10-Q 1 a12-6803_110q.htm 10-Q

Table of Contents

 

 

 

UNITED STATES
SECURITIES AND EXCHANGE COMMISSION

WASHINGTON, DC 20549

 

FORM 10-Q

 

(Mark One)

 

x

Quarterly report pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934

 

For the quarterly period ended March 31, 2012

 

Or

 

o

Transition report pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934

 

For the transition period from                     to                    

 

Commission file number:  1-32266

 

POLYPORE INTERNATIONAL, INC.

(Exact Name of Registrant as Specified in Its Charter)

 

Delaware

 

43-2049334

(State or Other Jurisdiction of

 

(IRS Employer

Incorporation or Organization)

 

Identification No.)

 

11430 North Community House Road, Suite 350

 Charlotte, North Carolina

 

28277

(Address of Principal Executive Offices)

 

(Zip Code)

 

(704) 587-8409

(Registrant’s Telephone Number, Including Area Code)

 

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.  x Yes  o No

 

Indicate by check mark whether the registrant has submitted electronically and posted on its corporate website, if any, every Interactive Data File required to be submitted and posted pursuant to Rule 405 of Regulation S-T (§ 232.405 of this chapter) during the preceding 12 months (or for such shorter period that the registrant was required to submit and post such files).  x Yes  o No

 

Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, a non-accelerated filer or a smaller reporting company. See the definitions of “large accelerated filer”, “accelerated filer” and “smaller reporting company” in Rule 12b-2 of the Exchange Act.

 

Large accelerated filer x

 

Accelerated filer o

 

 

 

Non-accelerated filer o

 

Smaller reporting company o

 

Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act).  o Yes  x No

 

There were 46,533,576 shares of the registrant’s common stock outstanding as of April 25, 2012.

 

 

 



Table of Contents

 

Polypore International, Inc.

Index to Quarterly Report on Form 10-Q

For the Three Months Ended March 31, 2012

 

 

 

Page

PART I

FINANCIAL INFORMATION

 

 

 

 

Item 1.

Financial Statements

4

Item 2.

Management’s Discussion and Analysis of Financial Condition and Results of Operations

18

Item 3.

Quantitative and Qualitative Disclosures About Market Risk

24

Item 4.

Controls and Procedures

24

 

 

 

PART II

OTHER INFORMATION

 

 

 

 

Item 1.

Legal Proceedings

24

Item 6.

Exhibits

26

 

 

 

SIGNATURES

27

 

In this Quarterly Report on Form 10-Q, the words “Polypore International,” “Company,” “we,” “us” and “our” refer to Polypore International, Inc. together with its subsidiaries, unless the context indicates otherwise.

 

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Forward-looking Statements

 

This Quarterly Report on Form 10-Q includes “forward-looking statements” within the meaning of Section 27A of the Securities Act of 1933, as amended (the “Securities Act”), and Section 21E of the Securities Exchange Act of 1934, as amended (the “Exchange Act”), and the Private Securities Litigation Reform Act of 1995. All statements other than statements of historical facts included in this Quarterly Report on Form 10-Q that address activities, events or developments that we expect, believe or anticipate will or may occur in the future are forward-looking statements, including, in particular, the statements about Polypore International’s plans, objectives, strategies and prospects regarding, among other things, the financial condition, results of operations and business of Polypore International and its subsidiaries. We have identified some of these forward-looking statements with words like “believe,” “may,” “will,” “should,” “expect,” “intend,” “plan,” “predict,” “anticipate,” “estimate” or “continue” and other words and terms of similar meaning. These forward-looking statements may be contained under the captions “Management’s Discussion and Analysis of Financial Condition and Results of Operations” or “Controls and Procedures,” the Company’s financial statements or the notes thereto or elsewhere in this Quarterly Report on Form 10-Q.

 

These forward-looking statements are based on current expectations about future events affecting us and are subject to uncertainties and factors relating to our operations and business environment, all of which are difficult to predict and many of which are beyond our control. Many factors mentioned in our discussion in this Quarterly Report on Form 10-Q, including the risks outlined under the caption entitled “Item 1A. Risk Factors” in our Annual Report on Form 10-K for the fiscal year ended December 31, 2011, will be important in determining future results. Although we believe that the expectations reflected in our forward-looking statements are reasonable, we do not know whether our expectations will prove correct. They can be affected by inaccurate assumptions we might make or by known or unknown risks and uncertainties, including with respect to Polypore International, the following, among other things:

 

·      the highly competitive nature of the markets in which we sell our products;

·      the failure to continue to develop innovative products;

·      the loss of our customers;

·      the vertical integration by our customers of the production of our products into their own manufacturing process;

·      increases in prices for raw materials or the loss of key supplier contracts;

·      our substantial indebtedness;

·      interest rate risk related to our variable rate indebtedness;

·      our inability to generate cash;

·      restrictions related to the senior secured credit agreement;

·      employee slowdowns, strikes or similar actions;

·                  product liability claims exposure;

·                  risks in connection with our operations outside the United States, including compliance with applicable anti-corruption laws;

·                  the incurrence of substantial costs to comply with, or as a result of violations of, or liabilities under environmental laws;

·      the failure to protect our intellectual property;

·      the loss of senior management;

·      the incurrence of additional debt, contingent liabilities and expenses in connection with future acquisitions;

·      the failure to effectively integrate newly acquired operations;

·      the absence of expected returns from the intangible assets we have recorded;

·      the adverse impact from legal proceedings on our financial condition; and

·      natural disasters, epidemics, terrorist acts and other events beyond our control.

 

Because our actual results, performance or achievements could differ materially from those expressed in, or implied by, the forward-looking statements, we cannot give any assurance that any of the events anticipated by the forward-looking statements will occur or, if any of them do, what impact they will have on Polypore International’s results of operations and financial condition. You are cautioned not to place undue reliance on these forward-looking statements, which speak only as of the date of this Quarterly Report on Form 10-Q. We do not undertake any obligation to update these forward-looking statements to reflect new information, future events or otherwise, except as may be required under federal securities laws.

 

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PART I — FINANCIAL INFORMATION

 

Item 1.  Financial Statements

 

Polypore International, Inc.

Condensed consolidated balance sheets

 

 

 

March 31, 2012

 

 

 

(in thousands, except share data)

 

(unaudited)

 

December 31, 2011*

 

Assets

 

 

 

 

 

Current assets:

 

 

 

 

 

Cash and cash equivalents

 

$

78,956

 

$

92,574

 

Accounts receivable, net

 

120,013

 

134,016

 

Inventories

 

107,297

 

90,444

 

Deferred income taxes

 

3,145

 

3,171

 

Prepaid and other

 

23,457

 

21,560

 

Total current assets

 

332,868

 

341,765

 

Property, plant and equipment, net

 

571,452

 

527,778

 

Goodwill

 

469,319

 

469,319

 

Intangibles and loan acquisition costs, net

 

129,198

 

133,586

 

Other

 

7,843

 

9,431

 

Total assets

 

$

1,510,680

 

$

1,481,879

 

 

 

 

 

 

 

Liabilities and shareholders’ equity

 

 

 

 

 

Current liabilities:

 

 

 

 

 

Accounts payable

 

$

34,941

 

$

34,332

 

Accrued liabilities

 

52,609

 

61,907

 

Income taxes payable

 

3,341

 

5,881

 

Current portion of debt

 

3,696

 

3,682

 

Total current liabilities

 

94,587

 

105,802

 

Debt, less current portion

 

706,199

 

705,836

 

Pension obligations, less current portion

 

81,493

 

78,086

 

Deferred income taxes

 

80,909

 

76,601

 

Other

 

16,204

 

16,161

 

Commitments and contingencies

 

 

 

 

 

 

 

 

 

 

 

Shareholders’ equity:

 

 

 

 

 

Preferred stock — 15,000,000 shares authorized, no shares issued and outstanding

 

 

 

Common stock, $.01 par value — 200,000,000 shares authorized, 46,533,576 and 46,499,180 issued and outstanding at March 31, 2012 and December 31, 2011

 

465

 

465

 

Paid-in capital

 

531,797

 

527,243

 

Retained earnings (accumulated deficit)

 

3,590

 

(15,183

)

Accumulated other comprehensive loss

 

(8,558

)

(17,127

)

Total Polypore shareholders’ equity

 

527,294

 

495,398

 

Noncontrolling interest

 

3,994

 

3,995

 

Total shareholders’ equity

 

531,288

 

499,393

 

Total liabilities and shareholders’ equity

 

$

1,510,680

 

$

1,481,879

 

 


* Derived from audited consolidated financial statements

 

See notes to condensed consolidated financial statements

 

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Table of Contents

 

Polypore International, Inc.

Condensed consolidated statements of income

(unaudited)

 

 

 

Three Months Ended

 

(in thousands, except per share data)

 

March 31, 2012

 

April 2, 2011

 

Net sales

 

$

173,705

 

$

185,674

 

Cost of goods sold

 

102,681

 

106,208

 

Gross profit

 

71,024

 

79,466

 

Selling, general and administrative expenses

 

33,886

 

30,550

 

Operating income

 

37,138

 

48,916

 

Other (income) expense:

 

 

 

 

 

Interest expense, net

 

8,791

 

8,899

 

Foreign currency and other

 

451

 

1,598

 

 

 

9,242

 

10,497

 

Income before income taxes

 

27,896

 

38,419

 

Income taxes

 

9,123

 

12,738

 

Net income

 

$

18,773

 

$

25,681

 

 

 

 

 

 

 

Net income per share:

 

 

 

 

 

Basic

 

$

0.40

 

$

0.56

 

Diluted

 

$

0.40

 

$

0.55

 

 

 

 

 

 

 

Weighted average shares outstanding:

 

 

 

 

 

Basic

 

46,497,701

 

45,685,520

 

Diluted

 

47,215,006

 

46,797,646

 

 

See notes to condensed consolidated financial statements

 

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Polypore International, Inc.

Condensed consolidated statements of comprehensive income

(unaudited)

 

 

 

Three Months Ended

 

(in thousands)

 

March 31, 2012

 

April 2, 2011

 

Net income

 

$

18,773

 

$

25,681

 

Other comprehensive income (loss):

 

 

 

 

 

Foreign currency translation adjustment, net of income tax expense of $534 in 2012 and $1,558 in 2011

 

8,889

 

9,707

 

Change in net actuarial loss and prior service credit

 

(320

)

(368

)

Comprehensive income

 

$

27,342

 

$

35,020

 

 

See notes to condensed consolidated financial statements

 

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Table of Contents

 

Polypore International, Inc.

Condensed consolidated statements of cash flows

(unaudited)

 

 

 

Three Months Ended

 

(in thousands)

 

March 31, 2012

 

April 2, 2011

 

Operating activities:

 

 

 

 

 

Net income

 

$

18,773

 

$

25,681

 

Adjustments to reconcile net income to net cash provided by operating activities:

 

 

 

 

 

Depreciation expense

 

9,441

 

7,962

 

Amortization expense

 

4,091

 

4,121

 

Amortization of loan acquisition costs

 

617

 

608

 

Stock-based compensation

 

4,270

 

1,035

 

Loss on disposal of property, plant and equipment

 

289

 

163

 

Foreign currency loss

 

1,128

 

1,726

 

Deferred income taxes

 

4,115

 

6,778

 

Changes in operating assets and liabilities:

 

 

 

 

 

Accounts receivable

 

15,510

 

(11,998

)

Inventories

 

(15,384

)

(784

)

Prepaid and other current assets

 

575

 

(2,126

)

Accounts payable and accrued liabilities

 

(10,470

)

5,532

 

Income taxes payable

 

(2,345

)

956

 

Other, net

 

(394

)

(1,574

)

Net cash provided by operating activities

 

30,216

 

38,080

 

Investing activities:

 

 

 

 

 

Purchases of property, plant and equipment, net

 

(45,350

)

(29,677

)

Net cash used in investing activities

 

(45,350

)

(29,677

)

Financing activities:

 

 

 

 

 

Principal payments on debt

 

(924

)

(1,738

)

Proceeds from stock option exercises

 

284

 

2,295

 

Noncontrolling interest

 

(31

)

(14

)

Payments for loan acquisition costs

 

 

(275

)

Net cash provided by (used in) financing activities

 

(671

)

268

 

Effect of exchange rate changes on cash and cash equivalents

 

2,187

 

4,241

 

Net increase (decrease) in cash and cash equivalents

 

(13,618

)

12,912

 

Cash and cash equivalents at beginning of period

 

92,574

 

89,955

 

Cash and cash equivalents at end of period

 

$

78,956

 

$

102,867

 

 

See notes to condensed consolidated financial statements

 

7



Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

1.             Description of Business and Basis of Presentation

 

Description of Business

 

Polypore International, Inc. (the “Company”) is a leading global high technology filtration company that develops, manufactures and markets specialized microporous membranes used in separation and filtration processes. The Company has a global presence in the major geographic markets of North America, South America, Europe and Asia.

 

Basis of Presentation

 

The accompanying unaudited condensed consolidated financial statements include the accounts of the Company and all majority-owned subsidiaries after elimination of intercompany accounts and transactions.  The unaudited condensed consolidated financial statements are prepared in accordance with U.S. generally accepted accounting principles for interim financial information. Accordingly, the unaudited condensed consolidated financial statements and notes do not contain certain information included in the Company’s annual financial statements. In the opinion of management, all normal and recurring adjustments that are necessary for a fair presentation have been made. Certain amounts previously presented in the condensed consolidated financial statements for prior periods have been reclassified to conform to current classifications. Operating results for the three months ended March 31, 2012 are not necessarily indicative of the results that may be expected for the fiscal year ending December 29, 2012. The unaudited condensed consolidated financial statements should be read in conjunction with the consolidated financial statements in the Company’s Annual Report on Form 10-K for the fiscal year ended December 31, 2011.

 

2.             Recent Accounting Pronouncements

 

In June 2011, the FASB issued guidance on the disclosure and presentation requirements for comprehensive income. This new guidance requires comprehensive income to be presented in either a single continuous financial statement or in two separate but consecutive financial statements. The adoption of this guidance in the Company’s March 31, 2012 condensed consolidated financial statements only affected presentation and did not have an impact on the Company’s financial condition or results of operations.

 

In September 2011, the FASB amended the guidance on the annual testing of goodwill for impairment. The amended guidance will allow companies to assess qualitative factors to determine if it is more likely than not that goodwill might be impaired and whether it is necessary to perform the two-step goodwill impairment test required under current accounting standards. The guidance is effective for annual and interim goodwill impairment tests performed for fiscal years beginning after December 15, 2011. The Company will adopt this guidance in performing its annual goodwill impairment test as of the first day of the fourth quarter of 2012.  The adoption of this guidance is not expected to have an impact on the Company’s financial condition or results of operations.

 

3.             Inventories

 

Inventories are carried at the lower of cost or market using the first-in, first-out method of accounting and consist of:

 

(in thousands)

 

March 31, 2012

 

December 31, 2011

 

Raw materials

 

$

38,218

 

$

35,423

 

Work-in-process

 

22,370

 

18,351

 

Finished goods

 

46,709

 

36,670

 

 

 

$

107,297

 

$

90,444

 

 

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Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

4.             Debt

 

Debt, in order of priority, consists of:

 

(in thousands)

 

March 31, 2012

 

December 31, 2011

 

Senior credit agreement:

 

 

 

 

 

Revolving credit facility

 

$

 

$

 

Term loan facilities

 

344,895

 

344,518

 

 

 

344,895

 

344,518

 

7.5% senior notes

 

365,000

 

365,000

 

 

 

709,895

 

709,518

 

Less current maturities

 

3,696

 

3,682

 

Long-term debt

 

$

706,199

 

$

705,836

 

 

5.             Fair Value of Financial Instruments

 

The Company’s financial instruments include cash and cash equivalents, accounts receivable, accounts payable, accrued liabilities and long-term debt. The carrying value of cash and cash equivalents, accounts receivable, accounts payable and accrued liabilities approximates their fair value due to the short-term maturities of these assets and liabilities. The carrying amount of borrowings under the senior credit agreement approximates fair value because the interest rates adjust to market interest rates. The fair value of the 7.5% senior notes, based on a quoted market price and classified as level one in the fair value hierarchy, was $385,075,000 at March 31, 2012.

 

6.             Income Taxes

 

The income tax provision for the interim periods presented is computed at the effective rate expected to be applicable in each respective full year using the statutory rates on a country-by-country basis. Income tax expense recorded in the financial statements differs from the federal statutory income tax rate due to a variety of factors, including state income taxes, the mix of income between U.S. and foreign jurisdictions taxed at varying rates and changes in estimates of permanent differences and valuation allowances.

 

7.             Pension Plans

 

The Company and its subsidiaries sponsor multiple defined benefit pension plans based in subsidiaries located outside of the United States. The following table provides the components of net periodic benefit cost:

 

 

 

Three Months Ended

 

(in thousands)

 

March 31, 2012

 

April 2, 2011

 

Service cost

 

$

422

 

$

380

 

Interest cost

 

1,207

 

1,230

 

Expected return on plan assets

 

(215

)

(223

)

Amortization of prior service cost

 

(13

)

(13

)

Recognized net actuarial loss

 

119

 

19

 

Net periodic benefit cost

 

$

1,520

 

$

1,393

 

 

8.             Environmental Matters

 

Environmental obligations are accrued when such expenditures are probable and reasonably estimable. The amount of liability recorded is based on currently available information, including the progress of remedial investigations, current status of discussions with regulatory authorities regarding the method and extent of remediation, presently enacted laws and existing technology. Accruals for estimated losses from environmental obligations are adjusted as further information develops or

 

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Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

circumstances change. Costs of future expenditures for environmental obligations are not discounted to their present value. The Company does not currently anticipate any material loss in excess of the amounts accrued. However, the Company’s future remediation expenses may be affected by a number of uncertainties including, but not limited to, the difficulty in estimating the extent and method of remediation, the evolving nature of environmental regulations and the availability and application of technology. The Company does not expect the resolution of such uncertainties to have a material adverse effect on its consolidated financial position or liquidity. Recoveries of environmental costs from other parties are recognized as assets when their receipt is deemed probable.

 

In connection with the acquisition of Membrana GmbH (“Membrana”) in 2002, the Company recorded a reserve for environmental obligations. The reserve provides for costs to remediate known environmental issues and operational upgrades which are required in order for the Company to remain in compliance with local regulations. The initial estimate and subsequent finalization of the reserve was included in the allocation of purchase price at the date of acquisition. The environmental reserve for the Membrana facility, which is denominated in euros, was $11,599,000 and $11,957,000 at March 31, 2012 and December 31, 2011, respectively. The Company anticipates the expenditures associated with the reserve will be made in the next twelve months. At March 31, 2012, the reserve was included in “Accrued liabilities” in the accompanying condensed consolidated balance sheets.

 

The Company has indemnification agreements for certain environmental matters from Acordis A.G. (“Acordis”) and Akzo Nobel N.V. (“Akzo”), the prior owners of Membrana. Akzo originally provided broad environmental protections to Acordis with the right to assign such indemnities to Acordis’s successors. Akzo’s indemnifications relate to conditions existing prior to December 1999, which is the date that Membrana was sold to Acordis. In addition to the Akzo indemnification, Acordis provides separate indemnification of claims incurred from December 1999 through February 2002, the acquisition date. The Company receives indemnification payments under the indemnification agreements after expenditures are made against approved claims. At March 31, 2012 and December 31, 2011, the amounts receivable under the indemnification agreements were $12,462,000 and $12,099,000, respectively. At March 31, 2012, the receivable under the indemnification agreements was included in “Prepaid and other” in the accompanying condensed consolidated balance sheets.

 

9.             Government Grants

 

In 2010, the Company was awarded a $49,264,000 grant from the U.S. Department of Energy (“DOE”) to help fund an expansion of its U.S. lithium battery separator production capacity. As of March 31, 2012, the Company has recognized $48,479,000 from the DOE grant. The Company has also been awarded state and local grants in connection with certain of its U.S. expansions.

 

The Company recognized grant awards for capital expenditures of $1,910,000 and $6,416,000 for the three months ended March 31, 2012 and April 2, 2011, respectively. The Company recognized grant awards for expenses of $604,000 and $532,000 for the three months ended March 31, 2012 and April 2, 2011, respectively. At March 31, 2012 and December 31, 2011, amounts due from government agencies were $271,000 and $1,483,000, respectively.

 

10.          Related Party Transactions

 

The Company’s German subsidiary has a 33% equity investment in a patent and trademark service provider and a 25% equity investment in a research company. The investments are accounted for under the equity method of accounting and were $789,000 and $588,000 at March 31, 2012 and December 31, 2011, respectively. Charges from the affiliates for work performed were $327,000 and $281,000 for the three months ended March 31, 2012 and April 2, 2011, respectively. Amounts due to the affiliates were $75,000 and $107,000 at March 31, 2012 and December 31, 2011, respectively.

 

11.          Noncontrolling Interest

 

In 2010, the Company entered into a joint venture agreement with a customer, Camel Group Co., Ltd (“Camel”), a leading battery manufacturer in China, to produce lead-acid battery separators primarily for Camel’s use. The joint venture, Daramic Xiangyang Battery Separator Co., Ltd. (“Daramic Xiangyang”), is located at Camel’s facility and is expected to start production in 2012. In accordance with the joint venture agreement, the Company has made cash contributions of $7,370,000 for a 65% ownership interest in the joint venture, and Camel has contributed cash of $2,554,000 and land for a 35% ownership interest. In exchange for notes payable, Daramic Xiangyang has purchased production assets from the Company’s former facility in Potenza, Italy, and will purchase a building currently under construction from Camel.

 

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Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

12.          Segment Information

 

The Company’s operations are principally managed on a products basis and are comprised of three reportable segments for financial reporting purposes. The Company’s three reportable segments are presented in the context of its two primary businesses — energy storage and separations media.

 

The energy storage business produces and markets membranes that provide the critical function of separating the cathode and anode in a variety of battery markets and is comprised of the following reportable segments:

 

·                  Electronics and EDVs - produces and markets membranes for lithium-ion batteries that are used in portable electronic devices, cordless power tools and electric drive vehicles (“EDVs”).

 

·                  Transportation and industrial - produces and markets membranes for lead-acid batteries that are used in automobiles, other motor vehicles, forklifts and uninterruptible power supply systems.

 

The separations media business is one reportable segment and produces and markets membranes used as the high technology filtration element in various medical and industrial applications.

 

The Company evaluates the performance of segments and allocates resources to segments based on operating income before depreciation and amortization. In addition, it evaluates business segment performance before stock-based compensation and certain non-recurring and other costs.

 

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Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

Financial information relating to the reportable segments is presented below:

 

 

 

Three Months Ended

 

(in thousands)

 

March 31, 2012

 

April 2, 2011

 

Net sales to external customers (by major product group):

 

 

 

 

 

Electronics and EDVs

 

$

42,388

 

$

42,144

 

Transportation and industrial

 

86,202

 

94,440

 

Energy storage

 

128,590

 

136,584

 

Healthcare

 

27,545

 

30,531

 

Filtration and specialty

 

17,570

 

18,559

 

Separations media

 

45,115

 

49,090

 

Total net sales to external customers

 

$

173,705

 

$

185,674

 

 

 

 

 

 

 

Operating income:

 

 

 

 

 

Electronics and EDVs

 

$

16,795

 

$

18,387

 

Transportation and industrial

 

20,014

 

25,771

 

Energy storage

 

36,809

 

44,158

 

Separations media

 

13,863

 

16,390

 

Corporate and other

 

(8,696

)

(10,375

)

Segment operating income

 

41,976

 

50,173

 

Stock-based compensation

 

4,270

 

1,035

 

Non-recurring and other costs

 

568

 

222

 

Total operating income

 

37,138

 

48,916

 

Reconciling items:

 

 

 

 

 

Interest expense, net

 

8,791

 

8,899

 

Foreign currency and other

 

451

 

1,598

 

Income before income taxes

 

$

27,896

 

$

38,419

 

 

 

 

 

 

 

Depreciation and amortization:

 

 

 

 

 

Electronics and EDVs

 

$

3,161

 

$

1,873

 

Transportation and industrial

 

2,901

 

2,932

 

Energy storage

 

6,062

 

4,805

 

Separations media

 

3,322

 

3,093

 

Corporate and other

 

4,148

 

4,185

 

Total depreciation and amortization

 

$

13,532

 

$

12,083

 

 

12



Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

13.          Financial Statements of Guarantors

 

The Company’s senior notes are unconditionally guaranteed, jointly and severally, on a senior basis by certain of the Company’s 100% owned subsidiaries (“Guarantors”). Management has determined that separate complete financial statements of the Guarantors would not be material to users of the financial statements.

 

The following sets forth condensed consolidating financial statements of the Guarantors and non-Guarantor subsidiaries.

 

Condensed consolidating balance sheet
March 31, 2012

 

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Assets

 

 

 

 

 

 

 

 

 

 

 

Cash and cash equivalents

 

$

 

$

75,799

 

$

3,157

 

$

 

$

78,956

 

Accounts receivable, net

 

37,400

 

82,613

 

 

 

120,013

 

Inventories

 

37,147

 

70,150

 

 

 

107,297

 

Prepaid and other

 

5,090

 

21,481

 

31

 

 

26,602

 

Total current assets

 

79,637

 

250,043

 

3,188

 

 

332,868

 

Due from affiliates

 

482,640

 

297,887

 

410,018

 

(1,190,545

)

 

Investment in subsidiaries

 

167,329

 

321,035

 

607,432

 

(1,095,796

)

 

Property, plant and equipment, net

 

270,288

 

301,164

 

 

 

571,452

 

Goodwill

 

 

 

469,319

 

 

469,319

 

Intangibles and loan acquisition costs, net

 

 

 

129,198

 

 

129,198

 

Other

 

157

 

7,686

 

 

 

7,843

 

Total assets

 

$

1,000,051

 

$

1,177,815

 

$

1,619,155

 

$

(2,286,341

)

$

1,510,680

 

 

 

 

 

 

 

 

 

 

 

 

 

Liabilities and shareholders’ equity

 

 

 

 

 

 

 

 

 

 

 

Accounts payable and accrued liabilities

 

$

28,357

 

$

48,723

 

$

10,470

 

$

 

$

87,550

 

Income taxes payable

 

 

3,754

 

(413

)

 

3,341

 

Current portion of debt

 

 

467

 

3,229

 

 

3,696

 

Total current liabilities

 

28,357

 

52,944

 

13,286

 

 

94,587

 

Due to affiliates

 

506,909

 

271,395

 

412,241

 

(1,190,545

)

 

Debt, less current portion

 

 

44,002

 

662,197

 

 

706,199

 

Pension obligations, less current portion

 

 

81,493

 

 

 

81,493

 

Deferred income taxes and other

 

51,018

 

45,952

 

143

 

 

97,113

 

Shareholders’ equity

 

413,767

 

682,029

 

531,288

 

(1,095,796

)

531,288

 

Total liabilities and shareholders’ equity

 

$

1,000,051

 

$

1,177,815

 

$

1,619,155

 

$

(2,286,341

)

$

1,510,680

 

 

13



Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

Condensed consolidating balance sheet
December 31, 2011

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Assets

 

 

 

 

 

 

 

 

 

 

 

Cash and cash equivalents

 

$

 

$

65,495

 

$

27,079

 

$

 

$

92,574

 

Accounts receivable, net

 

51,831

 

82,185

 

 

 

134,016

 

Inventories

 

31,603

 

58,841

 

 

 

90,444

 

Prepaid and other

 

6,345

 

18,324

 

62

 

 

24,731

 

Total current assets

 

89,779

 

224,845

 

27,141

 

 

341,765

 

Due from affiliates

 

549,943

 

282,244

 

377,981

 

(1,210,168

)

 

Investment in subsidiaries

 

177,143

 

321,215

 

570,456

 

(1,068,814

)

 

Property, plant and equipment, net

 

235,051

 

292,727

 

 

 

527,778

 

Goodwill

 

 

 

469,319

 

 

469,319

 

Intangibles and loan acquisition costs, net

 

 

 

133,586

 

 

133,586

 

Other

 

157

 

9,274

 

 

 

9,431

 

Total assets

 

$

1,052,073

 

$

1,130,305

 

$

1,578,483

 

$

(2,278,982

)

$

1,481,879

 

 

 

 

 

 

 

 

 

 

 

 

 

Liabilities and shareholders’ equity

 

 

 

 

 

 

 

 

 

 

 

Accounts payable and accrued liabilities

 

$

41,301

 

$

51,391

 

$

3,547

 

$

 

$

96,239

 

Income taxes payable

 

 

5,231

 

650

 

 

5,881

 

Current portion of debt

 

 

453

 

3,229

 

 

3,682

 

Total current liabilities

 

41,301

 

57,075

 

7,426

 

 

105,802

 

Due to affiliates

 

554,230

 

247,424

 

408,514

 

(1,210,168

)

 

Debt, less current portion

 

 

42,832

 

663,004

 

 

705,836

 

Pension obligations, less current portion

 

 

78,086

 

 

 

78,086

 

Deferred income taxes and other

 

47,140

 

45,476

 

146

 

 

92,762

 

Shareholders’ equity

 

409,402

 

659,412

 

499,393

 

(1,068,814

)

499,393

 

Total liabilities and shareholders’ equity

 

$

1,052,073

 

$

1,130,305

 

$

1,578,483

 

$

(2,278,982

)

$

1,481,879

 

 

14



Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

Condensed consolidating statement of income
For the three months ended March 31, 2012

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Net sales

 

$

53,521

 

$

120,184

 

$

 

$

 

$

173,705

 

Cost of goods sold

 

17,412

 

85,269

 

 

 

102,681

 

Gross profit

 

36,109

 

34,915

 

 

 

71,024

 

Selling, general and administrative expenses

 

17,309

 

12,274

 

4,303

 

 

33,886

 

Operating income (loss)

 

18,800

 

22,641

 

(4,303

)

 

37,138

 

Interest expense and other

 

(2,584

)

2,797

 

9,029

 

 

9,242

 

Equity in earnings of subsidiaries

 

 

 

(28,663

)

28,663

 

 

Income before income taxes

 

21,384

 

19,844

 

15,331

 

(28,663

)

27,896

 

Income taxes

 

7,931

 

4,634

 

(3,442

)

 

9,123

 

Net income

 

$

13,453

 

$

15,210

 

$

18,773

 

$

(28,663

)

$

18,773

 

 

Condensed consolidating statement of income
For the three months ended April 2, 2011

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Net sales

 

$

61,745

 

$

123,929

 

$

 

$

 

$

185,674

 

Cost of goods sold

 

19,390

 

86,818

 

 

 

106,208

 

Gross profit

 

42,355

 

37,111

 

 

 

79,466

 

Selling, general and administrative expenses

 

17,015

 

12,431

 

1,104

 

 

30,550

 

Operating income (loss)

 

25,340

 

24,680

 

(1,104

)

 

48,916

 

Interest expense and other

 

(837

)

2,505

 

8,829

 

 

10,497

 

Equity in earnings of subsidiaries

 

 

 

(33,515

)

33,515

 

 

Income before income taxes

 

26,177

 

22,175

 

23,582

 

(33,515

)

38,419

 

Income taxes

 

8,964

 

5,873

 

(2,099

)

 

12,738

 

Net income

 

$

17,213

 

$

16,302

 

$

25,681

 

$

(33,515

)

$

25,681

 

 

15



Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

Condensed consolidating statement of comprehensive income

For the three months ended March 31, 2012

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Net income

 

$

13,453

 

$

15,210

 

$

18,773

 

$

(28,663

)

$

18,773

 

Other comprehensive income (loss):

 

 

 

 

 

 

 

 

 

 

 

Foreign currency translation adjustment

 

 

8,302

 

(271

)

858

 

8,889

 

Change in net actuarial loss and prior service credit

 

 

(320

)

 

 

(320

)

Equity in earnings of subsidiaries

 

 

 

8,840

 

(8,840

)

 

Comprehensive income

 

$

13,453

 

$

23,192

 

$

27,342

 

$

(36,645

)

$

27,342

 

 

Condensed consolidating statement of comprehensive income

For the three months ended April 2, 2011

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Net income

 

$

17,213

 

$

16,302

 

$

25,681

 

$

(33,515

)

$

25,681

 

Other comprehensive income (loss):

 

 

 

 

 

 

 

 

 

 

 

Foreign currency translation adjustment

 

 

12,374

 

(1,890

)

(777

)

9,707

 

Change in net actuarial loss and prior service credit

 

 

(368

)

 

 

(368

)

Equity in earnings of subsidiaries

 

 

 

11,229

 

(11,229

)

 

Comprehensive income

 

$

17,213

 

$

28,308

 

$

35,020

 

$

(45,521

)

$

35,020

 

 

16



Table of Contents

 

Polypore International, Inc.

Notes to condensed consolidated financial statements

(unaudited)

 

Condensed consolidating statement of cash flows
For the three months ended March 31, 2012

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Net cash provided by (used in) operating activities

 

$

26,400

 

$

6,121

 

$

(2,565

)

$

260

 

$

30,216

 

Investing activities:

 

 

 

 

 

 

 

 

 

 

 

Purchases of property, plant and equipment, net

 

(38,689

)

(6,661

)

 

 

(45,350

)

Net cash used in investing activities

 

(38,689

)

(6,661

)

 

 

(45,350

)

Financing activities:

 

 

 

 

 

 

 

 

 

 

 

Principal payments on debt

 

 

(117

)

(807

)

 

(924

)

Proceeds from stock option exercises

 

 

 

284

 

 

284

 

Intercompany transactions, net

 

12,289

 

8,774

 

(20,803

)

(260

)

 

Other

 

 

 

(31

)

 

(31

)

Net cash provided by (used in) financing activities

 

12,289

 

8,657

 

(21,357

)

(260

)

(671

)

Effect of exchange rate changes on cash and cash equivalents

 

 

2,187

 

 

 

2,187

 

Net increase (decrease) in cash and cash equivalents

 

 

10,304

 

(23,922

)

 

(13,618

)

Cash and cash equivalents at beginning of period

 

 

65,495

 

27,079

 

 

92,574

 

Cash and cash equivalents at end of period

 

$

 

$

75,799

 

$

3,157

 

$

 

$

78,956

 

 

Condensed consolidating statement of cash flows
For the three months ended April 2, 2011

 

(in thousands)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

The Company

 

Eliminations

 

Consolidated

 

Net cash provided by (used in) operating activities

 

$

29,374

 

$

9,990

 

$

(2,466

)

$

1,182

 

$

38,080

 

Investing activities:

 

 

 

 

 

 

 

 

 

 

 

Purchases of property, plant and equipment, net

 

(20,615

)

(9,062

)

 

 

(29,677

)

Net cash used in investing activities

 

(20,615

)

(9,062

)

 

 

(29,677

)

Financing activities:

 

 

 

 

 

 

 

 

 

 

 

Principal payments on debt

 

 

(123

)

(1,615

)

 

(1,738

)

Proceeds from stock option exercises

 

 

 

2,295

 

 

2,295

 

Intercompany transactions, net

 

(8,759

)

6,854

 

3,087

 

(1,182

)

 

Other

 

 

 

(289

)

 

(289

)

Net cash provided by (used in) financing activities

 

(8,759

)

6,731

 

3,478

 

(1,182

)

268

 

Effect of exchange rate changes on cash and cash equivalents

 

 

4,241

 

 

 

4,241

 

Net increase in cash and cash equivalents

 

 

11,900

 

1,012

 

 

12,912

 

Cash and cash equivalents at beginning of period

 

 

58,172

 

31,783

 

 

89,955

 

Cash and cash equivalents at end of period

 

$

 

$

70,072

 

$

32,795

 

$

 

$

102,867

 

 

17



Table of Contents

 

Item 2.  Management’s Discussion and Analysis of Financial Condition and Results of Operations

 

The following discussion of our financial condition and results of operations should be read together with our unaudited condensed consolidated financial statements and the related notes included elsewhere in this Quarterly Report on Form 10-Q and our audited consolidated financial statements and the related notes included in our Annual Report on Form 10-K for the fiscal year ended December 31, 2011.

 

Overview

 

We are a leading global high technology filtration company that develops, manufactures and markets specialized microporous membranes used in separation and filtration processes. In fiscal 2011, we generated total net sales of $763.1 million. We operate in two primary businesses: energy storage and separations media. We manufacture our products at facilities in North America, Europe and Asia. Net sales from foreign locations were $490.6 million for fiscal 2011.

 

Energy Storage

 

In the energy storage business, our membrane separators are a critical performance component in lithium batteries, which are primarily used in consumer electronics and electric drive vehicle (“EDV”) applications, and lead-acid batteries, which are used globally in transportation and numerous industrial applications. We believe that the long-term growth drivers for the energy storage business — growth in Asia, strong demand for consumer electronics and growing demand for EDVs — are positive. The energy storage business is comprised of two reportable segments, as described below.

 

Electronics and EDVs.  Lithium batteries are the power source in a wide variety of applications, including consumer electronics applications such as notebook computers, tablets, mobile phones and cordless power tools; EDVs; and emerging applications such as energy storage systems (“ESS”). Growth in lithium batteries is being driven by demand in consumer electronics and EDVs. Since late 2009, we have announced $334.0 million of capacity expansions, consisting of EDV-targeted expansions at our existing Charlotte, North Carolina facility and a new facility in Concord, North Carolina, and a consumer electronics-targeted expansion at our facility in Ochang, Korea.  We have completed the Charlotte and Ochang expansions and expect to complete and start ramping up production on the first phase of the Concord facility in mid-2012.  The remaining expansions at the Concord facility will be completed in two phases, one of which will start ramping up in late 2012 and the other in late 2013.  As of March 31, 2012, we have spent approximately $235.0 million on these expansions. We expect to complete the remaining capital expenditures associated with these expansions in 2012 or early 2013. The Charlotte and Concord expansions were partially funded by a grant from the U.S. Department of Energy (“DOE”) of $49.3 million.

 

Transportation and industrial.  In the lead-acid battery market, the high proportion of aftermarket replacement sales and the steady growth of the worldwide fleet of motor vehicles provide us with a growing recurring revenue base in lead-acid battery separators. Worldwide demand for lead-acid battery separators is expected to continue to grow at slightly more than annual economic growth. The Asia-Pacific region is the fastest growing market for lead-acid battery separators. Growth in this region is driven by the increasing penetration of automobile ownership, growth in industrial and manufacturing sectors, export incentives and ongoing conversion to the polyethylene-based membrane separators we produce. We have positioned ourselves to benefit from growth in Asia by expanding capacity at our Prachinburi, Thailand facility; acquiring battery separator manufacturing assets and subsequently expanding our operations in Bangalore, India; acquiring a production facility in Tianjin, China; establishing an Asian Technical Center in Thailand; and entering into a joint venture with a customer, Camel Group Co., Ltd. (“Camel”). The joint venture will produce lead-acid battery separators in China and is expected to start production in mid-2012. In February 2011, we started an additional expansion at our Prachinburi, Thailand facility that is expected to begin production in the second quarter of 2012.

 

Separations Media

 

In the separations media business, our filtration membranes and modules are used in healthcare and high-performance filtration and specialty applications. We believe that the separations media business will continue to benefit from continued growth in demand for higher levels of purity in a growing number of applications. The separations media business is a reportable segment.

 

For healthcare applications, we produce membranes used in blood filtration applications for hemodialysis, blood oxygenation and plasmapheresis. Growth in demand for hemodialysis membranes is driven by the increasing worldwide population of end-stage renal disease patients. We believe that conversion to single-use dialyzers and increasing treatment frequency will result in additional dialyzer market growth. In late 2011, we completed an expansion of our PUREMA® hemodialysis membrane production capacity to support future market growth.

 

18



Table of Contents

 

For filtration and specialty applications, we produce a wide range of membranes and membrane-based elements for micro-, ultra- and nanofiltration and gasification/degasification of liquids. Micro-, ultra- and nanofiltration membrane element market growth is being driven by several factors, including end-market growth in applications such as water treatment and pharmaceutical processing, displacement of conventional filtration media by membrane filtration due to membranes’ superior cost and performance attributes and increasing purity requirements in industrial and other applications.

 

Critical accounting policies

 

Critical accounting policies are those accounting policies that can have a significant impact on the presentation of our financial condition and results of operations, and that require the use of complex and subjective estimates based on past experience and management’s judgment. Because of the uncertainty inherent in such estimates, actual results may differ from these estimates. These policies are critical to the understanding of our operating results and financial condition and include policies related to the allowance for doubtful accounts, impairment of intangibles and goodwill, pension benefits, environmental matters and repairs and maintenance. For a discussion of each of these policies, please see the discussion entitled “Critical Accounting Policies” under Item 7 — Management’s Discussion and Analysis of Financial Condition and Results of Operations in our Annual Report on Form 10-K for the year ended December 31, 2011.

 

Results of Operations

 

The following table sets forth, for the periods indicated, certain operating data in amount and as a percentage of net sales:

 

 

 

 

 

 

 

Percentage of Net Sales

 

 

 

Three Months Ended

 

Three Months Ended

 

($’s in millions)

 

March 31, 2012

 

April 2, 2011

 

March 31, 2012

 

April 2, 2011

 

Net sales

 

$

173.7

 

$

185.7

 

100.0

%

100.0

%

 

 

 

 

 

 

 

 

 

 

Gross profit

 

71.0

 

79.5

 

40.9

 

42.8

 

Selling, general and administrative expenses

 

33.9

 

30.6

 

19.5

 

16.5

 

Operating income

 

37.1

 

48.9

 

21.4

 

26.3

 

Interest expense, net

 

8.8

 

8.9

 

5.1

 

4.8

 

Other

 

0.4

 

1.6

 

0.2

 

0.8

 

Income before income taxes

 

27.9

 

38.4

 

16.1

 

20.7

 

Income taxes

 

9.1

 

12.7

 

5.3

 

6.9

 

Net income

 

$

18.8

 

$

25.7

 

10.8

%

13.8

%

 

Comparison of the three months ended March 31, 2012 with the three months ended April 2, 2011

 

Net sales.  Net sales for the three months ended March 31, 2012 were $173.7 million, a decrease of $12.0 million, or 6.5%, from the same period in the prior year. The decrease was due to lower sales in the transportation and industrial segment and separations media segment and the negative impact of foreign currency translation of $3.1 million. Based on updated customer forecasts and production schedules, we expect full-year sales growth, primarily in the second half of the year.

 

Gross profit.  Gross profit was $71.0 million, a decrease of $8.5 million, or 10.7%, from the same period in the prior year.  Gross profit as a percent of net sales was 40.9% for the three months ended March 31, 2012, compared to 42.8% for the three months ended April 2, 2011.  The decrease in consolidated gross profit and gross profit margin was primarily due to lower sales and costs associated with growth investments, including $1.5 million of additional depreciation expense.

 

Selling, general and administrative expenses.  Selling, general and administrative expenses increased $3.3 million for the three months ended March 31, 2012 compared to the prior year, primarily due to costs associated with growth investments and higher stock-based compensation expense, partially offset by a decline in performance-based incentive compensation expense.

 

Segment operating income.  Segment operating income, which excludes stock-based compensation and certain non-recurring and other costs, was $42.0 million, a decrease of $8.2 million, or 16.3%, from the same period in the prior year. Segment operating income as a percent of net sales was 24.2% for the three months ended March 31, 2012, compared to 27.0% for the three months ended April 2, 2011.  The decrease in segment operating income and segment operating income margin was the result of lower sales and costs associated with growth investments, including non-cash depreciation expense, partially offset by a decline in performance-based incentive compensation expense.

 

19



Table of Contents

 

Interest expense.  Interest expense for the three months ended March 31, 2012 was $8.8 million, which was comparable to the same period in the prior year.

 

Income taxes.  The income tax expense for the interim periods presented is computed at the effective rate expected to be applicable in each respective full year using the statutory rates on a country-by-country basis. The effective tax rate was 32.7% for the three months ended March 31, 2012, compared to 33.2% for the same period in the prior year. The mix of earnings between the tax jurisdictions has a significant impact on the effective tax rate. Each tax jurisdiction has its own set of tax laws and tax rates, and income earned by our subsidiaries is taxed independently by these various jurisdictions.  Currently, the applicable statutory income tax rates in the jurisdictions in which we operate range from 0% to 39%.

 

The components of our effective tax rate are as follows:

 

 

 

Three Months Ended

 

 

 

March 31, 2012

 

April 2, 2011

 

U.S. federal statutory rate

 

35.0

%

35.0

%

State income taxes

 

1.1

 

1.2

 

Mix of income in taxing jurisdictions

 

(3.7

)

(3.3

)

Other permanent differences and valuation allowances

 

0.3

 

0.3

 

Total effective tax rate

 

32.7

%

33.2

%

 

Financial reporting segments

 

Electronics and EDVs

 

Comparison of the three months ended March 31, 2012 with the three months ended April 2, 2011

 

Net sales.  Net sales for the three months ended March 31, 2012 were $42.4 million, which was comparable to $42.1 million for the same period in the prior year. Compared to the fourth quarter of 2011, sales were lower primarily due to changes in the production schedules of two EDV customers. We expect sales in the second quarter of 2012 to also be impacted by the changes in production schedules and to be comparable to the first quarter, with higher sales occurring in the second half of the year.

 

Segment operating income.  Segment operating income was $16.8 million, a decrease of $1.6 million, or 8.7%, from the same period in the prior year.  Segment operating income as a percent of net sales was 39.6% for the three months ended March 31, 2012, compared to 43.7% for the three months ended April 2, 2011.  The decrease in segment operating income and segment operating income margin was due to growth investments associated with new capacity, including an additional $1.3 million of non-cash depreciation expense. We expect segment operating income margins to improve as we get the benefit of our growth investments through higher sales.

 

Transportation and Industrial

 

Comparison of the three months ended March 31, 2012 with the three months ended April 2, 2011

 

Net sales.  Net sales for the three months ended March 31, 2012 were $86.2 million, a decrease of $8.3 million, or 8.8%, from the same period in the prior year.  The decrease was primarily due to unseasonably mild winter weather in North America and Europe, which temporarily impacted replacement battery sales, and the $1.5 million negative effect of foreign currency translation.

 

Segment operating income.  Segment operating income was $20.0 million, a decrease of $5.8 million, or 22.5%, from the same period in the prior year.  Segment operating income as a percent of net sales was 23.2% for the three months ended March 31, 2012, compared to 27.3% for the three months ended April 2, 2011.  The decrease in segment operating income and segment operating income margin was due to lower sales and costs associated with growth investments in Asia.

 

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Separations Media

 

Comparison of the three months ended March 31, 2012 with the three months ended April 2, 2011

 

Net sales.  Net sales for the three months ended March 31, 2012 were $45.1 million, a decrease of $4.0 million, or 8.1%, from the same period in the prior year, including the negative effect of foreign currency translation of $1.6 million.  Healthcare sales decreased by $3.0 million primarily due to a shift in production by two contractually-bound customers from the first quarter to the remainder of the year and the effect of foreign currency translation.  Filtration and specialty product sales decreased $1.0 million, including the effect of foreign currency translation.

 

Segment operating income.  Segment operating income was $13.9 million, a decrease of $2.5 million, or 15.2%, from the same period in the prior year.  Segment operating income as a percent of net sales was 30.8% for the three months ended March 31, 2012, compared to 33.4% for the three months ended April 2, 2011. The decrease in segment operating income and segment operating income margin was due to lower sales and costs associated with our new hemodialysis production capacity.

 

Corporate and other costs

 

Comparison of the three months ended March 31, 2012 with the three months ended April 2, 2011

 

Corporate and other costs include costs associated with the corporate office and other costs that are not allocated to the reporting segments for segment reporting purposes, including amortization of identified intangible assets and performance-based incentive compensation.

 

Corporate and other costs for the three months ended March 31, 2012 were $8.7 million, compared to $10.4 million for the three months ended April 2, 2011. The decrease was due primarily to lower performance-based incentive compensation expense.

 

Liquidity and Capital Resources

 

Cash and cash equivalents decreased by $13.6 million during the three months ended March 31, 2012, as cash generated from operations and cash on hand were used to fund growth investments.

 

Operating activities.  Net cash provided by operating activities was $30.2 million in the three months ended March 31, 2012, consisting of cash generated from operations of $42.7 million, partially offset by changes in operating assets and liabilities. Accounts receivable decreased primarily due to lower sales as compared to the fourth quarter of 2011. Days sales outstanding is consistent with the prior year, and we have not experienced significant changes in accounts receivable aging or customer payment terms and believe that we have adequately provided for potential bad debts. Inventory increased based on production and capacity planning for expected customer order patterns. Inventory is generally not subject to obsolescence and does not have a shelf life, and we do not believe there is a significant risk of inventory impairment.  Accounts payable and accrued liabilities decreased primarily due to the payment of fiscal 2011 performance-based incentive compensation in the first quarter of 2012.

 

Investing activities.  In the three months ended March 31, 2012, total capital expenditures were $45.4 million, net of DOE grant awards of $1.9 million, compared to $29.7 million for the same period in the prior year. Capital expenditures were primarily related to capacity expansions in our electronics and EDVs segment. We expect total capital expenditures for fiscal 2012 to be approximately $150.0 million. As of March 31, 2012, we had $138.8 million of construction in progress which was primarily related to the capacity expansion projects.

 

Financing activities.  During the three months ended March 31, 2012, financing activities consisted primarily of scheduled principal payments under our credit agreement.

 

We intend to fund our ongoing operations with cash on hand, cash generated by operations and borrowings under the senior secured credit agreement. As of March 31, 2012, approximately 95% of our cash and cash equivalents were held by foreign subsidiaries. There were no significant restrictions on our ability to transfer funds with and among subsidiaries, or any material adverse tax consequences that would impact our ability to transfer funds held by foreign subsidiaries to the U.S.

 

Our senior secured credit agreement provides for a U.S. dollar term loan facility ($300.4 million outstanding at March 31, 2012), a euro term loan facility ($44.5 million outstanding at March 31, 2012) and a $90.0 million revolving credit facility. At March 31, 2012, we had no borrowings or undrawn standby letters of credit outstanding on the revolving credit facility. The term loans mature in July 2014 and the revolving credit facility matures in July 2013. Interest rates under the senior secured

 

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credit agreement are, at our option, equal to either an alternate base rate or Eurocurrency base rate plus a specified margin. At March 31, 2012, interest rates on the U.S. dollar term loan and euro term loan were 2.25% and 2.36%, respectively. When loans are outstanding under the revolving credit facility, we are required to maintain a senior leverage ratio of indebtedness to Adjusted EBITDA of less than 3.00 to 1.00. At March 31, 2012, our senior leverage ratio was 1.21 to 1.00 and therefore, had no effect on borrowings available under the revolving credit facility. Adjusted EBITDA, as defined under the senior secured credit agreement, was as follows:

 

(in millions) 

 

Twelve Months Ended
March 31, 2012

 

Net income

 

$

98.3

 

Add/Subtract:

 

 

 

Depreciation and amortization expense

 

52.8

 

Interest expense, net

 

34.3

 

Income taxes

 

48.2

 

Stock-based compensation

 

12.6

 

Foreign currency gain

 

(3.0

)

Loss on disposal of property, plant and equipment

 

0.5

 

Costs related to the FTC litigation

 

0.4

 

Other non-cash or non-recurring items

 

0.1

 

Adjusted EBITDA

 

$

244.2

 

 

As of March 31, 2012, the calculation of the senior leverage ratio, as defined under the senior secured credit agreement, was as follows:

 

(in millions)

 

 

 

Indebtedness (1)

 

$

294.9

 

Adjusted EBITDA

 

$

244.2

 

Actual leverage ratio

 

1.21x

 

 


(1)          Calculated as the sum of outstanding borrowings under the senior secured credit agreement, less cash on hand (not to exceed $50.0 million).

 

The senior secured credit agreement contains certain restrictive covenants which, among other things, limit capital spending, the incurrence of additional indebtedness, investments, dividends, transactions with affiliates, asset sales, acquisitions, mergers and consolidations, prepayments of other indebtedness, liens and encumbrances, and other matters customarily restricted in such agreements. The agreement also contains certain customary events of default, subject to grace periods, as appropriate. We believe that limitations imposed by the senior secured credit agreement will not significantly inhibit us from meeting our ongoing capital expenditure needs.

 

The 7.5% senior notes mature on November 15, 2017 and are guaranteed by most of our existing and future domestic restricted subsidiaries, subject to certain exceptions. Except under certain circumstances, the 7.5% senior notes do not require principal payments prior to their maturity in 2017. Interest on the 7.5% senior notes is payable semi-annually on May 15 and November 15. The 7.5% senior notes contain customary covenants and events of default, including covenants that limit our ability to incur debt, pay dividends and make investments.

 

Future debt service payments are expected to be paid out of cash flows from operations, borrowings on our revolving credit facility and future refinancing of our debt. Our cash interest requirements for the next twelve months are estimated to be $35.7 million.

 

We believe we have sufficient liquidity to meet our cash requirements over both the short (next twelve months) and long term (in relation to our debt service requirements). In evaluating the sufficiency of our liquidity, we considered cash on hand, expected cash flow to be generated from operations and available borrowings under our senior secured credit agreement compared to our anticipated cash requirements for debt service, working capital, cash taxes and capital expenditures and funding requirements for long-term liabilities. We anticipate that our cash on hand and operating cash flow, together with borrowings under the revolving credit facility, will be sufficient to meet our anticipated future operating expenses, capital expenditures and debt service obligations as they become due for at least the next twelve months. However, our ability to make scheduled payments of principal, to pay interest on or to refinance our indebtedness and to satisfy our other debt obligations will depend upon our future operating performance, which will be affected by general economic, financial, competitive, legislative, regulatory, business and other factors beyond our control. See “Item 1A. Risk Factors” in our most recent Annual Report on Form 10-K.

 

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From time to time, we may explore additional financing methods and other means to lower our cost of capital, which could include equity or debt financings and the application of the proceeds therefrom to the repayment of bank debt or other indebtedness. In addition, in connection with any future acquisitions, we may require additional funding, which may be provided in the form of additional debt or equity financing or a combination thereof. There can be no assurance that any additional financing will be available to us on acceptable terms or at all.

 

Foreign Operations

 

As of March 31, 2012, we manufacture our products at 14 strategically located facilities in North America, Europe and Asia. Net sales from the foreign locations were approximately $120.2 million and $123.9 million for the three months ended March 31, 2012 and April 2, 2011, respectively. Typically, we sell our products in the currency of the country where the manufacturing facility that produces the product is located. Sales to foreign customers are subject to numerous additional risks, including the impact of foreign government regulations, currency fluctuations, political uncertainties and differences in business practices. There can be no assurance that foreign governments will not adopt regulations or take other actions that would have a direct or indirect adverse impact on our business or market opportunities within such governments’ countries. Furthermore, there can be no assurance that the political, cultural and economic climate outside the United States will be favorable to our operations and growth strategy.

 

Environmental matters

 

Environmental obligations are accrued when such expenditures are probable and reasonably estimable. The amount of liability recorded is based on currently available information, including the progress of remedial investigations, current status of discussions with regulatory authorities regarding the method and extent of remediation, presently enacted laws and existing technology. Accruals for estimated losses from environmental obligations are adjusted as further information develops or circumstances change. Costs of future expenditures for environmental obligations are not discounted to their present value. We do not currently anticipate any material loss in excess of the amounts accrued. Future remediation expenses may be affected by a number of uncertainties including, but not limited to, the difficulty in estimating the extent and method of remediation, the evolving nature of environmental regulations and the availability and application of technology. We do not expect the resolution of such uncertainties to have a material adverse effect on our consolidated financial position or liquidity. Recoveries of environmental costs from other parties are recognized as assets when their receipt is deemed probable.

 

In connection with the acquisition of Membrana GmbH (“Membrana”) in 2002, we recorded a reserve for environmental obligations. The reserve provides for costs to remediate known environmental issues and operational upgrades which are required in order for us to remain in compliance with local regulations. The initial estimate and subsequent finalization of the reserve was included in the allocation of purchase price at the date of acquisition. The environmental reserve for the Membrana facility, which is denominated in euros, was $11.6 million at March 31, 2012. We anticipate the expenditures associated with the reserve will be made in the next twelve months.

 

We have indemnification agreements for certain environmental matters from Acordis A.G. (“Acordis”) and Akzo Nobel N.V. (“Akzo”), the prior owners of Membrana. Akzo originally provided broad environmental protections to Acordis with the right to assign such indemnities to Acordis’s successors. Akzo’s indemnifications relate to conditions existing prior to December 1999, which is the date that Membrana was sold to Acordis. In addition to the Akzo indemnification, Acordis provides separate indemnification of claims incurred from December 1999 through February 2002, the acquisition date. We will receive indemnification payments under the indemnification agreements after expenditures are made against approved claims. At March 31, 2012, amounts receivable under the indemnification agreements were $12.5 million.

 

Off-Balance Sheet Arrangements

 

We are not a party to any off-balance sheet arrangements that have, or are reasonably likely to have, a material current or future effect on our financial condition, revenues or expenses, results of operations, liquidity, capital expenditures or capital resources.

 

New Accounting Standards

 

See Note 2 to the condensed consolidated financial statements for information related to new accounting standards.

 

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Item 3.  Quantitative and Qualitative Disclosures About Market Risk

 

We are exposed to various market risks, which are potential losses arising from adverse changes in market rates and prices, such as interest rates and foreign exchange fluctuations. We do not enter into derivatives or other financial instruments for trading or speculative purposes.

 

Interest rate risk

 

At March 31, 2012, we had fixed rate debt of $365.0 million and variable rate debt of $344.9 million. To reduce the interest rate risk inherent in our variable rate debt, we may utilize interest rate derivatives. As of March 31, 2012, there were no outstanding interest rate derivatives. The pre-tax earnings and cash flow impact resulting from a 100 basis point increase in interest rates on our variable rate debt, holding other variables constant, would be $3.4 million per year.

 

Currency risk

 

Outside of the United States, we maintain assets and operations in Europe and Asia. The results of operations and financial position of our foreign operations are principally measured in their respective currency and translated into U.S. dollars. As a result, exposure to foreign currency fluctuations exists. The reported income of these subsidiaries will be higher or lower depending on a weakening or strengthening of the U.S. dollar against the respective foreign currency. Our subsidiaries and affiliates also purchase and sell products and services in various currencies. As a result, we may be exposed to cost increases relative to the local currencies in the markets in which we sell. Because the percentage of our sales in foreign currencies differs from the percentage of our costs in foreign currencies, a change in the relative value of the U.S. dollar could have a disproportionate impact on our sales compared to our costs, which could impact our margins. A portion of our assets are based in our foreign locations and are translated into U.S. dollars at foreign currency exchange rates in effect as of the end of each period, with the effect of such translation reflected in accumulated other comprehensive income (loss). Accordingly, our consolidated shareholders’ equity will fluctuate depending upon the weakening or strengthening of the U.S. dollar against the respective foreign currency, primarily the euro.

 

The dollar/euro exchange rates used in our financial statements for the periods ended as set forth below were as follows:

 

 

 

March 31, 2012

 

April 2, 2011

 

Period end rate

 

1.3339

 

1.4170

 

Period average rate for the three months ended

 

1.3099

 

1.3659

 

 

Our strategy for management of currency risk relies primarily on conducting our operations in a country’s respective currency and may, from time to time, involve foreign currency derivatives. As of March 31, 2012, we did not have any foreign currency derivatives outstanding.

 

Item 4.  Controls and Procedures

 

An evaluation of the effectiveness of our disclosure controls and procedures (as defined in Rule 13a-15(e) or 15d-15(e) promulgated under the Exchange Act) was performed under the supervision, and with the participation of, our management, including our Chief Executive Officer and Chief Financial Officer. Our disclosure controls are designed to ensure that information required to be disclosed in reports that we file or submit under the Exchange Act is recorded, processed, summarized and reported within the time periods specified in the rules and forms of the Securities and Exchange Commission. Based upon our evaluation, our Chief Executive Officer and Chief Financial Officer concluded that our disclosure controls and procedures were effective as of March 31, 2012 to ensure that information required to be disclosed in the reports that we file under the Exchange Act is recorded, processed, summarized and reported within the time periods specified in the Securities and Exchange Commission’s rules and forms, and is accumulated and communicated to management, including our Chief Executive Officer and Chief Financial Officer, as appropriate, to allow timely decisions regarding required disclosure.

 

During the three months ended March 31, 2012, there has been no change in our internal control over financial reporting (as defined in Rules 13a-15(f) or 15d-15(f) promulgated under the Exchange Act) 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

 

On March 20, 2008, we received a letter from the United States Federal Trade Commission (the “FTC”) requesting that we voluntarily provide certain documents and information to the FTC regarding our acquisition of Microporous Holding Corporation, the parent company of Microporous Products L.P. (“Microporous”), which was completed on February 29, 2008.

 

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Table of Contents

 

The letter stated that the FTC was conducting an investigation to determine whether the Microporous acquisition will substantially lessen competition in any relevant market and thereby violate federal antitrust laws. We voluntarily responded to the letter in writing and through supplemental telephone conversations and meetings.

 

On April 7, 2008, we and our wholly-owned subsidiary, Daramic LLC, each received from the FTC a subpoena and interrogatories requesting substantially similar documents and information as requested in the FTC’s initial letter, as well as additional documents and information. We responded fully to this request and met on several occasions with various members of the FTC staff and FTC commissioners (“Commissioners”) in an effort to answer their questions and resolve the investigation.

 

On September 9, 2008, the FTC issued an administrative complaint against us alleging that our actions and the acquisition of Microporous have substantially lessened competition in North American markets for lead-acid battery separators. We filed an answer to the complaint on October 15, 2008 denying the material allegations of the complaint. The matter was presented before an Administrative Law Judge (“ALJ”) of the FTC and the hearing concluded on June 12, 2009. In October 2009, the ALJ granted our request to re-open the record to take additional evidence. On February 22, 2010, the FTC’s ALJ issued an initial decision in which he recommended to the FTC that it order us to divest substantially all of the acquired Microporous assets, which include the manufacturing facilities located in Piney Flats, Tennessee and Feistritz, Austria, and restore the competitive environment to that which existed prior to the acquisition, while ruling in our favor on other portions of the complaint. On March 15, 2010, we filed a Notice of Appeal with the FTC. On November 5, 2010, we were notified that the Commissioners affirmed the relief initially granted by the FTC’s ALJ issued on February 22, 2010. The Commissioners ordered that we proceed with the ALJ’s recommendations to divest substantially all of the Microporous assets acquired in February 2008.

 

We believe that this decision is inconsistent with the law and the facts presented at the hearing and that the Microporous acquisition is and will continue to be beneficial to our customers and the industry. On January 28, 2011, we filed a petition with the U.S. Court of Appeals for the 11th Circuit to review the FTC’s November 5, 2010 order and opinion. It is not possible to predict with certainty whether we will be successful in the appellate process or the timing of a final decision. If the appellate court affirms the FTC’s decision, and we choose not to seek Supreme Court review or the Supreme Court denies our petition seeking review of the case, then we will be required to divest substantially all of the assets acquired in the Microporous acquisition, and we will be subject to some prospective restrictions on our future conduct.

 

We believe that a final judicial resolution to the challenge by the FTC to the Microporous acquisition could take one or more years. Although it is difficult to predict the outcome, timing or impact of this matter at this time, we believe that the final resolution will not have a material adverse impact on our business, financial condition or results of operations.

 

Our core energy storage business produces polymer-based membrane battery separators used in transportation, industrial and consumer electronic applications.  The acquisition of the Microporous business extended our product portfolio into the niche, mature deep cycle market for rubber-based battery separators, with considerable overlap to customers we currently serve with other products.  We do not believe that a required divestiture of all or a portion of the Microporous assets would significantly impact our core energy storage business or the long-term growth drivers impacting this business, including growth in Asia, strong demand for consumer electronics and growing demand for electric drive vehicles.

 

For the fiscal year ended December 31, 2011, the Microporous business represented approximately 10% of consolidated revenue and operating income, including the facility that we completed and shifted production to in Feistritz, Austria post-acquisition.  At December 31, 2011, Microporous assets were less than 5% of consolidated assets.  Based on the growth in revenues and profits that we have experienced in the last two years in our core energy storage and separations media businesses, as well as the impact of capacity expansions, we expect that the percentage of consolidated revenues and total assets represented by Microporous will continue to decline.  The impact of a final resolution to this matter may be affected by a number of uncertainties, including, but not limited to, whether we are required to divest all or a portion of the Microporous assets, the timing of a potential divestiture, the proceeds of such a divestiture and the incremental growth in our core businesses.  If we were required to divest of all or a portion of the Microporous assets, we would intend to sell the assets at fair market value and the proceeds of such a sale would be available to support continued investments in the faster growing and more profitable core energy storage and separations media businesses.

 

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Item 6.    Exhibits

 

Exhibit No.

 

Exhibit Description

 

 

 

31.1

 

Certification of Chief Executive Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002

31.2

 

Certification of Chief Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002

32.1

 

Certification of Chief Executive Officer pursuant to Section 906 of the Sarbanes-Oxley Act of 2002

32.2

 

Certification of Chief Financial Officer pursuant to Section 906 of the Sarbanes-Oxley Act of 2002

101

 

Interactive Data Files

 

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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.

 

 

Date: May 3, 2012

 

POLYPORE INTERNATIONAL, INC.

 

 

(Registrant)

 

 

 

 

 

 

 

By:

/s/ Robert B. Toth

 

 

Robert B. Toth

 

 

President and Chief Executive Officer

 

 

(principal executive officer)

 

 

 

 

 

 

 

By:

/s/ Lynn Amos

 

 

Lynn Amos

 

 

Chief Financial Officer

 

 

(principal financial officer and principal accounting officer)

 

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