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Segment Information
12 Months Ended
Dec. 31, 2011
Segment Information

12. Segment Information

 

On June 29, 2011, the Company sold its Affinity business (see Note 8), which had been included in OPS. Affinity designed and manufactured high precision, specialty engineered temperature-control equipment for semiconductor, pharmaceutical, life sciences and industrial applications. As a result of the sale, the Consolidated Financial Statements have been retroactively restated to reflect Affinity as a discontinued operation and the following segment information excludes Affinity’s net sales and operating income for all periods presented.

 

The Company’s reportable segments are Performance Materials and Thermal/Acoustical. The Performance Materials segment reports the results of the Industrial Filtration, Industrial Thermal Insulation and Life Sciences Filtration businesses. The Thermal/Acoustical segment reports the results of Lydall’s automotive business, which includes Metal parts, Fiber parts and related Tooling. OPS includes Life Sciences Vital Fluids.

 

In the first quarter of 2012, the Thermal/Acoustical segment continues to implement a comprehensive improvement plan in its fibers business. Internal organizational changes were made in the Company’s Thermal/Acoustical segment to better align the Company’s structure with its strategic direction. As a result, the Company is evaluating the impact of these changes on its reportable segments.

 

Performance Materials Segment

 

The Performance Materials segment includes filtration media solutions for air, fluid power, and industrial applications (“Industrial Filtration”), air and liquid life science applications (“Life Sciences Filtration”), and industrial thermal insulation solutions for building products, appliances, and energy and industrial markets (“Industrial Thermal Insulation”).

 

Industrial Filtration products include LydAir® MG (Micro-Glass) Air Filtration Media, LydAir® MB (Melt Blown) Air Filtration Media, LydAir® SC (Synthetic Composite) Air Filtration Media, and Arioso™ Membrane Composite Media. These products constitute the critical media component of clean-air systems for applications in clean-space, commercial, industrial and residential HVAC, power generation, and industrial processes. Lydall has leveraged its extensive technical expertise and applications knowledge into a suite of media products covering the vast liquid filtration landscape across the engine and industrial fields. The LyPore® Liquid Filtration Media and activated carbon containing ActiPure® Filtration Media series address a variety of application needs in fluid power including hydraulic filters, air-water and air-oil coalescing, industrial fluid processes, diesel filtration and fuel filtration.

 

Industrial Thermal Insulation products are high performance nonwoven veils, papers, mats and specialty composites for the cryogenic, building products, appliance, and high temperature insulation markets. The Manniglas® Thermal Insulation brand is diverse in its product application ranging from high temperature seals and gaskets in ovens and ranges to specialty veils for HVAC and cavity wall insulation. appLY® Mat Needled Glass Mats have been developed to expand Lydall’s high temperature technology portfolio for broad application into the appliance market and supplements the Lytherm® Insulation Media product brand, traditionally utilized in the industrial market for kilns and furnaces used in metal processing. Lydall’s Cryotherm® Super-Insulating Media, CRS-Wrap® Super-Insulating Media and Cryo-Lite™ Cryogenic Insulation products are industry standards for state-of-the-art cryogenic insulation designs used by manufacturers of cryogenic equipment for liquid gas storage, piping, and transportation.

 

Life Sciences Filtration products include the LyPore® and ActiPure® Filtration Media developed to meet the requirements of life science applications including biopharmaceutical pre-filtration and clarification, diagnostic and analytical testing, respiratory protection, life protection, medical air filtration, drinking water filtration and high purity process filtration such as that found in food and beverage and medical applications. Lydall also offers Solupor® Membrane specialty microporous membranes that are utilized in various markets and applications including air and liquid filtration and transdermal drug delivery. Solupor® membranes are based on ultra-high molecular weight polyethylene and incorporate a unique combination of mechanical strength, chemical inertness, and high porosity in a unique open structure.

 

Thermal/Acoustical Segment

 

The Thermal/Acoustical segment offers a full line of innovative engineered products to assist in noise and heat abatement within the transportation sector. Lydall products are found in the interior (dash insulators), underbody (wheel well, fuel tank, exhaust) and under hood (engine compartment) of cars, trucks, SUV’s, heavy duty trucks and recreational vehicles. Lydall’s patented products include ZeroClearance®, AMS®, Flexshield® and dBCore® comprised of organic and inorganic fiber composites (fiber parts) as well as metal combinations (metal parts).

 

Other Products and Services

 

The Life Sciences Vital Fluids business offers specialty products for blood filtration devices, blood transfusion single-use containers and bioprocessing single-use containers and products for containment of media, buffers and bulk intermediates used in biotech, pharmaceutical and diagnostic reagent manufacturing processes. 

 

Net sales by segment and for OPS, as well as reconciling items, to equal to consolidated net sales for the years ended December 31, 2011, 2010, and 2009 were as follows:

 

Consolidated Net Sales   For the Years Ended December 31,  
In thousands   2011     2010     2009  
Performance Materials Segment:                        
Industrial Filtration   $ 72,888     $ 71,480     $ 55,223  
Industrial Thermal Insulation     47,299       38,951       32,217  
Life Sciences Filtration     13,872       12,704       10,575  
Performance Materials Segment net sales     134,059       123,135       98,015  
Thermal/Acoustical Segment:                        
Metal parts   $ 142,646     $ 110,085     $ 76,263  
Fiber parts     78,722       48,329       30,472  
Tooling     15,406       20,637       21,058  
Thermal/Acoustical Segment net sales     236,774       179,051       127,793  
Other Products and Services:                        
Life Sciences Vital Fluids   $ 14,670     $ 15,562     $ 14,600  
Other Products and Services net sales     14,670       15,562       14,600  
Eliminations and Other     (1,915 )     (1,635 )     (676 )
Consolidated Net Sales   $ 383,588     $ 316,113     $ 239,732  

 

Operating income (loss) from continuing operations by segment and for OPS and Corporate Office Expenses for the years ended December 31, 2011, 2010, and 2009 were as follows:

 

Operating Income (Loss) from Continuing Operations   For the Years Ended December 31,  
In thousands   2011     2010     2009  
Performance Materials Segment   $ 18,194     $ 17,247     $ 7,593  
Thermal/Acoustical Segment     12,860       446       (10,337 )
Other Products and Services:                        
Life Sciences Vital Fluids     (1,040 )     (131 )     211  
Corporate Office Expenses     (13,826 )     (14,047 )     (12,754 )
Consolidated Operating Income (Loss) from Continuing Operations   $ 16,188     $ 3,515     $ (15,287 )

 

Operating results in 2011 and 2010 were impacted by a net gain on sale of a product line in the Performance Materials segment of $1.6 million and $2.5 million, respectively. Operating results in 2009 for the Thermal/Acoustical segment were impacted by restructuring related charges of $5.8 million.

 

Total assets by segment and for OPS and the Corporate Office were as follows at December 31, 2011, 2010 and 2009:

 

Total Assets   December 31,  
In thousands   2011     Revised
2010
    Revised
2009
 
Performance Materials Segment   $ 71,379     $ 74,895     $ 75,192  
Thermal/Acoustical Segment     122,765       122,572       113,733  
Other Products and Services     11,064       20,690       18,914  
Corporate Office     29,977       12,581       15,244  
Total Assets   $ 235,185     $ 230,738     $ 223,083  

 

Total capital expenditures and depreciation and amortization by segment and for OPS and the Corporate Office for the years ended December 31, 2011, 2010 and 2009 were as follows:

 

    Capital Expenditures     Depreciation and Amortization  
In thousands   2011     2010     2009     2011     2010     2009  
Performance Materials Segment   $ 3,801     $ 3,825     $ 2,542     $ 5,718     $ 5,340     $ 5,572  
Thermal/Acoustical Segment     3,561       6,988       1,430       7,746       7,708       8,487  
Other Products and Services     270       724       1,935       726       868       713  
Corporate Office     1,252       464       14       288       491       1,118  
Total   $ 8,884     $ 12,001     $ 5,921     $ 14,478     $ 14,407     $ 15,890  

 

Included in the above figures for OPS are immaterial capital expenditures relating to the Affinity business for 2011, 2010, and 2009 respectively. Depreciation and amortization expense of $0.1 million, $0.2 million and $0.3 million relating to the Affinity business are also included in the above figures for 2011, 2010 and 2009, respectively.

 

Net sales by geographic area for the years ended December 31, 2011, 2010 and 2009 and long-lived asset information by geographic area as of December 31, 2011, 2010 and 2009 were as follows:

 

    Net Sales     Long-Lived Assets  
In thousands   2011     2010     2009     2011     Revised
2010
    Revised
2009
 
United States   $ 239,101     $ 196,628     $ 144,924     $ 48,803     $ 54,945     $ 54,856  
France     58,974       51,079       37,779       17,621       18,757       22,780  
Germany     81,424       65,019       53,813       14,065       16,158       18,349  
Other     4,089       3,387       3,216       1,280       1,903       1,977  
Total   $ 383,588     $ 316,113     $ 239,732     $ 81,769     $ 91,763     $ 97,962  

 

Foreign sales are based on the country in which the sales originated (i.e., where the legal entity is domiciled).

 

Sales to Ford Motor Company in 2011, 2010 and 2009 were $62.2 million, $35.0 million and $24.1 million, respectively. These sales were reported in the Thermal/Acoustical segment. No other customers accounted for more than 10% of total net sales in 2011, 2010, or 2009.