environmental costs as discussed above. |
Engineered Wire Products, Inc.
| | Three months ended June 30, | |
| | 2009 | | | % of sales | | | 2010 | | | % of sales | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Net sales | | $ | 11,563 | | | | 100.0 | % | | $ | 12,991 | | | | 100.0 | % |
Cost of goods sold | | | (10,575 | ) | | | (91.5 | ) | | | (11,585 | ) | | | (89.2 | ) |
Gross margin | | | 988 | | | | 8.5 | | | | 1,406 | | | | 10.8 | |
| | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (748 | ) | | | (6.5 | ) | | | (533 | ) | | | (4.1 | ) |
Operating income before pension/OPEB | | $ | 240 | | | | 2.0 | % | | $ | 873 | | | | 6.7 | % |
| | Six months ended June 30, | |
| | 2009 | | | % of sales | | | 2010 | | | % of Sales | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Net sales | | $ | 18,724 | | | | 100.0 | % | | $ | 20,367 | | | | 100.0 | % |
Cost of goods sold | | | (17,409 | ) | | | (93.0 | ) | | | (18,757 | ) | | | (92.1 | ) |
Gross margin | | | 1,315 | | | | 7.0 | | | | 1,610 | | | | 7.9 | |
| | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (1,401 | ) | | | (7.5 | ) | | | (1,100 | ) | | | (5.4 | ) |
Operating income (loss) before pension/OPEB | | $ | (86 | ) | | | (0.5 | )% | | $ | 510 | | | | 2.5 | % |
The primary drivers of EWP’s sales, cost of goods sold and the resulting gross margin are as follows:
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | | | | | | | | | | | |
Sales volume (000 tons) – Wire mesh | | | 13 | | | | 15 | | | | 20 | | | | 23 | |
| | | | | | | | | | | | | | | | |
Average per-ton selling prices – Wire mesh | | $ | 910 | | | $ | 884 | | | $ | 968 | | | $ | 874 | |
| | | | | | | | | | | | | | | | |
Average per-ton wire rod cost of goods sold | | $ | 817 | | | $ | 638 | | | $ | 813 | | | $ | 617 | |
| | | | | | | | | | | | | | | | |
Increase (decrease) in LIFO reserve and cost of goods sold | | $ | (2,147 | ) | | $ | 63 | | | $ | (3,217 | ) | | $ | 157 | |
EWP’s operating performance during the second quarter and first six months of 2010 as compared to the same periods of 2009 was also impacted by the following factors:
· | significantly higher percentage of fixed costs included in cost of goods sold during 2009 due to reduced production volumes; and |
· | lower payroll and benefit expenses during 2010 as a result of a reduction in personnel. |
Keystone – Calumet, Inc.
| | Three months ended June 30, | |
| | 2009 | | | % of sales | | | 2010 | | | % of sales | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Net sales | | $ | 2,438 | | | | 100.0 | % | | $ | 5,735 | | | | 100.0 | % |
Cost of goods sold | | | (3,001 | ) | | | (123.1 | ) | | | (5,087 | ) | | | (88.7 | ) |
Gross margin (loss) | | | (563 | ) | | | (23.1 | ) | | | 648 | | | | 11.3 | |
| | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (157 | ) | | | (6.4 | ) | | | (149 | ) | | | (2.6 | ) |
Operating income (loss) before pension/OPEB | | $ | (720 | ) | | | (29.5 | )% | | $ | 499 | | | | 8.7 | % |
| | Six months ended June 30, | |
| | 2009 | | | % of sales | | | 2010 | | | % of sales | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Net sales | | $ | 4,356 | | | | 100.0 | % | | $ | 9,986 | | | | 100.0 | % |
Cost of goods sold | | | (7,330 | ) | | | (168.3 | ) | | | (8,985 | ) | | | (90.0 | ) |
Gross margin (loss) | | | (2,974 | ) | | | (68.3 | ) | | | 1,001 | | | | 10.0 | |
| | | | | | | | | | | | | | | | |
Selling and administrative expense | | | (217 | ) | | | (5.0 | ) | | | (355 | ) | | | (3.6 | ) |
Operating income (loss) before pension/OPEB | | $ | (3,191 | ) | | | (73.3 | )% | | $ | 646 | | | | 6.4 | % |
The primary drivers of sales, cost of goods sold and the resulting gross margin (loss) are as follows:
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | | | | | | | | | | | |
Sales volume (000 tons) - Bar | | | 3 | | | | 6 | | | | 5 | | | | 11 | |
| | | | | | | | | | | | | | | | |
Average per-ton selling prices - Bar | | $ | 752 | | | $ | 906 | | | $ | 812 | | | $ | 886 | |
| | | | | | | | | | | | | | | | |
Average per-ton billet cost of goods sold | | $ | 469 | | | $ | 475 | | | $ | 489 | | | $ | 459 | |
Throughout 2009 and continuing into 2010, Calumet has been conducting trials for many different customer-specific products and has expanded its sales force. Both of these developments are contributing to new customers and increased sales volume. Increased sales volume allows Calumet to achieve certain economies of scale which are key to this segment’s profitability.
Calumet’s operating performance during the second quarter and first six months of 2010 as compared to the same periods of 2009 was also impacted by the following factors:
· | impairment charges of $849,000 and $2.3 million during the second quarter and first six months of 2009, respectively, as Calumet determined it was probable they would not be able to recover the cost of certain inventory items in future selling prices, as compared to nominal impairment charges during the second quarter and first six months of 2010; and |
· | substantially reduced production volumes during 2009 which resulted in a much higher percentage of fixed costs included in cost of goods sold and increased variable costs of production as idle production facilities were difficult to re-start given cold winter temperatures. |
Pension Credit or Expense
Primarily due to a $58 million increase in our pension plans’ assets during 2009, we currently expect to record a defined benefit pension credit of $4.9 million during 2010 as compared to the $5.9 million defined benefit pension expense we recorded during 2009. Accordingly, we recorded a defined benefit pension credit of $1.2 million and $2.4 million during the second quarter and first six months of 2010, respectively, as compared to the $1.5 million and $3.0 million expense recorded during the second quarter and first six months of 2009, respectively.
Interest Expense
Interest expense during the second quarter and first six months of 2009 and 2010 and the primary drivers of interest expense are presented in the following table.
| | Three months ended June 30, | | | Six months ended June 30, | |
| | 2009 | | | 2010 | | | 2009 | | | 2010 | |
| | ($ in thousands) | |
| | | | | | | | | | | | |
Interest expense | | $ | 408 | | | $ | 622 | | | $ | 740 | | | $ | 1,065 | |
| | | | | | | | | | | | | | | | |
Average debt balance | | | 32,982 | | | | 47,227 | | | | 31,641 | | | | 38,326 | |
| | | | | | | | | | | | | | | | |
Weighted average interest rates | | | 4.2 | % | | | 4.3 | % | | | 3.9 | % | | | 4.5 | % |
The increase in the average debt balance for the 2010 periods as compared to the 2009 periods was due to the increased demand in 2010 that permitted the return to more normal production levels during 2010 as opposed to the substantially reduced production schedules of 2009, all of which resulted in higher levels of working capital to finance operations during 2010 as compared to 2009. The increase in the weighted average interest rates for the 2010 periods as compared to the same periods of 2009 was primarily due to an amendment of our primary credit agreement in October 2009. Prior to the amendment, interest rates on our variable-rate debt ranged from prime to prime plus 0.5% or LIBOR plus 2.0% to LIBOR plus 2.75%. As amended, our revolving credit facility bears interest at prime plus 1% or LIBOR plus 2.75% and interest rates on our credit facility’s term loan bears interest at prime plus 1.25% or LIBOR plus 3%. Additionally, during the 2009 periods the weighted average interest rates were negatively impacted by lower credit facility balances, resulting in our County Note (which bears interest at 7.5%) representing a larger portion of interest.
We expect to lower the interest rate on outstanding borrowings as part of the amendment to our Wells Fargo credit facility in August 2010, as discussed above and in Note 4 to our Condensed Consolidated Financial Statements.
Income Taxes
A tabular reconciliation of the difference between the U.S. Federal statutory income tax rate and our effective income tax rates is included in Note 8 to our Condensed Consolidated Financial Statements. Our effective income tax rate for the first six months of 2010 is higher than the effective income tax rate for the first six months of 2009 because our 2009 tax losses were not available in all of our state jurisdictions.
LIQUIDITY AND CAPITAL RESOURCES
Historical Cash Flows
Operating Activities
During the first half of 2010, net cash used in operations totaled $19.7 million as compared to net cash used in operations of $6.2 million during the first half of 2009. The $13.5 million increase in cash used for operating activities was primarily due to the net effects of:
· | increased working capital usage of $44.7 million in 2010 primarily due to substantially higher production levels during the first half of 2010 to meet increased demand as compared to extremely low production levels during the first half of 2009 as a result of a rapid decline in product demand (we pay for the majority of our production costs in advance or as incurred while we generally receive customer payments in periods subsequent to shipment) partially offset by higher operating income before pension and OPEB during the first half of 2010 of $17.5 million; |
· | higher net cash provided by relative changes in our accrued liabilities of $17.3 million in 2010 as a result of the payment of 2008 employee incentive compensation during the first quarter of 2009 which was significantly higher than 2009 employee incentive compensation paid during the first quarter of 2010; and |
· | higher income tax payments during the first half of 2010 of $2.5 million due to increased profitability. |
Financing Activities
We increased borrowings on our revolving credit facility during the first half of 2010 by $26.3 million as compared to increasing borrowings by $22.4 million during the first half of 2009. The increased borrowings during 2010 were primarily due to the increase in our production levels as discussed above, partially offset by the final payment on our 8% Notes of $9.1 million during the first half of 2009, which was funded by borrowings on our revolving credit facility.
Future Cash Requirements
Capital Expenditures
Capital expenditures for 2010 are expected to be approximately $13 million and are primarily related to upgrades of production equipment which are not critical to our operations. We expect to fund capital expenditures using cash flows from operations and borrowing availability under credit facilities.
Commitments and Contingencies
Our primary credit facility ($41.8 million balance at June 30, 2010) expires in August 2010. As discussed in Note 4 to our Condensed Consolidated Financial Statements, we expect to amend the facility upon its maturity to, among other things, lower the interest rate on outstanding borrowings, decrease the size of facility from $100 million to $70 million and extend the term of the facility for an additional five years. While we have agreed to the terms in the term sheet with Wells Fargo, the final agreement incorporating those terms is subject to definitive documentation, and we can make no assurance that the parties will agree on the terms and conditions set forth in the definitive documentation until such documentation is fully negotiated and signed.
Payments due on our other debt amount to $.8 million for the remainder of 2010.
See Note 5 to the Condensed Consolidated Financial Statements for a description of certain legal proceedings.
Pension and Other Postretirement Obligations
We currently do not expect to be required to make contributions to our defined benefit pension plans during 2010. As allowed under one of our amended benefit plans, we exercised our right to create supplemental pension benefits in lieu of certain 2010 benefit payments due under that OPEB plan. As such, we anticipate contributing an aggregate of $1.4 million to our OPEB plans during 2010. Future variances from assumed actuarial rates, including the rate of return on plan assets, may result in increases or decreases to pension and OPEB funding requirements in future periods.
Off-balance Sheet Financing Arrangements
We do not have any off-balance sheet financing agreements other than the operating leases discussed in our 2009 Annual Report.
Working Capital and Borrowing Availability
| | December 31, | | | June 30, | |
| | 2009 | | | 2010 | |
| | (In thousands) | |
| | | | | | |
Working capital | | $ | 49,063 | | | $ | 60,329 | |
Outstanding balance of revolving credit facility | | | 12,546 | | | | 38,853 | |
| | | | | | | | |
Additional borrowing availability | | | 38,637 | | | | 30,850 | |
The revolving credit facility requires us to use our daily cash receipts to reduce outstanding borrowings, which results in us maintaining zero cash balances when there are balances outstanding under this credit facility.
The amount of available borrowings under our revolving credit facility is based on formula-determined amounts of trade receivables and inventories, less the amount of outstanding letters of credit ($5.5 million at June 30, 2010).
Our current credit facility expires in August 2010. See the “Recent Developments” section of “Results of Operations” above for further discussion.
RECENT ACCOUNTING PRONOUNCEMENTS
There have been no recent accounting pronouncements affecting our consolidated financial statements for the six-month period ended June 30, 2010.
CRITICAL ACCOUNTING POLICIES AND ESTIMATES
For a discussion of our critical accounting policies, refer to Part I, Item 7 - “Management’s Discussion and Analysis of Financial Condition and Results of Operations” in the 2009 Annual Report. There have been no changes in our critical accounting policies during the first six months of 2010.
ITEM 3. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK
Reference is made to the 2009 Annual Report for a discussion of the market risks associated with changes in interest rates and ferrous scrap costs that affect us. There have been no material changes in such market risks during the first six months of 2010.
ITEM 4. CONTROLS AND PROCEDURES
Evaluation of Disclosure Controls and Procedures
We maintain a system of disclosure controls and procedures. The term "disclosure controls and procedures," as defined by regulations of the SEC, means controls and other procedures that are designed to ensure that information required to be disclosed in the reports we file or submit to the SEC under the Securities Exchange Act of 1934, as amended, is recorded, processed, summarized and reported, within the time periods specified in the SEC's rules and forms. Disclosure controls and procedures include, without limitation, controls and procedures designed to ensure that information we are required to disclose in the reports we file or submit to the SEC under the Act is accumulated and communicated to our management, including our principal executive officer and our principal financial officer, or persons performing similar functions, as appropriate to allow timely decisions to be made regarding required disclosure. Each of David L. Cheek, our President and Chief Executive Officer, and Bert E. Downing, Jr., our Vice President, Chief Financial Officer, Corporate Controller and Treasurer, have evaluated the design and operating effectiveness of our disclosure controls and procedures as of June 30, 2010. Based upon their evaluation, these executive officers have concluded that our disclosure controls and procedures were effective as of June 30, 2010.
Internal Control Over Financial Reporting
We also maintain internal control over financial reporting. The term “internal control over financial reporting,” as defined by SEC regulations, means a process designed by, or under the supervision of, our principal executive and principal financial officers, or persons performing similar functions, and effected by our board of directors, management and other personnel, to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with GAAP, and includes those policies and procedures that:
| · | pertain to the maintenance of records that in reasonable detail accurately and fairly reflect our transactions and dispositions of our assets, |
| · | provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with GAAP, and that our receipts and expenditures are made only in accordance with authorizations of our management and directors, and |
| · | provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use or disposition of our assets that could have a material effect on our Condensed Consolidated Financial Statements. |
Changes in Internal Control Over Financial Reporting
There has been no change to our internal control over financial reporting during the quarter ended June 30, 2010 that has materially affected, or is reasonably likely to materially affect, our internal control over financial reporting.
PART II. OTHER INFORMATION
ITEM 1. Legal Proceedings.
Reference is made to disclosure provided under the caption "Other current litigation" in Note 5 to our Condensed Consolidated Financial Statements.
ITEM 1A. Risk Factors.
Reference is made to our 2009 Annual Report for a discussion of risk factors related to our businesses. There have been no material changes in such risk factors during the first six months of 2010.
ITEM 6. Exhibits.
(a) | We have retained a signed original of any exhibit listed below that contains signatures, and we will provide any such exhibit to the Commission or its staff upon request. The following exhibit is included herein: |
SIGNATURES
Pursuant to the requirements 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.
Keystone Consolidated Industries, Inc.
(Registrant)
Date: August 6, 2010 | By/s/ Bert E. Downing, Jr. Bert E. Downing, Jr. Vice President, Chief Financial Officer, Corporate Controller and Treasurer |