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UNITED STATES SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549

 

Form 10-K

 

X   ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE SECURITIES EXCHANGE ACT OF 1934
FOR THE FISCAL YEAR ENDED DECEMBER 28, 2002

 

OR

 

TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE SECURITIES EXCHANGE ACT OF 1934

COMMISSION FILE NUMBER 0-19687

SYNALLOY CORPORATION
(Exact name of registrant as specified in its charter)

Delaware
(State or other jurisdiction of incorporation or organization)

 

57-0426694
I.R.S. Employer
Identification No.)

Croft Industrial Park, P.O. Box 5627, Spartanburg, South Carolina 29304
(Address of principal executive offices)               (Zip Code)

Registrant's telephone number, including area code: (864) 585-3605

Securities registered pursuant to Section 12(b) of the Act :                          Name of each exchange on which registered
                      
None                                                                  None
             Title of Class

Securities registered pursuant to Section 12(g) of the Act:

 

Common Stock, $1.00 Par Value
(Title of Class)

 

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 X             No ___

Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant's knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K. [X]

Indicate by check mark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Act).

Yes____              No X

Based on the closing price as of June 29, 2002, which was the last business day of the registrant's most recently completed second fiscal quarter, the aggregate market value of the common stock held by non-affiliates of the registrant was $18 million. Based on the closing price of February 25, 2003, the aggregate market value of common stock held by non-affiliates of the registrant was $24 million. The registrant did not have any non-voting common equity outstanding at either date.

The number of shares outstanding of the registrant's common stock as of February 25, 2003 was 5,964,304.

Documents Incorporated By Reference

Portions of the proxy statement for the annual shareholders' meeting are incorporated by reference into Part III.

PART I

Item 1 Business

Synalloy Corporation, a Delaware Corporation ("the Company"), was incorporated in 1958 as the successor to a chemical manufacturing business founded in 1945. Its charter is perpetual. The name was changed on July 31, 1967 from Blackman Uhler Industries, Inc. On June 3, 1988, the state of incorporation was changed from South Carolina to Delaware. The Company's executive offices are located at Croft Industrial Park, Spartanburg, South Carolina.

General

Metals Segment-- This segment is comprised of a wholly-owned subsidiary, Synalloy Metals, Inc. which owns 100 percent of Bristol Metals, L.P.,("Bristol") located in Bristol, Tennessee.

Bristol manufactures welded pipe, primarily from stainless steel, but also from other corrosion-resistant metals. Pipe is produced in sizes from one-half inch to 60 inches in diameter and wall thickness up to three-quarters inch. Sixteen-inch and smaller pipe is made on equipment that forms and welds the pipe in a continuous process. Pipe larger than sixteen inches is formed on presses or rolls and welded on batch welding equipment. Pipe is normally produced in standard 20-foot lengths. However, Bristol has unusual capabilities in the production of long length pipe without circumferential welds. This can reduce installation cost for the customer. Lengths up to 60 feet can be produced in sizes up to sixteen inches in diameter. In larger sizes Bristol has a unique ability among domestic producers to make 48-foot lengths in sizes up to 30 inches.

A significant amount of the pipe produced is further processed into piping systems that conform to engineered drawings furnished by the customers. This allows the customer to take advantage of the high quality and efficiency of Bristol's fabrication shop instead of performing all of the welding on the construction site. The pipe fabricating shop can make one and one-half diameter cold bends on one-half inch through eight-inch stainless pipe with thicknesses up through schedule 40. Most of the piping systems are produced from pipe manufactured by Bristol.

Bristol also has the capability of producing carbon and chrome piping systems from pipe purchased from outside suppliers since Bristol does not manufacture carbon or chrome pipe. Carbon and chrome pipe fabrication enhances the stainless fabrication business by allowing Bristol to quote inquiries utilizing any of these three material types. Bristol can also produce pressure vessels and reactors, tanks and other processing equipment.

In order to establish stronger business relationships, only a few raw material suppliers are used. Three suppliers furnish more than two-thirds of total dollar purchases of raw materials. However, raw materials are readily available from a number of different sources and the Company anticipates no difficulties in obtaining its requirements.

This segment's products are used principally by customers requiring materials that are corrosion-resistant or suitable for high-purity processes. The largest users are the chemical, petrochemical and pulp and paper industries with some other important industry users being mining, power generation, waste water treatment, brewery, food processing, petroleum and pharmaceutical.

Chemicals Group-- This group is comprised of two business segments: Colors Segment and Specialty Chemicals Segment. The Group includes three operating companies: Blackman Uhler Chemical Company (BU), a division of the Company, Manufacturers Soap and Chemical Company, which owns 100 percent of Manufacturers Chemicals, L.P. (MC), and Organic-Pigments Corporation (OP), all wholly-owned by the Company. BU has a plant in Spartanburg, South Carolina which is fully licensed for chemical manufacture and maintains a permitted waste treatment system. MC is located in Cleveland, Tennessee and Dalton, Georgia and is fully licensed for chemical manufacture. OP is located in Greensboro, North Carolina.

The Colors Segment's principal business is the manufacture and sale of dyes and pigments ("colors") to the textile, carpet, flexographic printing, graphic arts and coatings industries. BU produces dyes at the Spartanburg plant and pigments are produced at OP in Greensboro. Dyes are produced in both liquid and powder form, and pigments primarily as a specially formulated paste. Dyes fix themselves to textile fibers by a particular reaction or penetration into the yarn fiber, whereas pigments are normally applied as a surface coating during a printing operation. Dyeing of textile fabrics in solid colors is primarily accomplished by the use of dyes. Pigment colors are uniquely suitable for printing of multi-colored patterns. Raw materials used to manufacture colors consist chiefly of organic intermediates and inorganic chemicals which are purchased from manufacturers in the United States, Europe and Asia. Currently, raw materials are readily available and management does not anticipa te any difficulty in obtaining adequate supplies.

In the mid 1980s, management decided to better utilize its excellent reputation for sales and technical service by expanding its efforts to sell reactive dyes. These dyes are used for coloring cotton and rayon. The Company purchases finished and crude products that are either sold as is, or converted to liquid form for the convenience of customers. These dyes represented about 13 percent of the Colors Segment's sales in 2002. The Company has a distributorship agreement with a company that supplies about 90 percent of these products to the Company. The supplier has been the principal source of these products since 1985. Although the Company believes that this supplier will continue to be a source of these products in the future, there is no assurance of this. Loss of this supplier would have a materially adverse short-term effect on the Company's sales and net income. However, management believes that if the agreement with this supplier is not continued in the future, other supplier s could be found to replace most of the products.

In 1994, BU acquired a sulphur dye business and began the manufacture of sulphur dyes. These dyes are used to dye denim, fleece garments, knits, work clothes, men's casual wear, and a variety of cotton and cotton-polyester blends.

In 1998, the Company purchased OP which manufactures aqueous pigment dispersions sold to the textile industry and used in printing inks for use on paper and in paints for the industrial coatings industry. The combination of OP's and BU's pigment operations makes the Company one of the largest suppliers of pigments to the domestic textile market. The addition of OP also provides the ability to produce higher solid and finer particle size dispersions allowing the Colors Segment to diversify into non-textile applications.

In 1999, the Colors Segment began development of an additional product line for the dyeing of cotton - vat dyes. During 2000, the vat dyes were successfully introduced and the product line has been expanded. Vat dyes are used for industrial uniform fabrics (work wear) as well as other apparel fabrics and industrial fabrics that require excellent wash fastness. The addition of vat dyes gives BU product lines for the dyeing of cotton as broad as any other dyestuff supplier. BU now supplies azoic dyes (napthols, salts, bases, and rapidogen dyes for printing), reactive dyes, sulfur dyes and vat dyes for cotton and other cellulosic fibers.

The Specialty Chemicals Segment includes MC in Cleveland, Tennessee and Dalton, Georgia and specialty chemicals produced in the BU Spartanburg plant. The Segment is a producer of specialty chemicals for the textile, carpet, chemical, paper, metals, photographic, pharmaceutical, agricultural and fiber industries. The Company has been focusing on specialty chemicals as a primary growth area over the past several years. Facilities and equipment at the BU plant provide toll and custom manufacturing of organic chemicals using reactions that include nitrations, hydrogenation, distillation, diazotizations, methylation and custom drying. These chemicals are used in a wide array of products including sun screens, UV absorbers for plastics, Cetane improver for diesel fuel, absorbers for gaseous pollutants, herbicides, anti-wicking agents, fire retardants, processing aids for PVC and paper resins.

In1996, the Company purchased MC which produces defoamers, surfactants, dye assists, softening agents, polymers and specialty lubricants for the textile, paper, chemical and metals industries. MC also manufactures chelating agents and water treatment chemicals. Manufacturing capabilities include a wide range of chemical reactions and mixing and blending applications. MC's products are sold to direct users in a variety of manufacturing areas, directly to other chemical companies in the form of intermediates or as finished products for resale, and as contract manufacturing where the customer provides formula specifications and, in some cases, raw materials.

In June 2000, MC acquired the assets of a manufacturer of sulfated fats and oils. The manufacturing equipment for these products was moved to the Cleveland, Tennessee plant where both capacity and chilling capabilities were increased. These products are used as lubricants, wetting agents, detergents and emulsifiers in a variety of chemical formulations. The addition of these capabilities and processes broadens the range of sulfated products already manufactured at MC.

In July 2001, the Company completed an asset purchase of Global Chemical Resources (Dalton) located in Dalton, Georgia. Dalton manufactures and resells chemical specialties and heavy chemicals and blends and resells dyestuffs to the carpet and rug industries, selected textile mills and the wire drawing industry. The manufacture of liquid products was immediately transferred to the Cleveland plant, and the remaining warehousing and dye blending operation along with the shade matching lab and sales offices were moved to a leased facility in Dalton. In addition, Dalton markets the chemical specialties produced at other Specialty Chemicals Segment locations.

The Chemicals Group maintains eight laboratories for applied research and quality control which are staffed by 30 employees.

In 2000, management made the decision to close the Augusta, Georgia plant. In the fourth quarter of 2001, the Company completed the installation of hydrogenation and distillation equipment at its Spartanburg plant which completed the transfer of products produced in Augusta to Spartanburg.

Sales and Distribution

Metals Segment-- The Metals Segment utilizes separate sales organizations for its different product groups. Stainless steel pipe is sold nationwide under the Brismet trade name through authorized stocking distributors with over 200 warehouse locations throughout the country. In addition, large quantity orders are shipped directly from Bristol's plant to end-user customers. Producing sales and providing service to the distributors and end-user customers are the Vice President of Sales, two outside sales employees, four independent manufacturers' representatives and six inside sales employees.

Piping systems are sold nationwide under the Bristol Piping Systems trade name by two outside sales employees. They are under the direction of the Vice President in charge of piping systems who spends over half of his time in sales and service to customers. Piping systems are marketed to engineering firms and construction companies or directly to project owners. Orders are normally received as a result of competitive bids submitted in response to inquiries and bid proposals.

Colors Segment-- Five full-time outside sales employees and 14 manufacturers' representatives market colors to the textile industry nationwide. In 2002, OP added a market development manager who spends all of his time selling non-textile pigments. In addition, the President of OP and the market development manager of BU devote a substantial part of their time to sales.

Specialty Chemicals Segment-- Specialty chemicals are sold directly to various industries nationwide by ten full-time outside sales employees and four manufacturers' representatives. In addition, the President, market development manager and another employee of MC devote a substantial part of their time to sales.

Competition

Metals Segment-- Welded stainless steel pipe is the largest sales volume product of the Metals Segment. Although information is not publicly available regarding the sales of most other producers of this product, management believes that the Company is one of the largest domestic producers of such pipe. This commodity product is highly competitive with eight known domestic producers and imports from many different countries. The largest sales volume among the specialized products comes from fabricating light-wall stainless piping systems. Management believes the Company is one of the largest producers of such systems.

Colors Segment-- About six percent of the colors sales represent niche products for which the Company is the only producer. Another approximately 30 percent of these sales represent products of which the Company is an important producer with an estimated 20 to 30 percent market share. The Company has five percent or less of the market for the remainder of its dye products.

Specialty Chemicals Segment-- The Company is the sole producer of certain specialty chemicals manufactured for other companies under processing agreements. However, the Company's sales of specialty products are insignificant compared to the overall market for specialty chemicals. The market for most of the products is highly competitive and many competitors have substantially greater resources than does the Company.

Environmental Matters

Environmental expenditures that relate to an existing condition caused by past operations and that do not contribute to future revenue generation are expensed. Liabilities are recorded when environmental assessments and/or cleanups are probable and the costs of these assessments and/or cleanups can be reasonably estimated. See Note I to Consolidated Financial Statements for further discussion.

Research and Development Activities

The Company spent approximately $524,000 in 2002, $701,000 in 2001 and $840,000 in 2000 on research and development programs in its Chemicals Segment. Sixteen individuals, 11 of whom are graduate chemists, are engaged primarily in research and development of new products and processes, the improvement of existing products and processes, and the development of new applications for existing products.

Seasonal Nature of The Business

The annual requirements of certain specialty chemicals are produced over a period of a few months as requested by the customers. Accordingly, the sales of these products may vary significantly from one quarter to another.

Backlogs

The Colors and Specialty Chemicals Segments operate primarily on the basis of delivering products soon after orders are received. Accordingly, backlogs are not a factor in these businesses. The same applies to commodity pipe sales in the Metals Segment. However, backlogs are important in the piping systems products because they are produced only after orders are received, generally as the result of competitive bidding. Order backlogs for these products were $5,800,000, $3,700,000 and $9,200,000 at the 2002, 2001and 2000 respective year ends.

Employee Relations

As of December 28, 2002, the Company had 406 employees. The Company considers relations with employees to be satisfactory. The number of employees of the Company represented by unions at the Bristol, Tennessee facility is 163. They are represented by two locals affiliated with the AFL-CIO and one local affiliated with the Teamsters. Collective bargaining contracts will expire in February 2004, December 2004 and March 2005.

Item 2 Properties

The Company operates the major plants and facilities described herein, all of which are well maintained and in good condition. All facilities throughout the Company are adequately insured. The buildings are of various types of construction including brick, steel, concrete, concrete block and sheet metal. All have adequate transportation facilities for both raw materials and finished products. The Company owns all of these plants and facilities, except as noted.

(1) Leased facility.
(2) Plant closed in 2001.



Location



Principal Operations

Building Square Feet


Land  Acres

Spartanburg, SC

Corporate headquarters; Chemical
manufacturing and warehouse facilities

211,000

60.9

Cleveland, TN

Chemical manufacturing

90,000

8.6

Greensboro, NC

Chemical manufacturing

57,000

3.7

Bristol, TN

Manufacturing of stainless steel pipe and stainless steel and carbon piping systems


218,000


73.1

Dalton, GA

Dye blending and warehouse facilities (1)

32,000

2.0

Augusta, GA

Chemical manufacturing(2)

52,500

46.0

Item 3 Legal Proceedings

For a discussion of legal proceedings, see Note O to Consolidated Financial Statements.

Item 4 Submission of Matters to a Vote of Security Holders

No matters were submitted during the fourth quarter of the fiscal year covered by this report to a vote of security holders through the solicitation of proxies or otherwise.

PART II

Item 5 Market for the Registrant's Common Stock and Related Security Holder Matters

The Company had 1,082 common shareholders of record at December 28, 2002. The Company's common stock trades on the Nasdaq National Market System of The Nasdaq Stock Market under the symbol SYNC. On October 26, 2001, the Company's Board of Directors voted to suspend cash dividends. On July 26, 2002, the Company entered into a new credit agreement which prohibits the payment of dividends. The prices shown below are the last reported high and low sales prices for the common stock for each full quarterly period in the last two fiscal years as quoted on The Nasdaq National Market System.

 

2002

2001

Qtr

High

Low

Dividends Paid

High

Low

Dividends Paid

1

$5.05

$3.47

-

$6.25

$4.75

$.05

2

4.92

2.93

-

7.65

4.75

.05

3

4.10

1.69

-

7.15

4.50

.05

4

4.85

2.03

-

5.08

2.95

-

Item 6 Selected Financial Data

 

(Dollars in thousands except for
per share data)

2002

2001

2000

1999

1998

Operations

Net sales

$ 85,461

$ 91,104

$ 113,952

$ 116,884

$ 107,257

 

Gross profit

5,641

10,584

12,404

16,574

12,203

 

Selling, general and administrative expense


10,176


10,572


11,182


11,335


10,135

 

Long-lived asset impairment and
environmental remediation costs (1)


2,365

-


1,765


- -


1,439

 

Operating (loss) income

(6,900)

12

(543)

5,239

629

 

Net (loss) income

(4,843)

(318)

(1,083)

2,947

63

Financial Position

Total assets

59,966

69,846

73,344

78,053

71,374

 

Working capital

20,060

21,141

25,483

28,001

28,946

 

Long-term debt, less current portion

10,000

10,000

10,000

10,000

10,000

 

Shareholders' equity

33,874

38,949

40,173

44,660

45,848

Financial Ratios

Current ratio

2.5

2.2

2.4

2.5

3.7

 

Gross profit to net sales

7%

12%

11%

14%

11%

 

Long-term debt to capital

23%

20%

20%

18%

18%

 

Return on average assets

-

-

4%

4%

1%

 

Return on average equity

-

-

6%

7%

2%

Per Share Data

Net (loss) income - diluted

$ (.81)

$ (.05)

$ (.18)

$ .45

$ .01

 

Dividends declared and paid

-

.15

.20

.20

.40

 

Book value

5.68

6.53

6.74

7.10

6.82

Other Data

Depreciation and amortization

3,380

3,378

4,069

3,732

3,513

 

Capital expenditures

2,152

6,437

3,383

4,214

3,686

 

Employees at year end

406

472

510

622

564

 

Shareholders of record at year end

1,082

1,120

1,154

1,226

1,431

 

Average shares outstanding - diluted

5,964

5,965

6,166

6,559

6,794

Stock Price

Price range of Common Stock
High
Low
Close


$5.05
1.69
4.13


$7.65
2.95
3.60


$9.13
4.50
4.75


$10.75
6.25
7.50


$16.50
6.00
8.75

Special and Environmental Charges 

 

 

 

 

 

 

Environmental remediation costs (1)

97

-

1,765

-

1,439

 

Special charges (1)

4,738

-

4,064

-

-

(1) See Notes B and C to Consolidated Financial Statements

Item 7 Management's Discussion and Analysis of Financial Condition and Results of Operations

Critical Accounting Policies and Estimates

Management's Discussion and Analysis of Financial Condition and Results of Operations discusses the Company's consolidated financial statements, which have been prepared in accordance with generally accepted accounting principles in the United States. The preparation of these financial statements requires management to make estimates and assumptions that affect the reported amounts of assets and liabilities and the disclosure of contingent assets and liabilities at the date of the financial statements and the reported amounts of revenues and expenses during the reporting period. On an on-going basis, management evaluates its estimates and judgments based on historical experience and on various other factors that are believed to be reasonable under the circumstances, the results of which form the basis for making judgments about the carrying value of assets and liabilities that are not readily apparent from other sources. Actual results may differ from these estimates under differ ent assumptions or conditions. Management believes the following critical accounting policies, among others, affect its more significant judgments and estimates used in the preparation of the Company's consolidated financial statements.

The Company maintains allowances for doubtful accounts for estimated losses resulting from the inability of its customers to make required payments. A significant portion of the Company's accounts receivable in the Colors Segment are from domestic customers in the textile industry, which has been in a steady decline over the last several years. If the financial condition of these or any other customers of the Company were to deteriorate, resulting in an impairment of their ability to make payments, additional allowances may be required.

The Company writes down its inventory for estimated obsolescence or unmarketable inventory in an amount equal to the difference between the cost of inventory and the estimated market value based upon assumptions about future demand and current market conditions. If actual market conditions are less favorable than those projected by management, additional inventory write-downs may be required.

As with the accounts receivable, a significant portion of the Company's inventories in the Colors Segment are used by domestic customers in the textile industry. In addition, most of the key raw materials are imported from Asian countries causing the Company to maintain significant amounts of inventory for certain products in order to adequately service the Colors Segment's customers. If the financial condition of these customers were to deteriorate, resulting in the elimination or reduction of their demand for our products, additional inventory write-downs may be required.

As noted in Note I to Consolidated Financial Statements, the Company has accrued $1,584,000 in environmental remediation costs which, in management's best estimate, will satisfy anticipated costs of known remediation requirements as outlined in Note I. As a result of the evolving nature of the environmental regulations, the difficulty in estimating the extent and remedy of environmental contamination, and the availability and application of technology, the estimated costs for future environmental compliance and remediation are subject to uncertainties and it is not possible to predict the amount or timing of future costs of environmental matters which may subsequently be determined. Subject to the difficulty in estimating future environmental costs, the Company believes that the likelihood of material losses in excess of the amounts recorded is remote. However, any changes, including regulatory changes, may require the Company to record additional remediation reserves.

Liquidity and Capital Resources

The current ratio at 2002 year end was 2.5:1 which is up from the previous year end ratios of 2.2:1 in 2001 and 2.4:1 in 2000. Working capital decreased $1,081,000 to $20,060,000. Cash flows from operations, totaling $3,273,000, were derived primarily from declines in inventories of $3,115,000 and $1,209,000 in tax refunds received in 2002 related to 2001, offset by the net loss incurred totaling $1,463,000, before depreciation and amortization expense of $3,380,000, and $1,201,000 of environmental remediation costs paid in 2002. The decline in inventories came primarily from planned reductions in the Metals and Colors Segments. The Company also generated $1,881,000 of cash from the sale of non-operating investments and under utilized property, plant and equipment. Cash flows were used to reduce debt by $3,323,000 and make capital expenditures of $2,152,000. The Company expects that cash flows from 2003 operations and available borrowings will be sufficient to make debt payments and fund estimated capital expenditures of $4,200,000 and normal operating requirements. On July 26, 2002, the Company entered into a new Credit Agreement with a new bank to provide a $19,000,000 line of credit expiring on July 25, 2004, and refinanced the Company's notes payable and long term debt replacing the existing bank indebtedness. Although the line of credit does not expire until 2004, the Company anticipates reducing the amount owed under the line of credit to approximately $10,000,000 over the next twelve months and has therefore classified $3,863,000 as a current liability. Borrowings under the Agreement are limited to a borrowing base calculation including eligible accounts receivable, inventories, and cash surrender value of the Company's life insurance as defined in the Agreement. As of December 28, 2002, the amount available for borrowing was $17,138,000 of which $13,863,000 was borrowed leaving $3,276,000 of availability. Covenants include, among others, restrictions on the payment of divide nds.

Results of Operations

Consolidated sales were down for 2002, decreasing six percent from the same period one year ago, as the Company incurred a loss for 2002 of $.81 per share. This compares to a loss of $.05 per share in the prior year. For the fourth quarter of 2002, the Company had a profit of $17,000 on a 6 percent increase in sales to $21,675,000. This compares to a loss of $457,000 in the last quarter of 2001.

Consolidated operating results for 2002 were significantly impacted by several transactions that were recorded during the year. In the second quarter of 2002, the Company recorded charges discussed in the Segment comparisons below totaling $3,368,000, net of tax, or $.56 per share. The Company sold certain non-operating assets during 2002, including its investments in equity securities, for an after-tax gain of $392,000, or $.07 per share, of which $349,000, or $.06 per share, was recorded in the fourth quarter of 2002.

Consolidated selling, general and administrative expense for 2002 declined $396,000 to $10,176,000 compared to 2001, and was 12 percent of sales for both 2002 and 2001. Beginning in September 2002, cost reductions, including reductions of personnel and non-critical operating expenses, were implemented, many of which impacted selling, general and administrative expense.

Metals Segment-- The following table summarizes operating results and backlogs for the three years indicated. Reference should be made to Note R to the Consolidated Financial Statements.

 

2002

2001

2000

(Dollar amounts in thousands)

Amount

%

Amount

%

Amount

%

Net sales
Cost of goods sold

$ 43,364
41,411

100.0%
95.5%

 

$ 47,343
41,116

100.0%
86.8%

 

$ 66,771
53,810

100.0%
80.6%

 

------------

------------

 

------------

------------

 

------------

------------

Gross profit

1,953

4.5%

 

6,227

13.2%

 

12,961

19.4%

Selling and administrative expense

3,605

8.3%

3,783

8.0%

4,541

6.8%

 

------------

------------

 

------------

------------

 

------------

------------

Operating (loss) income

$ (1,652)

(3.8%)

$ 2,444

5.2%

$  8,420

12.6%

 

========

=======

 

========

=======

 

========

=======

Special charges described below
Write-down of inventories
Plant closure costs
Environmental remediation costs


$      671
- -
- -

 

 


$            -
- -
- -

 

 


$          -
295
57

 

 

========

=======

 

========

=======

 

========

=======

Year-end backlog - Piping systems

$ 5,800

 

 

$    3,700

 

 

$  9,200

 

========

 

 

========

 

 

========

 

 

Comparison of 2002 to 2001 - Metals Segment

Dollar sales for the year were down eight percent as the result of an 18 percent average decline in sales prices offset by a twelve percent increase in unit volumes. Extremely competitive market conditions, together with a change in product mix, with a lower percentage of sales coming from higher-priced fabricated piping systems, led to the fall in average selling prices. The increase in volume came primarily from the increase in sales of lower-margin smaller diameter commodity pipe. The market conditions, together with the change in product mix had a significant effect on profits as the Segment incurred an operating loss of $981,000 for 2002 compared to operating income of $2,444,000 in 2001. Also contributing to the loss was the recording of a $671,000 charge in the second quarter of 2002 to write down inventory. The Company has historically sold off excess inventory slowly to avoid distressed pricing that would be required to dispose of the excess inventory more quickly. With the price erosion that occurred over the first six months of the year and weak business conditions that existed, excess inventories were not reduced as much as planned. Most of the inventory write-down was the result of excess inventories of fittings, flanges and special alloy pipe related to the piping systems business. The unexpectedly low level of new orders impacted piping systems' products to the extent that use of some of this inventory became uncertain. Therefore, excess inventories were written down to reflect management's estimate of the values that could be realized under a plan to scrap, sell or return the excess inventory as quickly as feasible.

Although fabricated piping systems' volume was down for the year, it improved slightly in the fourth quarter compared to the first three quarters of this year. Management achieved modest success in obtaining non-stainless projects for fabricated piping systems during 2002 with most of the fourth quarter's sales coming from non-stainless projects. However, projects requiring stainless steel pipe, which is provided by the Segment's pipe manufacturing plant, were significantly below prior years' levels. This reduction in volume through the pipe manufacturing plant impacted the absorption of operating costs which also contributed to the lack of profitability by the Segment for the year.

Selling and administrative expense decreased $178,000, or five percent. However, it increased slightly as a percent of sales compared to last year as a result of the decline in sales in 2002 compared to 2001. Beginning in September, cost reductions, including reductions of personnel and non-critical operating expense items, were implemented many of which impacted selling and administrative expense. As a result, selling and administrative expense for the fourth quarter of 2002 declined to $717,000 or six percent of sales as compared to $933,000 or nine percent of sales for the same period last year.

Comparison of 2001 to 2000 - Metals Segment

Dollar sales for 2001 were down 29 percent from 2000 as the result of 18 percent lower unit volumes coupled with a 13 percent average decline in sales prices. A change in product mix, with a lower percentage of sales coming from higher-priced fabricated piping systems, led to about half of the fall in average selling prices. The other half of the reduction in sales resulted from lower prices for raw materials and the generally competitive market conditions. The unit volume decline was more than accounted for during the first half of the year when 2001 was characterized by weak markets and some inventory liquidation while the first six months of 2000 set record highs in unit volumes as the result of significant inventory building by our customers ahead of price increases. Operating income for 2001 was down 71 percent from the prior year level. During most of 2000, our selling prices were in an uptrend and end use demand was enhanced by inventory building during the first half of t he year. These generally favorable conditions, together with substantial gross profit increases from the rising prices, produced good profit margins. Unfortunately, 2001 was the mirror image of 2000. Our selling prices trended downward during all of 2001, leading to substantial gross profit declines. We estimate that raw material costs charged to cost of goods sold were approximately $2,500,000 more than our replacement costs during the year. In addition, reduced demand led to more intense competition, which put further pressure on profit margins.

Selling and administrative expense decreased $701,000, or 16 percent in 2001. However, it increased as a percent of sales to eight percent from seven percent compared to the prior year. The significant decline in sales in 2001 compared to 2000 was greater than the corresponding decline in sales commissions and other selling and administrative costs over the same periods.

For information related to environmental matters, see Note I to Consolidated Financial Statements.

Chemicals Group-- The following tables summarize operating results for the three years indicated. Reference should be made to Note R to Consolidated Financial Statements.

Colors Segment

 

2002

2001

2000

(Dollar amounts in thousands)

Amount

%

Amount

%

Amount

%

Net sales
Cost of goods sold

$ 19,182
18,983

100.0%
99.0%

 

$ 23,135
20,608

100.0%
89.1%

 

$ 25,960
24,013

100.0%
92.5%

 

------------

------------

 

------------

-----------

 

------------

------------

Gross profit

199

1.0%

 

2,527

10.9%

 

1,947

7.5%

Selling and administrative expense

3,003

15.7%

 

3,339

14.4%

 

3,297

12.7%

Long-lived asset impairment cost

1,786

9.3%

 

-

 

 

-

 

Environmental remediation costs

97

.5%

 

-

 

1,708

6.6%

 

------------

------------

 

------------

-----------

 

------------

------------

Operating loss

$ (4,687)

(24.5%)

 

$   (812 )

(3.5%)

 

$ (3,058)

(11.8%)

 

========

=======

 

=======

======

 

=======

=======

Special charges described below
Write-down of inventories
Write-down of plant and equipment
Environmental remediation costs


$   1,800
1,786
97

 

 


$           -
- -
- -

 

 


$       555
- -
1,708

 

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=======

 

=======

======

 

=======

=======

Specialty Chemicals Segment

 

2002

2001

2000

(Dollar amounts in thousands)

Amount

%

Amount

%

Amount

%

Net sales
Cost of goods sold

$ 22,915
19,426

100.0%
84.8%

 

$ 20,626
18,796

100.0%
91.1%

 

$ 21,221
23,725

100.0%
111.8%

 

------------

------------

 

------------

-----------

 

------------

------------

Gross profit

3,489

15.2%

 

1,830

8.9%

 

(2,504 )

(11.8%)

Selling and administrative expense

2,786

12.2%

2,573

12.5%

 

2,241

10.6%

Long-lived asset impairment cost

481

2.1%

 

-

 

-

 

 

------------

------------

 

------------

-----------

 

------------

------------

Operating income (loss)

$ 222

.9%

 

$ (743 )

(3.6%)

 

$ (4,745 )

(22.4%)

 

========

=======

 

=======

======

 

=======

=======

Special charges described below
Write-down of plant and equipment
Augusta operating and closure costs


$ 481
- -

 

 


$          -
- -

 

 


$ 2,324
2,780

 

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=======

 

=======

======

 

=======

=======

 Chemicals Group

 

2002

2001

2000

(Dollar amounts in thousands)

Amount

%

Amount

%

Amount

%

Net sales
Cost of goods sold

$ 42,097
38,409

100.0%
91.2%

 

$ 43,761
39,404

100.0%
90.0%

 

$ 47,181
47,738

100.0%
101.2%

 

------------

------------

 

------------

-----------

 

------------

------------

Gross profit

3,688

8.8%

 

4,357

10.0%

 

(557 )

(1.2% )

Selling and administrative expense

5,789

13.8%

 

5,912

13.5%

 

5,538

11.7%

Long-lived asset impairment and environmental
  remediation costs


2,364


5.6%

 

-

 


1,708


3.6%

 

------------

------------

 

------------

-----------

 

------------

------------

Operating loss

$ (4,465 )

(10.6%)

 

$ (1,555 )

(3.5%)

 

$ (7,803 )

(16.5%)

========

=======

 

=======

======

 

=======

=======

Comparison of 2002 to 2001 - Colors Segment

Sales declined 17 percent for the year from the same period last year reflecting the continuing contraction of the textile industry. The operating loss for 2002 occurred primarily from the recording of an impairment charge of $1,786,000, described below, an inventory charge of $1,800,000 and an environmental charge of $97,000, all recorded in the second quarter of 2002. The poor sales performance also contributed to the loss, as market conditions continued to be extremely competitive impacting margins and creating unabsorbed operating costs. The Segment implemented an aggressive inventory reduction program in the first two quarters of 2002 which also impacted profitability. As previously stated, the Company has historically sold off excess inventory slowly to avoid distressed pricing that would be required to dispose of the excess inventory more quickly. With the price erosion that occurred over the first six months of the year and weak business conditions that existed, excess in ventories were not reduced as much as planned and the inventory charge was recorded.

Sales demand had shown limited improvement in the third quarter and first half of the fourth quarter of 2002. In addition, cost reductions implemented at the beginning of September, including reductions of personnel and non-critical operating expense items had a positive impact on the last half of the year. However, the improved sales activity diminished over the last half of the fourth quarter. The reduced sales volume caused the Segment to incur an operating loss for the fourth quarter. The loss was disappointing since the Segment had $77,000 of operating profit for the third quarter of 2002 after four consecutive quarters of operating losses. The Segment was able to generate $1,644,000 of cash flow for 2002, resulting primarily from the inventory reduction program.

Selling and administrative expense for 2002 totaled $3,003,000 which is $336,000 below the prior year's amount primarily as a result of the cost reductions discussed previously. However, selling and administrative expense as a percent of sales was 16 percent which was one percent above the prior year's percentage due to the significant decline in sales.

The Spartanburg plant, which includes the Colors Segment dye business and part of the Specialty Chemicals Segment's operations, was substantially under utilized and generating operating losses, primarily because of deteriorating market conditions. The Segments were able to minimize the operating losses for these operations through the first quarter of 2002 and 2002 business plans for this facility showed positive cash flows for these operations going forward. Although the Colors Segment experienced a significant decline of textile dye sales in the first quarter of 2002, management believed that this situation was temporary and seasonal and would not continue. Indications existed that conditions should improve in the near term, such as increases in month-to-month sales and sales order activity, supporting the evaluation. Based on historical results and management's projections, the operations were expected to generate positive cash flows and did not support a write down at the end of the first quarter. Although conditions improved slightly during the second quarter, there were sufficient new indications, including the unexpected loss of expected dye business, increases in pricing pressure from competitors, and reductions in expected revenues in the Specialty Chemicals Segment's tolling business, to require management to revise its projections to better reflect what management believed were current market conditions. After completing an analysis of the businesses, evaluations of the plant and equipment values at the site, completing projected cash flow calculations, and exploring other options that were available, it became apparent that the facility could not adequately recover costs related to the facility under current business conditions. Accordingly, an impairment charge of $2,267,000, $1,786,000 related to the Colors Segment and $481,000 to the Specialty Chemicals Segment was recorded in the second quarter of 2002 to write down the plant and equipment reflecting the undiscounted cash flow assessments.

For information related to environmental matters, see Note I to Consolidated Financial Statements.

Comparison of 2001 to 2000 - Colors Segment

The eleven percent decline in Colors Segment sales in 2001 resulted from the relentless and well-chronicled downsizing of the domestic textile industry that has been evident since 1995. Cost cutting efforts moderated the operating loss so that it was only two percent worse than a year earlier before the special charges in 2000 outlined in the table above. The textile industry downsizing has been faster and of greater magnitude than almost anyone forecast. This made it impossible for us to cut costs and downsize our own Colors Segment operations fast enough to maintain profitability. The majority of the decline in sales and operating loss came in the fourth quarter, as sales for the fourth quarter of 2001 declined $937,000 from the fourth quarter of 2000. Of the $812,000 loss experienced for 2001, $695,000 occurred in the fourth quarter.

Selling and administrative expense for 2001 increased $42,000, or one percent from the prior year, and increased as a percent of sales primarily from an increase in salary expense.

Comparison of 2002 to 2001 - Specialty Chemicals Segment

Sales were up 11 percent for the year from the same period last year and the Segment had operating profits for 2002 of $222,000, including a $481,000 impairment charge as discussed above, compared to an operating loss of $743,000 for 2001. The improved performance was experienced at both of the Segment's locations as both operations ended the year profitable. Several factors, including improved business conditions, increases in toll and other contract business compared to last year, and cost reductions implemented in the third quarter, including reductions of personnel and non-critical operating expense items, led to the increase in sales and profits. These factors were most prevalent in the last six months of 2002 as the Segment had $594,000 of operating income compared to an operating loss of $372,000 for the first six months of 2002.

Selling and administrative expense for 2002 totaled $2,786,000 which is $213,000 above last year's amount primarily as a result of increased selling expenses from the acquisition of the Dalton, Georgia business in the third quarter of 2001, offset by the cost reductions described above. Selling and administrative expenses as a percent of sales remained consistent at twelve percent for 2002 and 2001.

Comparison of 2001 to 2000 - Specialty Chemicals Segment

Sales in the Specialty Chemicals Segment were down three percent because of generally weak economic conditions and some business lost because of the closure of the Augusta, Georgia plant. On the other hand, sales from the acquisition of Global Chemical Resources in July of 2001 helped minimize the decline. The operating loss for 2001 was an improvement of 57 percent from the prior year loss before special charges outlined in the table above. The reduced loss resulted from closing the Augusta plant. The weak economy, which appeared to decline steadily over the last half of 2001, caused sales to reduce to levels causing the Segment to incur significant negative manufacturing variances at both of its plants. This was offset somewhat at the MC Cleveland plant in the second half of 2001, when the manufacture of liquid products by the Dalton plant was transferred to Cleveland in July providing more through-put and improving efficiency. Most of the loss, $553,000 of the $743,000 loss fo r 2001, occurred in the fourth quarter. The MC Cleveland plant experienced weaker sales in November and December of 2001 coupled with increased operating costs. Due to the timing of certain toll contracts, the mix of products produced at the BU Spartanburg plant in the fourth quarter generated lower revenues and profit margins. The combination of both of these factors caused the decline in profitability.

Selling and administrative expense for 2001 increased $332,000, or 15 percent from the prior year, and increased as a percent of sales as a result of increased selling expenses from the acquisition of the Dalton, Georgia business in the third quarter of 2001.

For information related to environmental matters, see Note I to Consolidated Financial Statements.

Unallocated Income and Expense

Reference should be made to Note R to Consolidated Financial Statements for the schedule of these items.

Comparison of 2002 to 2001 - Corporate

Corporate expense declined $94,000, or 11 percent to $783,000 for 2002 compared to 2001. The decline resulted primarily from cost reductions implemented at the beginning of September, including reductions of personnel and non-critical operating expense items. Other expense, net in 2002 declined $291,000 from last year's total. The Company sold certain non-operating assets during 2002, including its investment in a foreign corporation, for pre-tax gains of $605,000. In 2001 the company recognized gains from the sale of its Whiting plant in Camden, South Carolina of $143,000 and $68,000 from the partial sale of one of its investments. Interest expense in 2002 decreased $72,000 compared to last year from decreases in borrowings under the lines of credit with a bank. Interest income decreased $183,000 primarily from interest received in 2001 under a Metals Segment's contract with a customer.

Comparison of 2001 to 2000 - Corporate

Corporate expense for 2001 declined $283,000, or 24 percent to $877,000 from 2000. The decline resulted primarily from two factors. Included in the special adjustments for 2000 is an unexpected $158,000 payment made under a contract related to a pre 1973 employment matter recorded in the first quarter of 2000. In addition, $103,000 in outside consulting costs was expensed during 2000 related to the installation of a new data processing system. Other expense, net declined $625,000 as interest expense decreased $266,000 from decreases in borrowings and interest rates under the lines of credit with a bank. The Company also recognized gains from the sale of its Whiting plant in Camden, South Carolina of $143,000, and $68,000 from the partial sale of one of its investments. Interest income increased $143,000 primarily from interest received under a Metals Segment's contract with a customer.

Current Conditions and Outlook

Metals Segment's dollar sales for the fourth quarter of 2002 were up six percent as unit volumes increased four percent and sales prices improved two percent compared to the same period last year. Almost all of the volume increase came from lower-margin smaller diameter commodity pipe which resulted in the $127,000 operating loss experienced for the quarter compared to operating income of $471,000 for the same period last year. The Segment achieved modest success in obtaining non-stainless projects for fabricated piping systems during 2002 with most of the fourth quarter's sales coming from non-stainless projects. However, projects requiring stainless steel pipe, which is provided by the Segment's pipe manufacturing plant, were significantly below prior years' fourth quarter levels. This reduction in volume through the pipe manufacturing plant impacted the absorption of operating costs which also contributed to the lack of profitability by the Segment for the fourth quarter. The loss incurred in the quarter was offset somewhat by cost reductions, implemented in September of 2002. The poor economy that currently exists has had a significant impact on domestic capital spending and, coupled with the competitive environment that exists in this Segment's industry, has made it very difficult to maintain profitability. Sales in December 2002 and the first few weeks of 2003 have been very weak. However, order activity appears to be increasing and a price increase, instituted in December, appears to be holding. In addition, fabricated piping systems' backlog has increased 56 percent to $5,800,000 from 2001, much of which requires stainless steel pipe. Although the piping systems' backlog increased significantly, the timing of the projects is spread throughout the year and management does not expect to increase piping systems production significantly in the first quarter.

Colors Segment's sales for the fourth quarter of 2002 were 15 percent below the same quarter last year. Even though sales were down, the operating loss experienced in the fourth quarter declined by more than 50 percent from the loss incurred in the same quarter last year. The improvement in results reflects the cost reductions implemented at the beginning of September 2002. Although the Segment experienced improved sales activity over the last half of 2002, this diminished over the last half of the fourth quarter. The reduced sales volume caused the Segment to incur an operating loss for the fourth quarter. Although the poor sales activity has continued into the first few weeks of 2003, management believes this reflects a seasonal trend and duplicates sales activity that occurred over similar periods last year. Management believes that sales will return to a more normal level before the end of the first quarter and is hopeful that this will provide the opportunity for the Segment to improve operating results, although there is no assurance that this will occur.

Specialty Chemicals Segment sales increased 15 percent for the fourth quarter of 2002 compared to the same period of the prior year. Several factors, including improved business conditions, increases in toll and other contract business compared to last year, and cost reductions implemented in the third quarter led to the increase in sales and a $236,000 operating profit realized in the quarter compared to the $553,000 operating loss incurred for the same period last year. Management believes that the existing favorable conditions described above should continue into 2003. However, first quarter revenues and profitability have historically been poor for this Segment due primarily to the timing of toll and contract work. The poor economic conditions that currently exist along with the timing of the Segment's toll and contract business can have a negative impact on sales and profitability. Management believes the Segment is better positioned to minimize this impact, although there i s no assurance that this will occur.

Forward-Looking Statements

This Annual Report on Form 10-K includes and incorporates by reference "forward-looking statements" within the meaning of the securities laws. All statements that are not historical facts are "forward looking statements." The words "estimate," "project," "intend," "expect," "believe," "anticipate," "plan" and similar expressions identify forward-looking statements. The forward-looking statements are subject to certain risks and uncertainties, including without limitation those identified below, which could cause actual results to differ materially from historical results or those anticipated. Readers are cautioned not to place undue reliance on these forward looking statements. The following factors could cause actual results to differ materially from historical results or those anticipated: adverse economic conditions, the impact of competitive products and pricing, product demand and acceptance risks, raw material and other increased costs, customer delays or difficulties in the production of products, unavailability of debt financing on acceptable terms and exposure to increased market interest rate risk, inability to comply with covenants and ratios required by our debt financing arrangements and other risks detailed from time to time in Synalloy's Securities and Exchange Commission filings. Synalloy Corporation assumes no obligation to update the information included in this Annual Report on Form 10-K.

Item 7a Quantitative and Qualitative Disclosures About Market Risks

The Company is exposed to market risks from adverse changes in interest rates. In this regard, changes in U. S. interest rates affect the interest earned on the Company's cash and cash equivalents as well as interest paid on its indebtedness. As a policy, the Company does not engage in speculative or leveraged transactions, nor does it hold or issue financial instruments for trading purposes. The Company is exposed to changes in interest rates primarily as a result of its borrowing activiti