10-K 1 gti_10k-2005.htm GTI FORM 10-K FYE 12/31/2005

__________________________________________________________________________________________________

UNITED STATES

SECURITIES AND EXCHANGE COMMISSION

Washington, D.C. 20549

______________________

 

FORM 10-K

______________________

(Mark One)

ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934
for the fiscal year ended December 31, 2005

OR

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: 1-13888

______________________

 


GRAFTECH INTERNATIONAL LTD.

(Exact name of registrant as specified in its charter)

Delaware

 

06-1385548

(State or other jurisdiction of

 

(I.R.S. Employer

incorporation or organization)

 

Identification Number)

______________________

12900 Snow Road

 

 

Parma, Ohio

 

44130

(Address of principal executive offices)

 

(Zip Code)

Registrant’s telephone number, including area code: (216) 676-2000

______________________

 

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

Title of each class

Name of each exchange on which registered

Common stock, par value $.01 per share

Preferred Share Purchase Rights

New York Stock Exchange

New York Stock Exchange

______________________

 

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

None

 

Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act. Yes No

Indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or Section 15(d) of the Act. Yes No

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 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. Yes No

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

 

Large Accelerated Filer

Accelerated Filer

Non-Accelerated Filer

 

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

The aggregate market value of our outstanding common stock held by non-affiliates, computed by reference to the closing price of our common stock on June 30, 2005, was approximately $361 million. On January 31, 2006, 97,879,203 shares of our common stock were outstanding.

______________________

DOCUMENTS INCORPORATED BY REFERENCE

The information required under Part III is incorporated by reference from the GrafTech International Ltd. Proxy Statement for the Annual Meeting of Stockholders to be held on May 24, 2006, which will be filed on or about April 11, 2006.

_________________________________________________________________________________________________

 

 

 

Table of Contents

 
PART  I 4
           Preliminary Notes 4
           Item 1.  Business 8
                         Introduction 8
                         Our Segments 10
                         Synthetic Graphite Segment 10
                         Other Segment 14
                         Business Strategies 18
                         Production Planning 21
                         Manufacturing 22
                         Distribution 25
                         Sales and Customer Service 25
                         Technology 27
                         Competition 29
                         Environmental Matters 31
                         Insurance 33
                         Employees 33
           Item  1A.  Risk Factors 33
                         Risks Relating to Us 34
                         Risks Relating to Our Securities and Pledges of Our Assets 43
                         Forward Looking Statements 53
           Item  1B.  Unresolved Staff Comments 55
           Item  2.  Properties 56
           Item  3.  Legal Proceedings 57
           Item  4.  Submission of Matters to a Vote of Security Holders 57
PART  II 58
           Item  5.  Market for Registrant's Common Equity and Related Stockholder Matters 58
                          Market Information 58
                          Dividend Policies and Restrictions 58
                          Fourth Quarter Unregistered Stock Issuance 59
 

           Item  6.  Selected Financial Data 60
           Item  7.  Management's Discussion and Analysis of Financial Condition and
                          Results of Operations
64
                           General 64
                           Global Economic Conditions and Outlook 64
                           Financing Transactions 67
                           Antitrust Litigation Against Us 67
                           Other Proceedings Against Us 68
                           Product Warranties 68
                           Realizability of Net Deferred Tax Assets and Valuation Allowances 68
                           Customer Base 69
                           Results of Operations 69
                           Effects of Inflation 80
                           Currency Translation and Transactions 81
                           Effects of Changes in Currency Exchange Rates 81
                           Liquidity and Capital Resources 83
                           Costs Relating to Protection of the Environment 90
                           Critical Accounting Policies 90
                           Recent Accounting Pronouncements 92
                           Description of Our Financing Structure 93
           Item   7A.  Quantitative and Qualitative Disclosures About Market Risk 93
           Item   8.  Financial Statements and Supplementary Data 97
                           Management’s Report on Internal Control Over Financial Reporting 98
                           Report of Independent Registered Public Accounting Firm 99
                          CONSOLIDATED BALANCE SHEETS 102
                          CONSOLIDATED STATEMENTS OF OPERATIONS 103
                          CONSOLIDATED STATEMENTS OF CASH FLOWS 104
                          CONSOLIDATED STATEMENTS OF CASH FLOWS (Continued) 105
                          CONSOLIDATED STATEMENT OF STOCKHOLDERS' DEFICIT 106
                          NOTES TO CONSOLIDATED FINANCIAL STATEMENTS 107
                          (1)  Discussion of Business and Structure 107
                         (2)  Summary of Significant Accounting Policies 107
                         (3)  New Accounting Standards 115

2

 

                         (4)  Segment Reporting 118
                         (5)  Long-Term Debt and Liquidity 120
                         (6)  Financial Instruments 125
                         (7)  Interest Expense 128
                         (8)  Other (Income) Expense, Net 129
                         (9)  Supplementary Balance Sheet Detail 130
                         (10)  Leases and Other Long Term Obligations 131
                         (11)  Benefit Plans 132
                         (12)  Restructuring and Impairment Charges 139
                         (13)  Management Compensation and Incentive Plans 142
                         (14)  Contingencies 145
                         (15)  Income Taxes 146
                         (16)  Earnings Per Share 150
                         (17)  Stockholder Rights Plan 150
                          (18)  Financial Information About the Issuer, the Guarantors and the
                                   Subsidiaries Whose Securities Secure the Senior Notes, the
                                   Debentures and Related Guarantees
151
                          (19)  Discontinued Operations 161
                          (20)  Subsequent Events 162
           Item  9.  Changes in and Disagreements with Accountants on Accounting
                         and Financial Disclosure
163
           Item  9A.  Controls and Procedures 163
           Item  9B.  Other Information 164
PART  III 165
           Items 10 to 14 (inclusive)   165
                          Executive Officers and Directors 165
                          Executive Officers 165
                          Directors 166
                          NYSE Certification 168
PART  IV 168
           Item 15.  Exhibits and Financial Statement Schedules 168
EXHIBIT INDEX 177

3

PART I

Preliminary Notes

Important Terms. We use the following terms to identify various matters. These terms help to simplify the presentation of information in this Report.

“AET” refers to Advanced Energy Technology Inc. only. AET is our 97.5% owned subsidiary engaged in the development, manufacture and sale of natural graphite products. Prior to January 1, 2003, AET was named Graftech Inc.

“Carbone Savoie” refers to Carbone Savoie S.A.S. and its subsidiaries. Carbone Savoie is our 70% owned subsidiary engaged in the development, manufacture and sale of cathodes.

“Common stock” means GTI common stock, par value $.01 per share.

Credit Agreement” refers to the credit agreement providing for our senior secured credit facilities, as amended or amended and restated at the relevant time. “Revolving Facility” refers to the revolving credit facility provided under the Credit Agreement, at the relevant time. Prior to January 22, 2004, the Credit Agreement provided for a tranche B term loan facility (the “Tranche B Loans” and, together with the Revolving Facility, the “Senior Facilities”), which was repaid and terminated on that date. On February 8, 2005, the Credit Agreement was amended and restated to, among other things, extend the maturity of the Revolving Facility, eliminate references to the Tranche B Loans and add provisions to permit establishment of additional credit facilities thereunder.

“Debt Securities” means our 10.25% senior notes due 2012 (the “Senior Notes”) and our 1 5/8% convertible senior debentures due 2024 (the “Debentures”) . The Senior Notes were issued under an Indenture dated February 15, 2002 (as supplemented, the “Senior Note Indenture”). The Debentures were issued under an Indenture dated January 22, 2004 (as supplemented, the “Debenture Indenture”).

“GrafTech Finance” refers to GrafTech Finance Inc. only. GrafTech Finance is a direct wholly-owned, special purpose finance subsidiary of GTI and the borrower under the Revolving Facility. GrafTech Finance is the issuer of the Senior Notes and a guarantor of the Debentures.

“GrafTech Global” refers to GrafTech Global Enterprises Inc. only. GrafTech Global is a direct wholly-owned subsidiary of GTI and the direct or indirect holding company for all of our operating subsidiaries. GrafTech Global is a guarantor of the Senior Notes, the Debentures and the Revolving Facility.

“GTI” refers to GrafTech International Ltd. only. GTI is our public parent company and the issuer of the Debentures and our publicly traded common stock and the related preferred share purchase rights registered under the Exchange Act and listed on the NYSE. GTI is a guarantor of the Senior Notes and the Revolving Facility.

 

 

4

 

 

 

“Subsidiaries” refers to those companies that, at the relevant time, are or were majority owned or wholly-owned directly or indirectly by GTI or its predecessors to the extent that those predecessors’ activities related to the graphite and carbon business. All of GTI’s subsidiaries have been wholly-owned (with de minimis exceptions in the case of certain foreign subsidiaries) since January 1, 2000 or earlier, except for:

Carbone Savoie, which has been and is 70% owned; and

AET, which was 100% owned until it became 97.5% owned in June 2001.

“UCAR Carbon” refers to UCAR Carbon Company Inc. only. UCAR Carbon is our wholly-owned subsidiary through which we conduct most of our U.S. operations. UCAR Carbon is a guarantor of the Senior Notes, the Debentures and the Revolving Facility.

We,” “us” or “our” refers to GTI and its subsidiaries collectively or, if the context so requires, GTI, GrafTech Global or GrafTech Finance, individually.

Presentation of Financial, Market and Legal Data. We present our financial information on a consolidated basis. As a result, the financial information for Carbone Savoie and AET is consolidated on each line of the Consolidated Financial Statements and the equity of the other owners in those subsidiaries is reflected on the lines entitled “minority stockholders’ equity in consolidated entities” and “minority stockholders’ share of income.” We use the equity method to account for 50% or less owned interests.

References to cost in the context of our low cost advantages and strategies do not include the impact of special charges, expenses or credits, such as those related to investigations, lawsuits, claims, restructurings or impairments, or the impact of changes in accounting principles.

Unless otherwise noted, when we refer to “dollars”, we mean U.S. dollars. Unless otherwise noted, all dollars are presented in thousands.

References to spot prices for graphite electrodes mean prices under individual purchase orders (not part of an annual or other extended purchase arrangement) for near term delivery for standard size graphite electrodes used in large electric arc steel melting furnaces (sometimes called “melters” or “melter applications”) as distinct from, for example, a ladle furnace or a furnace producing non-ferrous metals.

Neither any statement made in this Report nor any charge taken by us relating to any legal proceedings constitutes an admission as to any wrongdoing.

Unless otherwise noted, market and market share data in this Report are our own estimates. Market data relating to the steel, aluminum, electronics, semiconductor, thermal management, transportation, petrochemical and other metals industries, our general expectations concerning such industries and our market position and market share within such industries, both domestically and internationally, are derived from trade publications relating to those industries and other industry sources as well as assumptions made by us, based on such data and our knowledge of such industries. Market data relating to the fuel cell power generation industry,

 

5

 

 

our general expectations concerning such industry and our market position and market share within such industry, both domestically and internationally, are derived from publications by securities analysts relating to Ballard Power Systems Inc., other industry sources and public filings, press releases and other public documents of Ballard Power Systems as well as assumptions made by us, based on such data and our knowledge of the industry. Market and market share data relating to the graphite and carbon industry as well as cost information relating to our competitors, our general expectations concerning such industry and our market position and market share within such industry, both domestically and internationally, are derived from the sources described above and public filings, press releases and other public documents of our competitors as well as assumptions made by us, based on such data and our knowledge of such industry. Our estimates involve risks and uncertainties and are subject to change based on various factors, including those discussed under “Risk Factors-Risks Relating to Us” and “Risk Factors - Forward Looking Statements” in this Report. We cannot guarantee the accuracy or completeness of this market and market share data and have not independently verified it. None of the sources mentioned above has consented to the disclosure or use of data in this Report.

Unless otherwise noted, references to “market shares” are based on sales volumes for the relevant year and references to “natural graphite products” do not include mined natural graphite flake. References to graphite electrode market share exclude the demand for domestic non-melter graphite electrode applications in China.

Unless otherwise noted, references to “capacity utilization rates” for the graphite electrode industry refer to actual or effective annual manufacturing capacity as opposed to theoretical or rated annual manufacturing capacity and references to maximum or virtually maximum operating levels or utilization rates mean capacity utilization rates in excess of 95%. In determining capacity utilization rates, we use the available capacity estimated as of the end of the relevant year, and we exclude the domestic graphite electrode manufacturing capacity and demand for non-melter applications in China.

Unless otherwise noted, references to productivity mean annual graphite electrode production volume (in metric tons) per graphite electrode employee or fixed cost per unit of output.

Unless otherwise noted, references to constraint utilization rates for GTI’s synthetic graphite and natural graphite facilities refer to actual annual hours of operation divided by actual annual hours available for operation. We believe that constraint time and constraint utilization are meaningful measures of our operating capability. We strive to maximize revenue per constraint hour to maximize our profitability.

Unless otherwise noted, references to throughput refer to the amount of cash generated per day at the defined constraint.

The GRAFTECH logo, GRAFCELL®, eGRAF®, GRAFOIL® and SpreaderShield™ are our trademarks and trade names used in this report. This Report also contains trademarks and trade names belonging to other parties.

 

 

6

 

 

 

We make available, free of charge, on or through our web site, copies of our proxy statements, our annual reports on Form 10-K, our quarterly reports on Form 10-Q, our current reports on Form 8-K and amendments to those reports filed or furnished pursuant to Section 13(a) or 15(d) of the Exchange Act as soon as reasonably practicable after we electronically file them with, or furnish them to, the SEC. We maintain our website at http://www.graftech.com. The information contained on our web site is not part of this Report.

 

We have a code of ethics (which we call our Code of Conduct and Ethics) that applies to our principal executive officer, principal financial officer, principal accounting officers and controller, and persons performing similar functions, as well as our other employees, and which is intended to comply, at a minimum, with the listing standards of the NYSE as well as the Sarbanes-Oxley Act of 2002 and the SEC rules adopted thereunder. A copy of our Code of Conduct and Ethics is available on our web site at http://www.graftech.com/GrafTech/About+Our+Company/Corporate+Policies/Code+of+Conduct_Ethics.htm

 

We also have corporate governance guidelines (which we call the Charter of the Board of Directors) which is available on our website at http://www.graftech.com/GrafTech/About+Our+Company/Corporate+Governance/Corporate+Governance+Guidelines.htm as required by the NYSE. You may request a copy of the Charter of the Board of Directors, at no cost, by oral or written request to: GrafTech International Ltd., 12900 Snow Road, Parma, Ohio, 44130, Attention: Michael A. Carr, Manager of Investor Relations, Telephone (216) 676-2525.

 

 

7

 

 

 

Item 1. Business

(Unless otherwise noted, all dollars are presented in thousands)

 

Introduction

Our vision is to enable customer leadership, better and faster than our competition, through the creation, innovation and manufacture of graphite and carbon material science-based solutions. We have over 100 years of experience in the research and development of graphite and carbon-based solutions and our intellectual property portfolio is extensive. Our business was founded in 1886 by the National Carbon Company.

We are one of the world’s largest manufacturers of the broadest range of high quality graphite electrodes, products essential to the production of electric arc furnace (“EAF”) steel and various other ferrous and nonferrous metals. We are the largest manufacturer of high quality natural graphite products enabling thermal management solutions for the electronics industry and fuel cell solutions for the transportation and power generation industries. We are one of the world’s largest manufacturers and providers of other synthetic graphite and carbon products, as well as related technical services, including cathodes for the aluminum industry and other advanced graphite and carbon materials for the semiconductor, transportation, petrochemical and other metals markets. We service customers in about 80 countries, including industry leaders such as Arcelor S.A., Bao Steel, Gerdau S.A. and Mittal Steel in steel, Alcoa and Alcan in aluminum, Dell, Samsung and Sony in electronics, MEMC Electronic Materials in semiconductors and Ballard Power Systems in fuel cells.

We currently manufacture our products in 13 state-of-the-art manufacturing facilities strategically located on four continents and have more diverse locations than the facilities of any of our competitors. We believe our unique global manufacturing network cannot be replicated by any of our competitors due to the capital investment, technology and process know-how required to do so. We believe our network has the largest manufacturing capacity, has one of the lowest manufacturing cost structures of all of our major competitors and delivers the highest-level quality products. We currently have the operating capability, depending on product demand and mix, to manufacture approximately 230,000 metric tons of graphite electrodes annually from our existing assets. We believe that our unique global manufacturing network provides us with significant competitive advantages in product quality, proximity to customers, timely and reliable product delivery, and product costs. Given our global network, we are well positioned to serve the growing number of consolidated, global, multi-plant steel and aluminum customers as well as certain smaller, regional customers and segments.

We operate the premier research, development and testing facilities in the graphite and carbon industry, and we believe we are the industry leader in graphite and carbon material science and high temperature processing know-how. We believe our technological capabilities for developing products with superior thermal, electrical and physical characteristics provide us with a competitive advantage. These capabilities have enabled us to accelerate development and commercialization of our technologies to exploit markets with high growth potential, including products for electronic thermal management and fuel cell applications.

 

 

8

 

 

 

Products and Reportable Segments. We have six major product categories: graphite electrodes, cathodes, carbon electrodes, carbon refractories, advanced graphite materials and natural graphite, the results of which are reported in the following segments: synthetic graphite, which consists of graphite electrodes, cathodes and advanced graphite materials and related services; and other, which consists of natural graphite, carbon electrodes and refractories and related services. The information required by Item 1 with respect to financial information regarding our reportable segments and geographic areas is set forth under “Segment Reporting” in Note 4 to the Consolidated Financial Statements and is incorporated herein by reference.

 

Synthetic Graphite. Our synthetic graphite segment manufactures and delivers high quality graphite electrodes, cathodes and advanced graphite materials as well as related services. Electrodes and cathodes are key components of the conductive power systems used to produce steel, aluminum and other non-ferrous metals. Advanced graphite materials include primary and specialty products for transportation, semiconductor and other markets.

We are one of the world’s largest manufacturers of the broadest range of high quality graphite electrodes. Approximately 70% of our graphite electrodes sold are consumed in the EAF steel melting process, the steel making technology used by all “mini-mills,” typically at a rate of one graphite electrode every eight to ten operating hours. We believe that mini-mills constitute the higher long-term growth sector of the steel industry and that there is currently no commercially viable substitute for graphite electrodes in EAF steel making. Therefore, graphite electrodes are essential to EAF steel production. The remaining 30% of our graphite electrodes sold are primarily used in various other ferrous and non-ferrous melting applications, including steel formulation (that is, ladle furnace operations for both EAF and blast oxygen furnace steel production), titanium dioxide production and chemical processing.

Cathodes are used in aluminum smelting furnaces, and demand for cathodes is driven by construction of new smelters and relines and upgrades of existing smelters. We believe there is currently no viable substitute for cathodes in aluminum smelting. We operate our cathode business through a 70% owned venture with Pechiney, the world’s recognized leader in aluminum smelting technology. In late 2003, Pechiney was acquired by Alcan, one of the world’s largest aluminum producers.

Other. We invented natural graphite products, consisting of advanced flexible graphite and flexible graphite. Advanced flexible graphite solutions include highly engineered thermal interface products, heat spreaders and heat sinks for electronic device applications. We are the largest manufacturer of high quality natural graphite solutions for the electronics industry. We are also the leading manufacturer of highly engineered natural graphite-based flow field plates and gas diffusion layers and other advanced flexible graphite solutions for proton exchange membrane (“PEM”) fuel cells and fuel cell systems for use in the power generation and transportation markets. Flexible graphite products include gasket and sealing material for high temperature and corrosive environments in automotive, petrochemical and other applications. We are one of the world’s largest manufacturers of natural graphite products for these uses and applications.

Carbon electrodes are used in the production of ferro-alloys and silicon metal, a raw material primarily used as an alloying agent in the manufacture of aluminum, and for production

 

9

 

 

of chemical products in the chemical industry. Refractories are used primarily as blast furnace and submerged arc furnace hearth walls and bottoms.

Our Segments

Carbon is one of the fundamental elements and is capable of forming an enormous variety of compounds. As a result of these characteristics, carbon is one of the most widely used elements in manufacturing processes of all kinds. Graphite is the crystalline form of carbon. Graphite can be processed to be resistant to corrosive materials, withstand high temperatures and act as either a conductor of, or an insulator from, heat and electricity. Graphite is both manmade (called “synthetic graphite”) and occurs naturally (called “natural graphite”). Synthetic graphite is made primarily from petroleum coke, a by-product of petroleum refining. Natural graphite is a mined mineral that is processed to increase its purity.

Synthetic Graphite Segment

Our synthetic graphite segment, which had net sales of $640,128 in 2003, $752,436 in 2004 and $784,148 in 2005, manufactures and delivers high quality graphite electrodes, cathodes and advanced graphite materials as well as customer technical services. Graphite electrodes accounted for about 74% of the net sales of this segment in 2005. Cathodes are manufactured by our subsidiary, Carbone Savoie, and accounted for about 14% of the net sales of this segment in 2005.

We estimate that, in 2005, the worldwide market for graphite electrodes, cathodes and advanced graphite materials was over $3 billion. Customers for these products are located in all major geographic markets.

Graphite Electrodes.

Use of graphite electrodes in electric arc furnaces. There are two primary technologies for steel making:

basic oxygen furnace steel production (sometimes called “integrated steel production”); and

electric arc furnace steel production (the technology used by all “mini-mills”).

Graphite electrodes are consumed primarily in electric arc furnace steel production, the steel making technology used by all “mini-mills,” typically at a rate of one graphite electrode every eight to ten operating hours. Electric arc furnace steel makers are called “mini-mills” because of their historically smaller capacity as compared to basic oxygen furnace steel makers and because they historically served more localized markets. We believe that mini-mills constitute the higher long term growth sector of the steel industry. Graphite electrodes are also consumed in the refining of steel in ladle furnaces and in other smelting processes such as production of titanium dioxide.

 

 

10

 

 

 

Electrodes act as conductors of electricity in the furnace, generating sufficient heat to melt scrap metal, iron ore or other raw materials used to produce steel or other metals. The electrodes are consumed in the course of that production.

Electric arc furnaces that produce steel typically range in size from those that produce about 25 metric tons of steel per production cycle to those that produce about 150 metric tons per production cycle. Electric arc furnaces operate using either alternating electric current (A/C) or direct electric current (D/C). The vast majority of electric arc furnaces use alternating current. Each of these furnaces typically uses nine electrodes (in three columns of three electrodes each) at one time. The other electric arc furnaces, which use direct current, typically use one column of three electrodes. The size of the electrodes varies depending on the size of the furnace, the size of the furnace’s electric transformer and the planned productivity of the furnace. In a typical furnace using alternating current and operating at a typical number of production cycles per day, one of the nine electrodes is fully consumed (requiring the addition of a new electrode), on average, every eight to ten operating hours. The actual rate of consumption and addition of electrodes for a particular furnace depends primarily on the efficiency and productivity of the furnace. Therefore, demand for graphite electrodes is directly related to the amount and efficiency of electric arc furnace steel production.

Electric arc furnace steel production requires significant heat (as high as 5,000 degrees Fahrenheit, which we believe is the hottest operating temperature in any industrial or commercial manufacturing process worldwide) to melt the raw materials in the furnace, primarily scrap metal. Heat is generated as electricity (as much as 150,000 amps) passes through the electrodes and creates an electric arc between the electrodes and the raw materials.

Graphite electrodes are currently the only products available that have the high levels of electrical conductivity and the capability of sustaining the high levels of heat generated in an electric arc furnace producing steel. Therefore, graphite electrodes are essential to the production of steel in electric arc furnaces. We believe there is currently no commercially viable substitute for graphite electrodes in electric arc furnace steel making. We estimate that, on average, the cost of graphite electrodes represents about 3% to 4% of the cost of producing steel in a typical electric arc furnace.

Electric arc furnace steel production for the last five years has grown at an estimated average annual growth rate of about 3%. We believe that EAF steel production will continue to grow at an average annual long term growth rate of about 3% to 4%. We estimate that there are currently approximately 2,000 electric arc steel production furnaces operating worldwide. Electric arc furnace steel production grew from approximately 90 million metric tons in 1970 to approximately 325 million metric tons in 2005, representing approximately a third of the world’s steel production. We estimate that steel makers worldwide added 11 million metric tons of new EAF capacity in 2005, not all of which was fully operational in 2005. We are aware of about 37 million metric tons of announced new electric arc furnace steel production capacity that is scheduled to be added in the 2006 through 2008 time period, approximately 11% of which is replacement capacity. Additionally, not all of such capacity is expected to be fully operational during this time period.

 

 

11

 

 

 

An electric arc furnace used for steel production provides significant operational flexibility. It can be shut down and restarted relatively quickly compared to a basic oxygen furnace in response to changing market dynamics. As a result, electric arc furnace steel producers are better able to adjust production to respond to changes in demand and prices for steel on a regional and global basis.

Relationship Between Graphite Electrode Demand and EAF Steel Production. The improved efficiency of electric arc furnaces has resulted in a decrease in the average rate of consumption of graphite electrodes per metric ton of steel produced in electric arc furnaces (called “specific consumption”). We estimate that specific consumption declined from about 4.3 kilograms of graphite electrodes per metric ton of steel produced in 1990 to about 2.2 kilograms per metric ton in 2005. We believe that the rate of decline of specific consumption over the long term has become lower. We believe that the decline in specific consumption will continue at a more gradual pace, on average, as the costs (relative to the benefits) increase for EAF steel makers to achieve further efficiencies in specific consumption. We further believe that the rate of decline in the future will be impacted by the addition of new EAF steel making capacity. To the extent that this new capacity replaces old capacity, it has the accelerated effect of reducing industry wide specific consumption due to the efficiency of new electric arc furnaces relative to the old. However, to the extent that this new capacity increases industry wide EAF steel production capacity and that capacity is utilized, it creates additional demand for graphite electrodes.

Increases in EAF steel production, offset by declines in specific consumption, resulted in corresponding changes in demand for graphite electrodes. Graphite electrode demand is expected to grow over the long term at an estimated average annual growth rate of about 1% to 2%, based on the anticipated growth of EAF steel production, partially offset by the decline in specific consumption described above. We believe that the graphite electrode industry manufacturing capacity utilization rate worldwide was about 96% in 2003, about 96% in 2004 and 95% in 2005.

Production Capacity. We believe that the worldwide total graphite electrode manufacturing capacity, excluding capacity used to make electrodes for domestic non-melter applications in China, is approximately 1.1 million metric tons. There are two global, and approximately seven other notable regional or local producers, who have approximately 815,000 metric tons of this capacity. The remaining capacity is maintained by over twenty other local or regional manufacturers.

We believe that there is over 1 million metric tons of demand that corresponds with this capacity, representing a utilization rate of over 90%. The global demand can be further delineated between melter and non-melter segments. We believe that the melter segment represents approximately 70% of the total electrode demand. There are process technology and raw material constraints related to converting non-melter capacity into melter capacity, however melter capacity can be utilized for non-melter production. All of our production capacity is capable of producing melter-segment electrodes, with the flexibility to produce non-melter segment electrodes as needed.

 

 

12

 

 

 

As a result of repositioning our global manufacturing network and other actions, as well as our proprietary process and technological improvements, we now have the capability, depending on product demand and mix, to manufacture approximately 230,000 metric tons of graphite electrodes annually from our existing assets. We believe that our Monterrey, Mexico facility is the largest graphite electrode manufacturing facility in the world.

Graphite Electrode Market Share. We estimate that about 56% of the EAF steel makers worldwide (other than in China, for which reliable information is not generally available) and about 77% of the EAF steel makers in the U.S. and the markets where we have manufacturing facilities, purchased all or a portion of their graphite electrodes from us in 2005. We further estimate that we supplied about 35% of all graphite electrodes purchased in the U.S. and the markets where we have manufacturing facilities, and about 20% worldwide (including China), in each case in 2005. We estimate that the worldwide market for graphite electrodes was about $2.5 billion in 2005 (including China).

We estimate that, in 2005, graphite electrode sales in the U.S. accounted for about 15% of the total net sales of our synthetic graphite segment and that we sold graphite electrodes in about 70 countries, with no other country accounting for more than 9% of the total net sales of our synthetic graphite segment.

Cathodes. The cathode market includes cathodes, sidewalls and ramming paste sold to the aluminum industry for installation of new and relining of existing furnaces used to smelt aluminum (called “pots”). Cathode blocks are used as a floor lining for, and act as conductors of electricity in, the pots. Cathodes are made from either carbon (anthracite and semi-graphitic) or graphite. Cathodes are currently the only products available that have the high levels of electrical conductivity and the capability of surviving the highly corrosive high temperature environment in an aluminum smelting pot. We believe that there are currently no commercially viable substitutes for cathodes in aluminum smelting pots. As cathodes are used in the construction of pots, demand for them is directly related to both the number of new aluminum smelting pots being built and the frequency with which existing pots are upgraded and relined. In a typical aluminum smelting pot operating at a typical rate and efficiency of production, the cathodes must be replaced every 5 to 8 years.

We operate our cathode business through a 70% owned venture with Pechiney, the world’s recognized leader in aluminum smelting technology. In late 2003, Pechiney was acquired by Alcan, one of the world’s largest aluminum producers. Alcan uses Pechiney technology in its own smelting operations (including all Pechiney operations) and licenses Pechiney technology to other aluminum producers. We believe that we are positioned as one of the highest quality producers of graphite cathodes, the preferred technology for deployment in new aluminum smelting pots due to their ability to provide substantial improvements in process efficiency. We are benefiting from Alcan/Pechiney’s smelting technology and our graphite technology and expertise in high temperature industrial applications to develop further improvements in graphite cathodes. We believe that our technological advances in graphite cathodes provide substantial improvement in process efficiency for our aluminum customers, extending the life of the cathode block by about 20%. Our cathodes are sold to Alcan/Pechiney for use in their own plants under supply contracts that remain in effect through 2006 and are marketed to Alcan/Pechiney’s licensees as well as to other aluminum producers.

 

 

13

 

 

 

We believe that worldwide demand for aluminum will continue to grow over the long term at an average annual rate of about 3%, primarily because of greater use of aluminum by the transportation industry and higher growth in demand in China. We also believe that, over the long term, new aluminum smelting furnaces will need to be built to meet the growth in demand.

The worldwide demand for all cathode grades in 2005 was about 260,000 metric tons. Carbon cathodes represented approximately two-thirds of the market, with graphite cathodes representing the balance. We believe that, over the long term, demand for graphite cathodes will increase relative to carbon cathodes as new smelting pots are built.

 

We believe that the cathode industry manufacturing capacity utilization rate worldwide was about 82% in 2005 (excluding for carbon cathodes, information relating to Russia and China, for which reliable information is generally not available). We believe that, currently, there is an excess supply of carbon cathodes, on a worldwide basis, resulting from a delay in relines of existing pots (as existing pots are operating longer to meet the strong aluminum demand) and an increase in the potlife of certain smelters due to technology improvements.

There are six notable producers of cathodes in the world. We believe that we are the largest manufacturer of cathodes in the world, offering the broadest range of products to the aluminum industry. We estimate that the worldwide market for cathodes was about $530 million in 2005 and that we sold about 16% of all cathodes sold in the world in 2005.

Advanced Graphite Materials. Advanced graphite materials include isomolded, molded and extruded products in a variety of shapes and grades, weighing from a few kilograms to ten metric tons, for diverse applications. These materials include primary products (such as bulk graphite blocks (called “billets”) that are sold to customers for further processing or finishing for end users) and specialty products (such as pressure casting molds for steel railroad car wheels).

Our isomolded products are used in applications including continuous casting and hot press manufacturing processes and resistance heating elements. Our molded products are used in applications including high temperature furnaces and crucibles, chemical processing equipment and centrifugal casting equipment. Our extruded products are used in applications including fused refractories, diamond drill bits and semiconductor components as well as in applications in aluminum refining. In addition, certain of our materials, when combined with advanced flexible graphite, provide superior heat management solutions for insulation packages, induction furnaces, high temperature vacuum furnaces and direct solidification furnaces and other industrial thermal management applications. We estimate the worldwide market for advanced graphite materials was about $550 million in 2005.

Other Segment

Natural Graphite. We manufacture advanced flexible graphite solutions and flexible graphite products from natural graphite. We also provide cost effective engineering and other technical services and license our proprietary technology to meet customer needs in markets where we do not anticipate engaging in manufacturing ourselves. Our natural graphite solutions are developed and manufactured by our subsidiary, AET. We currently sell our solutions primarily to the electronics, fuel cell power generation and sealing markets.

 

 

14

 

 

 

Advanced flexible graphite solutions include highly engineered eGRAF® thermal interface material, heat spreaders, including those sold under our SpreaderShield™ brand name, and heat sinks for electronic device applications. We also manufacture highly engineered GRAFCELL® flow field plates, gas diffusion layers and other advanced flexible graphite solutions for PEM fuel cells and fuel cell systems for use in the power generation and transportation markets. Flexible graphite products include gasket and sealing material for high temperature and corrosive environments in automotive, petrochemical and other applications. We are one of the world’s largest manufacturers of natural graphite products for all of these uses and applications.

The versatility of our proprietary processes and equipment enables us to modify natural graphite products to meet a variety of customer needs. We work with our customers to develop technologically advanced solutions, utilizing our industry-leading technology and manufacturing strengths and capabilities.

Electronic Thermal Management Solutions. Thermal management solutions are uniquely designed to dissipate heat generated by electronic devices. Electronics manufacturers are currently experiencing constraints in the development of ever more advanced compact devices because of limitations on the ability of current thermal management products and technologies to dissipate the higher levels of heat generated. We have developed and are continuing to develop and introduce highly engineered advanced flexible graphite solutions that improve thermal management in electronic devices. We expect demand for our products to grow as industry trends continue toward smaller, more powerful electronic devices which generate more heat and require more advanced thermal solutions.

Advanced flexible graphite solutions include highly engineered thermal interface materials, heat spreaders and heat sinks for current and next generation electronic device applications, including computers, servers, flat panel display devices, digital video devices, cell phones and other communications, industrial, military, office and automotive equipment. Thermal interface products reside between a chip set or other heat generating unit in a device and the remaining components in the heat dissipation system in the device. Heat sinks are finned units (similar to radiators) that dissipate heat via air movement into the surrounding environment. Heat spreaders are engineered plates or tubes that move or spread heat from hot spots, such as a processing chip, to other locations in the device for dissipation into the environment.

We expect that the superior ability of our products to manage heat will allow our customers and others to redesign electronic devices to improve performance through heat management while reducing cost, size and weight. Our unique solutions offer many advantages over competitive products, such as copper or aluminum. These advantages include:

excellent ability to conduct heat;

mechanical and thermal stability;

lightweight, compressible and conformable nature;

cost competitiveness; and

 

 

15

 

 

 

ease of handling.

Our product lines include eGRAF® heat spreaders, including those sold under our SpreaderShield™ brand name, heat sinks and other thermal management products and eGRAF® Hi-Therm™ thermal interface materials. We can provide both custom and off-the-shelf products and sophisticated solutions for cooling complex electronic devices.

During 2002, we began commercializing our line of eGRAF® thermal management products. Since then, we have obtained orders for eGRAF® products from industry leading electronic companies such as Agilent, Cisco, Hitachi, Dell, Samsung, Sony, Panasonic, and Nokia.

We estimate that the market for our current electronic thermal management products is about $350 million and expect it to grow at an annual rate in excess of 15% over the next three years. Sales of these products grew from about $2,476 in 2003 to $11,611 in 2004 and $18,738 in 2005.

We believe that the thermal management component market for computers, servers, flat panel display devices, digital video devices, cell phones and other communications, industrial, military, office and automotive equipment was about $3 billion in 2002.

Fuel Cell Products. We are the leading manufacturer of natural graphite products for PEM fuel cells and fuel cell systems. We manufacture highly engineered flow field plates, gas diffusion layers and other advanced flexible graphite solutions for PEM fuel cells and fuel cell systems. PEM fuel cells have the potential to generate power for:

 

transportation applications, such as automobiles, buses and other vehicles;

stationary applications, such as residences, commercial buildings and industrial operations; and

portable applications, such as machinery, equipment and electronic devices.

 

Fuel cells provide environmentally friendly electrical power generation by combining hydrogen (which can be obtained from a variety of sources such as methanol, natural gas and other fuels) with oxygen (from air, not necessarily pure) to produce electricity through an electrochemical process without combustion. The only material by-products from this process are water and heat. We believe that PEM fuel cells have emerged as the leading fuel cell technology because they offer higher power density, lower weight and lower costs relative to alternative fuel cell technologies. We expect significant growth from this opportunity over the next ten years.

We have been working with Ballard Power Systems since 1992 on developing natural graphite products for use in its PEM fuel cells. GRAFCELL® advanced flexible graphite solutions are a strategic material for the Mark 902, Ballard Power Systems’ most advanced PEM fuel cell platform to date.

 

 

16

 

 

 

In June 2001, we entered into an exclusive development and collaboration agreement and an exclusive long term supply agreement with Ballard Power Systems, which significantly expanded the scope and term of prior agreements. In addition, Ballard Power Systems became a strategic investor in AET, investing $5 million in shares of Ballard Power Systems’ common stock for a 2.5% equity ownership interest, to support the development and commercialization of natural graphite products for PEM fuel cells. As an investor in AET, Ballard Power Systems has rights of first refusal with respect to certain equity ownership transactions, tag along and drag along rights, and preemptive and other rights to acquire additional equity ownership under certain limited circumstances.

The scope of the current exclusive development and collaboration agreement includes natural graphite products, including flow field plates and gas diffusion layers, for use in PEM fuel cells and fuel cell systems for transportation, stationary and portable applications. The initial term of this agreement extends through 2011. Under the supply agreement, we are the exclusive manufacturer and supplier of natural graphite products for Ballard Power Systems’ fuel cells and fuel cell systems, other than those natural graphite products which Ballard Power Systems elects in the future to manufacture for itself. The initial term of this agreement, which contains customary terms and conditions (including certain license and royalty provisions), extends through 2016. We have the right to manufacture and sell, after agreed upon release dates, natural graphite for use in PEM fuel cells to other fuel cell producers.

In 2004, we were awarded a grant from the State of Ohio for $602 for further development of our gas diffusion layer for fuel cells.

We believe that the significant market opportunities for fuel cell vehicles will be supported by governmental programs. In January 2002, the Bush administration launched a new program called FreedomCAR aimed at spurring the growth of hydrogen fuel cells for cars and trucks. In January 2003, the Bush administration launched FreedomFUEL, focusing on technologies and infrastructure needed to produce, distribute and store hydrogen for fuel cells. About $1.7 billion of funding is proposed under these programs. The European Union and Japan have each announced similar initiatives, and the U.S. and the European Union have agreed to cooperate to overcome barriers to fuel cell commercialization.

We estimate that the market for our fuel cell products in 2012 will exceed $500 million.

Sealing products. Flexible graphite is lightweight, conformable, temperature-resistant and inert to most chemicals. Due to these characteristics, it is an excellent gasket and sealing material that to date has been used primarily in high temperature and corrosive environments in the automotive and petrochemical industries. For example, automotive applications for our flexible graphite products include head gaskets and exhaust gaskets as well as engine and exhaust heat shields. We market our flexible graphite products used in the sealing industry under the GRAFOIL® name.

Carbon Electrodes. Carbon electrodes are used in the production of ferro-alloys and silicon metal, a raw material primarily used as an alloying agent in the manufacture of aluminum, and for production of chemical products in the chemical industry. Carbon electrodes are also used in the production of thermal phosphorous. Carbon electrodes are used and

 

17

 

 

consumed in a manner similar to that of graphite electrodes, although at lower temperatures and with different consumption rates. We believe that demand for carbon electrodes fluctuates based primarily on changes in production of silicon metal. We also believe that the silicon metal industry is directly impacted by changes in global and regional economic conditions. We estimate that demand for carbon electrodes was about 81,000 metric tons in 2003, about 88,000 metric tons in 2004, and about 87,000 in 2005.

We estimate that we sold about 28% of the carbon electrodes sold in the world in 2005. We estimate that the worldwide market for carbon electrodes was about $128 million in 2005.

Our carbon electrode product line is facing significant production cost increases and pricing pressure. Given the recent performance of, and outlook for, this product line, we have been exploring strategic alternatives for this product line. In the first quarter of 2006, we announced that we expect to completely exit these operations over the next 12 months. Our carbon electrode net sales in 2005 were $36,407. We have produced carbon electrodes in Columbia, Tennessee for almost 70 years. The decision is expected to result in the termination of about 150 employees between June 2006 and March 2007.

Refractories. Refractories are made in a multitude of standard and custom shapes and sizes. Smaller refractories are sometimes called refractory bricks and larger ones are sometimes called refractory blocks. Graphite is added to some carbon refractories (called semi-graphitic refractories) to adjust performance characteristics. Carbon and semi-graphitic refractory bricks are used primarily as chemical industry tank and reactor linings and blast furnace and submerged arc furnace hearth walls. These refractory bricks have excellent resistance to corrosion and abrasion. Our carbon refractory brick is one of the established standards for blast furnaces in North America and submerged arc furnaces in South Africa. Our semi-graphitic refractory brick is used where higher conductivity is required or when additional abrasion resistance is desired.

We also manufacture graphite refractory blocks which are used primarily for their high thermal conductivity and the ease with which they can be machined to large or complex shapes. Common applications in blast furnace and submerged arc furnaces are cooling courses in the hearth bottoms for heat distribution and removal, backup linings in hearth walls for improved heat transfer and safety, and lintels over copper cooling plates where a single brick cannot span the cooling plate.

Carbon refractory blocks are used primarily as blast furnace and submerged arc furnace hearth bottoms, for which they are machined to shape and assembled in a variety of designs. We also provide special shapes (such as sidewall blocks, tap blocks, tuyere surrounds and runner liners) for blast furnaces, submerged arc furnaces and cupola furnaces.

We estimate that we sold about 32% of the carbon refractories sold in 2005 for blast and submerged arc furnaces. We estimate that this market for carbon refractories was about $100 million in 2005.

Business Strategies

Our goal is to increase our throughput by maximizing the amount and speed of cash generated from the defined constraint of our assets every day. We believe that, by maximizing the amount and speed of these cash flows, we will deliver enhanced financial performance and return on shareholder value. We have transformed our operations, building sustainable competitive advantages to enable us to compete successfully in our major product lines

 

18

 

 

regardless of changes in economic conditions, to realize enhanced performance as economic conditions improve and to exploit growth opportunities from our intellectual property portfolio. Our business strategies are designed to expand upon our competitive advantages by:

Leveraging Our Unique Global Manufacturing Network. We have repositioned our global manufacturing network by shutting down higher cost facilities and redeploying that capacity to our lower cost, strategically located facilities. We have also adopted a constraint-management philosophy that systematically seeks to drive higher utilization rates (constraint utilization) and more productivity from our existing assets. We believe that our unique global manufacturing network provides us with significant competitive advantages in product quality, product costs, proximity to customers, timely and reliable delivery, and operational flexibility to adjust product mix to meet the diverse needs of a wide range of market segments and customers. Currently, we have the operating capability, depending on product demand and mix, to manufacture approximately 230,000 metric tons of graphite electrodes annually from our existing assets.

We continue to leverage our network to seek to achieve significant increases in throughput generated from our existing assets, through productivity improvements, capital expenditures, and other efficiency initiatives. We believe we can further exploit our network by focusing our superior technical and customer service capabilities on:

the increasing number of large global customers created by the continuing consolidation trend within the steel and aluminum industries, to whom we believe we are better positioned than any of our competitors to offer products that meet their volume, product quality, product mix, delivery reliability and service needs at competitive prices; and

customers in targeted market segments where we have competitive advantages to meet identified customer needs due to the locations of our facilities, the range and quality of our products, the utilization of our capacity, the value of our customer technical service, our low cost supplier advantage and other factors.

We believe that, in many cases, the increasing number of large global steel and aluminum customers created by consolidation trends are more creditworthy than other customers and that we are able to better manage our exposure to trade credit risk as we increase the percentage of our total net sales sold to these customers.

We believe that our graphite electrode business has one of the top market shares in the world and that our cathode business has the number one market share in the world. In 2005, our worldwide market share was:

about 20% in graphite electrodes; and

about 16% in cathodes.

We sell graphite electrodes and cathodes in every major geographic market. Sales of these products outside the U.S. accounted for about 65% of net sales in 2004 and 66% in 2005.

 

19

 

 

No single customer or group of affiliated customers accounted for more than 5% of our total net sales in 2003, 2004 or 2005.

We believe that we operate the most technologically sophisticated advanced natural graphite production line in the world and we are the manufacturer best positioned to supply natural graphite products to the electronic thermal management and fuel cell markets. We are the world’s largest manufacturer of natural graphite for these markets and one of the largest manufacturers for automotive and petrochemical applications.

Driving Global Productivity and Efficiency Initiatives. During 2005, we identified various productivity enhancement opportunities. Major actions, identified in 2005 and planned for 2006, include:

streamlining and centralizing our organizational structure and reducing our salaried and administrative workforce;

rationalizing certain product and production capabilities, including synthetic graphite facilities in Brazil, France, Italy, the United States and Russia; and

reassessing alternatives for under-performing production assets.

We are committed to continuously maintaining and improving our low cost manufacturer status in the industry and we are seeking to maximize productivity from our existing assets while improving the cost efficiency of the supporting processes.

 

Accelerating Commercialization of Advantaged Technologies. We believe that our technological capabilities for developing products with superior thermal, electrical and physical characteristics provide us with a significant growth opportunity as well as a competitive advantage. We seek to exploit these capabilities and our intellectual property portfolio to accelerate development and commercialization of these technologies across all of our businesses, to improve existing products, including super-size graphite electrodes and large-diameter pinless electrodes used in the most demanding electric arc steel production furnaces, and to develop and commercialize new products for markets with high growth potential, such as electronic thermal management technologies. For the past three years, we have received R&D Magazine’s prestigious R&D 100 Award, granted to identify the 100 most technologically significant commercialized products each year. We received this award in 2003 and 2004 for our achievements in electronic thermal management products and in 2005 for our large-diameter pinless graphite electrodes.

We believe that we are one of the highest quality producers of graphite cathodes, the preferred technology for new aluminum smelting furnaces. We believe that our advanced graphite cathode technology enables us to increase our market share of graphite cathodes sold upon the commencement of operation of the new, more efficient aluminum smelting furnaces that are being built.

Delivering Exceptional and Consistent Quality. We believe that our products are among the highest quality products available in our industry. Since 1999, we have reduced our annual

 

20

 

 

cost for customer graphite electrode quality claims from $2,960 to $1,347. We have been recognized as a preferred or certified supplier by many major steel and aluminum companies and have received numerous technological innovation and other awards by industry groups, customers and others. Using our technological capabilities, we continually seek to improve the consistent overall quality of our products and services, including the performance characteristics of each product, the uniformity of the same product manufactured at different facilities and the expansion of the range of our products. We believe that improvements in overall quality create significant efficiencies and market opportunities for us, provide us the opportunity to increase sales volumes and market share, and create production efficiencies for our customers.

Providing Superior Technical Service. We believe that we are the recognized industry leader in providing value added technical services to customers for our major product lines. We believe that we have the largest customer technical service and related supporting engineering and scientific organizations in our industry, with more than 245 engineers, scientists and specialists around the world. Our employees assist key steel and other metals customers in furnace design, operation and upgrade to reduce energy consumption, improve raw material costs and increase output. In addition, our employees assist customers and others who design, develop or produce electronic devices to integrate our advanced flexible graphite solutions into their new devices.

Deleveraging and Building Stockholder Value. We believe that our business strategies support our goal of maximizing the amount and speed of cash generated and should accelerate our ability to enhance our capital structure by further reducing our gross debt obligations. We have, through successful offerings of the Senior Notes and the Debentures and our successful refinancing of the Revolving Facility, enhanced our financial stability and liquidity. Deleveraging remains a priority for us and we may from time to time purchase Senior Notes and Debentures in the open market or in privately negotiated transactions.

In connection with and building on our focus on deleveraging, we continually review our assets, product lines and businesses to seek out opportunities to maximize value, through re-deployment, divestiture or otherwise. We currently plan to sell certain real estate and may at any time sell other assets, product lines or businesses.

Production Planning

We plan and source our graphite electrode and cathode production globally. We have evaluated virtually every aspect of our global supply chain, and we have redesigned and implemented changes to our global manufacturing, marketing and sales processes to leverage the strengths of our repositioned manufacturing network. Among other things, we have eliminated manufacturing bottlenecks, improved product and service quality and delivery reliability, expanded our range of products, and improved our global sourcing and product mix for our customers. We continue to implement global productivity and efficiency initiatives, including improvements in performance through realignment and standardization of global supply chain processes.

We deploy synchronous work processes at most of our manufacturing facilities. We have also installed and continue to install and upgrade proprietary process technologies at our

 

21

 

 

synthetic graphite manufacturing facilities and use statistical process controls in our manufacturing processes for all products.

We utilize capabilities within our global information systems to seek to optimize our global sourcing for maximum profitability. Our global manufacturing network also helps us to minimize risks associated with dependence on any single economic region.

Manufacturing

Synthetic Graphite. The manufacture of a graphite electrode takes, on average, about two months. Graphite electrodes range in size from three inches to 30 inches in diameter and two feet to nine feet in length and weigh between 20 pounds and 4,800 pounds (2.2 metric tons).

The manufacture of graphite electrodes involves the six main processes described below:

Forming: Calcined petroleum coke is crushed, screened, sized and blended in a heated vessel with coal tar pitch. The resulting plastic mass is extruded through a forming press and cut into cylindrical lengths (called “green” electrodes) before cooling in a water bath.

Baking: The “green” electrodes are baked at about 1,400 degrees Fahrenheit in specially designed furnaces to purify and solidify the pitch and burn off impurities. After cooling, the electrodes are cleaned, inspected and sample-tested.

Impregnation: Baked electrodes are impregnated with a special pitch when higher density, mechanical strength and capability to withstand higher electric currents are required.

Rebaking: The impregnated electrodes are rebaked to solidify the special pitch and burn off impurities, thereby adding strength to the electrodes.

Graphitizing: Using a process that we developed, the rebaked electrodes are heated in longitudinal electric resistance furnaces at about 5,000 degrees Fahrenheit to restructure the carbon to its characteristically crystalline form, graphite. After this process, the electrodes are gradually cooled, cleaned, inspected and sample-tested.

Machining: After graphitizing, the electrodes are machined to comply with international specifications governing outside diameters, overall lengths and joint details. Tapered sockets are machine-threaded at each end of the electrode to permit the joining of electrodes in columns by means of correspondingly double-tapered machine-threaded graphite nipples (called "pins"), except in the case of our pinless graphite electrodes.

Cathodes range in size from 5 feet to 12 feet and weigh between 800 pounds and 3,700 pounds and are manufactured by a comparable process (excluding, in the case of carbon cathodes, impregnation and graphitization). We believe that we manufacture the broadest range

 

 

22

 

 

of sizes in graphite electrodes and cathodes and that the quality of our electrodes and cathodes is competitive with or better than that of comparable products of any other major manufacturer.

We generally warrant to our customers that our electrodes and cathodes will meet our specifications. Electrode and cathode returns and replacements have aggregated less than 1% of net sales in each of the last three years.

Graphite electrodes are manufactured in Brazil, Mexico, South Africa, France, Spain and Russia. Cathodes are manufactured in France and Brazil. We intend to cease producing graphite electrodes in Russia and cathodes in Brazil during 2006.

Advanced graphite materials are manufactured using raw materials, processes and technologies similar to those for graphite electrodes and cathodes. Our facilities have the capability to process a wide range of raw materials, extrude or mold small to very large graphite blocks, impregnate, bake and graphitize the blocks, purify the blocks to reduce the impurities to parts per million levels, and machine the blocks using advanced machining stations to manufacture products finished to high tolerances and unique shapes. Advanced graphite materials are manufactured in the U.S., France and South Africa.

Other. We use a proprietary process to convert mined natural graphite flake into expandable graphite, an intermediate product. During this process, we can manufacture expandable graphite with a number of specific properties. For example, we can change its sensitivity to temperature, modify its particle size and give it long-term stability. We manufacture flexible graphite by further processing expandable graphite. We fabricate finished gasket and sealing products by fabricating flexible graphite into sheet, laminate and tape products. We manufacture advanced flexible graphite by subjecting expandable or flexible graphite to additional proprietary processing. These additional processing steps alter the properties and characteristics of the graphite to make materials with modified electrical, thermal and strength characteristics.

Natural graphite operates two state-of-the-art manufacturing facilities in the U.S. These facilities have the capability to chemically treat natural graphite flake, bake the flake in high temperature furnaces to expand the graphite flake, mechanically form and calender the expanded flake, and form and shape intermediate and finished products. We believe that we operate the world’s most technologically sophisticated advanced natural graphite production line.

Carbon electrodes and refractories are manufactured in the United States. Carbon electrodes (which can be up to 55 inches in diameter) are primarily extruded in a comparable process to graphite electrodes (excluding impregnation and graphitization). Refractories are manufactured using a proprietary “hot press” process.

We intend to cease production of carbon electrodes in 2006. Our facility in Columbia, Tennessee that manufactures carbon electrodes will continue to service advance graphite materials and refractories.

 

Quality Standards and Maintenance. Most of our global manufacturing facilities are certified and registered to ISO 9001-2000 international quality standards and some are certified

 

23

 

 

to QS 9000-1998 standards. Natural graphite has a quality assurance system designed to meet the most stringent requirements of its customers and is ISO TS 16949:2002 certified. Major maintenance at our facilities is conducted on an ongoing basis.

Raw Materials and Suppliers. The primary raw materials for electrodes and cathodes are engineered by-products and residues of the petroleum and coal industries. We use these raw materials because of their high carbon content. The primary raw materials for graphite electrodes and graphite cathodes are calcined petroleum cokes (needle coke for electrodes and regular grade cokes for cathodes), coal tar pitch and petroleum pitch. The primary raw materials for carbon electrodes and carbon cathodes are calcined anthracite coal and coal tar pitch and, in some instances, a petroleum coke-based material. The primary raw material for our natural graphite products is natural graphite flake. We purchase raw materials from a variety of sources and believe that the quality and cost of our raw materials on the whole is competitive with or better than those available to our competitors. Except as discussed below with regard to petroleum needle coke, we believe that adequate supplies of these raw materials are available at market prices.

We have a strategic alliance with ConocoPhillips, the largest producer of petroleum coke, to improve the supply chain for our primary raw material and, since the beginning of 2001, we have purchased a majority of our requirements for petroleum coke, at annually negotiated prices, from multiple plants of ConocoPhillips under an evergreen supply agreement. This evergreen supply agreement contains customary terms and conditions, including price renegotiation, dispute resolution and termination provisions, including, upon a termination, a 3-year supply arrangement with reducing volume commitments.

In 2004, Unocal sold its interest in its needle coke production company in Lemont, Illinois, to its partner, Citgo. Citgo announced that it would convert its facility from producing needle grade coke to fuel grade coke. We believe that Citgo stopped producing needle coke in late 2005. Furthermore, we believe that the loss of this volume could lead to a shortage of premium needle coke. We do not believe that there are any needle coke expansion plans that would cover completely the loss of the coke previously produced in Lemont. In 2005, these events had little to no effect on our ability to procure premium quality needle coke. For 2006, we have secured all of our needle coke requirements at annually fixed prices.

We purchase calcined anthracite coal for our carbon products under a five year supply agreement that expires in June 2006. This agreement contains customary terms and conditions.

 

We purchase energy from a variety of sources. Electric power used in manufacturing processes is purchased from local suppliers under contracts with pricing based on rate schedules or price indices. Our electric costs can vary significantly depending on these rates and usage. Natural gas used in manufacturing processes is purchased from local suppliers primarily under annual volume contracts with pricing based on various natural gas price indices.

We have in the past entered into, and may in the future enter into, natural gas derivative contracts and short duration fixed rate purchase contracts to effectively fix some or all of our natural gas cost exposure. At December 31, 2005, we had fixed about 23% of

 

24

 

 

our worldwide natural gas exposure through 2006 using such contracts. As of February 15, 2006, we had fixed about 32% of our worldwide natural gas exposure through such contracts.

 

Distribution

We deploy various demand management and inventory management techniques to seek to ensure we can meet our customers’ delivery requirements while still maximizing the utilization of our production capacity. We can experience significant variation in our customers’ delivery requirements as their specific needs vary and change through the year. We generally seek to maintain appropriate inventory levels, taking into account these factors as well as the significant differences in manufacturing cycle times for synthetic graphite products and our customers’ products.

Finished products are generally stored at our manufacturing facilities. Limited quantities of some finished products are also stored at local warehouses around the world to meet customer needs. We ship our finished products to customers primarily by truck and ship, using “just in time” techniques, where practical.

Proximity of manufacturing facilities to customers can provide a competitive advantage in terms of cost of delivery of graphite electrodes. These costs are affected by changes in currency exchange rates, methods of shipment, import duties and whether the manufacturing facilities are located in the same economic trading region as the customer. We believe that our manufacturing facilities are uniquely located around the world to supply graphite electrodes globally and that the locations of our facilities provide us with a significant competitive advantage.

Sales and Customer Service

Our product quality and our unique global manufacturing network, its proximity to regional and local customers and market segments and the related low cost structure allows us to deliver a broad range of product offerings across various market segments. We differentiate and sell the value of our product offerings, depending on the market segment or specific product application, primarily based on product quality and performance, delivery reliability, price, and customer technical service.

We price our offers based on the value that we believe we deliver to our customers. Pricing may vary within any given industry, depending on the market segment within that industry and the value of the offer to a specific customer. We believe that we can achieve premium prices through our value added offerings to customers. In certain segments where the product is less differentiated, we may achieve little or no premium for our offer. We have also begun to modify the terms of our offers, specifically in the area of graphite electrode sales, so that we have a some ability to adjust the price of our customer orders to reflect changes in costs or market conditions. Substantially all of our graphite electrode customers generally seek to negotiate and secure the reliable supply of their anticipated volume requirements on a semi-annual or annual basis, sometimes called the “graphite electrode book building process”. The remainder of our graphite electrode customers purchase their electrodes as needed at then current market prices (i.e., at the spot price). Our cathode customers primarily enter into longer term

 

25

 

 

“made to order” supply contracts, although certain customers also purchase their cathodes as needed at then current market prices (i.e., at the spot price). Our carbon electrode customers primarily enter into annual contracts with us for a percentage of their annual requirements at a firm price. We have, in certain instances, entered into long term supply contracts with purchasers of our carbon electrodes, and we may, from time to time in the future, enter into long term supply contracts with purchasers of our other products. Orders taken pursuant to our standard terms and conditions are generally not cancelable by the customer. However, these orders are subject to renegotiation or adjustment to meet changing market conditions. Currently, we do not manage or operate based on a backlog.

We believe that we are the recognized industry leader in providing value added technical services to customers for our major product lines, and that we have the largest customer technical service and related supporting engineering and scientific organizations in our industry, with more than 245 engineers, scientists and specialists around the world.

We deploy these selling methods and our customer technical service to address the specific market needs of all products.

Synthetic Graphite. We sell our graphite electrodes in every major geographic market primarily through our direct sales force, whose members are trained and experienced with our products. Our direct sales force operates from 16 sales offices located around the world. We also sell products through independent sales agents and distributors. The sales and service groups of our synthetic graphite segment include those dedicated to cathodes that are employed by Carbone Savoie.

We have graphite electrode customer technical service personnel based around the world who assist customers to maximize their production and minimize their costs. We employ about 160 engineers and technicians to provide technical service and advice to key steel and other metals customers. These services include furnace design and operation, as well as furnace upgrades to reduce energy consumption, improve raw material costs and increase output. We believe that our synthetic graphite segment has more technical service engineers located in more countries than any of its competitors.

Other. Our natural graphite products are sold through direct field sales employees in the U.S., Europe and Asia and through independent sales agents and distributors. Customer service personnel, supported by development scientists and manufacturing engineers, assist customers in learning about and using our natural graphite products, improving their manufacturing processes and operations, and solving their technical dilemmas. A particular focus is assisting customers and others who design, develop or produce electronic devices to integrate our advantaged flexible graphite solutions into their new devices.

Our carbon electrode and refractory products are sold through their respective direct global sales force, located in all of their major markets, as well as through independent agents and distributors. A U.S. sales office coordinates the activities of an experienced sales staff and these agents and distributors. Our experienced engineering staff provides technical service to customers around the world, including specialized technical assistance to submerged arc and

 

26

 

 

other furnace operators with regard to product performance, furnace monitoring and operations analysis. We believe that our customer technical service staff is highly regarded.

Technology

We believe that we are the industry leader in graphite and carbon materials science and high temperature processing know-how and that we operate the premier research, development and testing facilities in our industry. We have over 100 years of experience in the research and development of graphite and carbon technologies. Over the past several years, we have analyzed our intellectual property portfolio to identify new product opportunities in markets with high growth potential for us, redirected research to enhance and exploit our portfolio and accelerated development of products for those markets.

Research and Development. We conduct our research and development both independently and in conjunction with our strategic partners, customers and others. We have two dedicated technology centers, one in Ohio, which focuses on all products, and the other in France, which is used by Carbone Savoie. We also have a pilot plant located in Ohio that has the capability to produce small or trial quantities of new or improved synthetic or natural graphite products. In addition, we have a state-of-the-art testing facility located in Ohio capable of conducting physical and analytical testing for those products. The activities at these centers and facilities are integrated with the efforts of our engineers at our manufacturing facilities who are focused on improving manufacturing processes.

Research and development expenses amounted to $10,410, $8,040 and $9,437 in 2003, 2004 and 2005, respectively.

We believe that our technological and manufacturing strengths and capabilities provide us with a significant growth opportunity as well as a competitive advantage and are important factors in the selection of us by industry leaders and others as a strategic partner. Our technological capabilities include developing products with superior thermal, electrical and physical characteristics that provide a differentiating advantage. We seek to exploit these strengths and capabilities across all of our businesses, to improve existing products and to develop and commercialize new products for markets with high growth potential.

Developments by us include:

larger and stronger graphite electrodes;

new chemical additives to enhance raw materials used in the manufacture of graphite electrodes;

patented advanced pin technology for graphite electrodes;

patent pending pinless large diameter graphite electrodes;

cold pastes with reduced environmental impact for use with cathodes;

 

 

27

 

 

 

patented processing technology for high performance graphite cathodes which have become the preferred products in the industry;

products for PEM fuel cells that are enabling fuel cell commercialization; and

new electronic thermal management technologies.

We have been awarded preferred or certified supplier status by many major steel, aluminum, and automotive supply companies and have received numerous technological innovation and other awards by industry groups, customers and others. For the past three years, we have received R&D Magazine’s prestigious R&D 100 Award, granted to identify the 100 most technologically significant commercialized products each year. We received this award in 2003 and 2004 for our achievements in electronic thermal management products and in 2005 for our large-diameter pinless graphite electrodes.

A significant portion of our research and development is focused on new product development, including advancements in electrode and cathode technology, achievement of the objectives of our strategic alliances with companies that use or specify the use of electronic thermal management technologies and our strategic alliance with Ballard Power Systems for PEM fuel cells.

Technology Licensing and Research, Testing and Other Services. We offer, through licensing contracts, rights to use our intellectual property to other firms developing or manufacturing products. We also provide, through service contracts:

research and development services;

extensive product testing services (such as high temperature testing and analysis);

high temperature heat treating services;

graphite and carbon process and product technology, consulting and development services; and

information services to customers, suppliers and universities to assist in their development of new or improved process and product technology.

Among other things, we provide cost-effective services for a broad range of markets and license our proprietary technology for a broad range of applications through our web site. The web site includes technical papers on graphite and carbon science, technical literature and search assistance, and industry news as well as access to our services.

Intellectual Property. We believe that our intellectual property, consisting primarily of patents and proprietary know-how and information, particularly the intellectual property relating to electronic thermal management and fuel cell power generation, provides us with competitive advantages and is important to our growth opportunities. Our intellectual property portfolio is extensive, with about 320 U.S. and foreign patents and over 370 U.S. and foreign pending patent applications, which we believe is more than any of our major competitors. Over 130 of these

 

28

 

 

patents were granted during the past four years. Among our competitors, we hold the largest number of patents for flexible graphite as well as the largest number of patents relating to the use of natural graphite for PEM fuel cell applications. In addition, we have obtained exclusive and non-exclusive licenses to various U.S. and foreign patents relating to our technologies. These patents and licenses expire at various times over the next two decades.

We own, and have obtained licenses to, various trade names and trademarks used in our businesses. For example, the trade name and trademark UCAR are owned by Union Carbide Corporation (which has been acquired by Dow Chemical Company) and are licensed to us on a worldwide, exclusive and royalty-free basis until 2015. This particular license automatically renews for successive ten-year periods. It permits non-renewal by Union Carbide commencing after the first ten-year renewal period upon five years’ notice of non-renewal. The trade name and trademark CARBONE SAVOIE are owned by Carbone Savoie and are used in connection with cathodes manufactured by it. The trademark CARBONE SAVOIE is registered in many countries throughout the world.

We rely on patent, trademark, copyright and trade secret laws as well as appropriate agreements to protect our intellectual property. Among other things, we seek to protect our proprietary know-how and information, through the requirement that employees, consultants, strategic partners and others, who have access to such proprietary information and know-how, enter into confidentiality or restricted use agreements.

Competition

Synthetic Graphite. Competition in the graphite electrode, cathode and advanced graphite material businesses is based primarily on product differentiation and quality, delivery reliability, price, and customer service, depending on the market segment or specific product application.

Global and regional economic conditions and prior antitrust investigations, lawsuits and claims have had an impact on the graphite electrode industry. We believe that, at a minimum, these impacts include increased price competition and increased debt or cost burdens, or both, for most manufacturers in the industry.

In the most demanding product applications (that is, graphite electrodes that can operate in the largest, most productive and demanding EAF steel mills in the world), we compete primarily on product quality, delivery reliability, price and customer technical service. We believe these are prerequisite capabilities that not all producers of graphite electrodes possess or can demonstrate consistently. In this market segment, we primarily compete with higher quality graphite electrode producers, although certain other lower quality producers can demonstrate adequacy in certain melters.

In other product applications, including ladle furnaces requiring less demanding performance and certain other ferrous and non-ferrous market segments, we compete based on product differentiation, product quality and price. Our product quality, unique global manufacturing network, proximity to regional and local customers and market segments and the

 

29

 

 

related lower cost structure allows us to deliver a broad range of product offerings across these various market segments.

We believe that there are no current commercially viable substitutes for graphite electrodes in EAF steel production or for cathodes in aluminum smelting furnaces.

We believe that there are significant barriers to entry into our industry, including the need for extensive product and process know-how and other intellectual property and a high initial capital investment. It also requires high quality raw material sources and a developed energy supply infrastructure. There have been no entrants in the graphite electrode industry for more than 50 years. We are not aware of any “greenfield” construction of new graphite electrode manufacturing facilities and believe that it is unlikely that new “greenfield” graphite electrode manufacturing facilities will be built during the next several years by existing competitors due to, among other things, the relatively high initial capital investment. We believe that one or more of our graphite electrode competitors in India are in the process of incrementally expanding their graphite electrode manufacturing capacity and are also providing technical know-how in connection with the potential manufacture of graphite electrodes in Iran. We believe that we can significantly expand our graphite electrode manufacturing capacity at a cost that is less than 25% of the initial investment for “greenfield” capacity.

There are only five multinational graphite electrode producers, GrafTech, SGL Carbon, Tokai Carbon, Showa Denko Carbon and Graphite India. We are the only manufacturer with production facilities in more than three continents. Other notable electrode producers include HEG (India), SEC (Japan) and NDK (Japan). There are several smaller, local manufacturers in the U.S., China and Russia. There are six notable manufacturers of cathodes in the world. We believe that we and SGL Carbon are the largest manufacturers of cathodes in the world. There are about four significant manufacturers of advanced graphite materials in the world.

Other. Competition in the natural graphite business with respect to existing products is based primarily on quality and price. Competition with respect to services and new products is based primarily on product and service innovation, performance and cost effectiveness as well as customer service, with the relative importance of these factors varying among services, products and customers.

Competitors include companies located around the world that develop and manufacture natural graphite products, including SGL Carbon, and companies that develop, manufacture or provide substitute or alternative materials, products, services or solutions. We are one of the largest manufacturers of natural graphite products in the world.

Our electronic thermal management solutions compete with a wide variety of materials, including copper and other metals, ceramics, conductive rubbers and greases. Our fuel cell products compete with other graphitic products, including fibers, composites and synthetic graphite, and metal products such as stainless steel. Our sealing and gasket products compete with various fiber products such as asbestos, cellulose and synthetic composites as well as stainless steel and other metals. Our fire retardant products compete with compounds containing phosphates, halogens and hydrated aluminas as well as many other materials. Our industrial

 

30

 

 

thermal management products compete with a wide variety of materials, including natural and synthetic fibers, other carbon forms and metal products.

Competition in the carbon electrode and refractory businesses is based primarily on product differentiation and quality, delivery reliability, price, and customer service, depending on the market segment or specific product application. We are aware of commercially viable technologies that are competitive with carbon electrodes. There are four significant manufacturers of carbon electrodes in the world.

Environmental Matters

We are subject to a wide variety of federal, state, local and foreign laws and regulations relating to the presence, storage, handling, generation, treatment, emission, release, discharge and disposal of hazardous, toxic and other substances and wastes, which govern our current and former properties, neighboring properties and our current operations. These laws and regulations (and the enforcement thereof) are periodically changed and are becoming increasingly stringent. We have experienced some level of regulatory scrutiny at most of our current and former facilities, and have been required to take corrective or remedial actions and incur related costs in the past, and may experience further regulatory scrutiny, and may be required to take further corrective or remedial actions and incur additional costs, in the future. Although it has not been the case in the past, these costs could have a material adverse effect on us in the future.

The principal U.S. laws and regulations to which we are subject include:

the Clean Air Act, the Clean Water Act and the Resource Conservation and Recovery Act and similar state and local laws which regulate air emissions, water discharges and hazardous waste generation, treatment, storage, handling, transportation and disposal;

the Comprehensive Environmental Response, Compensation and Liability Act of 1980, as amended by the Superfund Amendments and Reauthorization Act of 1986, and the Small Business Liability Relief and Brownfields Revitalization Act of 2002, and similar state laws that provide for the reporting of, responses to and liability for releases of hazardous substances into the environment; and

the Toxic Substances Control Act and related laws that are designed to track and control chemicals that are produced or imported into the United States and assess the risk to health and to the environment of new products at early developmental stages.

Further, laws adopted or proposed in various states impose or may impose, as the case may be, reporting or remediation requirements if operations cease or property is transferred or sold.

Our manufacturing operations outside the U.S. are subject to the laws and regulations of the countries in which those operations are conducted. These laws and regulations primarily relate to pollution prevention and the control of the impacts of industrial activities on the quality of the air, water and soil. Regulated activities include, among other things: use of hazardous

 

31

 

 

substances; packaging, labeling and transportation of products; management and disposal of toxic wastes; discharge of industrial and sanitary wastewater; and process emissions to the air.

We believe that we are currently in material compliance with the federal, state, local and foreign environmental laws and regulations to which we are subject. We have received and continue periodically to receive notices from the U.S. Environmental Protection Agency (the “USEPA”) or state environmental protection agencies, as well as claims from others, alleging that we are a potentially responsible party (a “PRP”) under Superfund and similar state laws for past and future remediation costs at hazardous substance disposal sites. Although Superfund liability is joint and several, in general, final allocation of responsibility at sites where there are multiple PRPs is made based on each PRP’s relative contribution of hazardous substances to the site. Based on information currently available to us, we believe that any potential liability we may have as a PRP will not have a material adverse effect on us.

As a result of amendments to the Clean Air Act enacted in 1990, certain of our facilities have been or will be required to comply with new standards for air emissions that have been or will be adopted by the USEPA and state environmental protection agencies over the next several years pursuant to regulations that have been or will be promulgated, including the USEPA’s anticipated promulgation of maximum achievable control technology standards for the carbon and graphite manufacturing industry. The regulations that have been promulgated to date will necessitate use of additional administrative and engineered controls, and changes in certain manufacturing processes, in order for us to achieve compliance with these regulations. Similar foreign laws and regulations have been or may also be adopted to establish new standards for air emissions, which may also require additional controls on our manufacturing operations outside the U.S. Based on information currently available to us, we believe that compliance with these regulations will not have a material adverse effect on us.

We have sold or closed a number of facilities that had operated solid waste landfills on-site. In most cases where we divested the properties, we have retained ownership of the landfills. When our landfills were or are to be sold, we obtained or seek to obtain financial assurance we believe to be adequate to protect us from any potential future liability associated with these landfills. When we have closed landfills, we believe that we have done so in material compliance with applicable laws and regulations. We continue to monitor these landfills pursuant to applicable laws and regulations. To date, the costs associated with the landfills have not been, and we do not anticipate that future costs will be, material to us.

We establish accruals for environmental liabilities where it is probable that a liability has been incurred and the amount of the liability can be reasonably estimated. We adjust accruals as new remediation and other commitments are made and as information becomes available which changes estimates previously made.

Estimates of future costs for compliance with environmental protection laws and regulations, and for environmental liabilities, are necessarily imprecise due to numerous uncertainties, including the impact of new laws and regulations, the availability and application of new and diverse technologies, the extent of insurance coverage, the discovery of contaminated properties, or the identification of new hazardous substance disposal sites at which we may be a PRP and, in the case of sites subject to Superfund and similar state and foreign laws, the ultimate

 

32

 

 

allocation of costs among PRPs and the final determination of remedial requirements. Subject to the inherent imprecision in estimating such future costs, but taking into consideration our experience to date regarding environmental matters of a similar nature and facts currently known, we believe that costs and capital expenditures (in each case, before adjustment for inflation) for environmental protection compliance and for remedial response will not increase materially over the next several years.

Insurance

We obtain insurance against civil liabilities relating to personal injuries to third parties, for loss of or damage to property, for business interruptions and for environmental matters, to the extent that it is currently available and provides coverage that we believe is appropriate upon terms and conditions and for premiums that we consider fair and reasonable. We believe that we have insurance providing coverage for claims and in amounts that we believe appropriate as described above. We cannot assure you, however, that we will not incur losses beyond the limits of or outside the coverage of our insurance.

Employees

Since 1998, we have reduced our global workforce by about 1,700 employees, or over 30%. At December 31, 2005, we had 3,851 employees, of which 1,745 were in Europe (including Russia), 903 were in Mexico and Brazil, 364 were in South Africa, 3 were in Canada, 829 were in the U.S. and 7 were in the Asia Pacific region. At December 31, 2005, 2,753 of our employees were hourly employees.

At December 31, 2005, about 69% of our worldwide employees were covered by collective bargaining or similar agreements, which expire at various times in each of the next several years. At December 31, 2005, about 1,355 employees, or 35% of our employees, were covered by agreements which expire, or are subject to renegotiation, at various times through December 31, 2006. We believe that, in general, our relationships with our unions are satisfactory and that we will be able to renew or extend our collective bargaining or similar agreements on reasonable terms as they expire. We cannot assure, however, that renewed or extended agreements will be reached without a work stoppage or strike or will be reached on terms satisfactory to us.

Excluding our subsidiaries prior to the time when we acquired them, we have not had any material work stoppages or strikes during the past decade.

Item 1A.  Risk Factors

(Unless otherwise noted, all dollars are presented in thousands)

 

An investment in our securities involves a high degree of risk. The risks described below are not the only ones facing us. Additional risks not presently known to us, or that we currently deem immaterial, may also have a material adverse effect on us. If any of the following risks actually occur, our financial condition, results of operations, cash flows or business could be harmed. In that case, the market price of our securities could decline, and you could lose part or all of your investment.

 

 

33

 

 

 

Risks Relating to Us

We are dependent on the global steel and aluminum industries and also sell products to the transportation, semiconductor, petrochemical and other metals industries. Our results of operations may deteriorate during global and regional economic downturns.

We sell graphite electrodes, which accounted for about 66% of our total net sales in 2005, primarily to the EAF steel production industry. We also sell cathodes, which accounted for about 13% of our total net sales in 2005, to the aluminum industry. Many of our other products are sold primarily to the transportation, semiconductor, petrochemical and other metals industries. These are global basic industries, and they are experiencing various degrees of growth and consolidation. Customers in these industries are located in every major geographic market. As a result, our customers are affected by changes in global and regional economic conditions. This, in turn, affects overall demand and prices for our products sold to these industries. As a result of changes in economic conditions, demand and pricing for our products sold to these industries has fluctuated significantly.

Demand for our products sold to these industries may be adversely affected by improvements in our products as well as in the manufacturing operations of customers, which reduce the rate of consumption or use of our products for a given level of production by our customers. In the case of graphite electrodes, we estimate that specific consumption declined from about 4.3 kilograms of graphite electrodes per metric ton of steel produced in 1990 to about 2.2 kilograms per metric ton in 2005. We believe that the rate of decline of specific consumption over the long term has become lower.

Sales volumes and prices of our products sold to these industries are impacted by the supply/demand balance as well as overall demand and growth of and consolidation within the end markets for our products. In addition to the factors mentioned above, the supply/demand balance is affected by factors such as business cycles, rationalization, increase in capacity and productivity initiatives within our industry and the end markets for our products, some of which factors are affected by decisions by us.

We cannot assure you that the EAF steel production industry will continue to be the higher long term growth sector of the steel industry, that the aluminum industry will continue to experience long term growth or that any of the other industries to which we sell products will continue to strengthen as a result of current economic conditions. Accordingly, we cannot assure you that there will be stability or growth in demand for or prices of graphite electrodes or our other products sold to these industries. An adverse change in global or certain regional economic conditions could adversely affect us in a material way.

The planned growth of our natural graphite sales, which depends primarily on the successful and profitable development, manufacture and sale of thermal management products for electronic devices and products for PEM fuel cells and fuel cell systems, may not be achieved.

 

 

34

 

 

 

Successful and profitable commercialization of products is subject to various risks, including risks beyond our control such as:

the possibility that we may not be able to develop viable products or, even if we develop viable products, that our products may not gain commercial acceptance;

the possibility that, until our products gain broad commercial acceptance, our sales may be concentrated in a limited number of customers;

the possibility that our commercially accepted products could be subsequently displaced by other products or technologies;

the possibility that, even if our products are incorporated in new products of our customers, our customers

new products may not become viable or commercially accepted or may be subsequently displaced;

the possibility that a mass market for our commercially accepted products, or for our customers’ products which incorporate our products, may not develop;

restrictions under our agreements with Ballard Power Systems on sales of our fuel cell products to, and collaboration with, others; and

failure of our customers to purchase our products in the quantities that we expect.

These risks could be impacted by factors such as adoption of new laws and regulations, changes in governmental programs, failure of necessary supporting systems (such as fuel delivery infrastructure for fuel cells) to be developed, and consumer perceptions about costs, benefits and safety.

Our financial condition could suffer if we experience unanticipated costs as a result of antitrust investigations and antitrust and securities class action lawsuits and claims.

Since 1997, we have been subject to antitrust investigations and related lawsuits and claims. Our insurance has not and will not cover any material liabilities that have or may become due in connection with antitrust investigations, lawsuits or claims.

We cannot assure you that remaining liabilities and expenses in connection with antitrust investigations, lawsuits and claims will not materially exceed any reserve related thereto or that the timing of payment thereof will not be sooner than anticipated. If such liabilities or expenses materially exceed any reserve or if the timing of payment thereof is sooner than anticipated, such events could materially adversely affect us.

In March 2006, we were served with a complaint commencing a securities class action lawsuit against us and certain of our officers. Securities class action lawsuits against various companies have resulted in material liabilities and expenses, some or all of which have not been covered by insurance. This lawsuit is in its earliest stages and we do not have any reserve related thereto.

 

 

35

 

 

 

We are highly leveraged and our substantial debt and other obligations could limit our financial resources and ability to compete and may make us more vulnerable to adverse economic events.

Our high leverage and other obligations could have important consequences, including the following:

our ability to restructure or refinance our debt or obtain additional debt or equity financing for payment of these obligations, or for working capital, capital expenditures, acquisitions or other general corporate purposes, may be impaired in the future;

a substantial portion of our cash flow from operations must be dedicated to debt service and payment of other obligations, thereby reducing the funds available to us for other purposes;

an increase in interest rates could result in an increase in the portion of our cash flow from operations dedicated to debt service or cash collateral requirements, in lieu of other purposes;

we may have substantially more leverage and other obligations than certain of our competitors, which may place us at a competitive disadvantage; and

our leverage and other obligations may hinder our ability to adjust rapidly to changing market conditions or other events and make us more vulnerable to insolvency, bankruptcy or other adverse consequences in the event of a downturn in general or certain regional economic conditions or in our business or in the event that these obligations are greater, or the timing of payment is sooner, than expected.

Our cash flow and capital resources may be insufficient to enable us to service our debt and meet our other obligations as they become due.

If our cash flow and capital resources are insufficient to enable us to service our debt and meet these obligations as they become due, we could be forced to: reduce or delay capital expenditures; sell assets or businesses; limit or discontinue, temporarily or permanently, business plans or operations; obtain additional debt or equity financing; or restructure or refinance debt.

We cannot assure you as to the timing of such actions or the amount of proceeds that could be realized from such actions.

We are subject to restrictive covenants under the Revolving Facility and the Senior Notes. These covenants could significantly affect the way in which we conduct our business. Our failure to comply with these covenants could lead to an acceleration of our debt.

The Revolving Facility and the Senior Notes contain a number of covenants that, among other things, restrict our ability to: sell assets; incur, repay or refinance indebtedness; create liens; make investments or acquisitions; engage in mergers or acquisitions; pay dividends; repurchase stock; or make capital expenditures.

 

 

36

 

 

 

The Revolving Facility also requires us to comply with specified financial covenants, including minimum interest coverage and maximum senior secured leverage ratios. We cannot borrow under the Revolving Facility if the additional borrowings would cause us to breach the financial covenants.

Further, substantially all of our assets are pledged to secure indebtedness as described under “Risks Relating to Our Securities and Pledges of Our Assets.”

Our ability to continue to comply may be affected by events beyond our control. The breach of any of the covenants contained in the Revolving Facility, unless waived, would be a default under the Revolving Facility. This would permit the lenders to terminate their commitments to extend credit under, and accelerate the maturity of, the Revolving Facility. An acceleration of maturity of the Revolving Facility would permit the holders of the Senior Notes and the Debentures to accelerate the maturity of the Senior Notes and the Debentures, respectively. A breach of the covenants under the Senior Notes, unless waived, would be a default under the Senior Notes. This would also permit the holders of the Senior Notes to accelerate the maturity of the Senior Notes. An acceleration of maturity of the Senior Notes would permit the holders of the Debentures to accelerate the maturity of the Debentures and the lenders to accelerate the maturity of the Revolving Facility. A breach of our obligations under the Debentures, unless waived, would be a default under the Debentures. This would also permit the holders of the Debentures to accelerate the maturity of the Debentures. Acceleration of maturity of the Debentures would permit the holders of the Senior Notes to accelerate the maturity of the Senior Notes and the lenders to accelerate the maturity of the Revolving Facility. The acceleration of our debt could have a material adverse effect on our financial condition and liquidity. If we were unable to repay our debt to the lenders and holders or otherwise obtain a waiver from the lenders and holders, we could be forced to take the actions described in the preceding risk factor and the lenders and holders could proceed against the collateral securing the Revolving Facility and the Senior Notes and exercise all other rights available to them. We cannot assure you that we will have sufficient funds to make these accelerated payments or that we will be able to obtain any such waiver on acceptable terms or at all.

We are subject to risks associated with operations in multiple countries.

A substantial majority of our net sales are derived from sales outside the U.S., and a substantial majority of our operations and our total property, plant and equipment and other long-lived assets are located outside the U.S. As a result, we are subject to risks associated with operating in multiple countries, including:

currency devaluations and fluctuations in currency exchange rates, including impacts of transactions in various currencies, impact on translation of various currencies into dollars for U.S. reporting and financial covenant compliance purposes, and impacts on results of operations due to the fact that costs of our foreign subsidiaries are primarily incurred in local currencies while their products are primarily sold in dollars and euros;

creation of tax attributes in certain jurisdictions that we may not be able to utilize due to the lack of taxable income in relevant jurisdictions and creation or reversal of

 

37

 

 

valuation allowances with respect to the related deferred tax assets due to changes in such circumstances and our estimates of the likely utilization of such assets;

imposition of or increases in customs duties and other tariffs;

imposition of or increases in currency exchange controls, including imposition of or increases in limitations on conversion of various currencies into dollars or euros, making of intercompany loans by subsidiaries or remittance of dividends, interest or principal payments or other payments by subsidiaries;

imposition of or increases in revenue, income or earnings taxes and withholding and other taxes on remittances and other payments by subsidiaries;

imposition of or increases in investment or trade restrictions and other restrictions or requirements by non-U.S. governments;

inability to definitively determine or satisfy legal requirements, inability to effectively enforce contract or legal rights and inability to obtain complete financial or other information under local legal, judicial, regulatory, disclosure and other systems; and

nationalization and other risks which could result from a change in government or other political, social or economic instability.

We cannot assure you that such risks will not have a material adverse effect on us or that we would be able to mitigate such material adverse effects in the future.

In general, our results of operations and financial condition are affected by inflation in each country in which we have a manufacturing facility. We cannot assure you that future increases in our costs will not exceed the rate of inflation or the amounts, if any, by which we may be able to increase prices for our products.

Our ability to grow and compete effectively depends on protecting our intellectual property. Failure to protect our intellectual property could adversely affect us.

We believe that our intellectual property, consisting primarily of patents and proprietary know-how and information, particularly the intellectual property relating to electronic thermal management and fuel cell power generation, is important to our growth. Failure to protect our intellectual property may result in the loss of the exclusive right to use our technologies. We rely on patent, trademark, copyright and trade secret laws and confidentiality and restricted use agreements to protect our intellectual property. Some of our intellectual property is not covered by any patent or patent application or any such agreement.

Patents are subject to complex factual and legal considerations. Accordingly, there can be uncertainty as to the validity, scope and enforceability of any particular patent. Therefore, we cannot assure you that:

 

 

38

 

 

 

any of the U.S. or foreign patents now or hereafter owned by us, or that third parties have licensed to us or may in the future license to us, will not be circumvented, challenged or invalidated;

any of the U.S. or foreign patents that third parties have non-exclusively licensed to us, or may non-exclusively license to us in the future, will not be licensed to others; or

any of the patents for which we have applied or may in the future apply will be issued at all or with the breadth of claim coverage sought by us.

Moreover, patents, even if valid, only provide protection for a specified limited duration.

We cannot assure you that agreements designed to protect our proprietary know-how and information will not be breached, that we will have adequate remedies for any such breach, or that our strategic alliance partners, consultants, employees or others will not assert rights to intellectual property arising out of our relationships with them.

In addition, effective patent, trademark and trade secret protection may be limited, unavailable or not applied for in the U.S. or in any of the foreign countries in which we operate.

Further, we cannot assure you that the use of our patented technology or proprietary know-how or information does not infringe the intellectual property rights of others.

Intellectual property protection does not protect against technological obsolescence due to developments by others or changes in customer needs.

The protection of our intellectual property rights may be achieved, in part, by prosecuting claims against others whom we believe have misappropriated our technology or have infringed upon our intellectual property rights, as well as by defending against misappropriation or infringement claims brought by others against us. Our involvement in litigation to protect or defend our rights in these areas could result in a significant expense to us, adversely affect the development of sales of the related products, and divert the efforts of our technical and management personnel, regardless of the outcome of such litigation.

If necessary, we may seek licenses to intellectual property of others. However, we can give no assurance to you that we will be able to obtain such licenses or that the terms of any such licenses will be acceptable to us. Our failure to obtain a license from a third party for its intellectual property that is necessary for us to make or sell any of our products could cause us to incur substantial liabilities and to suspend the manufacture or shipment of products or use of processes requiring the use of such intellectual property.

Our current and former manufacturing operations are subject to increasingly stringent health, safety and environmental requirements.

We use and generate hazardous substances in our manufacturing operations. In addition, both the properties on which we currently operate and those on which we have ceased operations are and have been used for industrial purposes. Further, our manufacturing operations involve

 

39

 

 

risks of personal injury or death. We are subject to increasingly stringent environmental, health and safety laws and regulations relating to our current and former properties, neighboring properties, and our current operations. These laws and regulations provide for substantial fines and criminal sanctions for violations and sometimes require the installation of costly pollution control or safety equipment or costly changes in operations to limit pollution or decrease the likelihood of injuries. In addition, we may become subject to potential material liabilities for the investigation and cleanup of contaminated properties, for claims alleging personal injury or property damage resulting from exposure to or releases of hazardous substances, or for personal injury as a result of an unsafe workplace. Further, alleged noncompliance with or stricter enforcement of, or changes in interpretations of, existing laws and regulations, adoption of more stringent new laws and regulations, discovery of previously unknown contamination or imposition of new or increased requirements could require us to incur costs or become the basis of new or increased liabilities that could be material.

We are dependent on supplies of raw materials and energy at affordable prices. Our results of operations could deteriorate if that supply is substantially disrupted for an extended period.

We purchase raw materials and energy from a variety of sources. In many cases, we purchase them under short term contracts or on the spot market, in each case at fluctuating prices. We purchase a majority of our requirements for petroleum coke, our principal raw material, from multiple plants of a single supplier under an evergreen supply agreement, containing customary terms and conditions, including price renegotiation, dispute resolution and termination provisions. The availability and price of raw materials and energy may be subject to curtailment or change due to:

limitations which may be imposed under new legislation or regulation;

suppliers’ allocations to meet demand of other purchasers during periods of shortage (or, in the case of energy suppliers, extended cold weather);

interruptions or cessations in production by suppliers; and

market and other events and conditions.

Petroleum and coal products, including petroleum coke and pitch, our principal raw materials, and energy, particularly natural gas, have been subject to significant price fluctuations.

We have in the past entered into, and may in the future enter into, natural gas derivative contracts and short duration fixed rate purchase contracts to effectively fix some or all of our natural gas cost exposure. At December 31, 2005, we had fixed about 23% of our worldwide natural gas exposure through 2006 using such contracts. As of February 15, 2006, we had fixed about 32% of our worldwide natural gas exposure through such contracts.

 

 

40

 

 

 

A substantial increase in raw material or energy prices which cannot be mitigated or passed on to customers or a continued interruption in supply, particularly in the supply of petroleum coke or energy, would have a material adverse effect on us.

Our results of operations could deteriorate if our manufacturing operations were substantially disrupted for an extended period.

Our manufacturing operations are subject to disruption due to extreme weather conditions, floods and similar events, major industrial accidents, strikes and lockouts, adoption of new laws or regulations, changes in interpretations of existing laws or regulations or changes in governmental enforcement policies, and other events. We cannot assure you that no such events will occur. If such an event occurs, it could have a material adverse effect on us.

We have significant non-dollar-denominated intercompany loans and have had in the past, and may in the future have, foreign currency financial instruments and interest rate swaps and caps. The related gains and losses have in the past been, and may in the future be, significant.

We have non-dollar-denominated intercompany loans between GrafTech Finance and some of our foreign subsidiaries. At December 31, 2004 and 2005, the aggregate principal amount of these loans was $414,457 and $318,663, respectively. These loans are subject to remeasurement gains and losses due to changes in currency exchange rates. A portion of these loans are deemed to be essentially permanent and, as a result, remeasurement gains and losses on these loans are recorded as a component of accumulated other comprehensive loss in the stockholders’ deficit section of the Consolidated Balance Sheets. The balance of these loans are deemed to be temporary and, as a result, remeasurement gains and losses on these loans are recorded as currency (gains) losses in other expense (income), net, on the Consolidated Statements of Operations. These gains or losses have in the past been and may in the future be substantial. These gains and losses may cause reported results to differ from actual cash operating results, and such difference may be material.

Additionally, we have in the past entered into, and may in the future enter into, interest rate swaps and caps to attempt to manage interest rate expense. We have also in the past entered into, and may in the future enter into, foreign currency financial instruments to attempt to hedge global currency exposures, net, relating to euro-denominated debt and identifiable foreign currency receivables, payables and commitments held by our foreign and domestic subsidiaries. We may purchase or sell these financial instruments, and open and close hedges or other positions, at any time. Changes in currency exchange rates or interest rates have in the past resulted, and may in the future result, in significant gains or losses with respect thereto. These instruments are marked-to-market monthly and gains and losses thereon are recorded in the Consolidated Statement of Operations.

Our results of operations for any quarter are not necessarily indicative of our results of operations for a full year.

Sales of graphite electrodes and other products fluctuate from quarter to quarter due to such factors as changes in economic conditions, changes in competitive conditions, scheduled

 

41

 

 

plant shutdowns by customers, national vacation practices, changes in customer production schedules in response to seasonal changes in energy costs, weather conditions, strikes and work stoppages at customer plants and changes in customer order patterns in response to the announcement of price increases or price adjustments. We have experienced, and expect to continue to experience, volatility with respect to demand for and prices of graphite electrodes and other products, both globally and regionally. We have also experienced volatility with respect to prices of raw materials and energy, and we expect to experience volatility in such prices in the future. Accordingly, results of operations for any quarter are not necessarily indicative of the results of operations for a full year.

The graphite and carbon industry is highly competitive. Our market share, net sales or net income could decline due to vigorous price and other competition.

Competition in the graphite and carbon products industry (other than with respect to new products) is based primarily on product differentiation and quality, delivery reliability, price and customer service. Electrodes, in particular, are subject to rigorous price competition. Price increases by us or price reductions by our competitors, decisions by us or our competitors with respect to prices, volumes or profit margins, technological developments, changes in the desirability or necessity of entering into long term supply contracts with customers or other competitive or market factors or strategies could adversely affect our market share, net sales or net income.

Competition with respect to new products is, and is expected to be, based primarily on product innovation, performance and cost effectiveness as well as customer service.

Competition could prevent implementation of price increases, require price reductions or require increased spending on research and development, marketing and sales that could adversely affect us.

To achieve our planned growth and successfully complete our overhead cost reduction and restructuring activities, we may need to attract qualified personnel. Failure to do so could adversely affect us.

 

We are seeking to achieve growth and cost-savings, and activities related thereto may require us to hire a substantial number of additional qualified personnel and promote or replace with new qualified personnel a substantial number of existing employees whose functions are changed, who elect not to relocate or who resign or are terminated for other reasons. Companies that experience rapid growth or substantial turnover in personnel frequently encounter higher costs and operating inefficiencies (which can adversely impact internal and disclosure control environments so as to result in errors, omissions and delays in financial statements and public reporting that may be material as well as adversely impact execution of business plans and financial performance) until the new personnel are integrated into the organization. If we are unable to hire, promote or replace such employees with qualified personnel and effectively and quickly integrate them into our organization, our growth, business operations or finance, legal and administrative activities would likely be adversely affected.

 

We may not be able to complete our planned asset sales.

 

We intend to continue to sell real estate, non-strategic businesses and certain other non-strategic assets. We cannot assure you if or when we will be able to complete these sales or that we will realize proceeds therefrom that meet our current expectations.

 

 

42

 

 

 

We have significant deferred income tax assets in multiple jurisdictions, and we may not be able to realize any benefits from those assets.

At December 31, 2005, we had $248,022 of gross deferred income tax assets, of which $208,393 required a valuation allowance. In addition we had $69,083 of gross deferred income tax liabilities. Our valuation allowance means that we do not believe that these assets are more likely than not to be realized. Until we determine that it is more likely than not that we will generate sufficient U.S. taxable income to realize our deferred income tax assets, income tax benefits in each current period will be fully reserved. This valuation allowance does not affect our ability and intent to utilize these assets to reduce taxes on future taxable income in the U.S. Future realization of the tax benefit from these tax assets depends on the existence of sufficient future taxable income of the appropriate character within the relevant periods and jurisdictions under the existing tax laws. We cannot assure you of the existence of such sufficient taxable income.

Risks Relating to Our Securities and Pledges of Our Assets

The Senior Notes and the related guarantees have limited security, and the Debentures and the related guarantees have no security. As a result, the Debt Securities are effectively subordinated to the Revolving Facility, which is secured by most of our assets, and to certain other secured debt and obligations. This could result in holders of the Debt Securities receiving less on liquidation than the lenders under the Revolving Facility and certain other creditors. In addition, this could result in holders of the Debentures receiving less on liquidation than the holders of the Senior Notes.

The borrower under the Revolving Facility is GrafTech Finance. The Revolving Facility is guaranteed by all of our domestic subsidiaries (other than AET) and certain of our foreign subsidiaries. Substantially all of the assets of such subsidiaries (except for the unsecured intercompany term note obligations described below) are pledged to secure obligations of GrafTech Finance as borrower under the Revolving Facility, guarantees by such subsidiaries of the Revolving Facility or intercompany loans to such guarantors under the Revolving Facility. Proceeds of borrowings under the Revolving Facility are required to be:

used by GrafTech Finance for its own purposes; or

loaned by GrafTech Finance to GTI or certain of our other domestic subsidiaries or to our Swiss subsidiary under intercompany revolving notes that are pledged to secure the Revolving Facility.

In addition, other funds loaned by GrafTech Finance to our Swiss subsidiary are generally required to be loaned under such intercompany revolving notes. Proceeds of loans to our Swiss subsidiary are required to be:

used by our Swiss subsidiary for its own purposes; or

loaned by our Swiss subsidiary to our other foreign subsidiaries.

 

 

43

 

 

 

Any such loans to our other foreign subsidiaries that are not guarantors of the Revolving Facility are guaranteed by most of such other foreign subsidiaries. Such loans and guarantees are secured by a pledge of most of the assets of such other foreign subsidiaries and are pledged by our Swiss subsidiary under the Revolving Facility. As a result, most of our assets are pledged in respect of the Revolving Facility. Further, our obligation to pay the balance of the DOJ antitrust fine is secured by a lien on all of the assets of GTI.

The Senior Notes have been issued by GrafTech Finance, and the Debentures have been issued by GTI. Unsecured intercompany term notes in an aggregate principal amount equal to $506,887 and unsecured guarantees of those unsecured intercompany term notes by certain of our foreign subsidiaries have been pledged by GrafTech Finance to secure the Senior Notes, subject to the limitation that at no time will the combined value of the pledged portion of any foreign subsidiary’s unsecured intercompany term note and unsecured guarantee of unsecured intercompany term notes issued by other foreign subsidiaries exceed 19.99% of the principal amount of the then outstanding Senior Notes. As a result of this limitation, at December 31, 2005, the aggregate principal amount of unsecured intercompany term notes pledged to secure the Senior Notes equaled $323,026 or about 74% of the aggregate principal amount of the then outstanding Senior Notes. The remaining unsecured intercompany term notes held by GrafTech Finance in an aggregate principal amount at December 31, 2005 of $183,861, and any pledged unsecured intercompany term notes that cease to be pledged due to a reduction in the principal amount of the then outstanding Senior Notes due to redemption, repurchase or other events, are not subject to any pledge and are available to satisfy the claims of creditors (including the lenders under the Revolving Facility, the holders of the Senior Notes and, pursuant to the guarantee by GrafTech Finance of the Debentures, the holders of the Debentures) of GrafTech Finance, as their interests may appear. The Senior Notes contain provisions restricting the pledge of those unsecured intercompany term notes to secure any debt or obligation. The foreign subsidiaries who are obligors under any of such unsecured intercompany term notes or the related guarantees are called “unsecured intercompany term note obligors” and their obligations thereunder are called “unsecured intercompany term note obligations.

The guarantees of the unsecured intercompany term notes by foreign subsidiaries that are pledged to secure the Senior Notes are limited as required to comply with applicable law. Many of these laws effectively limit the amount of the guarantee to the net worth of the foreign subsidiary guarantor or some portion thereof.

Neither the Senior Notes nor the Debentures contain limitations on new secured intercompany term or revolving loans under the Revolving Facility to, or intercompany guarantees of such intercompany loans by, foreign subsidiaries, including foreign subsidiaries that are unsecured intercompany term note obligors.

The Senior Notes are guaranteed by GTI, UCAR Carbon and other U.S. subsidiaries (other than AET) that collectively hold a substantial majority of our U.S. operating assets. The Debentures are guaranteed by GrafTech Finance, UCAR Carbon and other U.S. subsidiaries (other than AET) that collectively hold a substantial majority of our U.S. operating assets. The obligors (including the guarantors) under the Senior Notes and the Debentures are the same. The guarantees of the Senior Notes and the Debentures are unsecured, except the guarantee of the Senior Notes by UCAR Carbon. Each of the obligors (including guarantors) under the Senior

 

44

 

 

Notes and the Debentures is also an obligor (including a guarantor) under the Revolving Facility. The guarantee of the Senior Notes by UCAR Carbon is secured by a pledge of all of the shares of capital stock (constituting 97.5% of the outstanding shares of capital stock) of AET held by UCAR Carbon (called the “AET Pledged Stock”). While all of the AET Pledged Stock is pledged to secure the UCAR Carbon guarantee of the Senior Notes, at no time will the value of the pledged portion of the AET Pledged Stock exceed 19.99% of the principal amount of the then outstanding Senior Notes. Moreover, the pledge of the AET Pledged Stock is junior to the pledge of the same shares to secure the UCAR Carbon guarantee of the Revolving Facility.

None of our foreign subsidiaries has guaranteed the Senior Notes or the Debentures.

The lenders and creditors whose debt and obligations are secured will have prior claims on our assets, to the extent of the lesser of the value of the assets securing, or the amount of, the respective debt or obligations. If we become bankrupt or insolvent or are liquidated or if maturity of such debt or obligations is accelerated, the secured lenders and creditors will be entitled to exercise the remedies available to a secured party under applicable law and pursuant to the relevant agreements and instruments, including the ability to foreclose on and sell the assets securing such debt or obligations to satisfy such debt or obligations. If they exercise such remedies, it is possible that our remaining assets could be insufficient to repay in full the debts and obligations to creditors whose debt and obligations are unsecured, including holders of the Debentures and, to the extent that the Senior Notes are not repaid in full upon exercise of the remedies available to holders thereof as secured parties under applicable law and pursuant to the relevant agreement and instruments, the holders of the Senior Notes.

We have a holding company structure. The issuer of the Senior Notes is a special purpose finance company. The issuer of the Debentures is our parent holding company. Accordingly, the Senior Notes and the Debentures are structurally subordinated to certain of our obligations.

The issuer of the Debentures is our parent holding company. It is a holding company with no operations, limited assets (all of which are pledged to secure the Revolving Facility and the DOJ antitrust fine) and substantial debt, liabilities and obligations.

GrafTech Finance, the issuer of the Senior Notes, is a special purpose finance company with limited operations, limited assets (a substantial majority of which are pledged to secure the Revolving Facility and the Senior Notes) and substantial debt.

A majority of our operations is conducted by, and a majority of our cash flow from operations is derived from, our foreign subsidiaries. The foreign subsidiaries that have issued unsecured intercompany term notes that are pledged to secure the Senior Notes are our operating subsidiaries in Mexico, South Africa and Switzerland and our holding company in France. The obligations of the holding company in France in respect of its unsecured intercompany term note are guaranteed, on an unsecured basis, by our operating company in France engaged in the graphite electrode business. The unsecured intercompany term notes are guaranteed, on an unsecured basis, by our operating subsidiaries in Brazil, Canada, Mexico, Spain, Switzerland and the United Kingdom and the holding company in France.

 

 

45

 

 

 

Our advanced graphite materials operating subsidiary in Italy, our operating subsidiary in Russia and Carbone Savoie, AET and certain immaterial domestic and foreign operating and holding companies are neither guarantors of the Senior Notes or the unsecured intercompany term notes nor guarantors of the Debentures. At December 31, 2005, the aggregate combined book value of their assets was about $209,498. For 2005, their aggregate combined net loss was about $2,331 and their aggregate combined net cash provided by operations was about $25,854.

GrafTech Finance has made and may continue to make secured intercompany revolving loans to our Swiss subsidiary that are pledged under the Revolving Facility. At December 31, 2005, the aggregate principal amount of the intercompany revolving loan to our Swiss subsidiary was $12,758. To the extent that our Swiss subsidiary loans proceeds of such secured intercompany revolving loans to foreign subsidiaries that are not guarantors of the Revolving Facility, these loans will be secured, and guaranteed on a secured basis, by other such foreign subsidiaries and will be pledged under the Revolving Facility. Neither the Senior Notes nor the Debentures contain limitations on existing or new secured intercompany revolving loans pursuant to the Revolving Facility to domestic or foreign subsidiaries that are guarantors of the Senior Notes or unsecured intercompany term note obligors.

GTI relies upon interest and principal payments on intercompany loans, as well as dividends, loans and advances from our subsidiaries, to generate the funds necessary to meet its debt service obligations with respect to the Debentures. GrafTech Finance relies upon interest and principal payments on intercompany loans, as well as loans, advances and contributions from GTI and our other subsidiaries, to generate the funds necessary to meet its debt service obligations with respect to the Revolving Facility and the Senior Notes. GTI and our subsidiaries are separate entities that are legally distinct from each other. Our subsidiaries that are neither guarantors of the Senior Notes nor unsecured intercompany term note obligors have no obligation, contingent or otherwise, to pay debt service on the Senior Notes or to make funds available for such payments. Our subsidiaries that are not guarantors of the Debentures have no obligation, contingent or otherwise, to pay debt service on the Debentures or to make funds available for such payments. The ability of GTI and our subsidiaries to make these payments, loans, advances or contributions is subject to, among other things and to the extent applicable, their earnings and cash flows, their need for funds for business purposes, the covenants of their other debt, guarantees and obligations, and restrictions on dividends, distributions or repatriation of earnings under applicable corporate laws and foreign currency exchange regulations.

The ability of the holders of the Senior Notes or the Debentures to realize upon the assets of any subsidiary that is neither a guarantor of the Senior Notes or the Debentures, respectively, nor, in the case of the Senior Notes only, an unsecured intercompany term note obligor in any liquidation, bankruptcy, insolvency or similar proceedings involving such subsidiary will be subject to the claims of their respective creditors, including their respective trade creditors, holders of their respective debt and their respective preferred stockholders.

As a result, the Senior Notes and the Debentures are structurally subordinated to all existing and future debt and other obligations, including trade payables and obligations to preferred stockholders, of our subsidiaries that are neither guarantors of the Senior Notes or the Debentures, respectively, nor, in the case of the Senior Notes only, unsecured intercompany term note obligors, and the ability of the issuers and guarantors of the Senior Notes and the

 

46

 

 

Debentures to receive (and therefore the ability of the holders of the Senior Notes and the Debentures to participate in) the assets of any subsidiary upon liquidation, bankruptcy, insolvency or similar proceedings involving any such subsidiary will be subject to the claims of the holders of such debt and other obligations, including trade creditors and preferred stockholders. In addition, to the extent that the issuers and guarantors of the Senior Notes and the Debentures are creditors of any such subsidiary, whether as trade creditors, creditors under the unsecured intercompany term notes or otherwise, their rights as a creditor could be equitably subordinated to such claims. At December 31, 2005, the debt and liabilities of such subsidiaries totaled $88,465 (including intercompany trade and other miscellaneous liabilities of $54,078).

Except as otherwise specifically stated, the financial information included in this Report is presented on a consolidated basis, including both our domestic and foreign subsidiaries. As a result, such financial information does not completely indicate the assets, liabilities or operations of each source of funds for payment of debt service on the Senior Notes or the Debentures.

The provisions of the unsecured intercompany term note obligations can be changed, and the unsecured intercompany term notes can be prepaid in whole or in part, without the consent of the holders of the Senior Notes under certain circumstances. Prepayment would increase the structural subordination of the Senior Notes. Prepayment or changes in such provisions could reduce or eliminate the ability of holders of the Senior Notes to seek recovery directly from our foreign subsidiaries upon a default under the Senior Notes.

In general, the unsecured intercompany term notes and the unsecured intercompany term note guarantees cannot be changed, and the unsecured intercompany term notes cannot be prepaid or otherwise discharged, without the consent of the holders of the Senior Notes. However, without the consent of the holders of the Senior Notes:

the interest rate, interest payment dates, currency of payment of principal and interest and currency in which an unsecured intercompany term note is denominated (subject to certain limitations) can be amended;

provisions of an unsecured intercompany term note obligation can be amended to comply with changes in applicable law, so long as such amendments do not change the enforceability, principal amount, stated maturity, average life, ranking or priority or prepayment provisions of an unsecured intercompany term note or the enforceability of or obligations guaranteed under an unsecured intercompany term note guaranty; and

an unsecured intercompany term note can be prepaid in whole or in part if the proceeds received by GrafTech Finance from such prepayment are (i) invested in or loaned to a guarantor of the Senior Notes, (ii) loaned to another foreign subsidiary pursuant to an unsecured intercompany note that is pledged to secure the Senior Notes and is, to the extent permitted by applicable law, guaranteed by the unsecured intercompany term note obligors or (iii) applied to an offer to purchase Senior Notes at a purchase price equal to 100% of the principal amount of the Senior Notes, plus accrued and unpaid interest.

 

 

47

 

 

 

The principal amount (expressed in dollars) of any unsecured intercompany term note that is not denominated in dollars could increase or decrease at any time due to changes in currency exchange rates.

A reduction in the principal amount of one or more unsecured intercompany notes could increase the structural subordination of the Senior Notes, as described in the preceding risk factors, and reduce the ability of holders of the Senior Notes to realize upon the assets of our foreign subsidiaries upon a default under the Senior Notes. A change in the provisions of the unsecured intercompany note obligations could also limit such ability.

In the event of the bankruptcy or insolvency of any of the subsidiary guarantors of the Senior Notes or the unsecured intercompany term note obligors, the guarantee of the Senior Notes by such guarantor or the unsecured intercompany term note and the unsecured intercompany term note guarantee of such obligor could be voided or subordinated. In the event of the bankruptcy or insolvency of any of the subsidiary guarantors of the Debentures, the guarantee of the Debentures by such guarantor could be voided or subordinated.

In the event of the bankruptcy or insolvency of any of the subsidiary guarantors of the Senior Notes or the Debentures or any of the unsecured intercompany term note obligors, its guarantee, unsecured intercompany term note guarantee or unsecured intercompany term note would be subject to review under relevant fraudulent conveyance, fraudulent transfer, equitable subordination and similar statutes and doctrines in a bankruptcy or insolvency proceeding or a lawsuit by or on behalf of creditors of that guarantor or obligor. Under those statutes and doctrines, if a court were to find that the guarantee or note was incurred with the intent of hindering, delaying or defrauding creditors or that the guarantor or obligor received less than a reasonably equivalent value or fair consideration for its guarantee or note and, at the time of its incurrence, the guarantor or obligor:

was insolvent or rendered insolvent by reason of the incurrence of its guarantee or note; or

was engaged in a business or transaction for which its remaining unencumbered assets constituted unreasonably small capital to carry on its business; or

intended to, or believed that it would, incur debts beyond its ability to pay as they matured or became due;

then the court could void or subordinate its guarantee or note.

The measure of insolvency varies depending upon the law of the jurisdiction being applied. Generally, however, a company will be considered insolvent at a particular time if the sum of its debts at that time is greater than the then fair saleable value of its assets or if the fair saleable value of its assets at the time is less than the amount that would be required to pay its probable liability on its existing debts as they become absolute and mature. At the time of incurrence, we believed that each of the guarantors and obligors was:

 

 

48

 

 

 

neither insolvent nor rendered insolvent by reason of the incurrence of its guarantee or note;

in possession of sufficient capital to run its business effectively; and

incurring debts within its ability to pay as the same mature or become due.

The assumptions and methodologies used by us in reaching these conclusions about solvency may not be adopted by a court, and a court may not concur with these conclusions. If the guarantee of a guarantor or the unsecured intercompany term note guarantee or unsecured intercompany term note of an unsecured intercompany term note obligor is voided or subordinated, holders of the Senior Notes, holders of the Debentures or both would effectively be subordinated to all indebtedness and other liabilities of that guarantor or, in the case of holders of the Senior Notes, all indebtedness and other liabilities of that obligor.

The unsecured intercompany term note obligors are incorporated in jurisdictions other than the U.S. and are subject to the bankruptcy and insolvency laws of such other jurisdictions. We cannot assure you that the bankruptcy and insolvency laws of such jurisdictions will be as favorable to the interests of the holders of the Debt Securities as creditors, as the laws of the U.S.

We may not have the ability to purchase the Senior Notes upon a change of control as required by the Senior Notes. We may not have the ability to purchase the Debentures upon a fundamental change or upon specified dates as required by the Debentures.

Upon the occurrence of certain change of control events, we will be required to offer to purchase the outstanding Senior Notes at a purchase price equal to 101% of the principal amount, plus accrued and unpaid interest. Upon the occurrence of certain fundamental change events, we will be required to offer to purchase the outstanding Debentures at a purchase price equal to 100% of the principal amount, plus accrued and unpaid interest (including liquidated damages). These events are the same under the Senior Notes and the Debentures, except that, in the case of the Debentures, these events also include the failure of the capital stock (or certain equivalents) into which they are convertible to be listed on a U.S. securities exchange or market and no offer to purchase is required to be made if certain trading price or transaction consideration thresholds are met. In addition, on January 15, 2011, January 15, 2014 and January 15, 2019, at the option of a holder of Debentures, such holder may require us to purchase some or all of its Debentures at the same purchase price.

If such an event (including the exercise of such option) were to occur, we cannot assure you that we would have sufficient funds to pay the purchase price, and we expect that we would require third party financing to do so. We cannot assure you that we would be able to obtain this financing on favorable terms or at all. Upon the occurrence of certain of these events, we may be required to repay all borrowings under the Revolving Facility or obtain the consent of the lenders under the Revolving Facility to purchase the Senior Notes and the Debentures. If we do not obtain such consent or repay such borrowings, we may be prohibited from purchasing the Senior Notes and the Debentures. In such case, our failure to purchase tendered Senior Notes or Debentures would constitute a default under the Senior Notes or the Debentures, respectively. If the holders of the Senior Notes or the Debentures were to accelerate the maturity of the Senior

 

49

 

 

Notes or the Debentures, respectively, upon such default, the lenders under the Revolving Facility would have the right to terminate their commitment to extend credit under, and to accelerate the maturity of, the Revolving Facility. We cannot assure you that we will have the financial ability to purchase outstanding Senior Notes and Debentures and repay such borrowings upon the occurrence of any such event.

The Senior Notes, the Debentures and the respective related guarantees rank equally with each other and certain of our other debt and liabilities.

The Senior Notes and the related guarantees, and the Debentures and the related guarantees, are general senior obligations of the respective issuers and guarantors. Payments in respect thereof rank equally with each other and with payments in respect of all other present or future senior indebtedness of such issuers and guarantors, respectively, and senior to all present or future subordinated obligations of such issuers and guarantors, respectively. Such payments are effectively subordinated to all present or future secured indebtedness and obligations (including the secured obligations or guarantees in respect of the Revolving Facility and, in the case of GTI as issuer or guarantor, the secured DOJ antitrust fine), to the extent of the value of the assets securing such indebtedness and obligations. We currently have no subordinated indebtedness.

GTI, GrafTech Finance and our other subsidiaries may from time to time incur additional debt, including senior indebtedness and secured indebtedness, as well as other liabilities. Such additional debt may include indebtedness of obligors in respect of the Senior Notes or the Debentures to subsidiaries that are not obligors in respect of the Senior Notes or the Debentures, subject to certain limitations under the Revolving Facility (but not under the Senior Notes or the Debentures). GTI, GrafTech Finance and our other subsidiaries are subject to certain limitations on incurrence of debt under the Revolving Facility and the Senior Notes (but not under the Debentures).

As a result of such ranking, holders of the Senior Notes and the Debentures may receive less upon liquidation, bankruptcy, insolvency or similar proceedings than they would have received if they had a more senior or secured ranking.

The value of the conversion right associated with the Debentures may be substantially lessened or eliminated if we are party to a merger, consolidation or other similar transaction.

If we are party to a merger, consolidation, binding share exchange, sale, transfer or lease of all or substantially all of our assets or similar transaction pursuant to which our common stock is converted into, or into the right to receive, cash, securities or other property, then, at the effective time of the transaction, the right to convert a Debenture into our common stock will be changed into a right to convert into the kind and amount of cash, securities or other property which the holder would have received if the holder had converted its Debenture immediately prior to the transaction. This change could substantially lessen or eliminate the value of the conversion right associated with the Debentures.

 

 

50

 

 

 

The conditional conversion feature of the Debentures could result in a holder receiving less than the value of the common stock into which a Debenture is convertible.

The Debentures are convertible into our common stock only if specified conditions are met. If these conditions are not met, a holder will not be able to convert its Debentures, and a holder may not be able to receive the value of our common stock into which its Debentures would otherwise be convertible.

A holder of Debentures is not entitled to any rights with respect to our common stock, but will be subject to all changes made with respect to our common stock.

Holders of Debentures are not entitled to any rights with respect to our common stock (including rights to vote, to receive dividends or other distributions and to participate in other transactions), but will be subject to all changes affecting our common stock. A holder will have rights with respect to our common stock only if and when we deliver shares of our common stock to such holder upon conversion of its Debentures and, to a limited extent, by virtue of the conversion rate adjustments applicable to the Debentures. If a holder converts its Debenture near the record date for the determination of stockholders entitled to vote, receive a dividend or distribution or participate in other transactions, it is possible that such record date could pass before such delivery is made.

The Debenture Indenture contains only limited covenants, which may not protect a holder’s investment if we experience significant adverse changes or engage in a highly leveraged transaction.

The Debenture Indenture does not:

require us to maintain any financial ratios or specified levels of net worth, revenues, income, cash flow or liquidity and, therefore, does not protect holders of the Debentures in the event that we experience significant adverse changes in our financial condition or performance;

limit our ability to incur additional indebtedness, including indebtedness that is equal in right of payment to the Debentures;

restrict our ability to pledge our assets;

restrict our ability to pay dividends or make other payments in respect of our common stock or other securities ranking junior to the Debentures;

restrict our ability to make investments; or

restrict our ability to issue new securities.

Such events may, however, result in an adjustment to the conversion rate applicable to the Debentures.

 

 

51

 

 

 

Adjustments to the conversion rate applicable to the Debentures may result in a taxable distribution to a holder of Debentures.

The conversion rate applicable to the Debentures will be adjusted if we distribute cash with respect to our common stock and in certain other circumstances. Under Section 305(c) of the Internal Revenue Code, an increase in the conversion rate as a result of our distribution of cash to common stockholders generally will result in a deemed distribution to a holder of Debentures. Other adjustments in the conversion rate (or failures to make such adjustments) that have the effect of increasing a holder’s proportionate interest in our assets or earnings may have the same result. Any deemed distribution to a holder will be taxable as a dividend to the extent of our current or accumulated earnings and profits.

Conversion or repurchase of Debentures into or with our common stock will dilute the ownership interests of other stockholders. In addition, to the extent that outstanding options to purchase shares of our common stock are exercised, there will be further dilution.

Our stock price may be volatile due to the nature of our business as well as the nature of the securities markets, which could affect the value of an investment in our common stock, the Debentures or the Senior Notes.

Many factors may cause the market price for our common stock to decline or fluctuate, perhaps substantially, including:

failure of net sales, results of operations or cash flows from operations to meet the expectations of securities analysts or investors;

recording of additional restructuring, impairment or other charges or costs;

downward revisions in revenue, earnings or cash flow estimates of securities analysts;

downward revisions or announcements that indicate possible downward revisions in the ratings on the Senior Notes or the Debentures;

speculation in the press or investor perception concerning our industry or our prospects; and

changes in general capital market conditions.

The stock markets in general have experienced extreme volatility that has often been unrelated to the operating performance of particular companies. These broad market fluctuations may adversely affect the market price of our common stock.

Companies that have experienced volatility in the market price of their stock have been the subject of securities class action litigation. We are involved in a securities class action litigation. Such litigation could result in substantial costs and a diversion of management’s attention and resources.

 

 

52

 

 

 

Forward Looking Statements

This Report contains forward looking statements. In addition, we or our representatives have made or may make forward looking statements on telephone or conference calls, by webcasts or emails, in person, in presentations or written materials, or otherwise. These include statements about such matters as: future production and sales of steel, aluminum, electronic devices, fuel cells and other products that incorporate or that are produced using our products; future prices and sales of and demand for such products; future operational and financial performance of our businesses; strategic plans and business projects; impacts of regional and global economic conditions; interest rate management activities; deleveraging activities; rationalization, restructuring, realignment, strategic alliance, raw material and supply chain, technology development and collaboration, investment, acquisition, venture, operational, tax, financial and capital projects; legal and litigation matters; consulting projects; potential offerings, sales and other actions regarding debt or equity securities of us or our subsidiaries; and future asset sales, costs, working capital, revenues, business opportunities, debt levels, cash flows, cost savings and reductions, margins, earnings and growth. The words “will,” “may,” “plan,” “estimate,” “project,” “believe,” “anticipate,” “expect,” “intend,” “should,” “would,” “could,” “target,” “goal” and similar expressions identify some of these statements.

Actual future events and circumstances (including future results and trends) could differ materially from those set forth in these statements due to various factors. These factors include:

the possibility that additions to capacity for producing steel in electric arc furnaces may not occur or that increases in graphite electrode manufacturing capacity may occur, which may impact demand for or prices or sales volume of graphite electrodes;

the possibility that continued global consolidation of the world’s largest steel producers could impact our business or industry;

the possibility that average graphite electrode revenue per metric ton in the future may be different than current spot prices due to changes in product mix, changes in currency exchange rates, changes in competitive market conditions or other factors;

the possibility that price increases, adjustments or surcharges may not be realized;

the possibility that economic or technological developments may adversely affect growth in the use of graphite cathodes in lieu of carbon cathodes in the aluminum smelting process;

the possibility that additions to aluminum smelting capacity may not occur or that increases in production of cathodes by competitors may occur, which may impact demand for or prices or sales volume of cathodes;

the possibility of delays in or failure to achieve successful development and commercialization of new or improved electronic thermal management or other products or that they could be subsequently displaced by other products or technologies;

 

 

53

 

 

 

the possibility of delays in or failure to achieve widespread commercialization of PEM fuel cells which use our natural graphite-based products or that manufacturers of PEM fuel cells may obtain those products from other sources;

the possibility of delays in expanding or failure to expand our manufacturing capacity to meet growth in demand for existing, new or improved products, if any;

the possibility that we may be unable to protect our intellectual property or may infringe the intellectual property rights of others;

the occurrence of unanticipated events or circumstances relating to antitrust investigations, lawsuits or claims, a securities class action lawsuit or other litigation;

the possibility that our provision for income taxes and effective income tax rate or cash tax rate may fluctuate significantly due to changes in tax planning, profitability, estimates of future ability to use foreign tax credits, tax laws and other factors;

the occurrence of unanticipated events or circumstances relating to health, safety or environmental compliance or remediation obligations or liabilities to third parties or relating to labor relations;

the possibility of changes in interest or currency exchange rates, in competitive conditions, or in inflation;

the possibility that our high leverage, substantial debt and other obligations could limit our financial resources and ability to compete and may make us more vulnerable to adverse economic events;

the possibility that our outlook could be significantly impacted by, among other things, changes in interest rates by the U.S. Federal Reserve Board or other central banks, changes in fiscal policies by the U.S. and other governments, developments in the Middle East, the occurrence of further terrorist acts and developments (including increases in security, insurance, data back-up, energy and transportation and other costs, transportation delays and continuing or increased economic uncertainty and weakness) resulting from terrorist acts and the war on terrorism;

the possibility that interruption in our major raw material, energy or utility supplies due to, among other things, natural disasters, process interruptions, actions by producers, and capacity limitations, may adversely affect our ability to manufacture and supply our products or result in higher costs;

the possibility of interruptions in production at our facilities due to, among other things, critical equipment failure, which may adversely affect our ability to manufacture and supply our products or result in higher costs;

 

 

54

 

 

 

the possibility that we may not complete planned asset sales for amounts or at times anticipated or at all, or that we may not achieve the earnings that we provide as guidance from time to time;

the possibility that the anticipated benefits from organizational and work process redesign or other system changes, including operating efficiencies, production cost savings and improved operational performance, including leveraging infrastructure for greater productivity and contributing to our continued growth, may be delayed or may not occur;

the possibility that our disclosure or internal controls may become inadequate because of changes in conditions or that the degree of compliance with our policies and procedures related to those controls may deteriorate or that those controls may not operate effectively and may not prevent or detect misstatements or errors;

the possibility that delays may occur in the financial statement closing process due to a change in our internal control environment; and

other risks and uncertainties, including those described elsewhere in this Report or our other SEC filings, as well as future decisions by us.

 

Occurrence of any of the events or circumstances described above could also have a material adverse effect on our business, financial condition, results of operations, cash flows or the market price of our common stock, the Senior Notes or the Debentures.

No assurance can be given that any future transaction about which forward looking statements may be made will be completed or as to the timing or terms of any such transaction.

All subsequent written and oral forward looking statements by or attributable to us or persons acting on our behalf are expressly qualified in their entirety by these factors. Except as otherwise required to be disclosed in periodic reports required to be filed by public companies with the SEC pursuant to the SEC’s rules, we have no duty to update these statements.

 

Item 1B.  Unresolved Staff Comments

None.

 

55

 

 

 

Item 2.  Properties

(Unless otherwise noted, all dollars are presented in thousands)

 

We currently operate the following facilities, which are owned or leased as indicated.

Location of Facility
Primary Use
Owned or
Leased

U.S.          
Parma, Ohio   Corporate Headquarters, Technology Center, Testing Facility, Pilot Plant and Advanced Flexible Graphite Manufacturing Facility   Owned  
Wilmington, Delaware   Administrative Offices   Leased  
Lakewood, Ohio   Flexible Graphite Manufacturing Facility and Sales Office   Owned  
Clarksville, Tennessee  Sales Office and Machine Shop  Leased 
Columbia, Tennessee  Carbon Electrode Manufacturing Facility and Sales Office  Owned 
Lawrenceburg, Tennessee   Refractories Manufacturing Facility   Owned  
Clarksburg, West Virginia   Advanced Graphite Materials Manufacturing Facility and Sales Office   Owned  

Europe
 
Calais, France  Graphite Electrode Manufacturing Facility  Owned 
Notre Dame, France   Graphite Electrode, Advanced Graphite Materials and Cathode Manufacturing Facility and Sales Office   Owned  
Vénissieux, France  Cathode Manufacturing Facility and Technology Center  Owned 
Caserta, Italy  Graphite Electrode Machine Shop  Owned 
Malonno, Italy   Advanced Graphite Materials Machine Shop and Sales Office   Owned  
Saronno, Italy  Sales Office  Leased 
Moscow, Russia  Sales Office  Leased 
Vyazma, Russia  Graphite Electrode Manufacturing Facility  Owned 
Pamplona, Spain  Graphite Electrode Manufacturing Facility and Sales Office  Owned 
Etoy, Switzerland  Sales Office and European Headquarters  Owned 

Other International
 
Salvador Bahia, Brazil  Graphite Electrode and Cathode Manufacturing Facility  Owned 
Sao Paulo, Brazil  Sales Office  Leased 
Beijing, China  Sales Office  Leased 
Hong Kong, China  Sales Office  Leased 
Singapore  Sales Office  Leased 
Monterrey, Mexico  Graphite Electrode Manufacturing Facility and Sales Office  Owned 
Meyerton, South Africa  Graphite Electrode Manufacturing Facility and Sales Office  Owned 

We believe that our facilities, which are of varying ages and types of construction, are in good condition, are suitable for our operations and generally provide sufficient capacity to meet our requirements for the foreseeable future. We plan to cease operations, in whole or in part, at certain of our facilities as described elsewhere in this Report.

 

56

 

 

 

Item 3.  Legal Proceedings

The information required by Item 3 is set forth under “Contingencies” in Note 14 to the Consolidated Financial Statements and under “Subsequent Events” in Note 20 to the Consolidated Financial Statements and is incorporated herein by reference.

Item 4.  Submission of Matters to a Vote of Security Holders

None.

 

 

57

 

 

 

PART II

Item 5.  Market for Registrant’s Common Equity and Related Stockholder Matters

(Unless otherwise noted, all dollars are presented in thousands)

 

Market Information

Our common stock is listed on the NYSE under the trading symbol “GTI.” The closing sale price of our common stock was $6.22 on December 30, 2005, the last trading day of our last fiscal year. The following table sets forth, for the periods indicated, the high and low closing sales price per share for our common stock as reported by the NYSE.

High
Low
2004          
          First Quarter     $ 14 .95 $ 11 .77
          Second Quarter       15 .50   7 .97
          Third Quarter       13 .95   9 .35
          Fourth Quarter       14 .03   8 .14
2005      
          First Quarter       9 .35   5 .41
          Second Quarter       5 .73   3 .21
          Third Quarter       6 .27   4 .24
          Fourth Quarter      7 .14   4 .86

 

At January 31, 2006, there were 94 record holders of common stock. We estimate that there were about 8,613 stockholders represented by nominees.

Our common stock is included in the Russell 2000 Index.

The information required by this Item 5 with respect to GTI’s Stockholder Rights Plan is set forth under “Stockholder Rights Plan” in Note 17 to the Consolidated Financial Statements contained in this Report and is incorporated herein by reference.

Dividend Policies and Restrictions

It is the current policy of GTI’s Board of Directors to retain earnings to finance strategic and other plans and programs, conduct business operations, fund acquisitions, meet obligations and repay debt. Any declaration and payment of cash dividends or repurchases of common stock will be subject to the discretion of GTI’s Board of Directors and will be dependent upon our financial condition, results of operations, cash requirements and future prospects, the limitations contained in the Revolving Facility and the Senior Notes and other factors deemed relevant by GTI’s Board of Directors. We do not anticipate paying cash dividends or repurchasing common stock in the foreseeable future.

GTI is a holding company that derives substantially all of its cash flow from issuances of its securities and cash flows of its subsidiaries. Accordingly, GTI’s ability to pay dividends or repurchase common stock from cash flow from sources other than issuance of its securities is

 

 

 

 

 

 

58

 

 

dependent upon the cash flows of its subsidiaries and the advance or distribution of those cash flows to GTI.

Under the Revolving Facility, in general, GTI is permitted to pay dividends and repurchase common stock in an aggregate amount (cumulative from February 2005) equal to up to $25 million (or up to $75 million, if certain leverage ratio requirements are satisfied), plus, each year, an aggregate amount equal to 50% of our consolidated net income in the prior year.

Under the Senior Notes, in general, GTI is permitted to pay dividends and repurchase common stock only in an aggregate amount (cumulative from February 2002) equal to $25 million, plus, if certain leverage ratio requirements are satisfied, an amount of up to the sum of 50% of certain consolidated net income (cumulative from April 2002), 100% of net cash proceeds from certain sales of common stock (subsequent to February 1, 2002) and certain investment returns.

The Debentures do not restrict the payment of dividends or repurchase of our common stock, but such payment or repurchase may result in an adjustment to the conversion rate applicable to the Debentures.

Fourth Quarter Unregistered Stock Issuance

On December 12, 2005, we granted 14,000 shares of restricted stock to certain employees under the 2005 Equity Incentive Plan.  The fair market value (as defined thereunder) of such shares on the date of grant was $6.99 per share. These shares vest over a three-year period, with one-third of the shares vesting on August 31, 2006, 2007 and 2008. Each grant was exempt from registration under the Securities Act of 1933 pursuant to the exemption for transactions not involving a public offering afforded by Section 4(2) of such Act.

 

59

 

 

 

Item 6.  Selected Financial Data

(Unless otherwise noted, all dollars are presented in thousands)

 

The following selected consolidated financial data at and for the years ended December 31 2001, 2002, 2003, 2004 and 2005 have been derived from our audited annual Consolidated Financial Statements, except for the data under “Other Operating Data.” The data set forth below should be read in conjunction with “Part I. Preliminary Notes-Presentation of Financial, Market and Legal Data,” “Item 7. Management’s Discussion and Analysis of Financial Condition and Results of Operations” and the Consolidated Financial Statements and Notes thereto.

Year Ended December 31,
  2001
2002
2003
2004
2005
  (Dollars in thousands, except per share data)
 Statement of Operations Data:                        
   Net sales   $ 634,104   $ 595,714   $ 712,337   $ 847,701   $ 886,699  
   Income (loss) from continuing operations (a)    (89,177 )  (19,313 )  (25,314 )  17,041    (125,180 )
 
   Basic earnings per common share:  
     Income (loss) from continuing operations   $ (1.79 ) $ (0.35 )  (0.38 ) $ 0.18   $ (1.28 )
     Income from discontinued operations    0.04    0.02    0.02          





     Net income (loss)   $ (1.75 ) $ (0.33 ) $ (0.36 ) $ 0.18   $ (1.28 )





 
     Weighted average common shares outstanding  
       (in thousands)    49,720    55,942    67,981    96,548    97,689  





 
Diluted earnings per common share:  
     Income (loss) from continuing operations   $ (1.79 ) $ (0.35 ) $ (0.38 ) $ 0.17   $ (1.28 )
     Income from discontinued operations    0.04    0.02    0.02          





     Net income (loss)   $ (1.75 ) $ (0.33 )  (0.36 )  0.17    (1.28 )





 
     Weighted average common shares outstanding  
       (in thousands)    49,720    55,942    67,981    98,149    97,689  





 
Balance sheet data (at period end):  
   Total assets   $ 781,968   $ 847,659   $ 966,389   $ 1,067,818   $ 886,820  
   Other long-term obligations (b)    231,494    249,622    204,214    149,462    107,704  
   Total long-term debt    631,201    722,449    533,934    671,446    703,743  
 
Other financial data:  
   Net cash provided by (used in) operating
     activities from continuing operations
   $ 13,967   $ (61,102 ) $ (26,528 ) $ (132,266 ) $ 7,989  
   Net cash used in investing activities    (38,242 )  (49,539 )  (22,113 )  (56,310 )  (60,381 )
   Net cash provided by financing activities    14,599    78,525    69,133    176,606    36,184  

______________________

(a)

For 2001, includes a restructuring charge of $11,466, pertaining primarily to the corporate realignment of our businesses, the relocation of our corporate headquarters, the shutdown of graphite electrode manufacturing operations in Clarksville and Columbia, Tennessee, the mothballing of graphite electrode manufacturing operations in Caserta,

 

 

60

 

 

Italy and the shutdown of coal calcining operations in Niagara Falls, New York. For 2001, includes an impairment charge of $80,389, primarily related to the shutdowns in Tennessee and New York, the corporate realignment of our subsidiaries, the mothballing in Italy and an impairment loss related to available-for-sale securities.

For 2002, includes a restructuring charge of $5,800, pertaining primarily to the mothballing of graphite electrode manufacturing operations in Caserta, Italy. For 2002, includes an impairment charge of $16,982, primarily related to impairment losses on long-lived carbon electrode assets in Columbia, Tennessee, on available-for-sale securities, and on our investment in our venture with Jilin Carbon Ltd. in China.

For 2003, includes a restructuring charge of $19,765, pertaining primarily to the closure and settlement of our U.S. non-qualified defined benefit plan for the participating salaried workforce, with the remaining due to further organizational changes. For 2003, includes an impairment charge of $6,991, primarily related to the closure of the majority of the graphite electrode manufacturing operations in Caserta, Italy and a net write-off of the remaining book value of assets of our former graphite electrode manufacturing operations in Clarksville, Tennessee.

For 2004, includes a restructuring benefit of $548, pertaining primarily to a net benefit associated with the closure of our graphite electrode manufacturing operations in Caserta, Italy, offset by severance programs and related benefits associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom and changes in estimates related to U.S. voluntary and selective severance programs.

For 2005, includes a restructuring charge of $9,729, pertaining primarily to a $6,100 charge associated with the rationalization of our synthetic graphite facilities, including those in Brazil, France, and Russia, a $3,194 charge associated with the closure of our graphite electrodes manufacturing operations at Caserta, Italy, a $523 charge primarily associated with the relocation of our corporate headquarters from Wilmington, Delaware to Parma, Ohio, an $804 charge associated with the phase out of our graphite electrode machining operations in Clarksville, Tennessee and a $430 charge associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom, offset by a $1,322 benefit associated with a change in estimate pertaining to the closure of certain graphite electrode manufacturing operations.

For 2005, includes a $2,904 charge related to the impairment of our long-lived carbon electrode fixed assets in Columbia, Tennessee. The future estimated undiscounted cash flows expected to result from the use of these assets were below their respective carrying amounts. As a result, an impairment loss was measured as the difference between the assets’ carrying amount and fair value, which was based on current estimates of market price.

For 2005, provision for income taxes was a charge of $165,813 primarily due to a charge resulting from a net change in the total valuation allowance for 2005 of $153,079. During the 2005 year end financial accounting closing process, we determined that the timing of when we will generate sufficient U.S. taxable income to realize our U.S. deferred tax assets became less certain; therefore, we recorded valuation allowances, primarily against our net federal deferred tax assets in the U.S. of $149,734. We recorded similar valuation allowances in certain other

 

61

 

 

jurisdictions in both the second and fourth quarters of 2005, which resulted in charges totaling $3,345.

 

(b)

Represents liabilities and expenses in connection with antitrust investigations and related lawsuits and claims, pension and post-retirement benefits and related costs, employee severance liabilities and miscellaneous other long-term obligations.

 

The following quarterly selected consolidated financial data have been derived from the Consolidated Financial Statements for the periods indicated, which have not been audited. The selected quarterly consolidated financial data set forth below should be read in conjunction with “Part I. Preliminary Notes–Presentation of Financial, Market and Legal Data,” “Item 7. Management’s Discussion and Analysis of Financial Condition and Results of Operations” and the Consolidated Financial Statements and Notes thereto.

First
Quarter

Second
Quarter

Third
Quarter

Fourth
Quarter

(Dollars in thousands, except per share data)
2004                            
Net sales     $ 196,564   $ 213,158   $ 206,089   $ 231,890  
    Net income (loss) (a)    (39 )  17,618    (9,402 )  8,865  
 
Basic earnings per common share:  
    Net income (loss) per share    -    0.18    (0.10 )  0.09  
 
Diluted earnings per common share:  
    Net income (loss) per share    -    0.16    (0.10 )  0.09  

2005
Net sales     $ 211,096   $ 220,146   $ 208,195   $ 247,263  
    Net income (loss) (b)    1,505    5,690    15,589    (147,964 )
 
Basic earnings per common share:  
 Net income (loss) per share    0.02    0.06    0.16    (1.51 )
 
Diluted earnings per common share:  
    Net income (loss) per share    0.02    0.06    0.15    (1.51 )

________________

(a)

The 2004 first quarter includes a $1,005 restructuring charge, primarily associated with changes in estimates for the U.S. voluntary and selective severance program.

The 2004 second quarter includes a $2,875 restructuring charge, primarily associated with the completion of severance agreements for approximately two-thirds of the employees terminated in connection with closure of our graphite electrode manufacturing operations in Caserta, Italy.

The 2004 third quarter includes a net restructuring benefit of $2,603, primarily due to a $3,484 reduction in restructuring cost estimates associated with the closure of our graphite electrode manufacturing operations in Caserta, Italy, partially offset by a $881 charge relating primarily to severance programs and related benefits associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom.


 

62

 

 

 

The 2004 fourth quarter includes a net restructuring benefit of $1,825, primarily associated with changes in estimates related to U.S. voluntary and selective severance programs and the closure of our graphite electrode manufacturing operations in Caserta, Italy.

(b)

The 2005 first quarter includes a $363 restructuring charge, primarily pertaining to the closure of our advanced graphite machining operations in Sheffield, United Kingdom.

The 2005 second quarter and 2005 third quarter include nominal restructuring charges or benefits.

The 2005 fourth quarter includes a restructuring charge of $9,335, pertaining primarily to a $6,100 charge associated with the rationalization of our synthetic graphite facilities, including those in Brazil, France, and Russia, a $3,327 charge associated with the closure of our graphite electrode manufacturing operations at Caserta, Italy, a $604 charge primarily associated with the relocation of our corporate headquarters from Wilmington, Delaware to Parma, Ohio, and a $626 charge associated with the phase out of our graphite electrode machining operations in Clarksville, Tennessee, offset by a $1,322 benefit associated with a change in estimate pertaining to the closure of certain graphite electrode manufacturing operations.

The 2005 fourth quarter also includes a $2,904 charge related to the impairment of our long-lived carbon electrode fixed assets in Columbia, Tennessee. The future estimated undiscounted cash flows expected to result from the use of these assets were below their respective carrying amounts. As a result, an impairment loss was measured as the difference between the assets’ carrying amount and fair value, which was based on current estimates of market price.

The 2005 fourth quarter provision for income taxes was a charge of $157,337 primarily due to a charge resulting from a net change in the total valuation allowance for 2005 of $153,079. During the 2005 year end financial accounting closing process, we determined that the timing of when we will generate sufficient U.S. taxable income to realize our U.S. deferred tax assets became less certain; therefore, we recorded a valuation allowance, primarily against our net federal deferred tax assets in the U.S., of $149,734. We recorded similar valuation allowances in certain other jurisdictions in the fourth quarter of 2005.

 

 

63

 

 

 

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

(Unless otherwise noted, all dollars are presented in thousands)

General

We have six major product categories: graphite electrodes, cathodes, carbon electrodes, carbon refractories, advanced graphite materials and natural graphite, the results of which are reported in the following segments:

Synthetic graphite, which primarily serves the steel, aluminum, transportation and semiconductor industries and includes graphite electrodes, cathodes and advanced graphite materials and related services. We have a strategic alliance in the cathode business with Alcan/Pechiney, one of the world’s largest aluminum producers, which is a 30% owner of our cathode subsidiary, Carbone Savoie.

Other, which includes carbon electrodes, refractories and natural graphite. Our natural graphite activities, which are conducted by AET, primarily serve the electronics, automotive, petrochemical and power generation industries and include advanced flexible graphite and flexible graphite solutions and related services. We have a strategic alliance in the natural graphite business with Ballard Power Systems, the world’s recognized leader in PEM fuel cells. Ballard Power Systems became a strategic investor in AET in June 2001, by investing $5 million in shares of Ballard Power Systems common stock for a 2.5% equity ownership interest in AET. Our other carbon product activities serve the silicon metal, steel and ferro-alloy industries.

Reference is made to the information under “Part I” for background information on our businesses, industry and related matters.

Global Economic Conditions and Outlook

We are impacted in varying degrees, both positively and negatively, as global, regional or country conditions fluctuate.

2003. Over the three years prior to the 2003 first half, we faced extremely challenging business and industry conditions. Adverse global and regional economic conditions negatively impacted many of the end markets for our products. Many of the customers in these markets reduced production levels, became less creditworthy, filed for bankruptcy protection or were acquired as part of consolidation trends within their industries. In addition, for most of this period, industry-wide capacity for most of our products exceeded demand. Such factors reduced demand and prices for products sold by us.

Global and certain regional economic conditions began to strengthen in the 2003 second half. Steel production increased globally and was particularly strong in China. We estimate that worldwide steel production was about 965 million metric tons in 2003. We estimate that EAF steel production increased to about 305 million metric tons in 2003.

 

 

64

 

 

 

We believe that the graphite electrode industry manufacturing capacity utilization rate was about 93% in 2002 and 96% in 2003. We operated our graphite electrode manufacturing capacity at very high levels in 2003. The strengthening in the steel industry in 2003 and the tightening of the graphite electrode supply/demand balance lead to an increase in average graphite electrode prices in 2003 as compared to 2002.

Demand for cathodes in 2003 (excluding China) decreased from 2002 because of reduced construction of new aluminum smelters. We operated our cathode manufacturing capacity at relatively high operating levels in 2003. Demand for carbon refractories was strong in 2003 as a result of our increased penetration of various markets, including Europe and China, and increased blast furnace construction and refurbishment. Weak economic conditions resulted in relatively low demand and weak pricing in 2003 for most of our other products.

2004. Global and regional economic conditions continued to strengthen throughout 2004 and steel demand and production remained strong. We estimate that worldwide steel production was about 1.05 billion metric tons in 2004, about 9% higher than in 2003. We estimate that electric arc furnace steel production increased 6% in 2004 to 324 million metric tons.

Worldwide graphite electrode demand increased to approximately 1 million metric tons driven by increased steel production and, in particular, EAF steel production. Graphite electrode supply remained tight for graphite electrodes used in EAF melter applications. Graphite electrode prices for the EAF melter segment increased over the course of 2004.

We believe that the graphite electrode industry manufacturing capacity utilization rate was about 96% in 2004. We operated our graphite electrode manufacturing capacity at virtually maximum operating levels throughout 2004.

We estimate that worldwide aluminum production was about 29.8 million metric tons in 2004, about 7% higher than in 2003. Demand for cathodes increased slightly in 2004 as compared to 2003, primarily due to the construction of new aluminum smelting furnaces, offset by delays in relines of existing furnaces as a result of longer pot life from technology improvements. Consolidation of aluminum companies, including Alcan’s acquisition of Pechiney, also delayed the start of known new smelter projects. We believe that, in 2004, there was an excess supply of cathodes, on a worldwide basis.

Demand for carbon refractories strengthened consistent with growth in integrated steel production in 2004 and related increases in blast furnace lining refurbishments and, to a lesser extent, new blast furnace construction. Demand for carbon electrodes strengthened consistent with increases in production of silicon metal.

Demand for our advanced graphite materials strengthened in 2004 as compared to 2003, consistent with increased production by the customers we serve in the semiconductor, electronics, energy and transportation industries.

Throughout 2004, we experienced upward pressure on most of our raw material costs, including freight, energy and petroleum-based raw materials. These cost increases impacted almost all of our product lines. We believe these cost increases were experienced industry-wide.

 

 

65

 

 

 

Demand for thermal management solutions in smaller, more powerful electronic devices continued to grow rapidly in 2004. Our ETM solutions are enabling some of the most advanced, thinnest and lightest products being sold today. These devices include, among others, plasma display panels, liquid crystal displays, ultra-lightweight laptops and cell phones. Sales of our ETM products grew significantly to $11,585 in 2004 as compared to $2,393 in 2003.

2005. Graphite electrode demand is primarily linked with the global production of steel in electric arc furnaces and, to a lesser extent, with the total production of steel and certain other metals. This production is linked to global and regional economic conditions. Overall, global and regional economic conditions remained relatively stable in 2005. We estimate that worldwide steel production was about 1.13 billion metric tons in 2005, about an 8% increase as compared to 2004. China’s steel production, however, grew almost 25% in 2005 and represented the single largest contributor to the growth in global steel demand. Although approximately 88% of Chinese steel production is blast oxygen furnace steel production, China is also the growth leader for new EAF steel production. Overall, EAF steel production capacity continued to grow, primarily driven by new EAF furnaces in China, and to a lesser extent, in Russia, the Middle East and North America. This contributed to a more favorable global pricing environment in 2005.

Notwithstanding the growth in worldwide steel production, the steel industry in most of our major markets operated at lower operating rates in 2005. We believe that these lower operating rates resulted in a reduction of steel inventories in the U.S. and, to a lesser extent, in other regions of the world.

Our venture with Alcan/Pechiney, which is a 30% owner of our cathode business and which purchases cathodes from us under requirements contracts that remain in effect through 2006, continues to position us as the leading supplier of cathodes to the aluminum industry.

Our refractories business is linked primarily to construction and refurbishment of blast furnaces in the integrated segment of the global steel industry and, to a lesser extent, submerged arc furnaces in the ferroalloy industry. We have benefited from the growth of steel production in China through 2005, and have expanded our global sales to large markets such as India and Russia as well as several smaller markets.

Excluding China, carbon electrode demand in 2005 was essentially the same as in 2004. In 2005, certain silicon metal producers (who are the primary carbon electrode consumers) announced plans to idle capacity. We expect growth in China to continue to replace idle capacity elsewhere, leaving overall demand relatively flat in the near future. Carbon electrode average selling prices in 2005 remained at 2004 levels.

Demand for our advanced graphite materials increased in 2005 as compared to 2004. The increases were mainly in the energy related markets, including solar, silicon and oil and gas exploration, and defense and transportation industries. We operated our advanced graphite materials capacity at very high levels in 2005.

Demand for thermal management solutions in smaller, thinner, more powerful electronic devices continued to grow rapidly in 2005. Our ETM solutions are enabling some of the most advanced, thinnest and lightest products being sold today. These devices include, among others, flat panel displays, plasma and liquid crystal display (LCD), ultra-lightweight laptops, cell phones, and LED lighting applications. The flat panel display market is expected to grow from 27 million units (15% of the TV market) to 75 million units (40%) by 2008. Sales of our ETM products grew significantly, to about $19 million in 2005 as compared to about $12 million in 2004.

Throughout 2005, we continued to experience upward pressure on most of our raw material costs, including freight, energy and petroleum based materials. These cost increases impacted almost all of our product lines.

Outlook.  Global and regional economic conditions are expected to remain relatively stable in 2006, with global EAF steel production growth of approximately 3%. We estimate that worldwide total steel production will increase to about 1.17 billion metric tons in 2006, about 4% higher than in 2005.

Worldwide graphite electrode demand is also expected to remain stable in 2006. We expect demand growth of approximately 2%, driven primarily by new EAF product capacity and higher EAF operating rates.

We expect net sales of graphite electrodes to increase approximately 15% in 2006. We expect graphite electrode sales volume to be approximately 210,000 to 215,000 metric tons, depending on market conditions. We expect upward pressure on most of our raw material costs, including freight, energy and petroleum-based raw materials. These cost increases will impact almost all of our product lines. We believe our graphite electrode production costs will increase approximately 10% to 12% in 2006 as compared to 2005.

We estimate that worldwide production of aluminum will increase in 2006 by about 2% – 3% over 2005. We expect demand for cathodes in 2006 to increase as compared to 2005, primarily due to the construction of new aluminum smelting furnaces and increased demand for relining, or expansion, of existing smelters. We believe that, in 2006, there will be an excess supply of cathodes, on a worldwide basis.

In 2006, we believe that the overall demand for advanced graphite materials will remain at a high level, resulting from continued strength in the energy markets and defense and transportation industries.

In 2006, we expect continued strong demand for our carbon refractories. The integrated steel industry is expected to remain strong through 2006, with growth continuing in China, India, and Brazil. A number of large expansion projects are known to be in the planning, engineering, and early construction phases. In addition, the Chinese government has announced its intention to close all small, inefficient blast furnaces, which we believe will require significant replacement capacity in the coming years.

For 2006, we expect net sales of ETM products of about $30 million. We continue to see the need for efficient thermal management in electronic devices as a major challenge for manufacturers. The move toward increased functionality and convergence is creating the need for larger amounts of memory in devices, larger color displays in portable devices, wireless and increased speed of data transmission, all resulting in significant thermal management issues. As a result, our ETM materials and solutions address these challenges and at the same time enable device manufacturers to capitalize on these growing trends in a more cost efficient manner.

Our outlook could be significantly impacted by, among other things, factors described under “Item 1A – Risk Factors” and “Item 1A – Forward Looking Statements” in this Report.

Financing Transactions

During 2004, we repurchased Senior Notes for cash or in exchange for shares of our common stock. See Note 5 to the Consolidated Financial Statement for more detailed information.

On January 22, 2004, we completed an offering of $225,000 aggregate principal amount of Debentures at a price of 100% of principal amount. The net proceeds from the offering were approximately $218,812. We used the net proceeds to repay the remaining $21,398 of term loans outstanding under the Senior Facilities, to make provisional payments of $74,064 against the fine (the “EU antitrust fine”) that was assessed against us in 2001 by the Directorate General IV of the European Communities (the “EU Competition Authority”), and to fund general corporate purposes, including replacement of financing previously provided by factoring of accounts receivable and strategic acquisitions that are complementary to our businesses. The balance was invested in short-term, investment quality, interest-bearing securities or deposits.

On February 8, 2005, we completed a substantial amendment and restatement of the Credit Agreement to effect a refinancing of the Revolving Facility. We believe the refinancing has enhanced our stability and liquidity. The Revolving Facility now provides for loans and letters of credit in a maximum amount outstanding at any time of up to $215 million and matures in July 2010. As a result of the refinancing, we have no material debt scheduled to mature prior to July 2010.

Antitrust Litigation Against Us

In 1997, the DOJ and the EU Competition Authority commenced investigations into alleged violations of the antitrust laws in connection with the sale of graphite electrodes. The antitrust authorities in Canada, Japan and Korea subsequently began similar investigations. The EU Competition Authority also commenced an investigation into alleged antitrust violations in connection with the sale of specialty graphite. These antitrust investigations have been resolved. Several of the investigations resulted in the imposition of fines against us. These fines, or payments in accordance with a payment schedule in the case of the DOJ antitrust fine, have been timely paid.

 

 

67

 

 

 

We have settled virtually all of the civil antitrust lawsuits (including class action lawsuits) previously pending against us, certain civil antitrust lawsuits threatened against us and certain possible civil antitrust claims against us arising out of alleged antitrust violations occurring prior to the date of the relevant settlement in connection with the sale of graphite electrodes, carbon electrodes and bulk graphite products. All settlement payments due have been timely paid. There remain, however, certain pending claims as well as pending lawsuits in the U.S. relating to the sale of graphite electrodes sold to foreign customers. It is also possible that additional antitrust lawsuits and claims could be asserted against us in the U.S. or other jurisdictions. We are currently not reserved for such matters.

Other Proceedings Against Us

On March 1, 2006, the Company was served with a complaint commencing a securities class action in the United States District Court for the District of Delaware. The complaint alleges that GTI and certain of our executive officers violated federal securities law by making false statements or failing to disclose adverse facts about us in, or in relation to, a press release issued by us on November 3, 2005. Our analysis and investigation relating to this lawsuit is in its earliest stages, and, as a result, we are not able to assess the likelihood of loss, if any, or the amount thereof. We have not yet filed a response to the complaint. We intend to vigorously defend against this lawsuit.

We are involved in various other investigations, lawsuits, claims and other legal proceedings incidental to the conduct of our business. While it is not possible to determine the ultimate disposition of each of them, we do not believe that their ultimate disposition will have a material adverse effect on our financial position, results of operations or cash flows.

Product Warranties

We generally sell products with a limited warranty. We accrue for known warranty claims if a loss is probable and can be reasonably estimated. Claims accrued but not yet paid amounted to $646 at December 31, 2004 and $610 at December 31, 2005. The following table presents the activity in this accrual for 2005:

Balance at December 31, 2004     $ 646  
Product warranty charges    2,402  
Payments and settlements    (2,438 )

Balance at December 31, 2005   $ 610  

 

Realizability of Net Deferred Tax Assets and Valuation Allowances

At December 31, 2005, we had $248,022 of gross deferred income tax assets, of which $208,393 required a valuation allowance. In addition, we had $69,083 of gross deferred income

 

 

 

68

 

 

tax liabilities. Deferred income tax assets and liabilities are classified on a net current and net non-current basis for each tax jurisdiction.

              The net change in gross deferred income tax assets for 2005 was an increase of $37,962, of which $27,447 was recorded in the fourth quarter with a full valuation allowance. The net change in the total valuation allowance for 2005 was a increase of $185,204. During the 2005 year end financial accounting closing process, we determined that the timing of when we will generate sufficient U.S. taxable income to realize our U.S. deferred tax assets became less certain. Accordingly, during the fourth quarter of 2005, we recorded a valuation allowance of $149,734 against deferred tax assets in the U.S. and $1,722 in certain non-U.S. jurisdictions, which resulted in a total net charge of $151,456. Until we determine that it is more likely than not that we will generate sufficient U.S. taxable income to realize our deferred income tax assets, income tax benefits in each current period will be full reserved. This adjustment does not affect our ability and intent to utilize the deferred income tax assets as we generate sufficient future profitability in the U.S.

We are executing current strategies, and developing future strategies, to improve sales, reduce costs and improve our capital structure in order to improve U.S. taxable income to a level sufficient to fully realize these benefits in future years. The current U.S. tax attributes, if utilized, will allow us to significantly reduce our cash tax obligations in the U.S. We currently expect our overall 2006 book tax rate to be 37% to 40% and our overall 2006 cash tax rate to be 32% to 35%.

 

Customer Base

We are a global company and serve all major geographic markets. Sales of our products to customers outside the U.S. accounted for about 76% of our net sales in 2003, 76% of our net sales in 2004 and 70% of our net sales in 2005. In 2005, four of our ten largest customers were based in Europe, three were in the U.S. and one was in each of Brazil, Canada, and Korea.

In 2005, three of our ten largest customers were purchasers of non-graphite electrode products. No single customer or group of affiliated customers accounted for more than 5% of our net sales in 2005.

Results of Operations

Financial information discussed below omits our non-strategic composite tooling business that was sold in June 2003 and has been accounted for as discontinued operations. The results of our discontinued operations were not material to our consolidated results of operations.

 

 

69

 

 

 

2004 Compared to 2003.

Consolidated. Net sales of $847,701 in 2004 represented a $135,364, or 19%, increase from net sales of $712,337 in 2003 primarily due to higher net sales of graphite electrodes, which increased $90,721, primarily due to higher sales volume and higher average graphite electrode sales revenue per metric ton. Higher sales volumes of carbon refractory products resulted in an increase of $14,057 while higher electronic thermal management sales resulted in an increase of $9,192. The remaining $21,394 increase in net sales occurred almost equally within advanced graphite materials and cathodes.

Cost of sales of $638,186 in 2004 represented a $93,990, or 17%, increase from cost of sales of $544,196 in 2003. Cost of sales increased $56,869 due to higher sales volumes and the impact of a less favorable product sales mix, $25,497 due to the net unfavorable impacts of currency exchange rate changes, $16,003 due to higher operating costs and $4,964 primarily due to increased electronic thermal management sales, partially offset by $9,343 of improvements of productivity throughout our manufacturing network.

Gross profit of $209,515 in 2004 represented a $41,374, or 25%, increase from gross profit of $168,141 in 2003. Gross margin increased to 24.7% of net sales in 2004 from 23.6% of net sales in 2003. See below for further details regarding such changes.

Selling, administrative and other expenses increased $3,823 from $85,546 in 2003 to $89,369 in 2004. The increase was due to investments to improve global business processes, primarily new global information systems and Sarbanes-Oxley compliance efforts. These changes in business processes resulted in higher costs of $5,000. In addition, we incurred higher selling expenses of $3,000 in 2004 as a result of higher net sales. The net unfavorable impact of changes in currency exchange rates increased costs by $2,000. These higher costs were partially offset by $8,000 of lower employee benefit costs consisting primarily of lower variable compensation expenses and, to a lesser extent, lower post retirement expense. Other costs which increased selling, administrative and other expenses were individually insignificant.

Research and development expenses decreased $2,370 from $10,410 in 2003 to $8,040 in 2004. The decrease was primarily due to both higher benefits from external funding proceeds from grants awarded to us in 2004 by the State of Ohio to support fuel cell development programs and lower net costs due to our 2003 voluntary severance programs and workforce attrition. These personnel reductions are net of increases in research and development resources dedicated to electronic thermal management development activities.

Other (income) expense, net, was expense of $21,189 in 2004 as compared to income of $12,060 in 2003. The net increase in expense of $33,249 was primarily due to the following:

losses due to changes in currency exchange rates, primarily associated with Euro-denominated intercompany loans, increasing $33,622 for 2004 as compared to 2003;

losses attributable to a reduction of Senior Notes outstanding (due to debt for equity exchanges and repurchases), increasing $8,166 for 2004 as compared to 2003;

 

 

70

 

 

 

expenses pertaining to legal, environmental and other related costs increasing $5,840 for 2004 as compared to 2003; offset by

losses on foreign currency exchange rate contract, decreasing $6,244 for 2004 as compared to 2003;

charges for employee benefit curtailment and other costs, decreasing $3,686 for 2004 as compared to 2003; and

other costs, net, decreasing $4,449 in 2004 as compared to 2003.

 

In 2003, we recorded a net restructuring charge of $19,765, consisting of an $11,266 charge associated with the closure and settlement with certain of our U.S pension plans, with the remaining primarily due to further organizational changes.

In 2004, we recorded a net restructuring benefit of $548, comprised primarily of the following:

a $2,473 net benefit associated with the closure of our graphite electrode manufacturing operations in Caserta, Italy (consisting of a reduction in cost estimate, partially offset by the completion of further severance agreements for employees terminated in connection with the closure), offset by

a $1,329 charge relating primarily to severance programs and related benefits associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom; and

a $596 charge associated primarily with changes in estimates related to U.S. voluntary and selective severance programs.

The restructuring accrual is included in other accrued liabilities and other long-term obligations on the Consolidated Balance Sheets. The following table summarizes activity relating to the accrual:

Severance
and
Related
Costs

Plant Shutdown and
Related
Costs

Total
(Dollars in thousands)
 
Balance at January 1, 2003     $ 2,441   $ 11,543   $ 13,984  
 
Restructuring charges       19,044     721     19,765  
Payments and settlements,
    including non-cash items of $721
      (2,763 )   (3,650 )   (6,413 )
Effect of change in currency exchange rates      531     796     1,327  



Balance at December 31, 2003    $ 19,253   $ 9,410   $ 28,663  



Restructuring charges       4,321     985     5,306  
Change in estimates           (5,854 )   (5,854 )

 

 

71

 

Severance
and
Related
Costs

Plant
Shutdown and
Related
Costs

Total
Payments and settlements,
    including non-cash items of $2,814
      (18,367 )   (1,300 )   (19,667 )
Effect of change in currency exchange rates      340     64     404  



Balance at December 31, 2004    $ 5,547   $ 3,305   $ 8,852  



 

 

In 2003, we recorded impairment charges of $6,991. Such charges consisted of $5,370 pertaining primarily to write-off of the remaining fixed assets in connection with the closure of our graphite electrode manufacturing operation in Caserta, Italy and $1,621 pertaining primarily to the net write-off of the remaining book value of assets of our former graphite electrode manufacturing operations in Clarksville, Tennessee.

We recorded a $32,073 charge in 2003 relating to the EU antitrust fine.

We recorded a $1,262 charge for additional potential liabilities and expenses in connection with antitrust investigations and related lawsuits and claims in the 2004 first quarter. This charge was offset by a gain due to the refund of €10 million ($12,163 based on currency exchange rates then in effect) that we received from the EU Competition Authority as a result of the reduction of the EU antitrust fine to €42 million, plus accrued interest of a €7.7 million (which was calculated at a rate of 8.04% per annum), an aggregate of about $59 million at currency exchange rates in effect at the time the decision on our appeal thereof was issued.

The following table presents an analysis of interest expense:

  For the Year
Ended
December 31,

  2003
2004
  (Dollars in thousands)
Interest incurred on debt     $ 62,351   $ 49,808  
Interest rate swap benefit    (13,022 )  (10,092 )
Amortization of fair value adjustments for terminated hedge
    instruments
    (2,222 )  (2,468 )
Accelerated amortization of fair value adjustments for terminated  
    hedge instruments due to reduction of Senior Notes    (5,734 )  (4,746 )
Amortization of debt issuance costs    3,148    4,834  
Interest on DOJ antitrust fine, including imputed interest    955    710  
Amortization of premium on Senior Notes    (687 )  (243 )
Amortization of discount on Debentures        867  
     Interest incurred on other items    352    508  


    Interest expense   $ 45,141   $ 39,178  


 

 

72

 

 

 

Average total debt outstanding was $675,553 in 2004 as compared to $696,723 in 2003. The average annual interest rate was 5.5% in 2004 as compared to 7.1% in 2003. These average annual rates include the benefits of our interest rate swaps, but exclude imputed interest on the DOJ antitrust fine, the amortization of the effective discount on the debentures, the amortization of the net proceeds from the sale of swaps and the acceleration of the amortization of gains realized from the sale of interest rate swaps due to the early extinguishment of debt from our exchange of common stock for, and repurchases of, Senior Notes outstanding.

We recorded interest income in 2004 of $1,161 primarily attributable to interest earned on cash proceeds from the issuance and sale of the Debentures.

Provision for income taxes was a charge of $46,310 in 2004 as compared to a charge of $4,695 in 2003. The effective income tax rate was 72% in 2004. The higher effective income tax rate was primarily due to the implementation of a standard tax election known as “Check-the-Box” (the “2004 special tax election”) that accelerated $215,177 of taxable income in the U.S. that resulted in the utilization of approximately $26,219 in deferred tax assets, of which approximately $19,969 were existing foreign tax credits. This resulted in tax expense that was $26,219 higher in 2004 than if we had not made this election. The effective rate in 2004 was also impacted by a benefit from the EU Competition Authority refund, which was non-taxable in the U.S., and by nondeductible expenses associated with certain restructuring charges. The effective income tax rate was not meaningful in 2003 because we incurred income tax expense of $4,695, even though we recognized a loss from continuing operations of $19,374, primarily due to tax expense of $8,362 associated with nondeductible antitrust related charges and an additional $4,989 from adjustments increasing the deferred tax asset valuation allowance. The effective income tax rate was 36% in 2004 and 40% in 2003, in each case excluding the impact of restructuring charges, antitrust charges or benefits, and the tax expense resulting from the 2004 special tax election.

During 2003, we recorded a $561 gain from the sale of our non-strategic composite tooling business. The discontinued business recorded a net income from operations of $476 in 2003.

As a result of the matters described above, net income was $17,041 in 2004 as compared to net loss of $24,277 in 2003.

Synthetic Graphite. Net sales of $752,436 in 2004 represented a $112,308, or 18%, increase from net sales of $640,128 in 2003, primarily due to higher sales volume of graphite electrodes and higher average graphite electrode sales revenue per metric ton.

Volume of graphite electrodes sold was 222,000 metric tons in 2004 as compared to 200,500 metric tons in 2003. The higher volume of graphite electrodes sold represented an increase of $50,668 in net sales. Average sales revenue per metric ton of graphite electrodes in 2004 was $2,515 per metric ton as compared to $2,344 per metric ton in 2003. The higher

 

73

 

 

average sales revenue per metric ton represented an increase of $48,033 in net sales, approximately one-third of which was due to the positive impact of net changes in currency exchange rates. Such increases were partially offset by a decrease in net sales of $7,981 due primarily to changes in product and geographical mix.

The remaining $21,843 increase in net sales in the synthetic graphite segment occurred almost equally within advanced graphite materials and cathodes. Advanced graphite materials sales increased primarily due to the strengthening in the semiconductor, electronics, energy and transportation markets. Higher volumes of products sold increased net sales by $4,910 while improved pricing increased net sales by $1,497. Remaining increases were due to net favorable impacts of currency exchange rate changes. Cathode net sales increased primarily due to $9,191 net favorable impacts of currency exchange rate changes and $6,992 due to a favorable change in product mix, offset by negative pricing impacts.

Cost of sales of $565,583 in 2004 represented a $76,453, or 16%, increase from cost of sales of $489,130 in 2003. Cost of sales increased $44,861 due to higher sales volumes and the impact of a less favorable product sales mix, $25,497 due to the net unfavorable impacts of currency exchange rate changes and $15,830 due to higher operating costs, partially offset by $9,343 of improvements in productivity throughout our manufacturing network and $393 of improvements in other costs.

As a result, gross profit in 2004 was $186,854, 24% or $35,856 higher than in 2003. Gross margin was 24.8% of net sales in 2004, while gross margin was 23.6% of net sales in 2003.

Other. Net sales of $95,265 in 2004 represented a $23,056, or 32%, increase from net sales of $72,209 in 2003. Refractory product sales increased $14,057 primarily due to higher sales volumes. Remaining increases of $8,999 were due primarily to higher electronic thermal management sales, offset by decreases in sales of other products.

Cost of sales of $72,604 in 2004 represented a $17,538, or 32%, increase from cost of sales of $55,066 in 2003. Increases of $13,065 were primarily due to higher sales volumes of carbon refractory products and upward pressure on energy and raw material costs in both refractories and carbon electrodes. Remaining increases were primarily due to increased electronic thermal management sales.

As a result, gross profit in 2004 was $22,661, 32% or $5,518 higher than in 2003. Gross margin was 24.7% of net sales in 2004, while gross margin was 23.7% of net sales in 2003.

 

2005 Compared to 2004.

Consolidated. Net sales of $886,699 in 2005 represented a $38,998, or 5%, increase from net sales of $847,701 in 2004. Net sales of graphite electrodes increased $14,162 primarily due to higher average graphite electrode sales revenue per metric ton, offset by lower sales volumes and a less favorable product sales mix. Advanced graphite materials net sales increased $9,326 due primarily to higher sales volumes and improved pricing. Net sales of cathodes increased $8,224 due to higher sales volumes along with a more favorable product sales mix,

 

74

 

 

offset by negative pricing impacts. Net sales of natural graphite increased $4,556 primarily due to an increase in ETM net sales, partially offset by decreases in sales of other natural graphite products. Remaining increases in net sales were primarily due to an increase in net sales of carbon electrodes, primarily driven by increased volumes.

Cost of sales of $654,342 in 2005 represented a $16,156, or 3%, increase from cost of sales of $638,186 in 2004. Cost of sales increased $33,679 due to higher operating costs, $2,992 due to a less favorable product sales mix, $7,265 due to the net unfavorable impacts of currency exchange rates and $2,716 due to other costs, partially offset by a decrease of $30,496 due to lower sales volumes.

Gross profit of $232,357 in 2005 represented a $22,842, or 11%, increase from gross profit of $209,515 in 2004. Gross margin increased to 26.2% of net sales in 2005 from 24.7% of net sales in 2004. See below for further details regarding such changes.

Selling, administrative and other expenses increased $11,070, or 12%, from $89,369 in 2004 to $100,439 in 2005. The increase was primarily due to higher selling expenses of approximately $2,320 associated with higher net sales, increased employee compensation costs of approximately $4,425 ($1,814 of which was associated with restricted stock grants), an increase in third party professional fees of $1,718 and $2,607 of other costs.

Research and development expenses increased $1,397, or 17%, from $8,040 in 2004 to $9,437 in 2005, with the increase primarily due to increased headcount to support growth in our ETM products and services.

Other (income) expense, net, was expense of $18,020 in 2005 as compared to expense of $21,189 in 2004. The net decrease in expense of $3,169 was primarily due to the following:

losses of $8,782 attributable to a reduction of Senior Notes outstanding (due to debt for equity exchanges and repurchases) occurred in 2004;

expenses pertaining to legal, environmental and other related costs decreased $5,696 in 2005 as compared to 2004;

non-income tax charges decreased $3,395 for 2005 as compared to 2004;

benefits pertaining to foreign currency exchange rate contracts of $1,674 as gains were recognized in 2005 as compared to losses in 2004;

a decrease in fair value adjustment losses on interest rate caps of $3,300 for 2005 as compared to 2004; and

the net decrease in other costs of $3,717; offset by

losses due to changes in currency exchange rates, primarily associated with Euro-denominated intercompany loans, increasing $23,395 for 2005 as compared to 2004.

In 2004, we recorded a net restructuring charge of $548, comprised primarily of the following:

 

 

75

 

 

 

a $2,473 net benefit associated with the closure of our graphite electrode manufacturing operations in Caserta, Italy (consisting of a reduction in cost estimate, partially offset by the completion of further severance agreements for employees terminated in connection with the closure); offset by

a $1,329 charge relating primarily to severance programs and related benefits associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom; and

a $596 charge associated primarily with changes in estimates related to U.S. voluntary and selective severance programs.

In 2005, we recorded a net restructuring charge of $9,729, comprised primarily of the following:

a $6,100 charge associated with the rationalization of our synthetic graphite facilities, including those in Brazil, France, and Russia;

a $3,194 charge associated with the closure of our graphite electrode manufacturing operations at Caserta, Italy;

a $523 charge primarily associated with the relocation of our corporate headquarters from Wilmington, Delaware to Parma, Ohio;

an $804 charge associated with the phase out of our graphite electrode machining operations in Clarksville, Tennessee, scheduled for completion in the third quarter of 2006, and the closure of our administrative offices in Clarksville, scheduled for completion at the end of the first quarter of 2006; and

a $430 charge associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom; offset by

a $1,322 benefit associated with a change in estimate pertaining to the closure of certain graphite electrode manufacturing operations.

We expect to record additional charges of approximately $7 million in 2006 and $2 million in 2007 related to such initiatives. Additionally, in the first quarter of 2006, we announced plans to shut down carbon electrode production operations at our Columbia, Tennessee manufacturing facility. This plan is expected to be completed by the end of the first quarter of 2007. We expect to record total charges of approximately $5 million throughout 2006 and 2007 related to such shut down.

 

As a result of the rationalization of our synthetic graphite facilities, we expect to achieve both operating efficiencies and production cost savings. The restructuring of our graphite electrode facilities is aimed at improving our operating performance, including leveraging our infrastructure for greater productivity and contributing to our continued growth. We anticipate annualized cost savings between $20 million and $22 million, with the full benefit of such savings expected to be realized in 2007 and beyond.

 

76

 

 

 

The restructuring accrual is included in other accrued liabilities and other long-term obligations on the Consolidated Balance Sheets. The following table summarizes activity relating to the accrual:

Severance
and
Related
Costs

Plant Shutdown
and
Related
Costs

Total
(Dollars in thousands)
 
Balance at January 1, 2004     $ 19,253   $ 9,410   $ 28,663  



 
Restructuring charges       4,321     985     5,306  
Change in estimates           (5,854 )   (5,854 )
Payments and settlements,
    including non-cash items of $2,814
      (18,367 )   (1,300 )   (19,667 )
Effect of change in currency exchange rates      340     64     404  



Balance at December 31, 2004      5,547     3,305     8,852  



 
Restructuring charges       10,880     474     11,354  
Change in estimates       (260 )   (1,365 )   (1,625 )
Payments and settlements,
    majority of which are cash payments
      (4,999 )   (1,671 )   (6,670 )
Effect of change in currency exchange rates      (435 )   51     (384 )



Balance at December 31, 2005    $ 10,733   $ 794   $ 11,527  



 

At December 31, 2005, the outstanding balance of our restructuring reserve was $11,527. We expect the majority of the remaining payments to be paid by the end of 2007. The components of the balance at December 31, 2005 consisted primarily of:

Synthetic Graphite:

 

$6,044 related to the rationalization of our synthetic graphite facilities, including Brazil, France, and Russia;

$3,897 related to the closure of our graphite electrode manufacturing operations in Caserta, Italy; and

$700 related to the phase out of our graphite electrode machining operations in Clarksville, Tennessee.

 

Other Segment and Corporate:

 

$794 related primarily to remaining lease payments on our former corporate headquarters; and

 

 

77

 

 

 

$92 related to the relocation of our corporate headquarters from Wilmington, Delaware to our research & development center in Parma, Ohio.

 

In 2005, we recorded a $2,904 charge related to the impairment of our long-lived carbon electrode fixed assets in Columbia, Tennessee as a result of our 2005 fourth quarter review of our carbon electrode forecasts. The future estimated undiscounted cash flows expected to result from the use of these assets were below their respective carrying amounts. As a result, an impairment loss was measured as the difference between the assets’ carrying amount and fair value, which was based on current estimates of market price.

 

We recorded a $1,262 charge for additional potential liabilities and expenses in connection with antitrust investigations and related lawsuits and claims in the 2004 first quarter. This charge was offset by a gain due to the refund of €10 million ($12,163 based on currency exchange rates then in effect) that we received from the EU Competition Authority as a result of the reduction of the EU antitrust fine to €42 million, plus accrued interest of a €7.7 million (which was calculated at a rate of 8.04% per annum), an aggregate of about $59 million at currency exchange rates in effect at the time the decision on our appeal thereof was issued.

The following table presents an analysis of interest expense:

  For the Year
Ended
December 31,

  2004
2005
  (Dollars in thousands)
Interest incurred on debt     $ 49,808   $ 50,984  
Interest rate swap benefit    (10,092 )  (1,633 )
Amortization of fair value adjustments for terminated hedge
    instruments
    (2,468 )  (1,744 )
Accelerated amortization of fair value adjustments for terminated  
    hedge instruments due to reduction of Senior Notes    (4,746 )  
Amortization of debt issuance costs    4,834    3,569  
Interest on DOJ antitrust fine       710     507  
Amortization of premium on Senior Notes     (243 )   (162 )
Amortization of discount on Debentures     867     885  
     Interest incurred on other items     508     310  


    Interest expense   $ 39,178   $ 52,716  


 

Average total debt outstanding was $675,553 in 2004 as compared to $708,791in 2005. The average annual interest rate was 5.5% in 2004 as compared to 6.9% in 2005. These average rates represent the average rates on total debt outstanding and include the benefits, if any, of our interest rate swaps.

We recorded interest income in 2004 of $1,161 primarily attributable to interest earned on cash proceeds from the issuance and sale of the Debentures. We recorded interest income in 2005 of $1,200 primarily attributable to interest earned on prepayments made to the government.

 

78

 

 

 

Provision for income taxes was a charge of $165,813 in 2005 as compared to a charge of $46,310 in 2004. The effective income tax rate was approximately 411% in 2005. The higher effective income tax rate was primarily due to a charge resulting from a net change in the total valuation allowance for 2005 of $153,079. During the 2005 year-end financial accounting closing process, we determined that the timing of when we will generate sufficient U.S. taxable income to realize our U.S. deferred tax assets became less certain; therefore, we recorded a valuation allowance, primarily against our net federal deferred tax assets in the U.S., of $149,734. We recorded similar valuation allowances in certain other jurisdictions in both the second and fourth quarters of 2005, which resulted in charges totaling $3,345.

 

The effective income tax rate was 72% in 2004. The higher effective income tax rate was primarily due to the implementation of the 2004 special tax election that accelerated approximately $215,177 of taxable income in the U.S. that resulted in the utilization of approximately $26,219 in deferred tax assets, of which approximately $19,969 were existing foreign tax credits, and $6,250 of net operating loss carryforward. The effective rate in 2004 was also impacted by a benefit from the EU Competition Authority refund, which was non-taxable in the U.S., and by nondeductible expenses associated with certain restructuring charges.

 

Excluding the change in valuation allowances, impact of restructuring charges and the tax expense resulting from the 2004 special tax election, the 2005 effective tax rate was 38%. Excluding the impact of restructuring charges, the tax expense resulting from the 2004 special tax election and the antitrust benefits, the 2004 effective tax rate was 36%.

 

As a result of the matters described above, our net loss was $125,180 in 2005 as compared to net income of $17,041 in 2004.

 

Synthetic Graphite. Net sales of $784,148 in 2005 represented a $31,712, or 4%, increase from net sales of $752,436 in 2004.

Net sales of graphite electrodes increased $14,162 primarily due to higher average graphite electrode sales revenue per metric ton, offset by lower sales volumes and a less favorable product sales mix. The average sales revenue per metric ton of graphite electrodes in 2005 was $2,846 per metric ton as compared to the average in 2004 of $2,515 per metric ton. The higher average sales revenue per metric ton represented an increase of $87,165 in net sales, including the net unfavorable impact of changes in currency exchange rates. Volume of graphite electrodes sold was 201,300 metric tons in 2005 as compared to 222,000 metric tons in 2004. The lower volumes of graphite electrodes sold represented a decrease of $52,780 in net sales and resulted primarily from pricing initiatives. The effect of a less favorable product sales mix decreased net sales $15,999. Other decreases in net sales amounted to $4,224.

Advanced graphite materials net sales increased $9,326 due primarily to higher sales volumes, which increased net sales $5,814, and improved pricing, which increased net sales $3,512, including the net favorable impact of changes in currency exchange rates of $377. Net sales of cathodes increased $8,224 due to higher sales volumes of $5,529 along with a more favorable product sales mix of $4,410, offset by negative pricing impacts.

 

 

79

 

 

 

Cost of sales of $573,220 in 2005 represented an $7,638, or 1%, increase from cost of sales of $565,582 in 2004. Cost of sales increased $25,178 due to higher operating costs, $3,545 due to a less favorable product sales mix, $7,265 due to the net unfavorable impact of changes in currency exchange rates and $2,939 due to other costs, partially offset by a decrease of $31,289 due to lower sales volumes.

As a result, gross profit in 2005 was $210,928, 13% or $24,074 higher than in 2004. Gross margin was 26.9% of net sales in 2005, while gross margin was 24.8% of net sales in 2004.

Other. Net sales of $102,551 in 2005 represented a $7,286, or 8%, increase from net sales of $95,265 in 2004. Net sales of natural graphite increased $4,556 primarily due to an increase in ETM net sales of $7,127, partially offset by decreases in sales of other natural graphite products, primarily relating to softer automotive end market conditions. Remaining increases in net sales of the other segment were primarily due to an increase in net sales of carbon electrodes, primarily driven by increased volumes.

Cost of sales of $81,122 in 2005 represented an $8,518, or 12%, increase from cost of sales of $72,604 in 2004. The cost of sales of carbon electrodes increased $3,283 due to higher sales volumes and higher costs. Cost of sales of natural graphite increased $4,662 primarily due to an increase in certain higher raw material costs and higher overhead costs. Remaining increases were primarily within refractories and were due primarily to higher production costs.

As a result, gross profit in 2005 was $21,429, 5% or $1,232 lower than in 2004. Gross margin was 20.9% of net sales in 2005, while gross margin was 23.8% of net sales in 2004.

 

Effects of Inflation

We incur costs in the U.S. and each of the six non-U.S. countries in which we have a manufacturing facility. In general, our results of operations, cash flows and financial condition are affected by the effects of inflation on our costs incurred in each of these countries. See “Currency Translation and Transactions” for a further discussion of highly inflationary countries.

During the past three years, we experienced higher freight, energy and other raw material costs primarily due to substantial increases in regional and worldwide market prices of natural gas and other petroleum-based raw materials. We seek to mitigate the effects of those increases on our cost of sales through improved operating efficiencies, higher prices for our products and ongoing cost savings, and, in some cases, fixed price or derivative contracts.

We have in the past entered into, and may in the future enter into, natural gas derivative contracts and short duration fixed rate purchase contracts to effectively fix some or all of our natural gas cost exposure. At December 31, 2005, we had fixed about 23% of our worldwide natural gas exposure through 2006 using such contracts. As of February 15, 2006, we had fixed about 32% of our worldwide natural gas exposure through such contracts.

 

 

80

 

 

 

Currency Translation and Transactions

We account for our non-U.S. subsidiaries under SFAS No. 52, “Foreign Currency Translation.” Accordingly, except for highly inflationary countries, the assets and liabilities of our non-U.S. subsidiaries are translated into dollars for consolidation and reporting purposes. Foreign currency translation adjustments are generally recorded as part of stockholders’ deficit and identified as part of accumulated other comprehensive loss on the Consolidated Balance Sheets until such time as their operations are sold or substantially or completely liquidated.

Highly inflationary economies are defined as having cumulative inflation of about 100% or more over a period of three calendar years. In general, the financial statements of foreign operations in highly inflationary economies are remeasured as if the functional currency of their economic environments were the dollar and translation gains and losses relating to these foreign operations are included in other (income) expense, net, on the Consolidated Statements of Operations rather than as part of stockholders’ deficit on the Consolidated Balance Sheets. We have subsidiaries in Russia, Mexico, Brazil and other countries which have had in the past, and may have in the future, highly inflationary economies.

We account for our Mexican and Russian subsidiaries using the dollar as their functional currency, as sales and purchases for each subsidiary are predominantly dollar-denominated. Our remaining subsidiaries use their local currency as their functional currency.

We also record foreign currency transaction gains and losses as part of other (income) expense, net.

Significant changes in currency exchange rates impacting us are described under “Effects of Changes in Currency Exchange Rates” and “Results of Operations.”

Effects of Changes in Currency Exchange Rates

We incur costs in dollars and the currency of each of the six non-U.S. countries in which we have a manufacturing facility, and we sell our products in multiple currencies. In general, our results of operations, cash flows and financial condition are affected by changes in currency exchange rates affecting these currencies relative to the dollar and, to a limited extent, each other.

When the currencies of non-U.S. countries in which we have a manufacturing facility decline (or increase) in value relative to the dollar, this has the effect of reducing (or increasing) the dollar equivalent cost of sales and other expenses with respect to those facilities. This effect is, however, partially offset by the cost of petroleum coke, a principal raw material used by us, which is priced in dollars. In certain countries where we have manufacturing facilities, and in certain instances where we price our products for sale in export markets, we sell in currencies other than the dollar. Accordingly, when these currencies increase (or decline) in value relative to the dollar, this has the effect of increasing (or reducing) net sales. The result of these effects is to increase (or decrease) operating profit and net income.

 

 

81

 

 

 

Many of the non-U.S. countries in which we have a manufacturing facility have been subject to significant economic changes, which have significantly impacted currency exchange rates. We cannot predict changes in currency exchange rates in the future or whether those changes will have net positive or negative impacts on our net sales, cost of sales or net income.

During 2003, the average exchange rate of the euro and the South African rand increased about 20% and 40%, respectively, when compared to the average exchange rate for 2002. During 2003, the average exchange rate for the Brazilian real and the Mexican peso declined about 1% and 11%, respectively, when compared to the average exchange rate for 2002. During 2004, the average exchange rate of the euro, South African rand, and Brazilian real increased about 10%, 17% and 5%, respectively, when compared to the average exchange rate for 2003. The Mexican peso declined about 5% when compared to the average exchange rate for 2003. During 2005, the average exchange rate of the euro, the South African rand, the Brazilian real and the Mexican peso increased about 1%, 2%, 21% and 4%, respectively, when compared to the average exchange rate for 2004.

 

In the case of net sales of graphite electrodes, the impact of these events was an increase of about $33,499 in 2003, an increase of about $18,484 in 2004 and a decrease of about $604 in 2005. In the case of cost of sales of graphite electrodes, the impact of these events was an increase of about $24,400 in 2003, an increase of about $17,900 in 2004 and an increase of about $5,262 in 2005. The impact of these events on net sales of cathodes was an increase of about $12,482 in 2003, an increase of about $9,191 in 2004 and a decrease of about $132 in 2005. The impact of these events on cost of sales of cathodes was an increase of about $10,529 in 2003, an increase of about $7,597 in 2004 and an increase of about $1,730 in 2005.

 

We have non-dollar denominated intercompany loans between GrafTech Finance and some of our foreign subsidiaries. At December 31, 2005, the aggregate principal amount of these loans was $414,622. These loans are subject to remeasurement gains and losses due to changes in currency exchange rates. A portion of these loans are deemed to be essentially permanent and, as a result, remeasurement gains and losses on these loans are recorded as a component of accumulated other comprehensive loss in the stockholders’ deficit section of the Consolidated Balance Sheets. The balance of these loans are deemed to be temporary and, as a result, remeasurement gains and losses on these loans are recorded as currency (gains) losses in other (income) expense, net, on the Consolidated Statements of Operations. In 2003, we had a net total of $42,149 in currency gains, including $41,920 of exchange gains due to the remeasurement of intercompany loans and translation of financial statements of foreign subsidiaries which use the dollar as their functional currency. In 2004, we had a net total of $8,527 in currency gains, including $9,835 of exchange gains due to the remeasurement of intercompany loans and translation of financial statements of foreign subsidiaries which use the dollar as their functional currency. In 2005, we had a net total of $14,868 of currency losses, including $14,611 of exchange losses due to the remeasurement of intercompany loans and translation of financial statements of foreign subsidiaries which use the dollar as their functional currency. We have in the past and may in the future use various financial instruments to manage certain exposures to specific financial market risks caused by changes in currency exchange rates, as described under “Item 7A–Quantitative and Qualitative Disclosures about Market Risks.”

 

 

82

 

 

 

Liquidity and Capital Resources

Our sources of funds have consisted principally of invested capital, cash flow from operations and debt and equity financings. Our uses of those funds (other than for operations) have consisted principally of capital expenditures, payment of fines, liabilities and expenses in connection with antitrust investigations, lawsuits and claims, payment of restructuring costs, pension and post-retirement contributions, debt reduction payments and other obligations.

 

We are highly leveraged and have other substantial obligations. At December 31, 2005, we had total debt of $704,148, cash and cash equivalents of $5,968 and a stockholders’ deficit of $209,577.

 

As part of our cash management activities, we manage accounts receivable credit risk, collections, and accounts payable and payments thereof to maximize our free cash at any given time and minimize accounts receivable losses. Certain subsidiaries sold receivables totaling $175,130 in 2003 and $7,036 in 2004. During 2005, certain subsidiaries sold receivables totaling $17,682, at a cost lower than the cost to borrow a comparable amount for a comparable period under the Revolving Facility. Proceeds of the sale of receivables were used to reduce debt. If we had not sold such receivables, our accounts receivable and our debt would have been unchanged at December 31, 2004 and about $13,095 higher at December 31, 2005. All such receivables sold during 2005 were sold without recourse, and no amount of accounts receivable sold remained on the Consolidated Balance Sheet at December 31, 2005.

 

We use cash and cash equivalents, funds available under the Revolving Facility (subject to continued compliance with the financial covenants and representations under the Revolving Facility) as well as cash flow from operations as our primary sources of liquidity. The Revolving Facility provides for maximum borrowings of up to $215 million. At December 31, 2005, $167,947 was available (after consideration of outstanding revolving and swingline loans of $39,000 and outstanding letters of credit of $8,053). It is possible that our future ability to borrow under the Revolving Facility may effectively be less because of the impact of additional borrowings upon our compliance with the maximum net senior secured debt leverage ratio permitted or minimum interest coverage ratio required under the Revolving Facility.

 

At December 31, 2005, we were in compliance with all financial and other covenants contained in the Senior Notes, the Debentures and the Revolving Facility, as applicable. Based on expected operating results and expected cash flows, we expect to be in compliance with these covenants over the next twelve months. If we were to believe that we would not continue to comply with these covenants, we would seek an appropriate waiver or amendment from the lenders thereunder. We cannot assure you that we would be able to obtain such waiver or amendment on acceptable terms or at all.

 

At December 31, 2005, 6% (or $40,376) of our total debt (excluding the fair value adjustments to debt and the unamortized bond premium and including the original value of the Debenture derivative liability relating to the Debentures redemption feature with a make-whole

 

83

 

 

provision) consists of variable rate obligations. Such amount includes $39,000 outstanding under the Revolving Facility and $1,376 of other debt.

 

At December 31, 2005, the Revolving Facility had an effective interest rate of 6.8%, our $434,631 principal amount of Senior Notes had a fixed rate of 10.25% and an effective rate of 10.02% (including the effect of the amortization of fair value adjustments for terminated hedge instruments) and our $225,000 principal amount of Debentures had a fixed rate of 1.625%. We estimate interest expense to be approximately $58 million for 2006.

 

We continue to implement interest rate management initiatives to seek to minimize interest expense and optimize the risk in our portfolio of fixed and variable interest rate obligations as described under “Item 7A–Quantitative and Qualitative Disclosures about Market Risk” in this Report.

Long-Term Contractual, Commercial and Other Obligations and Commitments. The following tables summarize our long-term contractual obligations and other commercial commitments at December 31, 2005.

  Payment Due By Period
  Total
Year
Ending
December
2006

Two
Years Ending
December
2008

Two
Years Ending
December
2010

Years
Ending After
December
2010

  (Dollars in thousands)
 
Contractual and Other Obligations                        
Long-term debt   $ 699,602   $ 39,045   $ 434   $ 191   $ 659,932  
Capital lease obligations                      
Operating leases    15,208    4,063    5,124    4,097    1,924  
Unconditional purchase obligations (a)     26,776    7,974    8,776    8,776    1,250  





     Total contractual obligations (a)     741,586     51,082     14,334     13,064     663,106  
Estimated liabilities and expenses in
   connection with antitrust
   investigations and related lawsuits
   and claims (b)
    26,000    20,625    5,375          
Postretirement, pension and related  
   benefits (c)    76,983    11,996    6,499    6,499    51,989  
Interest (d)    310,929    48,244    96,488    96,488    69,709  
Other long-term obligations    17,200    7,371    2,484    853    6,492  





      Total contractual and other
          obligations (a)(b)(c)
   $ 1,172,698   $ 139,318   $ 125,180   $ 116,904   $ 791,296  





 
Other Commercial Commitments  
Lines of credit (e)           $   $      
Letters of credit    8,017    7,747    270          
Guarantees    3,680    3,438    135        107  





     Total other commercial
          commitments
   $ 11,697   $ 11,185   $ 405   $   $ 107  





 

84

 

 

 

_________________

(a) Effective April 2001, we entered into a ten-year service contract with CGI Group Inc. (“CGI”) valued at that time at $75 million ($23 million of which is the unconditional purchase obligation at December 31, 2005 included in the above table). Pursuant to this contract, CGI became the delivery arm for our global information services. Under the outsourcing provisions of this contract, CGI managed our data center services, networks, desktops, telecommunications and legacy systems. This contract was amended, effective September 2005, to reduce the scope of CGI’s management of our data center services, networks, desktops and telecommunications. We are dependent on CGI for these services. A failure by CGI to provide any of these services to us in a timely manner could have an adverse effect on our results of operations.

  In the 2002 third quarter, we entered into a ten-year outsourcing contract with CGI valued at that time at $36 million. Such amounts are excluded from the above table, as these amounts do not include an unconditional purchase obligation. Pursuant to this contract, CGI became the delivery arm for our finance and accounting business process services (“BPS”), including accounts receivable and accounts payable activities, and provided various related analytical services such as general accounting, cost accounting and financial analysis activities. During the fourth quarter of 2005, we entered into a memorandum of agreement with CGI, terminating such services. The memorandum was entered into after the parties determined that the termination of the contract was in their mutual best interest. Such termination is effective during the first quarter of 2006. Thereafter, we will be solely and entirely responsible for all of the services previously rendered by CGI under the contract.

(b) Consists of the outstanding balance of the DOJ antitrust fine.

(c) Represents estimated postretirement, pension and related benefits obligations based on actuarial calculations.

(d) Excludes the accounting for deferred financing costs or gains on the sale of hedge instruments. Payments assume Senior Notes, with a fixed rate of interest of 10.25%, mature on February 15, 2012 and the Debentures, with a fixed rate of interest of 1.625%, effectively mature on January 15, 2011.

(e) Local lines of credit are established by our foreign subsidiaries for working capital purposes and are not part of the Revolving Facility. The total amount available under the lines of credit amounted to $19 million at December 31, 2005.

Cash Flow and Plans to Manage Liquidity. As a result of our significant leverage and other substantial obligations, our business strategies include efforts to enhance our capital structure by further reducing our gross obligations. Accordingly, we have placed the highest priority on accelerating the amount and speed of cash generated every day. Our efforts include leveraging our unique global manufacturing network by driving higher utilization rates and more productivity from our existing assets, accelerating commercialization initiatives across all of our businesses and realizing other global efficiencies. In addition, we may exchange or repurchase Senior Notes or Debentures as described below. We also continue to evaluate other

 

85

 

 

opportunities to reduce our obligations, including the obligations associated with our U.S. defined benefit plan, which was frozen in 2003.

 

Typically, the first quarter of each year results in neutral or negative cash flow from operations due to various factors. These factors include customer order patterns, fluctuations in working capital requirements and other factors. Typically, the other three quarters result in positive cash flow from operations. The third quarter tends to produce relatively less positive cash flow from operations primarily as a result of scheduled plant shutdowns by our customers for vacations. Our cash flow from operations in the first and third quarters typically is adversely impacted by the semi-annual interest payments on the Senior Notes and the Debentures. The second and fourth quarters correspondingly benefit from the absence of such interest payments.

 

In addition to the above factors, in 2003 and 2004, we had negative cash flow from operations primarily due to payments in connection with restructurings, antitrust investigations, lawsuits and claims and uses of cash from working capital. In 2005, we had positive cash flow from operations despite continued payments in connection with restructurings and antitrust investigations and the continued use of cash for working capital to, among other things, build inventories. For 2006, we expect increasingly positive cash flows from operations. In addition to the factors described above, we expect a weaker than normal 2006 first quarter due to, lower sales and profit because of weaker than normal customer shipments because graphite electrode customers took full contract volumes in the 2005 fourth quarter and a higher use of cash for temporarily higher inventory because of higher graphite electrode operating levels in the first quarter as compared to the lower shipments. This is expected to result in negative cash flow during the 2006 first quarter and debt levels that may be $40 million or more higher in the 2006 first quarter than those at the 2005 year end and generally higher than the average level expected for the full year 2006.

 

As part of our cash management activities, we seek to manage accounts receivable credit risk and collections, and payment of accounts payable to seek to maximize our free cash at any given time and minimize accounts receivable losses. In order to seek to minimize our credit risks, we reduced our sales of, or refused to sell (except for cash on delivery), graphite electrodes to some customers and potential customers in the U.S. and, to a limited extent, elsewhere. Our unrecovered trade receivables worldwide were only 0.1% of global net sales during the last 3 years. We cannot assure you that we will not be materially adversely affected by accounts receivable losses in the future. In addition, we have historically factored a portion of our accounts receivable and used the proceeds to reduce debt.

We use cash and cash equivalents, funds available under the Revolving Facility and cash flow from operations as our primary sources of liquidity. We believe that our business strategies will continue to improve the amount and speed of cash generated from operations under current economic conditions. Improvements in cash flow from operations resulting from these strategies are being partially offset by associated cash implementation costs while they are being implemented. We also believe that our planned asset sales together with these improvements in cash flow from operations should allow us to reduce our debt and other obligations over the long term.

We may from time to time and at any time repurchase Senior Notes or Debentures in open market or privately negotiated transactions, opportunistically on terms that we believe to be favorable. These purchases may be effected for cash (from cash and cash equivalents, borrowings under the Revolving Facility or new credit facilities, or proceeds from sale of debt or equity securities or assets), in exchange for common stock or other equity or debt securities, or a combination thereof. We will evaluate any such transaction in light of then prevailing market conditions and our then current and prospective liquidity and capital resources, including projected and potential needs and prospects for access to capital markets. Any such transactions may, individually or in the aggregate, be material.

 

 

86

 

 

 

Our high leverage and other substantial obligations could have a material impact on our liquidity. Cash flow from operations services payment of our debt and other obligations thereby reducing funds available to us for other purposes. Our leverage and these obligations make us more vulnerable to economic downturns in the event that these obligations are greater or timing of payment is sooner than expected.

We believe that the long term fundamentals of our business continue to be sound. Accordingly, although we cannot assure you that such will be the case, we believe that, based on our expected cash flow from operations, our existing capital resources, and taking into account our working capital needs and our efforts to reduce costs, improve efficiencies and product quality and accelerate commercialization of new products and cash flow, we will be able to manage our liquidity to permit us to service our debt and meet our obligations when due. Based on expected operating results and expected cash flows, we expect to be in compliance with financial covenants in 2006.

Related Party Transactions. Since January 1, 2003, we have not engaged in or been a party to any material transactions with affiliates or related parties other than transactions with our subsidiaries (including Carbone Savoie and AET) and compensatory transactions with directors and officers (including employee benefits, stock option and restricted stock grants, compensation deferral, executive employee loans and stock purchases).

Off-Balance Sheet Arrangements and Commitments. We have not undertaken or been a party to any material off-balance-sheet financing arrangements or other commitments (including non-exchange traded contracts), other than:

Interest rate caps, interest rate swaps, currency exchange rate contracts and natural gas contracts, which are described under “Item 7A – Quantitative and Qualitative Disclosures About Market Risk.”

Commitments under non-cancelable operating leases that, at December 31, 2004, totaled no more than $4 million in each year and about $7,697 in the aggregate, and, at December 31, 2005, totaled no more than $4 million in each year and about $15,208 in the aggregate.

Minimum required purchase commitments under our information technology outsourcing services agreement with CGI described above that, at December 31, 2004, totaled approximately $5 million in each year and about $32,484 in the aggregate and at December 31, 2005, totaled no more than $5 million in each year and about $23,276 in the aggregate.

Factoring accounts receivable as described above.

We are not affiliated with or related to any special purpose entity other than GrafTech Finance, our wholly-owned and consolidated finance subsidiary.

 

 

87

 

 

 

Cash Flows.

Cash Flow (Used in) Provided by Operating Activities. Cash flow (used in) provided by operating activities was ($25,106) in 2003, ($132,266) in 2004 and $7,989 in 2005.

Cash used in operating activities was $25,106 in 2003. Income from continuing operations, after adding back the net effect from non-cash items, amounted to $19,502. Such income was used in operating activities primarily as follows: a reduction in payables of $12,309 primarily due to timing of payment patterns, including our semi-annual interest payments on the Senior Notes and the Debentures, an increase in inventories of $8,674 to primarily support anticipated customer demand and an increase of $4,971 in accounts receivables.

 

Other uses in 2003 consisted of $4,588 of payments for antitrust investigations and related lawsuits and claims, $5,692 of restructuring costs related to severance and related payments and $9,796 of other payments consisting primarily of pension and post-retirement contributions and payments. Net cash provided from discontinued operations amounted to $1,422.

 

Cash used in operating activities was $132,266 in 2004. Net income, after adding back the net effect from non-cash items, amounted to $72,624. Such income was used in operating activities primarily as follows: an increase in accounts receivables of $66,300 primarily from the discontinuance of accounts receivable factoring and increased sales, and an increase in inventories of $6,276 primarily in anticipation of increased demand, offset by an increase in payables of $6,859 due primarily to timing of payment patterns.

Other uses in 2004 consisted of $83,480 of payments for antitrust investigations and related lawsuits and claims, $16,853 of restructuring costs related to severance and related payments and $38,840 of other payments consisting primarily of pension and post-retirement contributions and payments.

 

Cash provided by operating activities was $7,989 in 2005. Income from continuing operations, after adding back the net effect from non-cash items, amounted to $80,699. Such income was used in operating activities primarily as follows: an increase in inventories of $45,430 primarily to support anticipated growth in customer demand and an $2,690 decrease in payables primarily due to timing of payment patterns, offset by a decrease in accounts receivables of $10,921 primarily from increased factoring.

 

Other uses in 2005 consisted of $16,900 of payments for antitrust investigations and related lawsuits and claims, $6,670 of restructuring costs related to severance and related payments and $11,941 of other payments consisting primarily of pension and post-retirement contributions and payments.

 

Cash Flow Used in Investing Activities. Cash flow used in investing activities was $22,113 in 2003, $56,310 in 2004 and $60,381 in 2005.

 

Cash used in investing activities was $22,113 in 2003. Capital expenditures in 2003 were $40,485. Capital expenditures related primarily to the expansion of graphite electrode

 

88

 

 

manufacturing capacity, implementation of People Soft Enterprise One (formerly known as J.D. Edwards One World) information systems and essential capital maintenance. Expenditures were offset by $18,372 of cash, primarily provided from the sale of our non-strategic composite tooling business and the sale of other assets.

 

Cash used in investing activities was $56,310 in 2004. Capital expenditures in 2004 were $59,117 and related primarily to the expansion of graphite electrode manufacturing capacity, including expansion of our graphite electrode manufacturing facilities in Spain, France, and South Africa, implementation of People Soft Enterprise One (formerly known as J.D. Edwards One World) information systems and essential capital maintenance. Other investing uses of $3,539 pertained primarily to the purchase of derivative instruments. Such uses were offset by $6,346 in proceeds from the sale of assets, primarily pertaining to the sale of our fixed assets in connection with closure of our advanced synthetic graphite machining operations in Sheffield, United Kingdom.

Cash used in investing activities was $60,381 in 2005. Capital expenditures amounted to $48,071 in 2005 and related primarily to graphite electrode productivity and production stability initiatives and other essential capital maintenance. Such uses were offset primarily by proceeds from the sale of derivative instruments and the sale of other assets. Other investing uses of $15,597 pertained primarily to payments in connection with the sale of interest rate swaps. Such uses were partially offset by $3,287 from the sale of certain assets.

Cash Flow Provided by Financing Activities. Cash flow provided by financing activities was $69,133 in 2003, $176,606 in 2004 and $36,184 in 2005.

 

During 2003, we received net proceeds of $189,877 from a registered public offering of common stock and $30,188 from the sale of interest rate swaps. We used these proceeds primarily to repay term loans of $115,986 outstanding under the Senior Facilities, reduce the outstanding balance under the Revolving Facility and repay other short-term debt.

 

Cash provided by financing activities was $176,606 in 2004. During 2004, we received gross proceeds of $225,000 (less issuance costs of $7,355) from the issuance and sale of the Debentures and $7,843 from the exercise of stock options. We used these proceeds to repay term loans of $21,398 outstanding under the Senior Facilities, to pay $83,480 primarily to the EU Competition Authority and to replace cash previously provided by factoring of accounts receivable as described above in “Cash Flow Used in Operating Activities.” In addition, we purchased $22,869 aggregate principal amount of Senior Notes, plus accrued interest, for $27,342 in cash.

Cash provided by financing activities was $36,184 in 2005. During 2005, we incurred borrowings of $173,325, primarily under the Revolving Facility. We used these net borrowings to fund working capital requirements, primarily inventory that we have replenished and built in anticipation of stronger demand. Such borrowings were offset by payments under the Revolving Facility of $131,562 and $5,579 in financing and other costs.

 

 

89

 

 

 

Costs Relating to Protection of the Environment

We have been and are subject to increasingly stringent environmental protection laws and regulations. In addition, we have an on-going commitment to rigorous internal environmental protection standards. Environmental considerations are part of all significant capital expenditure decisions. The following table sets forth certain information regarding environmental expenses and capital expenditures.

For the Year Ended December 31,
2003
2004
2005
  (Dollars in thousands)
Expenses relating to environmental protection     $13,074   $13,056   $12,525  
Capital expenditures related to environmental protection    2,118    2,787    2,749  

Critical Accounting Policies

Critical accounting policies are those that require difficult, subjective or complex judgments by management, often as a result of the need to make estimates about the effect of matters that are inherently uncertain and may change in subsequent periods.

Our significant accounting policies are described in Note 2 to the Consolidated Financial Statements. The following accounting policies are deemed to be critical.

Reliance on Estimates. In preparing the Consolidated Financial Statements, we use and rely on estimates in determining the economic useful lives of our assets, obligations under our employee benefit plans, provisions for doubtful accounts, provisions for restructuring charges and contingencies, tax valuation allowances, evaluation of goodwill and other intangible assets, pension and postretirement benefit obligations and various other recorded or disclosed amounts. Estimates require us to use our judgment. While we believe that our estimates for these matters are reasonable, if the actual amount is significantly different than the estimated amount, our assets, liabilities or results of operations may be overstated or understated.

Employee Benefit Plans. We sponsor various retirement and pension plans, including defined benefit and defined contribution plans and postretirement benefit plans that cover most employees worldwide. Accounting for these plans requires assumptions as to the discount rate, expected return on plan assets, expected salary increases and health care cost trend rate. See Note 11 to the Consolidated Financial Statements for further details.

Financial Instruments. We are exposed to market risks primarily from changes in interest rates and currency exchange rates. We routinely enter into various transactions that have been authorized according to documented policies and procedures to manage well-defined currency exchange rate risks and interest rate risks. These transactions relate primarily to financial instruments described under “Item 7A–Quantitative and Qualitative Disclosures about Market Risks.” Since the counterparties to these financial instruments are large commercial banks and similar financial institutions, we do not believe that we are exposed to material counterparty credit risk. We do not use financial instruments for trading purposes. Accounting for financial instruments requires us to make judgments about the value of those instruments at specified dates. While we believe that our estimates of values are reasonable, if the actual values

 

 

 

90

 

 

are significantly different than the estimated values, our assets, liabilities or results of operations may be overstated or understated.

Derivative Liability Associated with our Debentures. In accordance with SFAS No. 133, “Accounting for Derivative Instruments and Hedging Activities,” as amended, the redemption option and its make-whole provision (the “Redemption Make-Whole Option”) contained in the Debentures, qualify as an embedded derivative that was not clearly and closely related to the characteristics of the Debentures upon issuance. Since the Redemption Make-Whole Option does not currently qualify for any scope exception within SFAS No. 133, it is required by SFAS No. 133 to be accounted for separately from the debt instrument and recorded as derivative financial instruments. The embedded derivative financial instrument was classified as a derivative liability upon issuance and is included in other long-term obligations in the Consolidated Balance Sheet.

We estimate the fair value of the Redemption Make-Whole Option using a financial model that uses several assumptions, including: historical stock price volatility, risk-free interest rates, remaining maturity and the closing price of our common stock to determine estimated fair value of our derivative liability. We believe that the assumption that has the greatest impact on the determination of fair value is the closing price of our common stock during each quarterly period.

Contingencies. We account for contingencies by recording an estimated loss or gain from a loss or gain contingency when information available prior to issuance of the Consolidated Financial Statements indicates that it is probable that an asset has been impaired or a liability has been incurred or a gain has become receivable at the date of the Consolidated Financial Statements and the amount of the loss or gain can be reasonably estimated. Accounting for contingencies such as those relating to environmental, legal and income tax matters requires us to use our judgment. While we believe that our accruals for these matters are adequate, if the actual loss or gain from a contingency is significantly different from the estimated loss or gain, our results of operations may be overstated or understated. Legal costs expected to be incurred in connection with a loss contingency are expensed as incurred.

Impairments of Long-Lived Assets. We record impairment losses on long-lived assets used in operations when events and circumstances indicate that the assets might be impaired and the discounted future cash flows estimated to be generated by those assets are less than the carrying amount of those assets. Recoverability of assets to be held and used is measured by a comparison of the carrying amount of an asset to estimated future net cash flows to be generated by the asset. If the asset is considered to be impaired, the impairment to be recognized is measured by the amount by which the carrying amount of the asset exceeds the estimated fair value of the asset. Assets to be disposed are reported at the lower of the carrying amount or fair value less estimated costs to sell. Estimates of the discounted future cash flows are subject to significant uncertainties and assumptions. If the actual value is significantly less than the estimated fair value, our assets may be overstated. Future events and circumstances, some of which are described below, may result in an impairment charge:

new technological developments that provide significantly enhanced benefits over our current technology;

 

 

91

 

 

 

significant negative economic or industry trends;

changes in our business strategy that alter the expected usage of the related assets;

significant increases or decreases in our cost of capital; and

future economic results that are below our expectations used in the current assessments.

Accounting for Income Taxes. When we prepare the Consolidated Financial Statements, we are required to estimate our income taxes in each of the jurisdictions in which we operate. This process requires us to make the following assessments:

estimate our actual current tax liability in each jurisdiction;

estimate our temporary differences resulting from differing treatment of items, such as lease revenue and related depreciation, for tax and accounting purposes (which result in deferred tax assets and liabilities that we include within the Consolidated Balance Sheets); and

assess the likelihood that our deferred tax assets will be recovered from future taxable income and, if we believe that recovery is not likely, establish a valuation allowance.

If our estimates are incorrect, our deferred tax assets or liabilities may be overstated or understated.

Recent Accounting Pronouncements

On December 16, 2004, the Financial Accounting Standards Board (“FASB”) issued SFAS No. 123(R), Share-Based Payment. SFAS No. 123(R) revises SFAS No. 123, Accounting for Stock-Based Compensation, and requires companies to expense the fair value of employee stock options and other forms of stock-based compensation. Under SFAS No. 123(R), companies are to (1) use fair value to measure stock-based compensation awards and (2) cease using the “intrinsic value” method of accounting, which Accounting Principles Board Opinion (“APB”) No. 25 allowed and resulted in no expense for many awards of stock options for which the exercise price of the option equaled the price of the underlying stock at the grant date. In addition, SFAS No. 123(R) retains the modified grant date model from SFAS No. 123. Under that model, compensation cost is measured at the grant date and adjusted to reflect actual forfeitures and the outcome of certain conditions. The fair value of an award is not remeasured after its initial estimation on the grant date (except in the case of a liability award or if the award is modified). SFAS No. 123(R) is effective for annual periods beginning after June 15, 2005. We will be required to adopt SFAS No. 123(R) in the first quarter of 2006. The actual impact of the adoption of SFAS No. 123(R) will depend upon the amount, nature and type of stock-based compensation awards outstanding upon implementation and that we may issue in the future. Based on the current stock-based compensation plans in effect and awards issued, our estimated expense in 2006 for stock-based compensation is $4,055, $3,338 of which relates to 2005 restricted stock grants and $717 of which relates to unvested stock options.

 

 

92

 

 

 

The information required by this Item 7 with respect to other recent accounting pronouncements is set forth under “New Accounting Standards” in Note 3 to the Notes to the Consolidated Financial Statements contained in this Report, and is incorporated herein by reference.

Description of Our Financing Structure

The information required by this Item 7 with respect to our financing structure is set forth under “Long-Term Debt and Liquidity” in Note 5 to the Notes to the Consolidated Financial Statements contained in this Report, and is incorporated herein by reference.

Item 7A.   Quantitative and Qualitative Disclosures About Market Risk

(Unless otherwise noted, all dollars are presented in thousands)

 

We are exposed to market risks primarily from changes in interest rates, currency exchange rates, commercial energy rates and changes to the fair value of the Redemption Make-Whole Option. We routinely enter into various transactions that have been authorized according to documented policies and procedures to manage these well-defined risks. These transactions relate primarily to financial instruments described below. Since the counterparties, if any, to these financial instruments are large commercial banks and similar financial institutions; we do not believe that we are exposed to material counterparty credit risk. We do not use financial instruments for trading purposes.

Our exposure to changes in currency exchange rates results primarily from:

sales made by our subsidiaries in currencies other than local currencies;

raw material purchases made by our foreign subsidiaries in currencies other than local currencies; and

investments in and intercompany loans to our foreign subsidiaries and our share of the earnings of those subsidiaries, to the extent denominated in currencies other than the dollar.

Our exposure to changes in energy costs results primarily from the purchase of natural gas and electricity for use in our manufacturing operations. Our exposure to changes in the fair value of the Redemption Make-Whole Option results primarily from changes in the closing price of our common stock.

 

Interest Rate Management. We implement interest rate management initiatives to seek to minimize our interest expense and optimize the risk in our portfolio of fixed and variable interest rate obligations. Use of these initiatives is allowed under the Senior Notes and the Revolving Facility. We use interest rate swaps to effectively convert fixed rate debt (represented by the Senior Notes) into variable rate debt. At December 31, 2004, we had swaps for a notional amount of $450 million. At December 31, 2005, we had no interest rate swaps outstanding.

 

At December 31, 2004, $434,631 (out of our total outstanding $450 million notional amount) of interest rate swaps were designated as hedging the exposure to changes in the fair

 

93

 

 

value of the related debt (called a fair value hedge). The related debt for those swaps is the Senior Notes, of which $434,631 aggregate principal amount was outstanding at December 31, 2004. At December 31, 2004 (excluding the offsetting value of our interest rate caps), the principal value of our debt was reduced by $9,891 as a result of our current fair value hedges. The market values of those interest rate swaps, excluding changes in value resulting from accrued interest payable or receivable from the counterparty, are recorded as part of other long-term obligations on the Consolidated Balance Sheets. Accrued interest receivable from or payable to the counterparty is recorded as a component of interest expense on the Consolidated Statement of Operations.

At December 31, 2004, the remaining $15 million of our interest rate swaps were not designated as hedging exposure to changes in the fair value of any specific debt instrument. Any changes in the market value of those swaps are recorded in other (income) expense, net, on the Consolidated Statement of Operations. In 2004, the mark-to-market impact of the undesignated swaps was $350.

All of our swaps are valued monthly, and we are required to provide cash collateral to the counterparty to the extent that the fair market value of the swap liability, net of the fair market value of our interest rate caps, exceeds a specific threshold. At December 31, 2004, all of our swaps were with one counterparty and this threshold was $15 million. We were not required to provide any cash collateral at December 31, 2004.

During the first quarter of 2005, we sold $15 million notional amount of undesignated swaps and paid a nominal fee. Additionally, we sold $150 million notional amount of our fair value hedge swaps and paid $2,950 in cash. Immediately thereafter, we repurchased $150 million notional amount of fair value hedge swaps with a different counterparty. During the second quarter of 2005, we sold $285 million notional amount of swaps and paid $4,831. During the fourth quarter of 2005, we sold $150 million notional amount of swaps and paid $6,845. As a result of these transactions, at December 31, 2005, we had no interest rate swaps outstanding.

 

At December 31, 2004, the variable interest rate was calculated based on the six month LIBOR rate as of the date of payment plus 5.7940%, calculated in arrears. During 2005, a portion of the variable interest rate was calculated based on the six month LIBOR rate as of the date of payment plus 5.7940% calculated in arrears and a portion of the variable interest rate was calculated based on the six month LIBOR, set in advance, plus 5.7967%. At December 31, 2005, the Senior Notes are at a fixed rate of 10.25% per annum.

 

When we sell a fair value hedge swap, the gain or loss is amortized as a credit or charge to interest expense over the remaining term of the Senior Notes. When we effectively reduce the outstanding principal amount of the Senior Notes (through debt-for-equity exchanges, repurchases or otherwise), the related portion of such credit or charge is accelerated and recorded in the period in which such reduction occurs. At December 31, 2004 and 2005, the principal value of our debt was increased by $24,484 and $7,404, respectively, as a result of gains realized from previously sold swaps. The net impact of current and terminated hedge instruments was a $14,593 and a $7,404 increase in the fair value of our debt at December 31, 2004 and 2005,

 

94

 

 

respectively, and was recorded on the Consolidated Balance Sheets on the line entitled “fair value adjustments for hedge instruments.”

 

Additional information with respect to the impact of our swaps on interest expense is set forth under “Interest Expense” in Note 7 to the Consolidated Financial Statements and is incorporated herein by reference.

We enter into agreements with financial institutions that are intended to limit, or cap, our exposure to the incurrence of additional interest expense due to increases in variable interest rates. These instruments effectively cap our interest rate exposure, represented by the net impact of our swaps on the Senior Notes, to no greater than 11.3% per annum. At December 31, 2004, we had interest rate caps for a notional amount of $500 million. During 2005, we sold all of our outstanding interest rate caps. All of our interest rate caps are marked-to-market monthly. Gains and losses are recorded in other (income) expense, net, on the Consolidated Statements of Operations. The fair value adjustment on caps was a $914 loss for 2003, a $3,827 loss for 2004, and a $527 loss for 2005.

Currency Rate Management. We enter into foreign currency instruments to attempt to manage exposure to changes in currency exchange rates. These foreign currency instruments, which include, but are not limited to, forward exchange contracts and purchased currency options, attempt to hedge global currency exposures, net, relating to euro-denominated debt and identifiable foreign currency receivables, payables and commitments held by our foreign and domestic subsidiaries. Forward exchange contracts are agreements to exchange different currencies at a specified future date and at a specified rate. Purchased foreign currency options are instruments, which give the holder the right, but not the obligation, to exchange different currencies at a specified rate at a specified date or over a range of specified dates. The result is the creation of a range in which a best and worst price is defined, while minimizing option cost. Forward exchange contracts and purchased currency options are carried at market value.

The notional amount of open foreign exchange contracts, used by us to minimize foreign currency exposure against euro depreciation, amounted to $54,481 at December 31, 2004. In 2005, one contract expired and we sold all remaining open foreign exchange contracts. As a result, at December 31, 2005, we had no such contracts outstanding. Gains and losses associated with these contracts amounted to a loss of $6,650 in 2003, a loss of $406 in 2004 and a gain of $1,268 in 2005.

Commercial Energy Rate Management. We have in the past entered into, and may in the future enter into, natural gas derivative contracts and short duration fixed rate purchase contracts to effectively fix some or all of our natural gas cost exposure. The unrealized gain on outstanding contracts at December 31, 2003 amounted to $917. At December 31, 2005, we had fixed about 23% of our worldwide natural gas exposure through 2006 using such contracts. The outstanding contracts at December 31, 2005 were a nominal receivable. As of February 15, 2006, we had fixed about 32% of our worldwide natural gas exposure through such contracts.

 

We are required to provide cash collateral to certain counterparties to the extent that the fair market value of the natural gas derivative contracts exceeds a specific threshold. At

 

95

 

 

December 31, 2005, this threshold was $15 million. We were not required to provide any cash collateral at December 31, 2005.

 

Derivative Liability Associated with the Debentures. The Redemption Make-Whole Option is accounted for separately from the underlying debt evidenced by the Debentures and is recorded as a derivative financial instrument. The embedded derivative financial instrument was classified as a derivative liability upon issuance and is included in the other long-term obligations in the Consolidated Balance Sheet. At each balance sheet date, we adjust the derivative liability to its estimated fair value. Upon issuance at January 22, 2004, the estimated fair value of the derivative liability was $6,462. At December 31, 2004, the estimated fair value of the derivative liability was $3,986. At December 31, 2005, the estimated fair value of the derivative liability was $1,284. We estimate the fair value by using a financial model that uses several assumptions, including historical stock price volatility, risk-free interest rates, remaining maturity and the closing price of our common stock. We believe that the assumption that has the greatest impact on the determination of fair value is the closing price of our common stock.

 

Sensitivity Analysis. We used a sensitivity analysis to assess the potential effect of changes in currency exchange rates on gross margin, changes in interest rates on interest expense and changes in the more relevant variables on the Redemption Make-Whole Option for 2005 (particularly our current stock price, historical stock price volatility and borrowing costs). Based on this analysis, a hypothetical 10% weakening or strengthening in the dollar across all other currencies would have changed our reported gross margin for 2005 by about $12 million. In addition, based on this analysis, a hypothetical increase in interest rates of 100 basis points across all maturities would have increased our interest expense for 2005 by about $3 million. The sensitivity analysis used to assess the potential effect of changes in the more relevant variables impacting the Redemption Make-Whole Option (which was based on hypothetical changes of 10%) did not result in material changes.

 

 

 

96

 

 

 

Item 8.  Financial Statements and Supplementary Data

(Unless otherwise noted, all dollars are presented in thousands)

 

Page               

Management’s Report on Internal Control over Financial Reporting 98

Reports of Independent Registered Public Accounting Firms 99

Consolidated Balance Sheets 102

Consolidated Statements of Operations 103

Consolidated Statements of Cash Flows 104

Consolidated Statements of Stockholders’ Deficit 106

Notes to Consolidated Financial Statements 107

See the Table of Contents located at the beginning of this Report for more detailed page references to information contained in this Item.

 

 

97

 

 

 

Management’s Report on Internal Control Over Financial Reporting

Management is responsible for establishing and maintaining adequate internal control over financial reporting. Internal control over financial reporting is defined in Rules 13a-15(f) and 15d-15(f) under the Exchange Act as a process, designed by, or under the supervision of, the chief executive officer and chief financial officer and effected by the board of directors, management and other personnel of a company, to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with generally accepted accounting principles, and includes those policies and procedures that:

pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect transactions and dispositions of assets of the company;

provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with generally accepted accounting principles and that receipts and expenditures of the company are being made only in accordance with authorizations of management and the board of directors; and

provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use or disposition of assets of the company that could have a material effect on its financial statements.

Internal control over financial reporting has inherent limitations which may not prevent or detect misstatements. Also, projections of any evaluation of effectiveness to future periods are subject to the risk that controls may become inadequate because of changes in conditions or because the level of compliance with related policies or procedures may deteriorate.

Management has assessed the effectiveness of our internal control over financial reporting as of December 31, 2005 using the criteria set forth by the Committee of Sponsoring Organizations of the Treadway Commission (COSO) in Internal Control-Integrated Framework. Based on that assessment, management concluded that our internal control over financial reporting was effective as of December 31, 2005.

Management’s assessment of the effectiveness of our internal control over financial reporting as of December 31, 2005 has been audited by PricewaterhouseCoopers LLP, an independent registered public accounting firm, as stated in their report on page 99 of this Report.

Date: March 15, 2006

 

                    /s/ Craig S. Shular                    

 

 

Craig S. Shular,                    

 

 

Chief Executive Officer, President and
          Interim Chief Financial Officer

 

 

 

98

 

 

 

Report of Independent Registered Public Accounting Firm

 

To the Board of Directors and Shareholders of GrafTech International Ltd.:

 

We have completed integrated audits of GrafTech International Ltd.’s 2005 and 2004 consolidated financial statements and of its internal control over financial reporting as of December 31, 2005, in accordance with the standards of the Public Company Accounting Oversight Board (United States). Our opinions, based on our audits, are presented below.

 

Consolidated financial statements  

 

In our opinion, the consolidated financial statements listed in the accompanying index  present fairly, in all material respects, the financial position of GrafTech International Ltd. and its subsidiaries at December 31, 2005 and December 31, 2004, and the results of their operations and their cash flows for each of the two years in the period ended December 31, 2005 in conformity with accounting principles generally accepted in the United States of America. These financial statements are the responsibility of the Company’s management. Our responsibility is to express an opinion on these financial statements based on our audits. We conducted our audits of these statements in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit of financial statements includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion.

 

Internal control over financial reporting

 

Also, in our opinion, management’s assessment, included in the accompanying Management's Report on Internal Control Over Financial Reporting, appearing in Item 8, that the Company maintained effective internal control over financial reporting as of December 31, 2005 based on criteria established in Internal Control - Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission (COSO), is fairly stated, in all material respects, based on those criteria. Furthermore, in our opinion, the Company maintained, in all material respects, effective internal control over financial reporting as of December 31, 2005, based on criteria established in Internal Control - Integrated Framework issued by the COSO. The Company’s management is responsible for maintaining effective internal control over financial reporting and for its assessment of the effectiveness of internal control over financial reporting. Our responsibility is to express opinions on management’s assessment and on the effectiveness of the Company’s internal control over financial reporting based on our audit. We conducted our audit of internal control over financial reporting in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether effective internal control over financial reporting was maintained in all material respects. An audit of

 

99

 

 

internal control over financial reporting includes obtaining an understanding of internal control over financial reporting, evaluating management’s assessment, testing and evaluating the design and operating effectiveness of internal control, and performing such other procedures as we consider necessary in the circumstances. We believe that our audit provides a reasonable basis for our opinions.

 

A company’s internal control over financial reporting is a process designed to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with generally accepted accounting principles. A company’s internal control over financial reporting includes those policies and procedures that (i) pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the transactions and dispositions of the assets of the company; (ii) provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with generally accepted accounting principles, and that receipts and expenditures of the company are being made only in accordance with authorizations of management and directors of the company; and (iii) provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use, or disposition of the company’s assets that could have a material effect on the financial statements.

 

Because of its inherent limitations, internal control over financial reporting may not prevent or detect misstatements. Also, projections of any evaluation of effectiveness to future periods are subject to the risk that controls may become inadequate because of changes in conditions, or that the degree of compliance with the policies or procedures may deteriorate.

 

/s/ PricewaterhouseCoopers LLP

Philadelphia, Pennsylvania

March 15, 2006

 

100

 

 

 

Report of Independent Registered Public Accounting Firm

 

To the Board of Directors and Stockholders

GrafTech International Ltd.

Wilmington, Delaware

 

We have audited the accompanying consolidated statements of operations, cash flows and stockholders’ deficit for the year ended December 31, 2003. These financial statements of Graftech International Ltd. and Subsidiaries are the responsibility of the Company’s management. Our responsibility is to express an opinion on these financial statements based on our audit.

 

We conducted our audit in accordance with auditing standards generally accepted in the United States of America. Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation.  We believe that our audit provides a reasonable basis for our opinion.

 

In our opinion, such consolidated financial statements present fairly, in all material respects, the results of operations and cash flows of Graftech International Ltd. for the year ended December 31, 2003 in conformity with accounting principles generally accepted in the United States of America.

 

/s/ Deloitte & Touche LLP

 

Philadelphia, Pennsylvania

March 12, 2004

 

 

101

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

CONSOLIDATED BALANCE SHEETS

(Dollars in thousands, except share data)

At December 31,
2004
2005
                                             ASSETS            
Current Assets:  
   Cash and cash equivalents   $ 23,484   $ 5,968  
   Accounts and notes receivable, net of allowance for doubtful accounts of $4,001 at  
     December 31, 2004 and $3,132 at December 31, 2005    205,981    184,580  
   Inventories    225,104    255,038  
   Prepaid expenses and other current assets    24,883    14,101  


     Total current assets    479,452    459,687  


 
  Property, plant and equipment    1,131,220    1,086,393  
  Less: accumulated depreciation    752,768    724,196  


     Net property, plant and equipment    378,452    362,197  
  Deferred income taxes    152,539    12,103  
  Goodwill    22,895    20,319  
  Other assets    34,480    32,514  


     Total assets   $ 1,067,818   $ 886,820  


                           LIABILITIES AND STOCKHOLDERS’ DEFICIT  
Current liabilities:  
  Accounts payable   $ 85,889   $ 92,192  
  Short-term debt    644    405  
  Accrued income and other taxes    38,162    24,826  
  Other accrued liabilities    98,802    96,990  


     Total current liabilities    223,497    214,413  


Long-term debt:  
  Principal value    655,242    694,893  
  Fair value adjustments for hedge instruments    14,593    7,404  
  Unamortized bond premium    1,611    1,446  


        Total long-term debt    671,446    703,743  


Other long-term obligations    149,462    107,704  
Deferred income taxes    46,259    43,669  
Commitments & contingencies          
Minority stockholders’ equity in consolidated entities    30,126    26,868  
Stockholders’ deficit:  
    Preferred stock, par value $.01, 10,000,000 shares authorized, none issued          
    Common stock, par value $.01, 150,000,000 shares authorized, 100,520,240 shares  
        issued at December 31, 2004 and 100,821,434 shares issued at December 31, 2005    1,017    1,023  
    Additional paid-in capital    941,075    944,581  
    Accumulated other comprehensive loss    (276,465 )  (311,429 )
    Accumulated deficit    (626,307 )  (751,487 )
    Less: cost of common stock held in treasury, 2,451,035 shares at December 31,  
        2004 and 2,455,466 shares at December 31, 2005    (85,583 )  (85,621 )
    Less: common stock held in employee benefit and compensation trusts, 522,732
        shares at December 31, 2004 and 518,301 shares at December 31, 2005
    (6,709 )  (6,644 )


Total stockholders’ deficit    (52,972 )  (209,577 )


    Total liabilities and stockholders’ deficit   $ 1,067,818   $ 886,820  



See accompanying Notes to Consolidated Financial Statements

 

102

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF OPERATIONS

(Dollars in thousands, except share and per share data)

 

  For the Year Ended December 31,
    2003
  2004
  2005
Net sales     $ 712,337   $ 847,701   $ 886,699  
Cost of sales    544,196    638,186    654,342  



   Gross profit    168,141    209,515    232,357  
Research and development    10,410    8,040    9,437  
Selling, administrative and other expenses    85,546    89,369    100,439  
Restructuring charges    19,765    (548 )  9,729  
Impairment loss on long-lived and other assets    6,991        2,904  
Antitrust investigations and related lawsuits and claims    32,073    (10,901 )    
Other (income) expense, net    (12,060 )  21,189    18,020  
Interest expense    45,141    39,178    52,716  
Interest income    (351 )  (1,161 )  (1,200 )



     187,515    145,166    192,045  
Income (loss) from continuing operations before provision for income
   taxes and minority stockholders’ share of income (loss)
    (19,374 )  64,349    40,312  
Provision for income taxes    4,695    46,310    165,813  



Income (loss) from continuing operations before minority interest    (24,069 )  18,039    (125,501 )
Less: minority stockholders’ share of income (loss)    1,245    998    (321 )



Income (loss) from continuing operations    (25,314 )  17,041    (125,180 )
Income from discontinued operations, net of tax    476          
Gain on sale of discontinued operations, net of tax    561          



       Net income (loss)   $ (24,277 ) $ 17,041   $ (125,180 )



Basic income (loss) per common share:  
   Net income (loss) per share from continuing operations   $ (0.38 ) $ 0.18   $ (1.28 )
   Net income per share from discontinued operations    0.02          



   Net income (loss) per share   $ (0.36 ) $ 0.18   $ (1.28 )



Diluted income (loss) per common share:  
   Net income (loss) per share from continuing operations   $ (0.38 ) $ 0.17   $ (1.28 )
   Net income per share from discontinued operations    0.02          



   Net income (loss) per share   $ (0.36 ) $ 0.17   $ (1.28 )



 

See accompanying Notes to Consolidated Financial Statements

 

103

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF CASH FLOWS

(Dollars in thousands)

For the Year Ended December 31,                    
2003
2004
   2005   
Cash flow from operating activities:                
   Net income (loss)   $ (24,277 ) $ 17,041   $ (125,180 )
   Income from discontinued operations    476          
   Gain on sale of discontinued operations    561          



   Income (loss) from continuing operations    (25,314 )  17,041    (125,180 )
   Adjustments to reconcile net income (loss) to cash provided by operations:  
      Depreciation and amortization    30,623    35,459    36,926  
      Deferred income taxes    529    26,582    154,819  
      Antitrust investigations and related lawsuits and claims    32,073    1,260    (119 )
      Restructuring charges    19,765    (548 )  9,729  
      Loss on exchange of common stock for Senior Notes        5,682      
      Impairment loss on long-lived and other assets    6,991        2,904  
      Interest expense        (2,159 )  1,596  
      Post retirement plan changes        (10,341 )  (14,000 )
      Gain on sale of assets        (2,847 )  (748 )
      Fair value adjustments on interest rate caps        3,827    652  
      Fair value adjustments on Redemption Make-Whole Option        (2,475 )  (2,702 )
      Other (credits) charges, net    (45,165 )  1,143    16,822  
   (Increase) decrease in working capital (see * on next page)    (36,180 )  (167,068 )  (61,787 )
   (Increase) decrease long-term assets and liabilities    (9,850 )  (37,822 )  (10,923 )



      Net cash (used in) provided by operating activities from continuing operations    (26,528 )  (132,266 )  7,989  
      Net cash provided by operating activities from discontinued operations    1,422          



      Net cash provided by (used in) operating activities    (25,106 )  (132,266 )  7,989  
Cash flow from investing activities:  
   Capital expenditures    (40,485 )  (59,117 )  (48,071 )
   Patent capitalization    (534 )  (298 )  (797 )
   Cost of interest rate swap termination            (14,800 )
   Purchase of derivative investments        (3,241 )    
   Sale of derivative investments        755    1,913  
   Proceeds from sale of assets    3,214    5,591    1,374  
   Proceeds from sale of discontinued operations    15,692          



      Net cash provided by (used in) investing activities    (22,113 )  (56,310 )  (60,381 )
Cash flow from financing activities:  
   Short-term debt borrowings (reductions), net    (18,891 )  (780 )  1,881  
   Revolving Facility borrowings    357,131        171,138  
   Revolving Facility payments    (367,266 )      (131,562 )
   Long-term debt borrowings    111    225,000    306  
   Long-term debt reductions    (115,986 )  (44,571 )  (338 )
   Proceeds from sale of interest rate swap    30,188          
   Purchase of interest rate caps    (5,512 )        
   Proceeds from sale of common stock    189,877          
   Proceeds from exercise of stock options    3,759    7,843      
   Financing costs    (529 )  (7,355 )  (5,241 )
   Premium on repurchase of Senior Notes        (3,531 )    
   Dividends paid to minority stockholders    (3,749 )        



       Net cash provided by (used in) financing activities    69,133    176,606    36,184  
 
Net increase (decrease) in cash and cash equivalents    21,914    (11,970 )  (16,208 )
Effect of exchange rate changes on cash and cash equivalents    1,482    1,448    (1,308 )
Cash and cash equivalents at beginning of period    10,610    34,006    23,484  



Cash and cash equivalents at end of period   $ 34,006   $ 23,484   $ 5,968  



Supplemental disclosures of cash flow information:   
   Net cash paid during the periods for:   
      Interest expense     61,467    39,052    43,547  
      Income taxes     10,629    11,967    28,183  
   Non-cash operating, investing and financing activities:   
      Exchanges of common stock for Senior Notes which decrease long-term debt     55,000    35,000      
      Common stock issued to savings and pension plan trusts     8,069    1,572    1,622  

 

104

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF CASH FLOWS (Continued)

(Dollars in thousands)

 

  For the Year Ended December 31,
  2003
2004
2005
*Net change in working capital due to the following components:                
   (Increase) decrease in current assets:  
           Accounts and notes receivable, net   $(4,971 ) $(21,642 ) $(2,174 )
           Effect of factoring of accounts receivable    -    (44,658 )  13,095  
           Inventories    (8,674 )  (6,276 )  (45,430 )
           Prepaid expenses and other current assets    54    (1,018 )  (1,018 )
      Payment for antitrust investigations and related lawsuits and claims    (4,588 )  (83,480 )  (16,900 )
      Restructuring payments    (5,692 )  (16,853 )  (6,670 )
      Increase (decrease) in accounts payables and accruals    (12,309 )  6,859    (2,690 )



        Increase in working capital   $ (36,180 ) $ (167,068 ) $ (61,787 )



 

See accompanying Notes to Consolidated Financial Statements

 

105

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

CONSOLIDATED STATEMENT OF STOCKHOLDERS’ DEFICIT

(Dollars in thousands, except share data)

 

Issued
Shares of
Common
Stock

Common
Stock

Additional
Paid-in
Capital

Accumulated
Other
Comprehensive
Loss

Accumulated
Deficit

Treasury
Stock

Common Stock
Held
in Employee
Benefit & Compensation
Trust

Total
Stockholders’
Deficit

Total
Comprehensive
Income (Loss)

Balance at January 1, 2003      59,211,664   $ 606   $ 635,956   $ (304,723 ) $ (619,071 ) $ (88,778 ) $ (5,551 ) $ (381,561 )     









Comprehensive loss:  
    Net loss                    (24,277 )           (24,277 ) $ (24,277 )
    Other comprehensive income (loss):  
        Minimum pension liability, net of $2,506 of tax                5,701                5,701    5,701  
        Unrealized losses on securities                (184 )              (184 )  (184 )
        Foreign currency translation adjustments .                12,418                12,418    12,418  

    Total comprehensive loss                                       $ (6,342 )

    Exchange of common stock for Senior Notes       9,888,870     100     57,286                     57,386        
    Treasury stock             (3,195 )           3,195                
    Common stock issued to savings and pension      
      plan trusts     1,403,475     10     8,059                     8,069        
    Stock-based compensation             972                 (615 )   357        
    Sale of common stock in equity offering, net .     25,300,000     257     189,620                     189,877        
    Sale of common stock under stock options     598,278     4     4,226                     4,230        








Balance at December 31, 2003    96,402,287    977    892,924    (286,788 )  (643,348 ) $(85,583 )  (6,166 )  (127,984 )      








Comprehensive loss:  
    Net income                     17,041             17,041   $ 17,041  
    Other comprehensive income (loss):  
        Minimum pension liability, net of $5,147 of tax                (11,520 )              (11,520 )  (11,520 )
        Unrealized losses on securities                (147 )              (147 )  (147 )
        Foreign currency translation adjustments,      
          net of $2,408 of tax                 21,990                 21,990     21,990  

    Total comprehensive income                                               $ 27,364  

    Exchange of common stock for Senior Notes     3,161,131     32     40,650                     40,682        
    Stock options granted            1,005                    1,005        
    Common stock issued to savings and
       pension plan trusts
     146,285         1,572                     1,572        
    Stock-based compensation        (1 )  (637 )              (543 )  (1,181 )     
    Sale of common stock under stock options    810,537    9    9,562                    9,571       
    Other stock option activity            (4,001 )                   (4,001 )     








Balance at December 31, 2004    100,520,240    1,017    941,075    (276,465 )  (626,307 )  (85,583 )  (6,709 )  (52,972 )     








Comprehensive income (loss):  
    Net income                    (125,180 )          (125,180 ) $ (125,180 )
    Other comprehensive income:  
        Minimum pension liability                (17,326 )              (17,326 )   (17,326 )
        Unrealized losses on securities                41                41     41  
        Foreign currency translation adjustments .                (17,679 )              (17,679 )  (17,679 )

    Total comprehensive income (loss)                                               $ (160,144 )

    Stock-based compensation             1,890                     1,890        
    Treasury stock                        (38 )      (38 )     
    Stock held in employee benefit and
       compensation trusts
                            65    65       
    Common stock issued to savings
       and pension plan trusts
    301,194    6    1,616                    1,622      








Balance at December 31, 2005    100,821,434   $ 1,023   $ 944,581   $ (311,429 ) $ (751,487 ) $(85,621 ) $ (6,644 ) $ (209,577 )     








 

See accompanying Notes to Consolidated Financial Statements

 

106

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Dollars in thousands, except as otherwise noted)

 

(1)           Discussion of Business and Structure

We have six major product categories: graphite electrodes, cathodes, carbon electrodes, carbon refractories, advanced graphite materials, and natural graphite, the results of which are reported in the following segments:

Synthetic graphite, which primarily serves the steel, aluminum, transportation and semiconductor industries and includes graphite electrodes, cathodes and advanced synthetic graphite materials and related services. We have a strategic alliance in the cathode business with Alcan/Pechiney, one of the world’s largest aluminum producers, which is a 30% owner of our cathode subsidiary, Carbone Savoie.

Other, which includes carbon electrodes, carbon refractories and natural graphite. Our natural graphite products business, which is conducted by AET, primarily serves the electronics, automotive, petrochemical and power generation industries and includes advanced flexible graphite and flexible graphite solutions and related services. We have a strategic alliance in the natural graphite business with Ballard Power Systems, the world’s recognized leader in PEM fuel cells. Ballard Power Systems became a strategic investor in AET in June 2001, by investing $5 million in shares of Ballard Power Systems common stock for a 2.5% equity ownership interest in AET. Our other carbon product businesses serve the silicon metal, steel and ferro-alloy industries.

Important Terms

Reference is made to “Part I. Preliminary Notes – Important Terms” for certain defined terms used in the Notes to the Consolidated Financial Statements.

(2)            Summary of Significant Accounting Policies

The Consolidated Financial Statements include the financial statements of GTI and its majority-owned subsidiaries. All significant intercompany transactions have been eliminated in consolidation.

Cash Equivalents

For purposes of the Consolidated Statements of Cash Flows, we consider all highly liquid debt instruments with original maturities of three months or less to be cash equivalents. Cash equivalents consist of overnight repurchase agreements and certificates of deposit.

Investments

Investments in marketable debt and equity securities are generally classified and accounted for as trading, held-to-maturity or available-for-sale securities. We determine the

 

107

 

 

appropriate classification of debt and equity securities at the time of purchase and reassess the classification at each reporting date. Debt securities classified as held-to-maturity are reported at amortized cost plus accrued interest. Securities classified as available-for-sale are reported at fair value with unrealized gains and losses, net of related tax, recorded as a separate component of comprehensive loss on the Consolidated Statement of Stockholders’ Deficit until realized. Interest and amortization of premiums and discounts for debt securities are included in interest expense. Gains and losses on securities sold are determined based on the specific identification method and are included in other (income) expense, net. Unrealized losses on investment securities that are other than temporary are recognized in net income (loss). We do not hold securities for speculative or trading purposes.

Revenue Recognition

Revenue from sales of our products is recognized when persuasive evidence of an arrangement exists, delivery has occurred, title has passed, the amount is determinable and collection is reasonably assured. Revenue from sales of services is recognized when persuasive evidence of an arrangement exists, services are completed, the amount is determinable and collection is reasonably assured. Product warranty claims and returns are estimated and recorded as a reduction to revenue. Volume discounts and rebates are recorded as a reduction of revenue in conjunction with the sale of the related products. Changes to estimates are recorded when they become probable. Shipping and handling revenues relating to products sold are included as an increase to revenue. Shipping and handling costs related to products sold are included as an increase to cost of sales.

Inventories

Inventories are stated at cost or market, whichever is lower. Cost is determined on the “first-in first-out” (“FIFO”) method.

Fixed Assets and Depreciation

Fixed assets are carried at cost. Expenditures for replacements are capitalized and the replaced assets are retired. Gains and losses from the sale of property are included in other (income) expense, net. Depreciation is calculated on a straight-line basis over the estimated useful lives of the assets. The average estimated useful lives are as follows:

Years
 
Buildings       25  
Land improvements    20  
Machinery and equipment    20  
Furniture and fixtures    10  
Transportation equipment    6  

 

The carrying value of fixed assets is assessed when events and circumstances indicating impairment are present. Recoverability of assets to be held and used is measured by a comparison of the carrying amount of the assets to future net cash flows expected to be generated

 

 

 

 

108

 

 

by the assets. If the assets are considered to be impaired, the impairment to be recognized is measured by the amount by which the carrying amount of the assets exceeds the fair value of the assets. Assets to be disposed are reported at the lower of the carrying amount or fair value less costs to sell.

Allowance for Doubtful Accounts

A considerable amount of judgment is required in assessing the realizability of receivables, including the current creditworthiness of each customer, related aging of the past due balances and the facts and circumstances surrounding any non-payment. We evaluate specific accounts when we become aware of a situation where a customer may not be able to meet its financial obligations. The reserve requirements are based on the best facts available to us and are reevaluated and adjusted as additional information is received. The allowance for doubtful accounts amounted to $4,001 and $3,132 at December 31, 2004 and 2005, respectively.

Capitalized Interest

We capitalize interest expense during the new construction or upgrade of qualifying assets. We capitalized $993, $1,412 and $952 of interest expense in 2003, 2004 and 2005, respectively.

Capitalized Bank Fees

We capitalize bank fees upon the incurrence of debt. At December 31, 2004 and December 31, 2005, capitalized bank fees amounted to $21,255 and $22,219, respectively. We amortize such amounts over the life of the respective debt instrument. The estimated useful life may be adjusted upon the occurrence of a triggering event. The expense associated with capitalized bank fees amounted to $6,823 and $5,051 in 2004 and 2005, respectively.

Derivative Financial Instruments

We do not use derivative financial instruments for trading purposes. They are used to manage well-defined currency exchange rate risks, interest rate risks and commercial energy contract risks.

In conjunction with the issuance of the Debentures, we incurred an embedded derivative financial instrument associated with the redemption option and the related make-whole provision (the “Redemption Make-Whole Option”) contained in the Debentures. Since the Redemption Make-Whole Option does not currently qualify for any scope exception within SFAS No. 133, it is required by SFAS No. 133 to be accounted for separately from the debt instrument and recorded as derivative financial instruments. The embedded derivative financial instrument was classified as a derivative liability upon issuance and is included in the other long-term obligations in the Consolidated Balance Sheet. At January 22, 2004, the estimated fair value of our derivative liability was $6,462.

At each balance sheet date, we adjust the Redemption Make-Whole Option to its estimated fair value. At December 31, 2004 and December 31, 2005, the estimated fair value of our derivative liability was $3,986 and $1,284, respectively. We estimate the fair value of the

 

109

 

 

Redemption Make-Whole Option using a financial model that uses several assumptions, including: historical stock price volatility, risk-free interest rates, remaining maturity and the closing price of our common stock.

We enter into foreign currency instruments to manage exposure to changes in currency exchange rates. These instruments, which include, but are not limited to, forward exchange contracts and purchased currency options, attempt to hedge global currency exposures, net, relating to euro-denominated debt and identifiable foreign currency receivables, payables and commitments held by our foreign and domestic subsidiaries. Forward exchange contracts are agreements to exchange different currencies at a specified future date and at a specified rate. Purchased foreign currency options are instruments which give the holder the right, but not the obligation, to exchange different currencies at a specified rate at a specified date or over a range of specified dates. The result is the creation of a range in which a best and worst price is defined, while minimizing option cost. Forward exchange contracts and purchased currency options are carried at market value. Changes in market values related to these contracts are recognized in other (income) expense, net, on the Consolidated Statements of Operations.

We implement interest rate management initiatives to seek to minimize our interest expense and optimize the risk in our portfolio of fixed and variable interest rate obligations. Use of these initiatives is allowed under the Senior Notes and the Revolving Facility. We may enter into interest rate swaps that effectively convert fixed rate debt into variable rate debt.

We also may enter into agreements with financial institutions that are intended to limit, or cap, our exposure to the incurrence of additional interest expense due to increases in variable interest rates. Interest rate caps are carried at market value. Changes in market values are recorded in other (income) expense, net, on the Consolidated Statements of Operations.

Since the counterparties to these financial instruments are large commercial banks and similar financial institutions, we do not believe that we are exposed to material counterparty credit risk.

We may enter into short duration fixed rate natural gas purchase contracts with certain of our natural gas suppliers in order to mitigate commodity price risk. In addition, we may enter into natural gas derivative contracts to effectively fix a portion of our natural gas cost exposure. Natural gas derivative contracts are carried at market value. Changes in market values are recorded as part of cost of sales on the Consolidated Statements of Operations.

Research and Development

Expenditures relating to the development of new products and processes, including significant improvements to existing products, are expensed as incurred.

Income Taxes

Income taxes are accounted for under the asset and liability method. Deferred tax assets and liabilities are recognized for the future tax consequences attributable to differences between the financial statement carrying amounts of existing assets and liabilities and their respective tax bases and for operating loss and tax credit carryforwards. Deferred tax assets and liabilities are

 

110

 

 

measured using enacted tax rates expected to apply to taxable income in the years in which temporary differences are expected to be recovered or settled. The effect on deferred tax assets and liabilities of a change in tax rate is recognized in the period that includes the enactment date. A valuation allowance is recorded when it is determined that it is more likely than not that any portion of a recorded deferred tax asset will not be realized.

Stock-Based Compensation Plans

We account for stock-based compensation plans under the recognition and measurement of Accounting Principles Board Opinion No. 25, “Accounting for Stock Issued to Employees,” and related interpretations. As such, compensation expense is recorded on the date of award only if the market price of the underlying stock exceeded the exercise price or if ultimate vesting is subject to performance conditions. If an award results in recognition of compensation expense, the total amount of recorded compensation expense is based on the number of awards that eventually vest. No compensation expense is recognized for forfeited awards, including awards forfeited due to a failure to satisfy a service requirement or failure to satisfy a performance condition. Our accruals of compensation expense for awards subject to performance conditions are based on our assessment of the probability of satisfying the performance conditions.

Compensation expense associated with our restricted stock grants has been recorded in the Consolidated Statements of Operation and in the stockholders’ deficit section of the Consolidated Balance Sheets. Compensation expense associated with options granted to non-employees has been recognized in the Consolidated Statements of Operations and in the stockholders’ deficit section of the Consolidated Balance Sheets. No compensation expense has been recognized for our time vesting options granted with exercise prices at not less than market price on the date of grant. At December 31, 2005, all awards subject to performance conditions were fully vested. If compensation expense for our stock-based compensation plans was determined by the fair value method prescribed by SFAS No. 123, “Accounting for Stock Based Compensation,” our net income (loss) and net income (loss) per share would have been reduced to the pro forma amounts indicated below:

 

111

 

 

 

For the Year Ended December 31,
2003
2004
2005
(Dollars in thousands, except per share data)
 
Net income (loss) as reported     $ (24,277 ) $ 17,041   $ (125,180 )
Add:  Total stock-based employee compensation expense, net
           of related tax effects included in the determination of net
           income as reported
        604    1,890  
Deduct:  Total stock-based employee compensation expense
                determined under fair value based method for all awards,
                net of related tax effects
    (564 )  (4,536 )  (9,485 )



Pro forma net income (loss)   $(24,841 ) $ 13,109   $(132,775 )



Earnings per share:  
      Basic--as reported     $ (0.36)   $ 0.18   $ (1.28)  
      Basic--pro forma    (0.37)    0.14    (1.36)  
      Diluted--as reported    (0.36)    0.17    (1.28)  
      Diluted--pro forma    (0.37)    0.13    (1.36)  

 

The calculation of weighted average common shares outstanding for the 2004 diluted calculations exclude the shares underlying the Debentures, as the effect would have been anti-dilutive.

The calculation of weighted average common shares outstanding for the 2005 diluted calculations exclude the effect of stock options, restricted stock and the shares underlying the Debentures, as the effect would have been anti-dilutive.

On November 30, 2005, the Compensation, Organization and Pension Committee of GrafTech’s Board of Directors approved the vesting of the remaining unvested stock options granted as part of the 2003-2005 Long Term Incentive Program, having an exercise price in the range of $6.56-$13.80 and held by current and former employees. Stock options relating to approximately 3 million shares of common stock were subject to this vesting. The decision to accelerate the vesting of these stock options was within the discretion of the Compensation, Organization and Pension Committee of GrafTech’s Board of Directors. Such decision was made due primarily to the achievement of a significant portion of the performance metrics for vesting as well as the achievement of other strategic initiatives.   In addition, the decision to accelerate the vesting of stock options may have a positive effect on employee morale, retention and perception of option value. This vesting eliminates an estimated $4.5 million of future pre-tax compensation expense that would have otherwise been recognized in the Consolidated Statement of Operations under SFAS No. 123(R).

Retirement Plans

The cost of pension benefits under our retirement plans is recorded in accordance with SFAS No. 87, “Employee Accounting for Pensions,” as determined by us with assistance from

 

 

 

 

 

 

 

 

 

 

 

112

 

 

independent actuarial firms using the “projected unit credit” actuarial cost method. Contributions to the qualified U.S. retirement plan are made in accordance with the requirements of the Employee Retirement Income Security Act of 1974. Benefits under the non-qualified retirement plan have been accrued, but not funded. Plan settlements and curtailments are recorded in accordance with SFAS No. 88, “Employers’ Accounting for Settlements and Curtailments of Defined Benefit Pension Plans and Termination Benefits.” Additional information with respect to benefits plans is set forth in Note 11 to the Consolidated Financial Statements.

Postretirement Health Care and Life Insurance Benefits

The estimated cost of future postretirement medical and life insurance benefits is determined by the Company with assistance from independent actuarial firms using the “projected unit credit” actuarial cost method. Such costs are recognized as employees render the service necessary to earn the postretirement benefits. Benefits have been accrued, but not funded. Effective November 1, 2001, the U.S. plan was modified to limit our cost of future annual postretirement medical benefits to the cost in 2001. Additional information with respect to benefits plans is set forth in Note 11 to the Consolidated Financial Statements.

Post-employment Benefits

We accrue the estimated cost of post-employment benefits expected to be paid before retirement, principally severance, over employees’ active service periods.

Environmental, Health and Safety Matters

Our operations are governed by laws addressing protection of the environment and worker safety and health. These laws provide for civil and criminal penalties and fines, as well as injunctive and remedial relief, for noncompliance and require remediation at sites where hazardous substances have been released into the environment.

We have been in the past, and may become in the future, the subject of formal or informal enforcement actions or proceedings regarding noncompliance with these laws or the remediation of company-related substances released into the environment. Historically, such matters have been resolved by negotiation with regulatory authorities resulting in commitments to compliance, abatement or remediation programs and in some cases payment of penalties. Historically, neither the commitments undertaken nor the penalties imposed on us have been material.

Environmental considerations are part of all significant capital expenditure decisions. Environmental remediation, compliance and management expenses were approximately $13,074 in 2003, $13,056 in 2004 and $12,525 in 2005. The accrued liability relating to environmental remediation was $7,669 at December 31, 2004 and $6,610 at December 31, 2005. When payments are fixed or determinable, the liability is discounted using a rate at which the payments could be effectively settled. A charge to income is recorded when it is probable that a liability has been incurred and the cost can be reasonably estimated. Our environmental liabilities do not take into consideration possible recoveries of insurance proceeds. Because of the uncertainties associated with environmental remediation activities at sites where we may be potentially liable, future expenses to remediate sites could be considerably higher than the accrued liability.

 

113

 

 

However, while neither the timing nor the amount of ultimate costs associated with known environmental remediation matters can be determined at this time, management does not believe that these matters will have a material adverse effect on our financial position, results of operations or net cash flows.

Foreign Currency Translation

We account for our non-U.S. subsidiaries under SFAS No. 52, “Foreign Currency Translation.” Accordingly, except for highly inflationary countries, the assets and liabilities of our non-U.S. subsidiaries are translated into dollars for consolidation and reporting purposes. Foreign currency translation adjustments are generally recorded as part of stockholders’ deficit and identified as part of accumulated other comprehensive loss on the Consolidated Balance Sheets until such time as the operations of such non-U.S. subsidiaries are sold or substantially or completely liquidated.

Highly inflationary economies are defined as having cumulative inflation of about 100% or more over a period of three calendar years. In general, the financial statements of foreign operations in highly inflationary economies are remeasured as if the functional currency of their economic environments were the dollar and translation gains and losses relating to these foreign operations are included in other (income) expense, net, on the Consolidated Statements of Operations rather than as part of stockholders’ deficit on the Consolidated Balance Sheets. We have subsidiaries in Russia, Mexico, Brazil and other countries which have had in the past, and may have in the future, highly inflationary economies.

We account for our Mexican and Russian subsidiaries using the dollar as their functional currency, as sales and purchases for each subsidiary are predominantly dollar-denominated. Our remaining subsidiaries use their local currency as their functional currency.

We also record foreign currency transaction gains and losses as part of other (income) expense, net, on the Consolidated Statements of Operations.

We have non-dollar denominated intercompany loans between GrafTech Finance and some of our foreign subsidiaries. These loans are subject to remeasurement gains and losses due to changes in currency exchange rates. A portion of these loans are deemed to be essentially permanent and, as a result, remeasurement gains and losses on these loans are recorded as a component of accumulated other comprehensive loss in the stockholders’ deficit section of the Consolidated Balance Sheets. The balance of these loans are deemed to be temporary and, as a result, remeasurement gains and losses on these loans are recorded as currency (gains/losses) in other (income) expense, net, on the Consolidated Statements of Operations.

Restructuring

Effective January 1, 2003, we adopted SFAS No. 146, “Accounting for Costs Associated with Exit or Disposal Activities,” which was effective for exit or disposal activities initiated after December 31, 2002. SFAS No. 146 requires that a liability for a cost associated with an exit or disposal activity be recognized when the liability is incurred.

 

 

114

 

 

 

Software Development Costs

In connection with our development and implementation of global enterprise resource planning systems with advanced manufacturing, planning and scheduling software, we capitalized certain computer software costs after technological feasibility was established. These capitalized costs are amortized utilizing the straight-line method over the economic lives of the related products. Total costs capitalized as of December 31, 2004 and 2005 amounted to $16,692 and $17,262, respectively. Amortization expense was $860 for 2004 and $1,393 for 2005.

Intangibles

Goodwill represents the excess of the purchase price over the fair value of net assets acquired. Effective January 1, 2002, we adopted SFAS No. 142, “Goodwill and Other Intangible Assets.” The adoption of SFAS No. 142 did not have a significant impact on our consolidated financial position, results of operations or net cash flows, except that we no longer amortize goodwill. In the 2005 fourth quarter, we performed the goodwill impairment reviews required by SFAS No. 142 and the results of these reviews did not require our existing goodwill to be written down. Goodwill, which pertains primarily to our synthetic graphite segment, amounted to $22,895 at December 31, 2004 and $20,319 at December 31, 2005, with the decrease due to changes in currency exchange rates.

Patents, net of accumulated amortization, amounted to $2,321 at December 31, 2004 and $2,784 at December 31, 2005.

Use of Estimates

We have made a number of estimates and assumptions relating to the recording and disclosure of assets and liabilities, including contingent assets and liabilities, to prepare the Consolidated Financial Statements in conformity with accounting principles generally accepted in the United States of America. Actual amounts and values could differ from those estimates.

Reclassification

Certain amounts previously reported have been reclassified to conform to the current year presentation.

(3)           New Accounting Standards

In February 2006, the Financial Accounting Standards Board (“FASB”) issued SFAS No. 155, “Accounting for Certain Hybrid Financial Instruments—an amendment of FASB Statements No. 133 and 140.” This Statement (1) permits fair value remeasurement for any hybrid financial instrument that contains an embedded derivative that otherwise would require bifurcation, (2) clarifies which interest-only strips and principal-only strips are not subject to the requirements of SFAS No. 133, (3) establishes a requirement to evaluate interests in securitized financial assets to identify interests that are freestanding derivatives or that are hybrid financial instruments that contain an embedded derivative requiring bifurcation; and (4) clarifies that concentrations of credit risk in the form of subordination are not embedded derivatives. SFAS

 

115

 

 

No. 155 is effective for all financial instruments acquired or issued after the beginning of our first fiscal year that begins after September 15, 2006. The fair value election of SFAS No. 155 may also be applied upon adoption of SFAS No. 155 for hybrid financial instruments that had been bifurcated under paragraph 12 of SFAS No. 133, prior to the adoption of this Statement. We will be required to adopt SFAS No. 155 in the first quarter of 2007. We are currently in the process of assessing the impact of the adoption of SFAS No. 155 on our consolidated results of operations and financial position.

On December 16, 2004, the FASB issued SFAS No. 123(R), “Share-Based Payment.” SFAS No. 123(R) revises SFAS No. 123, “Accounting for Stock-Based Compensation,” and requires companies to expense the fair value of employee stock options and other forms of stock-based compensation. Under SFAS No. 123(R), companies are to (1) use fair value to measure stock-based compensation awards and (2) cease using the “intrinsic value” method of accounting, which APB Opinion No. 25 allowed and resulted in no expense for many awards of stock options for which the exercise price of the option equaled the price of the underlying stock at the grant date. In addition, SFAS No. 123(R) retains the modified grant date model from SFAS No. 123. Under that model, compensation cost is measured at the grant date and adjusted to reflect actual forfeitures and the outcome of certain conditions. The fair value of an award is not remeasured after its initial estimation on the grant date (except in the case of a liability award or if the award is modified). This Statement is effective for annual periods beginning after June 15, 2005. We will be required to adopt SFAS No. 123(R) in the first quarter of 2006. The actual impact of the adoption of SFAS No. 123(R) will depend upon the amount, nature and type of stock-based compensation awards outstanding upon implementation and that we may issue in the future. Based on the current stock-based compensation plans in effect and awards issued our estimated expense in 2006 for stock-based compensation is $4,055, $3,338 of which relates to 2005 restricted stock grants and $717 of which relates to unvested stock options.

On October 18, 2005, the FASB Staff issued FASB Staff Position (“FSP”) No. FAS 123(R)-2, “Practical Accommodation to the Application of Grant Date as Defined in FASB Statement No. 123(R).” This FSP is in response to recent inquiries regarding the application of grant date as defined in SFAS No. 123(R). The definition of grant date under SFAS No. 123(R) includes criteria for determining that a share-based payment award has been granted. One of the criteria is a mutual understanding by the employer and employee of the key terms and conditions of a share-based payment award. Considering the practical difficulties of personally communicating the key terms and conditions of a share-based payment award, the FASB Staff believed a practical solution was warranted related to application of the concept of mutual understanding. As a practical accommodation, in determining the grant date of an award subject to SFAS No.123(R), a mutual understanding of the key terms and conditions of an award with an individual employee shall be presumed to exist at the date the award is approved in accordance with the relevant corporate governance requirements if both of the following conditions are met: (a) the award is a unilateral grant and, therefore, the recipient does not have the ability to negotiate the key terms and conditions of the award with the employer; and (b) the key terms and conditions of the award are expected to be communicated to an individual recipient within a relatively short time period from the date of approval.

 

On November 10, 2005, the FASB Staff issued FSP No. FAS 123(R)-3, “Transition Election Related to Accounting for the Tax Effects of Share-Based Payment

 

116

 

 

Awards.” This FSP provides a practical transition election related to accounting for the tax effects of share-based payment awards to employees. SFAS No. 123 (R), paragraph 81, indicates that, for purposes of calculating the pool of excess tax benefits available to absorb tax deficiencies recognized subsequent to the adoption of SFAS No. 123 (R) (an “APIC pool”), an entity shall include the net excess tax benefits that would have qualified as such had the entity adopted SFAS No. 123 for recognition purposes. The FASB Staff has learned that a significant number of constituents do not have this information readily available. As a result, this FSP provides an elective alternative transition method. An entity may follow either the transition guidance for the APIC pool in paragraph 81 of SFAS No. 123(R) or the alternative transition method described in this FSP. We may take up to one year from the initial adoption of SFAS No. 123(R) to evaluate our available transition alternatives and make our one time election.

 

On August 31, 2005, the FASB Staff issued FSP No. FAS 123(R)-1, “Classification and Measurement of Freestanding Financial Instruments Originally Issued in Exchange for Employee Services under FASB Statement No. 123(R)”, which defers, at this time, the requirement of SFAS No. 123 (revised 2004), Share-Based Payment, that a freestanding financial instrument originally subject to SFAS 123(R) becomes subject to the recognition and measurement requirements of other applicable generally accepted accounting principles (“GAAP”) when the rights conveyed by the instrument to the holder are no longer dependent on the holder being an employee of the entity. It is the current FASB Staff position that a freestanding financial instrument issued to an employee in exchange for past or future employee services that is subject to SFAS No. 123(R) or was subject to SFAS No. 123(R) upon initial adoption of that Statement shall continue to be subject to the recognition and measurement provisions of SFAS No. 123(R) throughout the life of the instrument, unless its terms are modified when the holder is no longer an employee. The guidance in this FSP supersedes EITF Issue No. 00-19-1, “Application of EITF Issue No. 00-19 to Freestanding Financial Instruments Originally Issued as Employee Compensation,” and amends paragraph 11(b) of SFAS No. 133, “Accounting for Derivative Instruments and Hedging Activities,” and SFAS No. 133 Implementation Issue No. C3, “Scope Exceptions: Exception Related to Share-Based Payment Arrangements.” The adoption of this FSP will not have a significant impact on our consolidated results of operations or financial position.

 

In May 2005, the FASB directed the FASB Staff to issue a Position on “Application of Emerging Issues Task Force Issue No. 00-19 to Freestanding Financial Instruments Originally Issued as Employee Compensation” to clarify the application of EITF Issue No. 00-19, “Accounting for Derivative Financial Instruments Indexed to, and Potentially Settled in, a Company’s Own Stock.” This FASB Staff Position clarifies that a requirement to deliver registered shares, in and of itself, will not result in liability classification for freestanding financial instruments originally issued as employee compensation. This clarification is consistent with the FASB’s intent in issuing SFAS No. 123(R). The adoption of this Position will not have a significant impact on our consolidated results of operations or financial position.

SFAS No.133 Implementation Issue No. B39 was posted by the FASB in June 2005. This Issue addresses circumstances in which an embedded call option (including a prepayment option), that can accelerate the settlement of a hybrid instrument containing a debt host contract, would not be subject to the conditions in paragraph 13(b) of SFAS No. 133. The FASB concluded that the conditions in paragraph 13(b) do not apply to an embedded call option in a

 

117

 

 

hybrid instrument containing a debt host contract if the right to accelerate the settlement of the debt can be exercised only by the debtor (issuer/borrower). Issue No. B39 will be effective for the first day of the first fiscal quarter beginning after December 15, 2005. The adoption of Issue No. B39 will not have any impact on our consolidated results of operations or financial position.

In May 2005, FASB issued SFAS No. 154, “Accounting Changes and Error Corrections, a replacement of APB Opinion No. 20 and FASB Statement No. 3,” which changes the requirements for the accounting for and reporting of a change in accounting principle.  This Statement applies to all voluntary changes in accounting principle.  It also applies to changes required by an accounting pronouncement in the unusual instance that the pronouncement does not include specific transition provisions. This Statement requires retrospective application to prior periods’ financial statements of changes in accounting principle, unless it is impracticable to determine either the period-specific effects or the cumulative effect of the change.  This Statement defines retrospective application as the application of a different accounting principle to prior accounting periods as if that principle had always been used or as the adjustment of previously issued financial statements to reflect a change in the reporting entity.  This Statement also redefines restatement as the revising of previously issued financial statements to reflect the correction of an error. This Statement shall be effective for accounting changes and corrections of errors made in fiscal years beginning after December 15, 2005. We will adopt this Statement effective January 1, 2006. Based on our current evaluation of this Statement, we do not expect the adoption of SFAS No. 154 to have a significant impact on our consolidated results of operations or financial position.

On November 24, 2004, the FASB issued SFAS No. 151, “Inventory Costs - an amendment of APB No. 43,” Chapter 4, which is the result of its efforts to converge U.S. accounting standards for inventories with International Accounting Standards. SFAS No. 151 requires abnormal amounts of idle facility expense, freight, handling costs and wasted material (spillage) to be recognized as current-period charges. It also requires that allocation of fixed production overheads to the costs of conversion be based on the normal capacity of the production facilities. SFAS No. 151 will be effective for inventory costs incurred during fiscal years beginning after June 15, 2005. Therefore, we are required to adopt this Statement effective January 1, 2006. We are currently in the process of assessing the impact of the adoption of SFAS No. 151 on our consolidated results of operations and financial position.

(4)          Segment Reporting

Our businesses are reported in the following reportable segments: synthetic graphite, which consists of graphite electrodes, cathodes and advanced graphite materials and related services; and other, which consists of natural graphite, carbon electrodes and refractories and related services.

We evaluate the performance of our segments based on gross profit. Intersegment sales and transfers are not material. The accounting policies of the reportable segments are the same as those for our Consolidated Financial Statements as a whole.

The following tables summarize financial information concerning our reportable segments.

 

 

118

 

 

 

For the Year Ended December 31,
2003
2004
2005
(Dollars in thousands)
 
Net sales to external customers:                
  Synthetic Graphite   $ 640,128   $ 752,436   $ 784,148  
  Other    72,209    95,265    102,551  



Net sales   $ 712,337   $ 847,701   $ 886,699  



Gross profit:  
  Synthetic Graphite   $ 150,998   $ 186,854   $ 210,928  
  Other    17,143    22,661    21,429  



Gross profit   $ 168,141   $ 209,515   $ 232,357  



Reconciliation of gross profit to income before provision for  
   income taxes and minority stockholders' share of income:  
  Gross profit   $ 168,141   $ 209,515   $ 232,357  
       Research and development    10,410    8,040    9,437  
       Selling, administrative and other expenses    85,546    89,369    100,439  
       Other (income) expense, net    (12,060 )  21,189    18,020  
       Restructuring charges    19,765    (548 )  9,729  
       Impairment loss on long-lived and other assets    6,991    --    2,904  
       Antitrust investigations and related lawsuits
          and claims charges
    32,073    (10,901 )  --  
       Interest expense    45,141    39,178    52,716  
       Interest (income)    (351 )  (1,161 )  (1,200 )



Income (loss) from continuing operations before provision for  
   (benefit from) income taxes and minority stockholders' share  
   of income (loss)   $ (19,374 ) $ 64,349   $ 40,312  



 

We do not report assets by reportable segment. Assets are managed based on geographic location because both reportable segments share certain facilities. The following tables summarize information as to our operations in different geographic areas.

For the Year Ended December 31,
2003
2004
2005
(Dollars in thousands)
Net sales (a):                
   U.S   $ 205,548   $ 240,303   $ 263,208  
   Canada    5,696    3,995    4,469  
   Mexico    33,442    36,913    47,936  
   Brazil    40,679    52,199    53,400  
   France    168,228    183,648    188,561  
   Italy    32,122    34,808    26,243  
   Switzerland    102,587    144,123    152,834  
   South Africa    65,488    69,558    75,947  
   Spain    27,665    39,419    22,066  
   Other countries    30,882    42,735    52,035  



     Total   $ 712,337   $ 847,701   $ 886,699  




___________

(a)    Net sales are based on location of seller.

 

 

 

119

 

 

 

At December 31,
2004
2005
(Dollars in thousands)
Long-lived assets (b):            
  U.S   $ 70,691   $ 74,365  
  Mexico    51,394    52,584  
  Brazil    27,990    32,982  
  France    151,232    130,701  
  Spain    36,723    31,428  
  South Africa    52,198    46,328  
  Switzerland    10,568    8,660  
  Other countries    551    5,468  


    Total   $ 401,347   $ 382,516  


 

___________

(b)    Long-lived assets represent fixed assets, net of accumulated depreciation and goodwill.

(5)         Long-Term Debt and Liquidity

 

The following table presents our long-term debt.

At December 31,
  2004
2005
  (Dollars in thousands)
 
Revolving Facility     $ -   $ 39,000  
Senior Notes:  
     Senior Notes due 2012    434,631    434,631  
     Fair value adjustments for current hedge instruments    (9,891 )  -  
     Fair value adjustments for terminated hedge instruments*    24,484    7,404  
     Unamortized bond premium    1,611    1,446  


          Total Senior Notes    450,835    443,481  
Debentures**    219,405    220,291  
Other European debt    1,206    971  


              Total   $ 671,446   $ 703,743  


 

  * Fair value adjustments for terminated hedge instruments will be amortized as a credit to interest expense over the remaining term of the Senior Notes.

  ** Excludes the derivative liability relating to our redemption feature with a make-whole provision, which amounts to $3,986 at December 31, 2004 and $1,284 at December 31, 2005 and is included in other long-term obligations on the Consolidated Balance Sheets.

 

The aggregate maturities of long-term debt (excluding the fair value adjustments to debt and unamortized bond premium relating to the Senior Notes and including the original value of the derivative liability relating to the Debentures redemption feature with a make-whole provision) for each of the four years subsequent to 2005 and thereafter are set forth in the following table:

 

120

 

 

 

2006
2007
2008
2009
2010
(and thereafter)

Total
  (Dollars in thousands)
 
      $ 45   $ 222   $ 212   $ 191   $ 698,932   $ 699,602  

 

At December 31, 2004 and 2005, we were in compliance with all financial and other covenants contained in the Senior Notes, the Debentures and the Senior Facilities, as applicable.

Revolving Facility

On February 8, 2005, we entered into an amended and restated Credit Agreement relating to the Revolving Facility. JPMorgan Chase Bank, N.A. is the administrative agent thereunder.

The Credit Agreement now provides for a Revolving Facility of $215 million, subject to provisions described below regarding the base credit limit. It also provides among other things, for an extension until July 15, 2010 of the maturity of the Revolving Facility and, subject to certain conditions (including a maximum senior secured leverage ratio test), an accordion feature that permits GrafTech Finance to establish additional credit facilities thereunder in an aggregate amount, together with the Revolving Facility, of up to $425 million.

The interest rate applicable to the Revolving Facility is, at our option, either LIBOR plus a margin ranging from 1.25% to 2.25% or, in the case of dollar denominated loans, the alternate base rate plus a margin ranging from 0.25% to 1.25%. The alternate base rate is the higher of (i) the prime rate announced by JP Morgan Chase Bank, N.A. or (ii) the federal fund effective rate plus 0.50%. GrafTech Finance pays a per annum fee ranging from 0.250% to 0.500% (depending on such ratio or rating) on the undrawn portion of the commitments under the Revolving Facility.

The Revolving Facility permits voluntary prepayments (without reducing availability for future revolving borrowings) and voluntary commitment reductions at any time, in each case without premium or penalty.

The obligations under the Revolving Facility are secured (with certain exceptions) by all of the assets of GrafTech Finance (except the unsecured intercompany term notes and unsecured intercompany term note guarantees created under, and pledged in part to secure, the Senior Notes). The obligations under the Revolving Facility are guaranteed (with certain exceptions) by GTI, each of our other domestic subsidiaries (other than AET) and our Swiss subsidiary, our French holding company, our French operating company engaged in the graphite electrode business, and our United Kingdom subsidiary. These guarantees and any intercompany loans of proceeds of borrowings under the Revolving Facility are secured (with certain exceptions, including the assets of AET) by all of the assets (including the AET Pledged Stock) of the respective guarantors and subsidiary borrowers.

Repayment of intercompany loans made to our foreign subsidiaries is restricted unless the relevant subsidiary borrower has no business use for the funds being repaid. The intent of this restriction is to seek to maximize the secured claims of the lenders against the assets of our foreign operating subsidiaries.

 

121

 

 

 

The guarantee of the Revolving Facility by our Swiss subsidiary is subject to the limitation under Swiss law that the amount guaranteed cannot exceed the amount that our Swiss subsidiary can distribute to its shareholders, after payment of any Swiss withholding tax. If such amount is or would become less than $100 million, our Swiss subsidiary will become subject to certain restrictions, including restrictions on distributions, investments and indebtedness.

The amount outstanding under the Credit Agreement (including any debt incurred under the accordion feature) at any time may not exceed a specified base credit limit. The intent of this provision is to seek to reduce credit availability under the Credit Agreement to the extent that there is a net diminution in the value of domestic or Swiss collateral. This provision would not affect the Revolving Facility until net diminution exceeded $110 million.

The Revolving Facility contains a number of covenants that restrict corporate activities. The covenants may restrict our ability to repurchase or redeem the Senior Notes and the Debentures, even if so required thereby. These covenants include financial covenants relating to specified minimum interest coverage ratios and maximum net senior secured debt leverage ratios (which is the ratio of our net senior secured debt to our EBITDA (as defined in the Revolving Facility)). The interest coverage ratio becomes more restrictive if our financial performance were to significantly deteriorate.

In addition to the failure to pay principal, interest and fees when due, events of default under the Revolving Facility include: failure to pay when due, or other defaults permitting acceleration of, other indebtedness exceeding $7.5 million or certain cash management arrangements or interest rate, exchange rate or commodity price derivatives; judgment defaults in excess of $7.5 million to the extent not covered by insurance; and certain changes in control.

Senior Notes

On February 15, 2002, GrafTech Finance issued $400,000 aggregate principal amount of Senior Notes. Interest on the Senior Notes is payable semi-annually on February 15 and August 15 of each year, commencing August 15, 2002, at the rate of 10.25% per annum. The Senior Notes mature on February 15, 2012.

On May 6, 2002, GrafTech Finance issued $150,000 aggregate principal amount of additional Senior Notes at a purchase price of 104.5% of principal amount, plus accrued interest from February 15, 2002, under the Senior Note Indenture. All of the Senior Notes constitute one class of debt securities under the Senior Note Indenture. The additional Senior Notes bear interest at the same rate and mature on the same date as the Senior Notes issued in February 2002. The $7 million premium received upon issuance of the additional Senior Notes was added to the principal amount of the Senior Notes shown on the Consolidated Balance Sheets and is amortized (as a credit to interest expense) over the term of the additional Senior Notes. As a result of our receipt of such premium, the effective annual interest rate on the additional Senior Notes is about 9.5%. Additional information regarding interest rate swaps is set forth in Note 6 to the Consolidated Financial Statements.

GrafTech Finance may not redeem the Senior Notes prior to February 15, 2007. On or after that date, GrafTech Finance may redeem the Senior Notes, in whole or in part, at specified redemption prices beginning at 105.125% of the principal amount redeemed for the year

 

122

 

 

commencing February 15, 2007 and reducing to 100.00% of the principal amount redeemed for the years commencing February 15, 2010 and thereafter, in each case plus accrued and unpaid interest to the redemption date.

 

Upon the occurrence of a change of control, GrafTech Finance will be required to make an offer to repurchase the Senior Notes at a price equal to 101.00% of the principal amount redeemed, plus accrued and unpaid interest to the redemption date. For this purpose, a change in control occurs on:

the date on which any person beneficially owns more than 35% of the total voting power of GTI;

the date on which individuals, who on the issuance date of the Senior Notes were directors of GTI (or individuals nominated or elected by a vote of 66 2/3% of such directors or directors previously so elected or nominated), cease to constitute a majority of GTI’s Board of Directors then in office;

the date on which a plan relating to the liquidation or dissolution of GTI is adopted;

the date on which GTI merges or consolidates with or into another person, or another person merges into GTI, or all or substantially all of GTI’s assets are sold (determined on a consolidated basis), with certain specified exceptions; or

the date on which GTI ceases to own, directly or indirectly, all of the voting power of GrafTech Global, UCAR Carbon and GrafTech Finance.

GTI, GrafTech Global and UCAR Carbon and other U.S. subsidiaries that collectively hold a substantial majority of our U.S. assets have guaranteed the Senior Notes on a senior unsecured basis, except for the guarantee by UCAR Carbon. The guarantee by UCAR Carbon has been secured by a junior pledge of all of the shares of capital stock (constituting 97.5% of the outstanding shares of capital stock) of AET held by UCAR Carbon (called the “AET Pledged Stock”), subject to certain limitations. Additional information with respect to the guarantees and the pledge is set forth in Note 18 to the Consolidated Financial Statements.

 

The Senior Notes contain a number of covenants that restrict corporate activities. The covenants may restrict our ability to repurchase or redeem the Debentures, even if so required thereby. In addition to the failure to pay principal and interest when due or to repurchase Senior Notes when required, events of default under the Senior Notes include: failure to pay at maturity or upon acceleration indebtedness exceeding $10 million; and judgment defaults in excess of $10 million to the extent not covered by insurance.

 

In 2004, we exchanged $35,000 aggregate principal amount of Senior Notes, plus accrued interest of $432, for 3.2 million shares of common stock. Additionally, we purchased $22,869 aggregate principal amount of Senior Notes, plus accrued interest of $942, for $27,342 in cash. These transactions resulted in a loss of $8,724, which has been recorded in other (income) expense, net, on the Consolidated Statements of Operations.

 

 

123

 

 

 

Debentures

On January 22, 2004, GTI issued $225,000 aggregate principal amount of Debentures. Interest on the Debentures is payable semi-annually on January 15 and July 15 of each year, commencing July 15, 2004, at the rate of 1.625% per annum. The Debentures mature on January 15, 2024, unless earlier converted, redeemed or repurchased. We recorded the Debentures at the discounted principal value of $218,538 at issuance. Upon issuance, we also recorded a derivative liability of $6,462 for the embedded derivative portion of the Debentures, which is included in other long-term obligations on the Consolidated Balance Sheets. The net proceeds from the offering were approximately $218,812.

A holder of Debentures may convert its Debentures into shares of our common stock at a conversion rate of 60.3136 shares per $1,000 principal amount (equal to a conversion price of approximately $16.58 per share), subject to adjustment upon certain events, only under the following circumstances:

prior to January 15, 2019, in any fiscal quarter after the fiscal quarter ending March 31, 2004, if the last reported sale price of our common stock for at least 20 trading days during the 30 consecutive trading days ending on the first trading day of such fiscal quarter is greater than 125% of the then current conversion price;

on or after January 15, 2019, at any time after the last reported sale price of our common stock on any date is greater than 125% of the then current conversion price;

during the 5 business days after any 10 consecutive trading days in which the trading price per $1,000 principal amount of Debentures for each such trading day was less than 98% of the product of the last reported sale price of our common stock and the then current conversion rate;

if the credit rating or ratings on the Debentures are reduced by two rating categories below those initially assigned to the Debentures by S&P and Moody’s;

if the Debentures are called for redemption; or

upon the occurrence of certain corporate transactions.

Upon conversion, GTI will have the right to deliver, in lieu of shares of our common stock, cash or a combination of cash and shares of our common stock.

Prior to January 15, 2011, the Redemption Make-Whole Option provides that GTI may redeem the Debentures, in whole or in part, at any time, for cash at a redemption price equal to 100% of principal amount, plus accrued and unpaid interest and liquidated damages, if any, only if the last reported sale price of our common stock has exceeded 125% of the then current conversion price for at least 20 trading days during the 30 consecutive trading days ending on the trading day prior to the date on which we mail the notice of redemption. If GTI so redeems the Debentures, GTI will make an additional “make-whole” payment in cash, shares of our common stock or a combination thereof on the redeemed Debentures equal to the present value of all remaining scheduled payments of interest on the redeemed Debentures through January 15,

 

124

 

 

2011. The Redemption Make-Whole Option qualified as an embedded derivative that was not clearly and closely related to the characteristics of the Debentures upon issuance. Since the Redemption Make-Whole Option does not currently qualify for any scope exception within SFAS No. 133, it is required by SFAS No. 133 to be accounted for separately from the debt instrument and recorded as derivative financial instruments. The embedded derivative financial instrument was classified as a derivative liability upon issuance and is included in the other long-term obligations in the Consolidated Balance Sheet.

On or after January 15, 2011, GTI may redeem the Debentures, in whole or in part, at any time, for cash at a redemption price equal to 100% of principal amount, plus accrued and unpaid interest and liquidated damages, if any.

A holder may require GTI to repurchase some or all of its Debentures on (i) January 15, 2011, January 15, 2014 or January 15, 2019, or (ii) if we experience a “fundamental change” at a repurchase price equal to 100% of principal amount, plus accrued and unpaid interest and liquidated damages, if any. For this purpose, a fundamental change occurs on:

the date on which a change in control (which has the same meaning as under the Senior Notes) occurs; or

subject to certain exceptions, the date on which our common stock ceases to be listed on a U.S. national or regional securities exchange or approved for trading on the NASDAQ National Market or similar system of automated dissemination of quotations of securities prices.

GrafTech Finance, GrafTech Global and UCAR Carbon and other U. S. subsidiaries that together hold a substantial majority of our U. S. assets have guaranteed the Debentures on a senior unsecured basis. Additional information with respect to the guarantees is set forth in Note 18 to the Consolidated Financial Statements.

Events of default under the Debentures are similar to those under the Senior Notes.

(6)           Financial Instruments

We use derivative financial instruments to manage well-defined currency exchange rate, interest rate and commercial energy contract risks. We do not use derivative financial instruments for trading purposes.

Foreign Currency Contracts

The notional amount of open foreign exchange contracts, used by us to minimize foreign currency exposure against euro depreciation, amounted to $54,481 at December 31, 2004. In 2005, one contract expired and we sold all remaining open foreign exchange contracts. As a result, at December 31, 2005, we had no such contracts outstanding. These contracts are marked-to-market monthly and gains and losses are recorded in other (income) expense, net, on the Consolidated Statements of Operations. Gains and losses associated with these contracts amounted to a loss of $6,650 in 2003, a loss of $406 in 2004, and a gain of $1,268 in 2005.

 

 

125

 

 

 

Interest Rate Risk Management

We implement interest rate management initiatives to seek to minimize our interest expense and optimize the risk in our portfolio of fixed and variable interest rate obligations. Use of these initiatives is allowed under the Senior Notes and the Revolving Facility. We use interest rate swaps to effectively convert fixed rate debt (represented by the Senior Notes) into variable rate debt. At December 31, 2004, we had swaps for a notional amount of $450 million.

At December 31, 2004, $434,631 (out of our total outstanding $450 million notional amount) of interest rate swaps were designated as hedging the exposure to changes in the fair value of the related debt (called a fair value hedge). The related debt for those swaps is the Senior Notes, of which $434,631 aggregate principal amount was outstanding at December 31, 2004. At December 31, 2004 (excluding the offsetting value of our interest rate caps), the principal value of our debt was reduced by $9,891 as a result of our current fair value hedges. The market values of those interest rate swaps, excluding changes in value resulting from accrued interest payable or receivable from the counterparty, are recorded as part of other long-term obligations on the Consolidated Balance Sheets. Accrued interest receivable from or payable to the counterparty is recorded as a component of interest expense on the Consolidated Statement of Operations.

At December 31, 2004, the remaining $15 million of our interest rate swaps were not designated as hedging exposure to changes in the fair value of any specific debt instrument. Any changes in the market value of those swaps are recorded in other (income) expense, net, on the Consolidated Statement of Operations. In 2004, the mark-to-market impact of the undesignated swaps was $350.

All of our swaps are valued monthly, and we are required to provide cash collateral to the counterparty to the extent that the fair market value of the swap liability, net of the fair market value of our interest rate caps, exceeds a specific threshold. At December 31, 2004, all of our swaps were with one counterparty and this threshold was $15 million. We were not required to provide any cash collateral at December 31, 2004.

During the first quarter of 2005, we sold $15 million notional amount of undesignated swaps and paid a nominal fee. Additionally, we sold $150 million notional amount of our fair value hedge swaps and paid $2,950 in cash. Immediately thereafter, we repurchased $150 million notional amount of fair value hedge swaps with a different counterparty. During the second quarter of 2005, we sold $285 million notional amount of swaps and paid $4,831. During the fourth quarter of 2005, we sold $150 million notional amount of swaps and paid $6,845. As a result of these transactions, at December 31, 2005, we had no notional amount of swaps outstanding.

 

At December 31, 2004, the variable interest rate was calculated based on the six month LIBOR rate as of the date of payment plus 5.7940%, calculated in arrears. During 2005, a portion of the variable interest rate was calculated based on the six month LIBOR rate as of the date of payment plus 5.7940% calculated in arrears and a portion of the variable interest rate was calculated based on the six month LIBOR, set in advance, plus 5.7967%. At December 31, 2005, the Senior Notes are at a fixed rate of 10.25% per annum.

 

 

126

 

 

 

When we sell a fair value hedge swap, the gain or loss is amortized as a credit or charge to interest expense over the remaining term of the Senior Notes. When we effectively reduce the outstanding principal amount of the Senior Notes (through debt-for-equity exchanges, repurchases or otherwise), the related portion of such credit or charge is accelerated and recorded in the period in which such reduction occurs. At December 31, 2004 and 2005, the principal value of our debt was increased by $24,484 and $7,404, respectively, as a result of gains realized from previously sold swaps. The net impact of current and terminated hedge instruments was a $14,593 and a $7,404 increase in the fair value of our debt at December 31, 2004 and 2005, respectively, and was recorded on the Consolidated Balance Sheets on the line entitled “fair value adjustments for hedge instruments.”

 

Additional information with respect to the impact of our swaps on interest expense is set forth in Note 7 to the Consolidated Financial Statements.

We enter into agreements with financial institutions that are intended to limit, or cap, our exposure to the incurrence of additional interest expense due to increases in variable interest rates. At December 31, 2004, we had interest rate caps for a notional amount of $500 million, which effectively capped our interest rate exposure, represented by the net impact of our swaps on the Senior Notes, to no greater than 11.3% per annum. During 2005, we sold all of our outstanding interest rate caps. All of our interest rate caps are marked-to-market monthly. Gains and losses are recorded in other (income) expense, net, on the Consolidated Statements of Operations. The fair value adjustment on caps was a $914 loss for 2003, a $3,827 loss for 2004, and a $527 loss for 2005.

Commercial Energy Rate Contracts

We have in the past entered into, and may in the future enter into, natural gas derivative contracts and short duration fixed rate purchase contracts to effectively fix some or all of our natural gas cost exposure. The unrealized gain on outstanding contracts at December 31, 2003 amounted to $917. At December 31, 2005, we had fixed about 23% of our worldwide natural gas exposure through 2006 using such contracts. The outstanding contracts at December 31, 2005 were a nominal receivable.

 

We are required to provide cash collateral to certain counterparties to the extent that the fair market value of the natural gas derivative contracts exceeds a specific threshold. At December 31, 2005, this threshold was $15 million. We were not required to provide any cash collateral at December 31, 2005.

 

Fair Market Value Disclosures

SFAS No. 107, “Disclosure about Fair Market Value of Financial Instruments,” defines the fair value of a financial instrument as the amount at which the instrument could be exchanged in a current transaction between willing parties. Such fair values must often be determined by using one or more methods that indicate value based on estimates of quantifiable characteristics as of a particular date. Values were estimated as follows:

 

 

127

 

 

 

Cash and cash equivalents, short-term notes and accounts receivables, accounts payable and other current payables—The carrying amount approximates fair value because of the short maturity of these instruments.

Long-Term Debt—Fair value of long-term debt, including the embedded derivative instrument in the Debentures was $720,175 at December 31, 2004 and $663,695 at December 31, 2005.

Foreign currency contracts—Foreign currency contracts are carried at market value. The fair market value of open foreign exchange contracts used by us to minimize foreign currency exposure was an asset of $528 at December 31, 2004. We did not have any such contracts outstanding at December 31, 2005.

Interest rate swaps and caps—The fair value of our interest rate swaps was $9,891 at December 31, 2004. The fair value of our interest rate caps was $769 at December 31, 2004. We had no such instruments outstanding at December 31, 2005. See “Interest Rate Risk Management” above.

Natural gas contracts—See “Commercial Energy Rate Contracts” above.

(7)           Interest Expense

 

The following table presents an analysis of interest expense:

For the Year Ended
December 31,

(Dollars in thousands)
2003
2004
2005
Interest incurred on debt     $ 62,351   $ 49,808   $ 50,984  
Interest rate swap benefit    (13,022 )  (10,092 )  (1,633 )
Amortization of fair value adjustments for terminated hedge  
   instruments    (2,222 )  (2,468 )  (1,744 )
Accelerated amortization of fair value adjustments for  
   terminated hedge instruments due to reduction of Senior  
   Notes    (5,734 )  (4,746 )  -  
Amortization of debt issuance costs    3,148    4,834    3,569  
Interest on DOJ antitrust fine, including imputed interest    955    710    507  
Amortization of premium on Senior Notes    (687 )  (243 )  (162 )
Amortization of discount on Debentures    -    867    885  
Interest incurred on other items    352    508    310  



     Total interest expense   $ 45,141   $ 39,178   $ 52,716  



Interest rates

At December 31, 2004, the Revolving Facility had an effective interest rate of 6.2%, our $435,000 principal amount of Senior Notes had an effective rate of 8.6% (i.e., a fixed rate of 10.25%, effectively swapped to a variable rate of the LIBOR plus 5.7940%) and our $225,000 principal amount of Debentures had a fixed rate of 1.625%.

 

 

128

 

 

 

At December 31, 2005, the Revolving Facility had an effective interest rate of 6.8%, our $434,631 principal amount of Senior Notes had a fixed rate of 10.25% and an effective rate of 10.02% (including the effect of the amortization of fair value adjustments for terminated hedge instruments) and our $225,000 principal amount of Debentures had a fixed rate of 1.625%.

 

(8)           Other (Income) Expense, Net

 

The following table presents an analysis of other (income) expense, net:

For the Year Ended
December 31,

(Dollars in thousands)
2003
2004
2005
Loss on reduction of Senior Notes     $ 616   $ 8,782   $ -  
Currency (gains) losses    (42,149 )  (8,527 )  14,868  
Bank and other financing fees    4,503    3,137    2,433  
Legal, environmental and other related costs    2,670    8,510    2,814  
Employee benefit curtailment, settlement and other    3,504    (182 )  (145 )
Fair value adjustments on interest rate caps    914    3,827    527  
Foreign currency exchange rate contracts (gains) losses    6,650    406    (1,268 )
Fair value adjustments on Debenture Redemption Make-Whole  
   Option    -    (2,475 )  (2,702 )
Former parent company lawsuit legal expenses    -    692    -  
Relocation expenses    820    927    905  
Non-income taxes    3,434    3,395    -  
Write-off of fixed or other assets    4,278    2,049    -  
Gain on sale of assets    (1,026 )  (2,847 )  (748 )
Write-off of capitalized bank fees and related debt  
   extinguishment costs    2,357    344    1,557  
Other    1,369    3,151    (221 )



Total other (income) expense, net   $ (12,060 ) $ 21,189   $ 18,020  




We have non-dollar-denominated intercompany loans between GrafTech Finance and some of our foreign subsidiaries. At December 31, 2004 and 2005, the aggregate principal amount of these loans was $414,457 and $318,663, respectively (based on currency exchange rates in effect at such date). These loans are subject to remeasurement gains and losses due to changes in currency exchange rates. A portion of these loans are deemed to be essentially permanent and, as a result, remeasurement gains and losses on these loans are recorded as a component of accumulated other comprehensive loss in the stockholders’ deficit section of the Consolidated Balance Sheets. The balance of these loans are deemed to be temporary and, as a result, remeasurement gains and losses on these loans are recorded as currency (gains) losses in other income (expense), net, on the Consolidated Statements of Operations. In 2003, we had a net total of $42,149 of currency gains, including $41,920 of exchange gains due to the remeasurement of intercompany loans and translation of financial statements of foreign subsidiaries which use the dollar as their functional currency. In 2004, we had a net total of $8,527 of currency gains, including $9,835 of exchange gains due to the remeasurement of intercompany loans and translation of financial statements of foreign subsidiaries which use the

 

 

 

 

 

 

 

 

 

 

 

129

 

 

dollar as their functional currency. In 2005, we had a net total of $14,868 of currency losses, including $14,611 of exchange losses due to the remeasurement of intercompany loans and translation of financial statements of foreign subsidiaries which use the dollar as their functional currency.

(9)          Supplementary Balance Sheet Detail

 

The following tables present supplementary balance sheet details:

At December 31,
2004
2005
(Dollars in thousands)
 
Accounts and notes receivable, net:            
     Trade   $ 184,363   $ 170,014  
     Other    25,619    17,698  


     209,982    187,712  
     Allowance for doubtful accounts    (4,001 )  (3,132 )


    $ 205,981   $ 184,580  


Inventories:  
     Raw materials and supplies   $ 59,388   $ 74,650  
     Work in process    141,586    150,816  
     Finished goods    24,130    29,572  


    $ 225,104   $ 255,038  


Property, plant and equipment:  
     Land and improvements   $ 30,516   $ 29,802  
     Buildings    159,910    154,947  
     Machinery and equipment and other    899,370    865,841  
     Construction in progress    41,424    35,803  


    $ 1,131,220   $ 1,086,393  


Accounts payable:  
     Trade   $ 66,967   $ 73,363  
     Interest    18,922    18,829  


    $ 85,889   $ 92,192  


Other accrued liabilities:  
     Accrued vendors payable   $ 40,426   $ 33,173  
     Payrolls (including incentive programs)    6,132    4,410  
     Restructuring    6,079    10,190  
     Employee compensation and benefits    12,098    11,828  
     Accrued interest    424    1,319  
     Liabilities and expenses associated with antitrust investigations
         and related lawsuits and claims
    17,077    20,625  
     Other    16,566    15,445  


    $ 98,802   $ 96,990  


Other long term obligations:  
     Postretirement benefits   $ 44,333   $ 25,749  
     Pension and related benefits    35,260    51,243  
     Liabilities and expenses associated with antitrust investigations  
         and related lawsuits and claims    26,000    5,375  
     Long-term environmental liabilities    4,990    4,429  
     Fair value of interest rate swap    9,891    -  
     Derivative liability (Redemption Make-Whole Option)    3,986    1,284  
     Restructuring    2,773    1,337  
     Other    22,229    18,287  


    $ 149,462   $ 107,704  



 

 

130

 

The following table presents an analysis of the allowance for doubtful accounts:

At December 31,
2004
2005
(Dollars in thousands)
Balance at beginning of year     $ 3,921   $ 4,001  
Additions    368    479  
Deductions    (288 )  (1,348 )


Balance at end of year   $ 4,001   $ 3,132  


(10)        Leases and Other Long Term Obligations

 

Lease commitments under non-cancelable operating leases extending for one year or more will require the following future payments:

(Dollars in thousands)
 
2006     $ 4,063  
2007    2,720  
2008    2,404  
2009    2,093  
2010    2,004  
After 2010    1,924  

Total lease and rental expenses under non-cancelable operating leases extending one year or more were about $2,248 in 2003, $2,227 in 2004 and $4,067 in 2005.

During 2001, we outsourced our information technology function to CGI Group Inc. (“CGI”). Under this ten-year agreement, CGI manages our data services, networks, desktops and telecommunications. This contract was amended in the third quarter of 2005, effectively reducing the scope of services provided by CGI. The following schedule sets forth the future payments for base services.

(Dollars in thousands)
 
2006     $ 4,474  
2007    4,388  
2008    4,388  
2009    4,388  
2010    4,388  
After 2010    1,250  

 

 

131

 

 

 

In September 2002, we entered into a ten-year outsourcing contract with CGI to provide finance and accounting business process services valued at $36 million. On November 15, 2005, we entered into a memorandum of agreement with CGI, terminating such services. The memorandum was entered into after the parties determined that the termination of the ten-year outsourcing contract was in their mutual best interest. Such termination is effective during the first quarter of 2006. Thereafter, we will be solely and entirely responsible for all of the services previously rendered by CGI under this contract. As a result, at December 31, 2005, our future payments amount to about $750 and will be paid during 2006.

(11)        Benefit Plans

Defined Benefit Plans

Until February 25, 1991, we participated in the U.S. retirement plan of Union Carbide Corporation (“Union Carbide”). Effective February 26, 1991, we formed our own U.S. retirement plan which covers substantially all U.S. employees. Retirement and death benefits related to employee service through February 25, 1991 are covered by the Union Carbide plan. Benefits paid by the Union Carbide plan are based on final average pay through February 25, 1991, plus salary increases (not to exceed 6% per year) until January 26, 1995 when Union Carbide ceased to own at least 50% of the equity of GTI. All our employees who retired prior to February 25, 1991 are covered under the Union Carbide plan. Pension benefits under our plan are based primarily on years of service and compensation levels prior to retirement. Prior to January 1, 2002, our plan was a defined benefit plan. Effective January 1, 2002, a new defined contribution plan was established for U.S. employees. Some employees had the option to remain in the defined benefit plan for an additional period of up to five years. Those employees without the option to remain in the defined benefit plan for an additional five years began participating in the defined contribution plan and their benefits under the defined benefit plan were frozen as of December 31, 2001. Those employees with the initial option to remain in the defined benefit plan began participating in the defined contribution plan as of April 1, 2003 and their benefits under the defined benefit plan were frozen as of March 31, 2003. Effective March 31, 2003, we froze the qualified defined benefit plan for our remaining U.S. employees and closed our non-qualified U.S. defined benefit plan for the participating salaried workforce. Under the new defined contribution plan, we make quarterly contributions to each individual employee’s account equal to 2.5% of the employee’s pay up to the social security wage base ($90 in 2004 and $94 in 2005) plus 5% of their pay above the social security wage base. In 2005, we recorded expense of $1,355 related to this plan.

Pension coverage for employees of foreign subsidiaries is provided, to the extent deemed appropriate, through separate plans. Obligations under such plans are systematically provided for by depositing funds with trustees, under insurance policies or by book reserves.

We use a December 31 measurement date for all of our plans.

 

132

 

 

 

The components of our consolidated net pension costs are set forth in the following table.

For the Year Ended December 31,
2003
2004
2005
U.S. Foreign U.S. Foreign U.S. Foreign
(Dollars in thousands)
 
Service cost     $ 2,050   $ 1,007   $ 912   $ 309   $ 740   $ 424  
Interest cost    7,904    4,178    7,528    4,349    7,714    4,434  
Expected return on assets .    (7,248 )  (3,907 )  (8,329 )  (4,123 )  (8,768 )  (4,265 )
Amortization    455    411    176    354    1,355    990  
Special termination benefits    2,490    298    -    -    -    485  
Settlement (gain) loss    (5,514 )  (128 )  -    (535 )  -    743  
Curtailment loss    254    366    -    1    -    (212 )

    $ 391   $ 2,225   $ 287   $ 355   $ 1,041   $ 2,599  

 

The reconciliation of beginning and ending balances of benefit obligations under, fair value of assets of and the funded status of our pension plans are as follows:

Pension Benefits at December 31,
2004
2005
U.S. Foreign U.S. Foreign
 
Changes in Benefit Obligation:                    
 Net benefit obligation at beginning of year   $ 124,875   $ 73,172   $ 131,009   $ 74,773  
 Service cost    912    309    740    424  
 Interest cost    7,528    4,349    7,714    4,434  
 Impact of plan amendments    -    528    -    -  
 Participant contributions    -    -    -    96  
 Foreign currency exchange rates    -    6,345    -    (7,464 )
 Actuarial loss    7,796    2,792    10,994    9,851  
 Divestiture    -    -    -    -  
 Curtailment    (1,901 )  -    -    -  
 Settlement    -    (9,374 )  -    (1,443 )
 New plan 87    -    -    -    1,189  
 Special termination benefits    -    241    -    485  
 Benefits paid    (8,203 )  (3,587 )  (8,381 )  (6,194 )

      Net benefit obligation at end of year   $ 131,007   $ 74,775   $ 142,076   $ 76,151  

Changes in Plan Assets:   
 Fair value of plan assets at beginning of year   $ 91,876   $ 59,714   $ 109,988   $ 63,834  
 Actual return on plan assets    3,307    5,473    1,227    9,141  
 New plan    -    -    -    1,420  
 Foreign currency exchange rate changes    -    5,442    -    (6,216 )
 Employer contributions    23,008    6,166    570    1,766  
 Employee contributions    -    -    -    96  
 Settlement    -    (9,374 )  -    (1,443 )
 Benefits paid    (8,203 )  (3,587 )  (8,381 )  (6,194 )

      Fair value of plan assets at end of year   $ 109,988   $ 63,834   $ 103,404   $ 62,404  

 

 

133

 

Pension Benefits at December 31,
2004
2005
U.S. Foreign U.S. Foreign
 
Reconciliation of funded status:   
 Funded status at end of year   $ (21,020 ) $ (10,941 ) $ (38,672 ) $ (13,748 )
 Unrecognized net transition asset       -     (1,179 )   -     (729 )
 Unrecognized prior service cost    -    1,673    -    1,328  
 Unrecognized net actuarial loss    25,180    14,959    42,362    16,490  

      Net amount recognized at end of year   $ 4,160   $ 4,512   $ 3,690   $ 3,341  

Amounts recognized in the statement of financial
position:
  
 Prepaid benefit cost   $-   $ 3,138   $ -   $ 2,630  
 Accrued benefit liability    (21,020 )  (8,012 )  (38,672 )  (7,845 )
 Intangible asset    -    642    -    491  
 Accumulated other comprehensive loss    25,180    8,744    42,362    8,065  

      Net amount recognized   $ 4,160   $ 4,512   $ 3,690   $ 3,341  

 

 

The accumulated benefit obligation for all defined pension plans was $197,607 at December 31, 2004 and $208,819 at December 31, 2005.

We annually re-evaluate assumptions and estimates used in projecting pension assets, liabilities and expenses. These assumptions and estimates may affect the carrying value of pension assets, liabilities and expenses in the Consolidated Financial Statements. Assumptions used to determine net pension costs and pension projected benefit obligations are set forth in the following table:

  Pension Benefit Obligations
At December 31,
2004
2005
Weighted average assumptions to determine
benefit obligations:
           
   Discount rate    5 .99%  5 .66%
   Rate of compensation increase    4 .20%  3 .51%


  Pension Benefit Costs
At December 31,
2004
2005
Weighted average assumptions to determine
net cost:
           
   Discount rate    6 .36%  5 .99%
   Expected return on plan assets    7 .73%  7 .71%
   Rate of compensation increase    4 .15%  3 .51%

 

We adjust our discount rate annually in relation to the rate at which the benefits could be effectively settled. Discount rates are set for each plan in reference to the yields available on AA-rated corporate bonds of appropriate currency and duration. The appropriate discount rate is derived by developing an AA-rated corporate bond yield curve in each currency. The discount rate for a given plan is the rate implied by the yield curve for the duration of that plan's liabilities. In certain countries, where little public information is available on which to base discount rate assumptions, the discount rate is based on government bond yields or other indices and approximate adjustments to allow for the differences in weighted durations for the specific plans and/or allowance for assumed credit spreads between government and AA corporate bonds.

 

 

134

 

 

 

The expected return on assets assumption represents our best estimate of the long-term return on plan assets and generally was estimated by computing a weighted average return of the underlying long-term expected returns on the different asset classes, based on the target asset allocations. The expected return on assets assumption is a long-term assumption that is expected to remain the same from one year to the next unless there is a significant change in the target asset allocation, the fees and expenses paid by the plan or market conditions.

 

The rate of compensation assumption is generally based on salary increases.

Plan Assets. The following table presents our retirement plan weighted average asset allocations at December 31, 2005, by asset category:

Percentage of Plan
Assets at December 31, 2005
U.S.
Foreign
Equity securities       69 %   35 %
Fixed Income    30   52  
Other    1   13  


Total       100 %  100 %


 

Investment Policy and Strategy. The investment policy and strategy of the U.S. plan is to invest approximately 75% (60% large cap, 25% small- and mid-cap, 15% international) in equities and approximately 25% in short duration fixed income securities. The trust allows the plan to be invested up to 80% in equities, including shares of our common stock. Rebalancing is undertaken monthly. The investment policy of the U.K. plan is to invest 0% to 40% in equities and 60% to 100% debt securities. The goal of both plans is to fully fund the plans as soon as possible while investing plan assets prudently. To the extent we maintain plans in other countries, asset diversification ranges are between 5%-30% for equity investments and between 7%-95% for fixed income investments. For each plan, the investment policy is set within both asset return and local statutory requirements.

The following table presents our retirement plan weighted average target asset allocations at December 31, 2005, by asset category:

Percentage of Targeted Plan
Assets at December 31, 2005
U.S.
Foreign
Equity securities       75 %   35 %
Fixed Income    25   53  
Other    -   12  


Total       100 %  100 %



The following table presents information for pension plans with an accumulated benefit obligation in excess of plan assets at December 31:

2004 2005
U.S.
Foreign
U.S.
Foreign
(Dollars in thousands)
Accumulated benefit obligation     $ 131,009   $ 59,252   $ 142,076   $ 64,989  
Fair value of plan assets    109,988    51,241    103,404    60,226  

 

135

 

 

 

The following table presents information for pension plans with a projected benefit obligation in excess of plan assets at December 31:

2004
2005
U.S.
Foreign
U.S.
Foreign
(Dollars in thousands)
Projected benefit obligation     $ 131,008   $ 74,774   $ 142,076   $ 75,187  
Fair value of plan assets    109,988    63,834    103,404    61,238  

 

The following table represents projected future pension plan cash flow by year:

U.S.
Foreign
(Dollars in thousands)
Expected contributions in 2006:            
     Expected employer contributions   $ 570   $ 4,250  
     Expected employee contributions    -    -  
 
Estimated future benefit payments reflecting expected future
     service for the fiscal years ending December 31:
  
     2006    9,022    8,753  
     2007    9,206    3,484  
     2008    9,108    3,082  
     2009    8,873    3,105  
     2010    8,848    3,627  
     2011-2015   45,819   34,671  

 

Postretirement Benefit Plans

We provide healthcare and life insurance benefits for eligible retired employees. These benefits are provided through various insurance companies and health care providers. We accrue the estimated net postretirement benefit costs during the employees’ credited service periods. We use a December 31 measurement date for all of our plans.

In July 2002, we amended our U.S. postretirement medical coverage. In 2003 and 2004, we discontinued the Medicare Supplement Plan (for retirees 65 years or older or those eligible for Medicare benefits). This change applied to all U.S. active employees and retirees. In June 2003, we announced the termination of the existing early retiree medical plan for retirees under age 65, effective December 31, 2005. In addition, we limited the amount of retiree’s life insurance after December 31, 2004. These modifications are accounted for prospectively. The impact of these changes is being amortized over the average remaining period to full eligibility of the related postretirement benefits and resulted in a $7,618 net benefit in 2003, a $11,902 net benefit in 2004 and a $14,000 net benefit in 2005, reflected on the Consolidated Statements of Operations.

 

136

 

 

 

The components of our consolidated net postretirement cost (benefit) are set forth in the following table:

  For the Year Ended December 31,
  2003
2004
2005
  U.S.
Foreign
U.S.
Foreign
U.S.
Foreign
(Dollars in thousands)
Service Cost     $ 278   $ 127   $ 109   $ 215   $ 18   $ 238  
Interest Cost    2,164    993    1,275    1,181    743    1,292  
Amortization    (11,195 )  15    (14,733 )  51    (16,387 )  96  






    $ (8,753 ) $ 1,135   $ (13,349 ) $ 1,447   $ (15,626 ) $ 1,626  

 

The reconciliation of beginning and ending balances of benefit obligations under, fair value of assets of and the funded status of our postretirement plans is set forth in the following table:

Postretirement Benefits at December 31,
2004
2005
U.S.
Foreign
U.S.
Foreign
Changes in Benefit Obligation:                    
 Net benefit obligation at beginning of year   $ 27,703   $ 16,090   $ 14,939   $ 18,793  
 Service cost    109    215    18    238  
 Interest cost    1,275    1,181    743    1,292  
 Impact of plan amendments    (12,077 )            
 Foreign currency exchange rates        1,776        (237 )
 Actuarial loss    1,767    861    (252 )  (157 )
 Divestiture                  
 Curtailment                  
 Settlement                  
 Special termination benefits                  
 Gross benefits paid    (3,838 )  (1,331 )  (3,202 )  (1,145 )




 Net benefit obligation at end of year   $ 14,939   $ 18,792   $ 12,246   $ 18,784  




Changes in Plan Assets:  
 Fair value of plan assets at beginning of year   $   $   $   $  
 Actual return on plan assets                  
 Foreign currency exchange rate changes                  
 Employer contributions    3,838    1,331    3,202    1,145  
 Settlement                  
 Gross benefits paid    (3,838 )  (1,331 )  (3,202 )  (1,145 )




Fair value of plan assets at end of year   $   $   $   $  




 

137

 

 

 

Postretirement Benefits at December 31,
2004
2005
U.S.
Foreign
U.S.
Foreign
Reconciliation of funded status:  
Funded status at end of year   $ (14,939 ) $ (18,792 ) $ (12,246 ) $ (18,784 )
Unrecognized prior service cost      (52,478 )  (4,301 )  (31,366 ) $ (4,165 )
Unrecognized net actuarial loss    39,536    6,641    34,559    6,253  




Net amount recognized at end of year   $ (27,881 ) $ (16,452 ) $ (9,053 ) $ (16,696  




Amounts recognized in the statement of financial position:  
Prepaid benefit cost     $-   $-   $-   $-  
Accrued benefit liability    (27,881 )  (16,452 )  (9,053 )  (16,969 )
Intangible asset                  
Accumulated other comprehensive income                  




 Net amount recognized   $ (27,881 ) $ (16,452 ) $ (9,053 ) $ (16,969 )




 

We annually re-evaluate assumptions and estimates used in projecting the postretirement liabilities and expenses. These assumptions and estimates may affect the carrying value of postretirement plan liabilities and expenses in our Consolidated Financial Statements. Assumptions used to determine net postretirement benefit costs and postretirement projected benefit obligation are set forth in the following table:

  Postretirement Benefit Obligations
At December 31,
2004
2005
Weighted average assumptions to determine
benefit obligations:
           
   Discount rate    6 .69%  6 .07%
   Health care cost trend on covered charges:
      Initial     8 .00%  8 .23%
      Ultimate    4 .79%  5 .77%
      Years to ultimate    9    8  

  Postretirement Benefit Costs
At December 31,
2004
2005
Weighted average assumptions to determine
net cost:
           
   Discount rate    6 .99%  6 .69%
   Health care cost trend on covered charges:
      Initial     8 .47%  7 .81%
      Ultimate    4 .13%  5 .62%
      Years to ultimate    9    7  

For 2003, 2004 and 2005, as a result of certain amendments to our U.S. postretirement benefits, health care cost trend rates have no material effect on the amounts reported for net postretirement benefits.

Discount rates are set for each plan in reference to the yields available on AA-rated corporate bonds of appropriate currency and duration. The appropriate discount rate is derived by developing an AA-rated corporate bond yield curve in each currency. The discount rate for a given plan is the rate implied by the yield curve for the duration of that plan's liabilities. In certain countries, where little public information is available on which to base discount rate assumptions, the discount rate is based on government bond yields or other indices and

 

 

138

 

 

approximate adjustments to allow for the differences in weighted durations for the specific plans and/or allowance for assumed credit spreads between government and AA-rated corporate bonds.

 

The following table represents projected future postretirement cash flow by year:

U.S.
Foreign
(Dollars in thousands)
Expected contributions in 2006:            
     Expected employer contributions     $ 383   $ 1,190  
     Expected employee contributions       -     -  
 
Estimated future benefit payments reflecting expected
  future service for the fiscal years ending December 31:
   
        2006       383     1,190  
        2007       340     1,244  
        2008       376     1,291  
        2009       510     1,351  
        2010       526     1,415  
        2011-2015       1,364     8,033  

 

Other Non-Qualified Benefit Plans

Since January 1, 1995, we have established various unfunded, non-qualified supplemental retirement and deferred compensation plans for certain eligible employees. We established benefits protection trusts (collectively, the “Trust”) to partially provide for the benefits of employees participating in these plans. At December 31, 2004 and December 31, 2005, the Trust had assets of approximately $505 and $915, respectively, which are included in other assets on the Consolidated Balance Sheets. These assets include 426,400 shares of common stock that we contributed to the Trust in March 2001. These shares, if later sold, could be used for partial funding of our future obligations under certain of our compensation and benefit plans. The shares held in Trust are not considered outstanding for purposes of calculating earnings per share until they are committed to be sold or otherwise used for funding purposes.

Savings Plan

Our employee savings plan provides eligible employees the opportunity for long-term savings and investment. On January 1, 2002, the plan was revised to allow employees to contribute up to 5% of pay as a basic contribution and an additional 45% of pay as supplemental contribution. For 2003, 2004 and 2005, we contributed on behalf of each participating employee, in units of a fund that invests entirely in our common stock, 100% on the first 3% contributed by the employee and 50% on the next 2% contributed by the employee. We contributed 128,241 shares in 2004, resulting in expense of $1,565 and 301,194 shares in 2005, resulting in expense of $1,622.

(12)        Restructuring and Impairment Charges

 

At December 31, 2005, the outstanding balance of our restructuring reserve was $11,527. We expect the majority of the remaining payments to be paid by the end of 2007. The components of the balance at December 31, 2005 consisted primarily of:

 

139

 

 

 

Synthetic Graphite Segment:

 

$6,044 related to the rationalization of our synthetic graphite facilities, including those in Brazil, France, and Russia;

$3,897 related to the closure of our graphite electrode manufacturing operations in Caserta, Italy; and

$700 related to the phase out of our graphite electrode machining operations in Clarksville, Tennessee.

 

Other Segment and Corporate:

 

$794 related primarily to remaining lease payments on our former corporate headquarters; and

$92 related to the relocation of our corporate headquarters from Wilmington, Delaware to Parma, Ohio.

 

In 2003, we recorded a net restructuring charge of $19,765, consisting of an $11,266 charge associated with the closure and settlement with certain of our U.S pension plans, with the remaining primarily due to further organizational changes.

 

In 2004, we recorded a net restructuring benefit of $548, comprised primarily of the following:

a $2,473 net benefit associated with the closure of our graphite electrode manufacturing operations in Caserta, Italy (consisting of a reduction in cost estimate, partially offset by the completion of further severance agreements for employees terminated in connection with the closure), offset by

a $1,329 charge relating primarily to severance programs and related benefits associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom; and

a $596 charge associated primarily with changes in estimates related to U.S. voluntary and selective severance programs.

In 2005, we recorded a net restructuring charge of $9,729, comprised primarily of the following:

a $6,100 charge associated with the rationalization of our synthetic graphite facilities, including those in Brazil, France, and Russia;

a $3,194 charge associated with the closure of our graphite electrode manufacturing operations at Caserta, Italy;

 

 

140

 

 

 

a $523 charge primarily associated with the relocation of our Corporate Headquarters from Wilmington, Delaware to Parma, Ohio;

an $804 charge associated with the phase out of our graphite electrode machining operations in Clarksville, Tennessee, scheduled for completion in the third quarter of 2006, and the closure of our administrative offices in Clarksville, scheduled for completion at the end of the first quarter of 2006; and

a $430 charge associated with the closure of our advanced graphite machining operations in Sheffield, United Kingdom; offset by

a $1,322 benefit associated with a change in estimate pertaining to the closure of certain graphite electrode manufacturing operations.

We expect to record additional charges in 2006 related to such initiatives.

The restructuring accrual is included in other accrued liabilities and other long-term obligations on the Consolidated Balance Sheets. The following table summarizes activity relating to the accrual:

Severance
and
Related
Costs

Plant Shutdown
and
Related
Costs

Total
(Dollars in thousands)
 
Balance at December 31, 2003     $ 19,253   $ 9,410   $ 28,663  



 
Restructuring charges       4,321     985     5,306  
Change in estimates           (5,854 )   (5,854 )
Payments and settlements,
    including non-cash items of $2,814
      (18,367 )   (1,300 )   (19,667 )
Effect of change in currency exchange rates      340     64     404  



Balance at December 31, 2004      5,547     3,305     8,852  



 
Restructuring charges       10,880     474     11,354  
Change in estimates       (260 )   (1,365 )   (1,625 )
Payments and settlements,
    majority of which are cash payments
      (4,999 )   (1,671 )   (6,670 )
Effect of change in currency exchange rates      (435 )   51     (384 )



Balance at December 31, 2005    $ 10,733   $ 794   $ 11,527  



 

In 2003, we recorded impairment charges of $6,991. Such charges consisted of $5,370 pertaining primarily to write-off of the remaining fixed assets in connection with the closure of our graphite electrode manufacturing operation in Caserta, Italy and $1,621 pertaining primarily

 

 

141

 

 

to the net write-off of the remaining book value of assets of our former graphite electrode manufacturing operations in Clarksville, Tennessee.

In 2005, we recorded a $2,904 charge related to the impairment of our long-lived carbon electrode fixed assets in Columbia, Tennessee. The future estimated undiscounted cash flows expected to result from the use of these assets were below their respective carrying amounts. As a result, an impairment loss was measured as the difference between the assets’ carrying amount and fair value, which was based on current estimates of market price.

 

(13)      Management Compensation and Incentive Plans

Stock Options

We historically have maintained several stock incentive plans. The aggregate number of shares reserved under the plans since their initial adoption was 14,500,000 shares at December 31, 2003 and December 31, 2004 and 19,300,000 shares at December 31, 2005. Such plans permitted options, restricted stock and other awards to be granted to employees and, in the case of two plans, also to non-employee directors.

The 2005 Equity Incentive Plan (the “2005 Plan”) was adopted in the second quarter of 2005. The 2005 Plan provides that the Management Stock Incentive Plan (Original Version), the Management Stock Incentive Plan (Senior Version), the Management Stock Incentive Plan (Mid-Management Version), the 1995 Equity Incentive Plan and the 1996 Mid-Management Equity Incentive Plan (collectively, the “existing plans”) are frozen and will remain in effect only to the extent of awards outstanding under the existing plans on May 25, 2005. The 2005 Plan initially covers 4,800,000 shares. Shares under the existing plans are added to and become available for awards under the 2005 Plan to the extent (but only to the extent) that stock options or stock grants outstanding on May 25, 2005 under the existing plans expire or are canceled or forfeited before they are exercised or vest, respectively, and limited to the extent of the current outstanding awards.

In 2003, we granted options to purchase shares as follows:

Options for 3,188,435 shares were issued to certain officers, management and directors at exercise prices ranging from $2.85 to $12.23 per share. We granted 10-year options for 91,935 shares that vest one year from the grant date and 10-year options for 25,000 shares that vest two years from the grant date. In addition, we granted options for 3,071,500 shares in connection with our long-term incentive program. These options were scheduled to vest on July 31, 2008 and expire December 31, 2008. Accelerated vesting occurs if certain cash flow performance targets are achieved in each of 2003, 2004 and 2005. At December 31, 2004, 1,109,634 of such options were vested. On November 30, 2005 the Compensation, Organization and Pension Committee of GrafTech’s Board of Directors vested the balance of these shares. At December 31, 2005, 3,061,767 of these options were vested.

 

 

142

 

 

 

In 2004, we granted options to purchase shares as follows:

Options for 199,421 shares were issued to certain officers, management and directors at exercise prices ranging from $8.91 to $14.82 per share. We granted 10-year options for 30,421 shares that vest one year from the grant date and 10-year options for 84,500 shares that vest two years from the grant date. In addition, we granted options for 84,500 shares in connection with our long-term incentive program. These options were scheduled to vest July 31, 2008 and expire December 31, 2008. Accelerated vesting could occur if certain cash flow performance targets were achieved in each of 2004 and 2005. At December 31, 2004, none of these options were vested. On November 30, 2005 the Compensation, Organization and Pension Committee of GrafTech’s Board of Directors vested such options. Therefore, at December 31, 2005, 114,921 of these options were vested.

In 2005, we granted 10-year options to purchase shares as follows:

Options for 195,000 shares were issued to certain officers and management at exercise prices ranging from $4.00 to $9.01 per share. All of these options vest two years from the date of grant. At December 31, 2005, none of these shares were vested.

The following table summarizes the status of our stock-based compensation plans at the dates and for the periods indicated:

  For the Year Ended December 31,
  2003
2004
2005
  Shares
Weighted-Average
Exercise Price

Shares
Weighted-Average Shares
Exercise Price

Shares
Weighted-Average
Exercise Price

  (Shares in thousands)
Time vesting options:                            
   Outstanding at beginning of year    9,005   $ 15.34    11,208   $ 13.14    10,631   $ 13.42  
   Granted at market price    3,208    6.59    199    12.01    195    6.62  
   Exercised    (552 )  8.45    (712 )  8.36    -  -  
   Forfeited/canceled    (453 )  15.81    (64 )  17.65    (243 )  13.81  






     Outstanding at end of year    11,208    13.14    10,631    13.42    10,583    13.28  






   Options exercisable at year end      7,593     15.44     7,108     16.32     10,240     13.40      
   Weighted-average fair value of
     options granted during year:
   At market           6.59           7.16           4.80  
Performance vesting options:  
   Outstanding at beginning of
     year
    378   $ 7.60    332   $ 7.60    242   $ 7.60  
   Granted    -    -    -    -    -    -  
   Exercised    (46 )  7.60    (90 )  7.60    -    -  
   Forfeited/canceled    -    -    -    -    -    -  






Outstanding at end of year    332    7.60    242    7.60    242    7.60  






   Options exercisable at year end     332   $ 7.60    242   $ 7.60    242   $ 7.60  

 

 

143

 

 

 

The fair value of each stock option is estimated on the grant date using the Black-Scholes option pricing model with the following weighted-average assumptions for grants in 2003, 2004 and 2005, respectively: dividend yield of 0.0% for all years; expected volatility of 76% in 2003, 67% in 2004 and 72% in 2005; risk-free interest rates of 4.0% in 2003, 3.7% in 2004 and 4.2% in 2005; and expected lives of 6 years in 2003, 6 years in 2004 and 8 years in 2005.

The following table summarizes information about stock options outstanding at December 31, 2005.

Options Outstanding
Options Exercisable
Range of Exercise Prices
Number
Outstanding

Weighted-
Average
Remaining
Contractual
Life

Weighted-
Average
Exercise
Prices

Number
Exercisable

Weighted-
Average
Exercise
Prices

(Shares in thousands)
   Time vesting options:            
        $2.83 to 11.10  6,609   4 years   $  7.51   6,414   $  7.54  
      $11.60 to $19.06  2,486   3 years   16.46   2,338   16.64  
      $22.82 to $29.22  116   2 years   25.54   116   25.54  
      $30.59 to $40.44  1,372   1 year   34.28   1,372   34.28  


    10,583       13.28   10,240   13.40  


Performance vesting options: 
                  $7.60  242   1 year   7.60   242   7.60  

Restricted Stock

In 2005, we granted 1,355,907 shares of restricted stock to certain directors, officers and employees at prices ranging from $3.80 to $8.49.  Of these shares, 40,000 shares vest one year from the date of grant, 455,907 shares vest two years from the date of grant and 860,000 shares vest over a three-year period, with one-third of the shares vesting on the anniversary date of the grant in each of the next three years. 

Incentive Compensation Plans

In 2000, we implemented global incentive programs for our worldwide salaried and hourly employees. These plans were based on our financial performance and achievement of strategic or, in the case of hourly employees, local targets. The cost for this plan was nil in 2002. In 2003, the Incentive Compensation Program (the “ICP”) replaced the former programs, creating one program for all employees. The ICP is based primarily on achieving cash flow targets and, to a lesser extent, strategic targets. The cost for the ICP was $11,413 in 2003 and nil in 2004 and 2005.

 

144

 

 

 

(14)        Contingencies

 

Antitrust Investigations

In 1997, the DOJ and the EU Competition Authority commenced investigations into alleged violations of the antitrust laws in connection with the sale of graphite electrodes. The antitrust authorities in Canada, Japan and Korea subsequently began similar investigations. The EU Competition Authority also commenced an investigation into alleged antitrust violations in connection with the sale of specialty graphite. These antitrust investigations have been resolved. Several of the investigations resulted in the imposition of fines against us. These fines, or payments in accordance with a payment schedule in the case of the DOJ antitrust fine, have been timely paid. At December 31, 2004 and December 31, 2005, $43,077 and $26,000 remained in the reserve for liabilities and expenses in connection with these antitrust investigations and related lawsuits and claims, respectively. The reserve is unfunded and represents the remaining DOJ antitrust fine obligation, with quarterly payments scheduled through January 2007.

Antitrust Lawsuits

Through December 31, 2005, except as described in the following paragraphs, we have settled or obtained dismissal of all of the civil antitrust lawsuits (including class action lawsuits) previously pending against us, certain civil antitrust lawsuits threatened against us and certain possible civil antitrust claims against us arising out of alleged antitrust violations occurring prior to the date of the relevant settlements in connection with the sale of graphite electrodes, carbon electrodes and bulk graphite products. All payments due have been timely paid.

In 1999 and 2000, we and other producers of graphite electrodes were served with three complaints commencing three separate civil antitrust lawsuits in the United States District Court for the Eastern District of Pennsylvania (“EDPA District Court”.) In March 2002, we were served with another complaint commencing a separate civil antitrust lawsuit in the EDPA District Court. These lawsuits are called the “foreign customer lawsuits.” The first complaint, entitled Ferromin International Trade Corporation, et al. v. UCAR International Inc., et al., was filed by 27 steelmakers and related parties, all but one of whom are located outside the U.S. The second complaint, entitled BHP New Zealand Ltd. et al. v. UCAR International Inc., et al. was filed by 4 steelmakers, all of whom are located outside the U.S. The third complaint, entitled Saudi Iron and Steel Company v. UCAR International Inc., et al., was filed by a steelmaker who is located outside the U.S. The fourth complaint, entitled Arbed, S.A., et al. v. Mitsubishi Corporation, et al., was filed by 5 steelmakers, all of whom are located outside the U.S. In each complaint, the plaintiffs allege that the defendants violated U.S. federal antitrust law in connection with the sale of graphite electrodes sold or sourced from the U.S. and those sold and sourced outside the U.S. The plaintiffs seek, among other things, an award of treble damages resulting from such alleged violations. We believe that we have strong defenses against claims alleging that purchases of graphite electrodes outside the U.S. are actionable under U.S. federal antitrust law. We filed motions to dismiss the first and second complaints. In June and July 2001, our motions to dismiss the first and second complaints were granted with respect to substantially all of the plaintiffs’ claims. The claims not dismissed relate to sales invoiced from the United States. Appeals were filed by the plaintiffs and the defendants with the U.S. Court of Appeals for the Third Circuit with regard to these dismissals. The U.S. Court of Appeals for the

 

145

 

 

Third Circuit heard oral argument on these appeals on March 11, 2003. The third complaint was dismissed without prejudice to refile pending the resolution of such appeals. We filed a motion to stay the lawsuit commenced by the fourth complaint pending resolution of appeals in the other foreign customer lawsuits, and such motion was granted in July 2002. In June 2004, the U.S. Supreme Court issued its decision in the case of F. Hoffman-LaRoche v. Empagran S.A. et al., an antitrust case brought by foreign purchasers against the participants in an international vitamins cartel. Because of the relevance of this decision to the foreign customer lawsuits, the U.S. Court of Appeals for the Third Circuit reviewed the impact of this decision on the pending appeals in the foreign customer lawsuits. Subsequently, in August 2004, the U.S. Court of Appeals for the Third Circuit remanded the case to the EDPA District Court for its consideration of the impact of the Empagran decision on the foreign customer lawsuits.

We have been vigorously defending, and intend to continue to vigorously defend, against the foreign customer lawsuits as well as all threatened lawsuits and possible unasserted claims. We may at any time, however, settle these lawsuits as well as any threatened lawsuits and possible claims. It is possible that additional civil antitrust lawsuits seeking, among other things, to recover damages could be commenced against us in the U.S. and in other jurisdictions. We are currently not reserved for such matters.

Other Proceedings Against Us

We are involved in various other investigations, lawsuits, claims and other legal proceedings incidental to the conduct of our business. While it is not possible to determine the ultimate disposition of each of them, we do not believe that their ultimate disposition will have a material adverse effect on our financial position, results of operations or cash flows.

Product Warranties

We generally sell products with a limited warranty. We accrue for known warranty claims if a loss is probable and can be reasonably estimated. Claims accrued but not yet paid amounted to $646 at December 31, 2004 and $610 at December 31, 2005. The following table presents the activity in this accrual for 2005:

Balance at December 31, 2004     $ 646  
Product warranty charges    2,402  
Payments and settlements    (2,438 )

Balance at December 31, 2005    $ 610  

 

(15)          Income Taxes

 

The following table summarizes the U.S. and non-U.S. components of income (loss) before provision for income taxes, minority interest and income from discontinued operations.

 

146

 

 

 

  For the Year Ended
December 31,

  2003
2004
2005
  (Dollars in thousands)
U.S     $ (49,414 ) $ (1,720 ) $ (43,891 )
Non-U.S    30,040    66,069    84,203  



    $ (19,374 ) $ 64,349   $ 40,312  




Total income taxes were allocated as set forth in the following table.

 

  For the Year Ended
December 31,

  2003
2004
2005
  (Dollars in thousands)
Income tax expense from continuing operations     $ 4,695 $ 46,310   $ 165,813  
Income tax expense from discontinued operations       644     -     -  



      $ 5,339   $ 46,310   $ 165,813  



 

Income tax expense (benefit) attributable to income from continuing operations consists of the items set forth in the following table.

 

  For the Year Ended
December 31,

  2003
2004
2005
  (Dollars in thousands)
U.S income taxes:                
    Current   $ (4,928 ) $ 1,968   $ -  
    Deferred    (6,906 )  27,996    155,575  



    $ (11,834 ) $ 29,964   $ 155,575  



Non-U.S. income taxes:  
    Current   $ 7,564   $ 17,760   $ 10,994  
    Deferred    8,965    (1,414 )  (756 )



    $ 16,529   $ 16,346   $ 10,238  



 

We have an income tax exemption from the Brazilian government on income generated from cathode and graphite electrode production through 2005 and 2006, respectively. The exemption did not reduce the net expense associated with income taxes for 2003 or 2004; however, the exemption reduced the net expense associated with income taxes by $490 in 2005.

Income tax expense (benefit) attributable to income from continuing operations differed from the amounts computed by applying the U.S. federal income tax rate of 35% to pretax income from operations as set forth in the following table.

 

 

147

 

 

 

For the Year Ended December 31,
2003
2004
2005
(Dollars in thousands)
            Tax at statutory U.S. federal rate     $ (6,781 ) $ 22,522   $ 14,109  
            Impact of U.S. special tax election for certain non-U.S  
            entities to be included in the U.S. tax return    -    27,524    -  
            Tax return adjustments to estimated tax expense    3,492    -    (2,417 )
            Adjustments to deferred tax asset valuation allowance, net    4,989    (2,337 )  153,079  
            Nondeductible expenses/(income) associated with antitrust
            investigations and related lawsuits and claims
    8,362    (4,175 )  -  
            State tax expense (benefit) (net of federal tax benefit) .    (5,312 )  (459 )  714  
            Restructuring charges/(reversal) with no tax benefit    2,974    (863 )  1,118  
            Impact of statutory tax rate changes    (724 )  (911 )  (2,391 )
            Impact of deemed and actual dividends of foreign earnings    -    6,475    2,667  
            Non-U.S. tax exemptions, holidays and credits    (1,179 )  (735 )  (920 )
            Tax effect of permanent differences    (1,659 )  586    781  
            Foreign withholding taxes for which no tax credit can  
               be claimed    1,506    -    -  
            Other    (973 )  (1,317 )  (927 )



            Total tax expense (benefit) from continuing operations   $ 4,695   $ 46,310   $ 165,813  



  

The tax effects of temporary differences that give rise to significant portions of the deferred tax assets and deferred tax liabilities at December 31, 2004 and December 31, 2005 are set forth in the following table.

 

At December 31,
2004
2005
(Dollars in thousands)
Deferred tax assets:            
  Fixed assets   $ 18,686   $ 19,783  
  Postretirement and other employee benefits    36,640    48,202  
  Foreign tax credit and other carryforwards    106,506    136,807  
  Provision for scheduled plant closings and other  
    restructurings    7,446    7,356  
  Terminated hedge instruments    8,569    2,591  
  Capitalized research and experimental costs    9,732    9,304  
  Other    22,481    23,979  


    Total gross deferred tax assets    210,060    248,022  
 
    Less: valuation allowance    (23,189 )  (208,393 )


        Total deferred tax assets   $ 186,871   $ 39,629  


  
Deferred tax liabilities:  
  Fixed assets   $ 60,525   $ 60,937  
  Inventory    6,918    6,160  
  Other    3,815    1,986  


    Total deferred tax liabilities    71,258    69,083  


       Net deferred tax asset/(liability)   $ 115,613   $ (29,454 )


 

Deferred income tax assets and liabilities are classified on a net current and non-current basis within each tax jurisdiction. Net deferred income tax assets are included in prepaid expenses and other current assets in the amount of $16,162 at December 31, 2004 and $8,257 at December 31, 2005 and separately stated as deferred income taxes in the amount of $152,539 at

 

148

 

 

December 31, 2004 and $12,103 at December 31, 2005. Net deferred tax liabilities are included in accrued income and other taxes in the amount of $6,829 at December 31, 2004 and $6,145 at December 31, 2005 and separately stated as deferred income taxes in the amount of $46,259 at December 31, 2004 and $43,669 at December 31, 2005.

The change in the total valuation allowance for 2005 was an increase of $185,204. During the 2005 year-end financial accounting closing process, we determined that the timing of when we will generate sufficient U.S. taxable income to realize our U.S. deferred tax assets became less certain. Accordingly, during the fourth quarter of 2005, we recorded a valuation allowance of $149,734 against deferred tax assets in the U.S. and $1,722 in certain non-U.S. jurisdictions, which resulted in a total net charge of $151,456. We also recorded additional deferred tax assets and related valuation allowances of $27,477. Until we determine that it is more likely than not that we will generate sufficient U.S. taxable income to realize our deferred income tax assets, income tax benefits in each current period will be full reserved.

We have total excess foreign tax credit carryforwards of $91,680 at December 31, 2005. Of these tax credit carryforwards, $1,089 expire in 2010, $17,499 expire in 2011, $36,646 expire in 2012, $1,517 expire in 2013, $31 expire in 2014, $8,787 expire in 2015 and $26,111 expire in 2016 and beyond. In addition, we have federal, state and foreign net operating losses, on a gross tax effected basis, of $32,126. Of these tax loss carryforwards, $511 expire in 2006, $2,907 expire in 2007, $3,292 expire in 2008, $1,409 expire in 2009, $857 expire in 2010, $10 expire in 2010, $1,907 expire in 2012, $2,156 expire in 2013, $1,503 expire in 2014 and $17,574 expire in 2015 and beyond. Based upon the level of historical taxable income and projections for future taxable income over the periods during which these credits are utilizable, we believe it is more likely than not that we will realize the tax benefits of these deferred tax assets consisting of net operating losses, net of the corresponding valuation allowances that exist at December 31, 2005.

In 2004, we implemented a tax planning strategy that together with other planning efforts, accelerated the utilization of certain tax assets. The strategy accelerated approximately $215,177 of taxable income to the U.S. through a standard election (commonly referred to as “check the box”) that resulted in the utilization of approximately $26,219 of deferred tax assets, of which approximately $19,969 were foreign tax credits.

With the exception of our Swiss, South African, U.K. and French subsidiaries (the “check the box” entities), taxes have not been provided on undistributed earnings of foreign subsidiaries because our intention is to reinvest these undistributed earnings indefinitely. To the extent that our circumstances change or future earnings are repatriated, we will provide for income tax on the earnings of the affected foreign subsidiaries. We believe that any U.S. income tax on repatriated earnings would be substantially offset by U.S. foreign tax credits.

 

149

 

 

 

(16)         Earnings Per Share

 

Basic and diluted EPS are calculated based upon the provisions of SFAS No. 128, “Earnings Per Share,” and EITF Issue No. 04-08, “Accounting Issues Related to Certain Features of Contingently Convertible Debt and the Effects on Diluted Earnings Per Share,” using the following data:

 

2003
2004
2005
(Dollars in thousands)
 
Net income, as reported     $ (24,277 ) $ 17,041   $ (125,180 )
Add: Interest on Debentures, net of tax benefit              
Add: Amortization of Debentures issuance costs, net
     of tax benefit
              



      Net income, as adjusted   $ (24,277 ) $ 17,041   $ (125,180 )



Weighted average common shares
     outstanding for basic calculation
    67,980,838    96,547,733    97,688,734  
Add: Effect of stock options and restricted stock        1,602,204      
Add: Effect of Debentures              



Weighted average common shares
     outstanding for diluted calculation
    67,980,838    98,149,937    97,688,734  



 

Basic earnings per common share are calculated by dividing net income by the weighted average number of common shares outstanding. Diluted earnings per share are calculated by dividing net income by the sum of the weighted average number of common shares outstanding plus the additional common shares that would have been outstanding if potentially dilutive securities, including those underlying the Debentures, had been issued. As a result of the net loss reported for 2003 and 2005, 508,215 of potential common shares underlying dilutive securities and 276,161 of potential common shares underlying dilutive securities, respectively have been excluded from the calculation of diluted earnings (loss) per share because their effect would reduce the loss per share.

The calculation of weighted average common shares outstanding for the diluted calculation excludes consideration of stock options covering 4,058,695 shares in 2003, 4,094,348 shares in 2004 and 9,809,780 shares in 2005, because the exercise of these options would not have been dilutive for those periods due to the fact that the exercise prices were greater than the weighted average market price of our common stock for each of those periods.

The calculation of weighted average common shares outstanding for the 2004 and 2005 diluted calculation also excludes the shares underlying the Debentures, as the effect would have been anti-dilutive.

(17)         Stockholder Rights Plan

Effective August 7, 1998, GTI adopted a Stockholder Rights Plan (the “Rights Plan”). Under the Rights Plan, one preferred stock purchase right (a “Right”) was distributed on September 21, 1998 to stockholders of record on August 20, 1998 as a dividend on each share of common stock outstanding on the record date. Each share of common stock issued after the record date is accompanied by a Right.

 

150

 

 

 

When a Right becomes exercisable, it entitles the holder to buy one one-thousandth of a share of a new series of preferred stock for $110. The Rights are subject to adjustment upon the occurrence of certain dilutive events. The Rights will become exercisable only when a person or group becomes the beneficial owner of 15% or more of the outstanding shares of common stock or 10 days after a person or group announces a tender offer to acquire beneficial ownership of 15% or more of the outstanding shares of common stock. No certificates representing the Rights will be issued, and the Rights are not transferable separately from the common stock, unless the Rights become exercisable.

Under certain circumstances, holders of Rights, except a person or group described above and certain related parties, will be entitled to purchase shares of common stock (or, in certain circumstances, other securities or assets) at 50% of the price at which the common stock traded prior to the acquisition or announcement (or 50% of the value of such other securities or assets). In addition, if GTI is acquired after the Rights become exercisable, the Rights will entitle those holders to buy the acquiring company’s common shares at a similar discount.

GTI is entitled to redeem the Rights for one cent per Right prior to the time when the Rights become exercisable. If not redeemed, the Rights will expire on August 7, 2008.

The preferred stock issuable upon exercise of Rights consists of Series A Junior Participating Preferred Stock, par value $.01 per share, of GTI. In general, each share of that preferred stock will be entitled to a minimum preferential quarterly dividend payment equal to the greater of $10.00 per share or 1,000 times the quarterly dividend declared on the common stock, will be entitled to a liquidation preference of $110,000 and will have 1,000 votes, voting together with the common stock.

(18)

Financial Information About the Issuer, the Guarantors and the Subsidiaries Whose Securities Secure the Senior Notes, the Debentures and Related Guarantees

On February 15, 2002, GrafTech Finance (“Finco”), a direct subsidiary of GTI (the “Parent”), issued $400,000 aggregate principal amount of Senior Notes and, on May 6, 2002, $150,000 aggregate principal amount of additional Senior Notes. All of the Senior Notes have been issued under a single Indenture and constitute a single class of debt securities. The Senior Notes mature on February 15, 2012. The Senior Notes have been guaranteed on a senior basis by the Parent and the following wholly-owned direct and indirect subsidiaries of the Parent: GrafTech Global, UCAR Carbon, UCAR International Trading Inc., UCAR Carbon Technology LLC, and UCAR Holdings V Inc. (“Holdings V”). The Parent, Finco and these subsidiaries together hold a substantial majority of our U.S. assets. Holdings V has no material assets or operations, and has been dissolved.

On January 22, 2004, the Parent issued $225,000 aggregate principal amount of Debentures. The guarantors of the Debentures are the same as the guarantors of the Senior Notes, except for the Parent (which is the issuer of the Debentures but a guarantor of the Senior Notes) and Finco (which is a guarantor of the Debentures but the issuer of the Senior Notes). The Parent and Finco are both obligors on the Senior Notes and the Debentures, although in different capacities.

 

 

151

 

 

 

The guarantors of the Senior Notes and the Debentures, solely in their respective capacities as such, are collectively called the “U.S. Guarantors.” Our other subsidiaries, which are not guarantors of either the Senior Notes or the Debentures, are called the “Non-Guarantors.”

All of the guarantees are unsecured, except that the guarantee of the Senior Notes by UCAR Carbon has been secured by a junior pledge of all of the shares of capital stock (constituting 97.5% of the outstanding shares of capital stock) of AET held by UCAR Carbon (called the “AET Pledged Stock”), subject to the limitation that in no event will the value of the pledged portion of the AET Pledged Stock exceed 19.99% of the principal amount of the then outstanding Senior Notes. All of the guarantees are full, unconditional and joint and several. Finco and each of the other U.S. Guarantors (other than the Parent) are 100% owned, directly or indirectly, by the Parent. All of the guarantees of the Senior Notes continue until the Senior Notes have been paid in full, and payment under such guarantees could be required immediately upon the occurrence of an event of default under the Senior Notes. All of the guarantees of the Debentures continue until the Debentures have been paid in full, and payment under such guarantees could be required immediately upon the occurrence of an event of default under the Debentures. If a guarantor makes a payment under its guarantee of the Senior Notes or the Debentures, it would have the right under certain circumstances to seek contribution from the other guarantors of the Senior Notes or the Debentures, respectively.

Provisions in the Revolving Facility restrict the payment of dividends by our subsidiaries to the Parent. At December 31, 2005, retained earnings of our subsidiaries subject to such restrictions were approximately $729,426. Investments in subsidiaries are recorded on the equity basis.

The following table sets forth condensed consolidating balance sheets at December 31, 2004 and December 31, 2005 and condensed consolidating statements of operations and cash flows for each of the years in the three-year period ended December 31, 2005 of the Parent, Finco, all other U.S. Guarantors and the Non-Guarantors.

 

152

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

Condensed Consolidating Balance Sheet

at December 31, 2004

Parent
(Issuer of
Debentures
and
Guarantor
of Senior
Notes)

Finco (Issuer
of Senior
Notes and
Guarantor of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
                      ASSETS                            
   Current assets:   
   Cash and cash equivalents   $ -   $ 12,000   $ 1,000   $ 11,000   $ -   $ 24,000  
          Intercompany loans    50,000    670,000    --    62,000    (782,000 )  --  
          Intercompany accounts receivable    3,000    3,000    35,000    30,000    (71,000 )  --  
          Accounts receivable - third party    --    3,000    33,000    170,000    --    206,000  






   Accounts and notes receivable, net    53,000    676,000    68,000    262,000    (853,000 )  206,000  






   Inventories    --    --    47,000    184,000    (6,000 )  225,000  
   Prepaid expenses and other current assets    13,000    --    4,000    22,000    (14,000 )  25,000  






          Total current assets    66,000    688,000    120,000    479,000    (873,000 )  480,000  






   Property, plant and equipment    --    --    45,000    338,000    (5,000 )  378,000  
   Deferred income taxes    72,000    12,000    73,000    2,000    (6,000 )  153,000  
   Investments in affiliates    27,000    --    --    --    (27,000 )  --  
   Goodwill    --    --    --    139,000    (116,000 )  23,000  
   Other assets    6,000    16,000    6,000    8,000    (2,000 )  34,000  






          Total assets   $ 171,000   $ 716,000   $ 244,000   $ 966,000   $ (1,029,000 ) $ 1,068,000  






         LIABILITIES AND STOCKHOLDERS'   
               EQUITY (DEFICIT)   
   Current liabilities:   
   Accounts payable   $ 2,000   $ 17,000   $ 7,000   $ 61,000   $ (1,000 ) $ 86,000  
      Intercompany loans    --    66,000    170,000    629,000    (865,000 )  --  
      Third party loans    --    --    --    1,000    --    1,000  






   Short-term debt    --    66,000    170,000    630,000    (865,000 )  1,000  
   Accrued income and other taxes    --    19,000    --    34,000    (15,000 )  38,000  
   Other accrued liabilities    --    --    34,000    67,000    (2,000 )  99,000  






          Total current liabilities    2,000    102,000    211,000    792,000    (883,000 )  224,000  






   Long-term debt    219,000    452,000    --    1,000    --    672,000  
   Other long-term obligations    3,000    9,000    86,000    47,000    4,000    149,000  
   Payable to equity of investees    --    --    73,000    --    (73,000 )  --  
   Deferred income taxes    --    --    --    56,000    (10,000 )  46,000  
   Commitments and contingencies    --    --    --    --    --    --  
   Minority stockholders' equity in
      consolidated entities
    --    --    --    30,000    --    30,000  
   Stockholders' equity (deficit)    (53,000 )  153,000    (126,000 )  40,000    (67,000 )  (53,000 )






          Total liabilities and stockholders'
             deficit
   $ 171,000   $ 716,000   $ 244,000   $ 966,000   $ (1,029,000 ) $ 1,068,000  






  

 

153

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

Condensed Consolidating Balance Sheet

at December 31, 2005

Parent
(Issuer of
Debentures
and
Guarantor
of Senior
Notes)

Finco (Issuer
of Senior
Notes and
Guarantor of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
                   ASSETS                            
Current assets:   
Cash and cash equivalents   $ 143   $   $ 36   $ 5,877   $ (88 ) $ 5,968  
       Intercompany loans    51,315    166,292        108,716    (326,323 )    
       Intercompany accounts receivable        2,676    27,689    31,079    (61,444 )    
       Accounts receivable - third party            36,569    148,011        184,580  






Accounts and notes receivable, net    51,315    168,968    64,258    287,806    (387,767 )  184,580  






Inventories            59,975    195,108    (45 )  255,038  
Prepaid expenses and other current assets .    7    16,431    1,793    12,287    (16,417 )  14,101  






       Total current assets    51,465    185,399    126,062    501,078    (404,317 )  459,687  






Property, plant and equipment, net            46,586    320,096    (4,485 )  362,197  
Deferred income taxes            8,980    4,067    (944 )  12,103  
Intercompany loans        506,887            (506,887 )    
Investments in affiliates                          
Goodwill                20,319        20,319  
Other assets    5,359    16,860    3,426    6,869        32,514  






       Total assets   $ 56,824   $ 709,146   $ 185,054   $ 852,429   $ (916,633 ) $ 886,820  






      LIABILITIES AND STOCKHOLDERS'   
            EQUITY (DEFICIT)   
Current liabilities:   
Accounts payable   $ 1,836   $ 17,242   $ 12,392   $ 60,810   $ (88 ) $ 92,192  
   Intercompany loans        109,284    217,009    61,655    (387,948 )    
   Third party loans                405        405  






Short-term debt        109,284    217,009    62,060    (387,948 )  405  
Accrued income and other taxes    1,939        20,963    18,341    (16,417 )  24,826  
Other accrued liabilities            34,644    62,346        96,990  






       Total current liabilities    3,775    126,526    285,008    203,557    (404,453 )  214,413  






Long-term debt    220,290    482,481        972        703,743  
Intercompany loans                506,903    (506,903 )    
Other long-term obligations    1,284    37    59,051    47,332        107,704  
Payable to equity of investees    41,045        (526,601 )      485,556      
Deferred income taxes    7            44,606    (944 )  43,669  
Commitments and contingencies                          
Minority stockholders' equity in  
   consolidated entities                26,868        26,868  
Stockholders' equity (deficit)    (209,577 )  100,102    367,596    22,191    (489,889 )  (209,577 )






       Total liabilities and stockholders'  
          deficit   $ 56,824   $ 709,146   $ 185,054   $ 852,429   $ (916,633 ) $ 886,820  







 

 

154

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

 

Condensed Consolidating Statements of Operations

for the Year Ended December 31, 2003

 

Parent
(Issuer of
Debentures
and
Guarantor of
Senior Notes)

Finco
(Issuer of
Senior
Notes and
Guarantor
of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
 
Net sales     $ -   $ -   $ 234,000   $ 629,000   $ (151,000 ) $ 712,000  
Cost of sales    -    -    186,000    509,000    (151,000 )  544,000  






    Gross profit    -    -    48,000    120,000    -    168,000  
Research and development    -    -    5,000    6,000    -    11,000  
Selling, administrative and other expenses    -    -    43,000    42,000    -    85,000  
Restructuring charge    -    -    20,000    -    -    20,000  
Impairment loss on long-lived and other assets    -    -    7,000    -    -    7,000  
Antitrust investigations and related lawsuits  
  and claims    -    -    32,000    -    -    32,000  
Other (income) expense, net    2,000    (32,000 )  8,000    10,000    -    (12,000 )
Interest expense    36,000    45,000    -    27,000    (63,000 )  45,000  
Interest income    (3,000 )  (60,000 )  -    -    63,000    -  






     Income (loss) from continuing operations    (35,000 )  47,000    (67,000 )  35,000    -    (20,000 )
     before provision for (benefit from) income  
     taxes and minority stockholders' share of  
     income  
Provision for (benefit from) income taxes    (108,000 )  21,000    76,000    16,000    -    5,000  
Minority stockholders' share of income    -    -    -    1,000    -    1,000  






   Income (loss) from continuing operations    73,000    26,000    (143,000 )  18,000    -    (26,000 )
Income from discontinued operations,  
   net of taxes    -    -    1,000    -    -    1,000  
Gain on sale of discontinued operations,
   net of taxes
    -    -    1,000    -    -    1,000  
Equity in earnings of subsidiaries    (97,000 )  -    18,000    -    79,000    -  






       Net income (loss)   $ (24,000 ) $ 26,000   $ (123,000 ) $ 18,000   $ 79,000   $ (24,000 )






 

 

155

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

 

Condensed Consolidating Statements of Operations

for the Year Ended December 31, 2004

 

Parent
(Issuer of
Debentures
and
Guarantor of
Senior Notes)

Finco
(Issuer of
Senior
Notes and
Guarantor
of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
 
Net sales     $ -   $ -   $ 261,000   $ 757,000   $ (170,000 ) $ 848,000  
Cost of sales    -    -    202,000    574,000    (138,000 )  638,000  






   Gross profit    -    -    59,000    183,000    (32,000 )  210,000  
Research and development    -    -    3,000    5,000    -    8,000  
Selling, administrative and other expenses    -    -    41,000    76,000    (27,000 )  90,000  
Restructuring charge    -    -    1,000    (1,000 )  -    -  
Antitrust investigations and related lawsuits
  and claims
    -    -    (11,000 )  -    -    (11,000 )
Other (income) expense, net    5,000    -    7,000    9,000    -    21,000  
Interest expense    29,000    43,000    20,000    22,000    (75,000 )  39,000  
Interest income    (9,000 )  (41,000 )  (25,000 )  (1,000 )  75,000    (1,000 )






   Income (loss) from continuing operations
     before provision for (benefit from) income
     taxes and minority stockholders' share of
     income
    (25,000 )  (2,000 )  23,000    73,000    (5,000 )  64,000  
Provision for (benefit from) income taxes    27,000    (11,000 )  10,000    19,000    1,000    46,000  
Minority stockholders' share of income    -    -    -    1,000    -    1,000  
Equity in earnings of subsidiaries    (75,000 )  -    (53,000 )  -    128,000    -  






      Net income (loss)   $ 23,000   $ 9,000   $ 66,000   $ 53,000   $ (134,000 ) $ 17,000  






 

 

 

156

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

 

Condensed Consolidating Statements of Operations

for the year ended December 31, 2005

 

Parent
(Issuer of
Debentures
and
Guarantor of
Senior Notes)

Finco
(Issuer of
Senior
Notes and
Guarantor
of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
 
Net sales     $ -   $ -   $ 264,104   $ 802,178   $ (179,583 ) $ 886,699  
Cost of sales    -    -    204,654    618,044    (168,356 )  654,342  






   Gross profit    -    -    59,450    184,134    (11,227 )  232,357  
Research and development    -    -    3,206    6,231    -    9,437  
Selling, administrative and other expenses    1,814    236    40,130    88,563    (30,304 )  100,439  
Restructuring charges    69    -    1,864    7,796    -    9,729  
Impairment loss on long-lived and other assets    -    -    2,904    -    -    2,904  
Antitrust investigations and related lawsuits  
   and claims    -    -    -    -    -    -  
Other (income) expense, net    (2,770 )  (5,412 )  1,027    (4,179 )  29,354    18,020  
Interest expense    5,262    47,685    4,797    24,152    (29,180 )  52,716  
Interest income    -    (37 )  -    (1,163 )  -    (1,200 )






   Income (loss) before provision for (benefit  
     from) income taxes and minority  
     stockholders' share of income    (4,375 )  (42,472 )  5,522    62,734    18,903    40,312  
Provision for (benefit from) income taxes    74,514    (3,164 )  84,571    9,833    59    165,813  
Minority stockholders' share of income (loss)    -    -    -    (321 )  -    (321 )
Deficit (equity) in earnings of subsidiaries    65,135    -    (53,222 )  -    (11,913 )  -  






      Net income (loss)   $ (144,024 ) $ (39,308 ) $ (25,827 ) $ 53,222   $ 30,757   $ (125,180 )






 

 

157

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

Condensed Consolidating Statements of Cash Flows

for the year ended December 31, 2003

Parent
(Issuer of
Debentures
and
Guarantor of
Senior Notes)

Finco
(Issuer of
Senior
Notes and
Guarantor
of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
 
Net cash provided by (used in) operating                            
   activities from continuing operations   $ 228,000   $ 3,000   $ (81,000 ) $ 40,000   $ (216,000 ) $ (26,000 )
Net cash provided by(used in) operating  
   activities from discontinued operations    -    -    1,000    -    -    1,000  






Net cash provided by (used in) operating activities    228,000    3,000    (80,000 )  40,000    (216,000 )  (25,000 )






Net cash by provided (used in) investing activities    -    (97,000 )  11,000    121,000    (57,000 )  (22,000 )






Net cash provided by (used in) financing activities    (228,000 )  107,000    65,000    (148,000 )  273,000    69,000  






Net increase (decrease) in cash and cash  
equivalents    -    13,000    (4,000 )  13,000    -    22,000  
Effect of exchange rate changes on cash and
   cash equivalents
    -    -    -    1,000    -    1,000  
Cash and cash equivalents at beginning of period    -    -    4,000    7,000    -    11,000  






Cash and cash equivalents at end of period   $ -   $ 13,000   $ -   $ 21,000   $ -   $ 34,000  






 

 

158

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

Condensed Consolidating Statements of Cash Flows

for the year ended December 31, 2004

Parent
(Issuer of
Debentures
and
Guarantor of
Senior Notes)

Finco
(Issuer of
Senior
Notes and
Guarantor
of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
 
Cash flow from operating activities:                            
   Net Income (loss)   $ 23,000   $ 9,000   $ 66,000   $ 53,000   $ (134,000 ) $17,000  
   Adjustment to reconcile net income (loss) to  
      cash provided by operations:  
       Depreciation and amortization    -    -    3,000    32,000    -    35,000  
       Deferred income taxes    23,000    (13,000 )  10,000    (2,000 )  8,000    26,000  
       Antitrust investigations and related  
         lawsuits and claims    -    -    1,000    -    -    1,000  
       Restructuring charge    -    -    1,000    (1,000 )  -    -  
       Adjustment from cost to equity    (75,000 )  -    (53,000 )  -    128,000    -  
       Loss on exchange of common stock for  
         Senior Notes    5,000    -    -    -    -    5,000  
       Interest expense    -    (2,000 )  -    -    -    (2,000 )
       Post retirement plan changes    -    -    (10,000 )  -    -    (10,000 )
       Gain of sale of assets    -    -    -    (3,000 )  -    (3,000 )
       Fair value adjustments on interest rate caps    -    4,000    -    -    -    4,000  
       Other charges, net    1,000    (4,000 )  -    4,000    -    1,000  
   (Increase) decrease in working capital    (62,000 )  (1,000 )  (253,000 )  (70,000 )  219,000    (167,000 )
   Long term assets and liabilities    (6,000 )  19,000    (46,000 )  4,000    (9,000 )  (38,000 )






         Net cash used in operating activities    (91,000 )  12,000    (281,000 )  17,000    212,000    (131,000 )
 
Cash flow from investing activities:  
   Intercompany investments    (141,000 )  45,000    299,000    9,000    (212,000 )  -  
   Capital expenditures    -    -    (17,000 )  (42,000 )  -    (59,000 )
   Patent capitalization    -    -    -    -    -    -  
   Purchase of derivative investments    -    (3,000 )  -    -    -    (3,000 )
   Sale of derivative investments    -    -    -    -    -    -  
   Proceeds from sales of assets    -    -    -    6,000    -    6,000  






         Net cash used in investing activities    (141,000 )  42,000    282,000    (27,000 )  (212,000 )  (56,000 )
 
Cash flow from financing activities:  
   Short-term debt borrowings (reductions), net    -    -    -    (1,000 )  -    (1,000 )
   Revolving Facility borrowings    -    -    -    -    -    -  
   Revolving Facility payments    -    -    -    -    -    -  
   Long-term debt borrowings    225,000    -    -    -    -    225,000  
   Long-term debt reductions    -    (44,000 )  -    -    -    (44,000 )
   Proceeds from exercise of stock options    7,000    -    -    -    -    7,000  
   Financing costs    -    (8,000 )  -    -    -    (8,000 )
   Premium on repurchase of Senior Notes    -    (3,000 )  -    -    -    (3,000 )






          Net cash provided by financing activities    232,000    (55,000 )  -    (1,000 )  -    176,000  
 
Net increase (decrease) in cash and cash  
   equivalents:    -    (1,000 )  1,000    (11,000 )  -    (11,000 )
Effect of exchange rate changes on cash and
   cash equivalents
    -    -    -    1,000    -    1,000  
Cash and cash equivalents at beginning of period    -    13,000    -    21,000    -    34,000  






Cash and cash equivalents at end of period     $ -   $ 12,000   $ 1,000   $ 11,000   $ -   $ 24,000  






 

 

159

 

 

 

GRAFTECH INTERNATIONAL LTD. AND SUBSIDIARIES

Condensed Consolidating Statements of Cash Flows

for the year ended December 31, 2005

Parent
(Issuer of
Debentures
and
Guarantor of
Senior Notes)

Finco
(Issuer of
Senior
Notes and
Guarantor
of
Debentures)

All Other
U.S.
Guarantors

Non-
Guarantors

Consolidation/
Eliminations

Consolidated
(Dollars in thousands)
 
Cash flow from operating activities:                            
Net Income (loss)   $ (78,889 ) $ (39,308 ) $ (79,049 ) $ 53,223   $ 18,843   $ (125,180 )
Adjustment to reconcile net income (loss) to net  
   cash (used in) provided by operations:  
Depreciation and amortization    -    -    4,055    31,408    1,463    36,926  
Deferred income taxes    74,514    (3,164 )  84,572    (1,099 )  (4 )  154,819  
Adjustment from cost to equity    (65,134 )  -    53,223    -    11,911    -  
Antitrust investigations and related lawsuits and
claims
    -    -    (119 )  -    -    (119 )
Interest expense    1,957    591    (952 )  -    -    1,596  
Restructuring charges    -    -    1,327    8,402    -    9,729  
Impairment loss on long-lived and other assets    -    -    2,904    -    -    2,904  
Gain on sale of assets    -    -    (801 )  53    -    (748 )
Fair value adjustment on Debenture redemption make  
   whole option    (2,702 )  -    -    -    -    (2,702 )
Fair value adjustments on interest rate caps    -    652    -    -    -    652  
Post retirement plan changes    -    -    (15,626 )  1,626    -    (14,000 )
Other (credits) charges, net    53,250    1,852    (105,522 )  81,231    (13,989 )  16,822  
(Increase) decrease in working capital    15,031    (34,555 )  12,761    (32,714 )  (22,310 )  (61,787 )
Long term assets and liabilities    -    -    (5,270 )  (5,653 )  -    (10,923 )






   Net cash used in operating activities    (1,973 )  (73,932 )  (48,497 )  136,477    (4,086 )  7,989  
 
Cash flow from investing activities:  
Intercompany loans receivable/payable    3,485    1,339    7,950    (12,030 )  (744 )  -  
Intercompany debt, net    (1,369 )  39,220    46,549    (89,075 )  4,675    -  
Capital expenditures    -    -    (8,253 )  (39,885 )  67    (48,071 )
Cost of sale of interest rate swaps    -    (14,800 )  -    -    -    (14,800 )
 
Proceeds from sale of assets    -    -    720    654    -    1,374  
Patent capitalization    -    -    (374 )  (423 )  -    (797 )
Sale (purchase) of derivative investments    -    1,913    -    -    -    1,913  






   Net cash used in investing activities    2,116    27,672    46,592    (140,759 )  3,998    (60,381 )
 
Cash flow from financing activities:  
Short-term debt borrowings (reductions), net    -    -    1,924    (43 )  -    1,881  
Revolving Facility borrowings    -    171,138    -    -    -    171,138  
Revolving Facility reductions    -    (131,562 )  -    -    -    (131,562 )
Long-term debt borrowings    -    -    -    306    -    306  
Long-term debt reductions    -    -    -    (338 )  -    (338 )
Financing costs    -    (5,241 )  -    -    -    (5,241 )






   Net cash provided by financing activities    -    34,335    1,924    (75 )  -    36,184  
 
Net increase (decrease) in cash and cash  
   equivalents    143    (11,925 )  19    (4,357 )  (88 )  (16,208 )
Effect of exchange rate changes on cash and cash
   equivalents
    -    -    -    (1,308 )  -    (1,308 )
Cash and cash equivalents at beginning of period    -    11,925    17    11,542    -    23,484  






Cash and cash equivalents at end of period   $ 143   $ -   $ 36   $ 5,877   $ (88 ) $ 5,968  






 

 

160

 

 

 

Unsecured intercompany term notes and unsecured guarantees of those unsecured intercompany term notes by certain of our foreign subsidiaries have been pledged by GrafTech Finance to secure the Senior Notes, subject to the limitation that at no time will the combined value of the pledged portion of any foreign subsidiary’s unsecured intercompany term note and unsecured guarantee of unsecured intercompany term notes issued by other foreign subsidiaries exceed 19.99% of the principal amount of the then outstanding Senior Notes. In addition, the guarantee of the Senior Notes by UCAR Carbon has been secured by a pledge of all of the AET Pledged Stock, subject to the limitation that at no time will the value of the pledged portion of the AET Pledged Stock exceed 19.99% of the principal amount of the then outstanding Senior Notes.

 

Rule 3-16 of Regulation S-X adopted by the SEC provides that, for each of the registrant’s affiliates whose securities constitute a “substantial” portion of the collateral for registered securities, financial statements (that would be required to be filed if the affiliate were a registrant) must be filed with an annual report on Form 10-K. Under Rule 3-16(b), securities of a person will be deemed to constitute a “substantial” portion of the collateral if the aggregate principal amount, par value, or book value of securities as carried by the registrant, or the market value of such securities, whichever is the greatest, equals 20% or more of the principal amount of the registered securities. In this case, the pledges of the AET Pledged Stock and the unsecured intercompany term notes and related guarantees have been limited such that they will never be more than 19.99% of the principal amount of the then outstanding Senior Notes. Therefore, no such financial statements are required to be included in this Report.

 

(19)         Discontinued Operations

 

As part of our ongoing asset sale program, we sold our non-strategic composite tooling business based in Irvine, California in June 2003 for approximately $15,692, including a $692 working capital adjustment. This business was previously included in “Other” for segment presentation in accordance with SFAS No. 131. As a result, under SFAS No. 144, “Accounting for the Impairment or Disposal of Long-Lived Assets,” the composite tooling business is reflected as a discontinued operation. We have reflected prior year results of the composite tooling business as a discontinued operation on the Consolidated Statements of Operations and reclassified the assets and liabilities of the business separately on the Consolidated Balance Sheets.

The following table sets forth the results of the discontinued operation.

For the Year Ended December 31,
2003
2004
2005
(Dollars in thousands)
 
Net sales     $ 9,053   $ -   $ -  
Income before provision for income taxes    1,681   $ -   $ -  
  

 

There were no assets or liabilities of the discontinued operation at December 31, 2004 or December 31, 2005.

 

161

 

 

 

(20)          Subsequent Events

Since December 31, 2005, and prior to the issuance of this Report, we have initiated the following actions in an effort to reduce overhead costs and improve the cash flow of our global organization:

On January 24, 2006, we announced plans to shut down all production operations at our Vyazma, Russia graphite electrode manufacturing facility. This plan is expected to be completed by the end of the third quarter of 2006.

On March 9, 2006, we announced plans to shut down carbon electrode production operations at our Columbia, Tennessee manufacturing facility. This plan is expected to be completed by the end of the first quarter of 2007.

 

On March 1, 2006, the Company was served with a complaint commencing a securities class action in the United States District Court for the District of Delaware (Civil Action No. 06-133). The complaint, entitled Edmund Spinney v. GrafTech International Ltd., et al., alleges that GrafTech, Craig S. Shular, the Chief Executive Officer, President and Interim Chief Financial Officer, Petrus J. Barnard, a Vice President and President, Graphite Electrodes, John J. Wetula, a Vice President and President, Natural Graphite, and Corrado De Gasperis, our former Chief Financial Officer, Chief Information Officer and Vice President, violated federal securities law by making false statements or failing to disclose adverse facts, in or in relation to press releases issued by us on November 3, 2005, about our graphite electrode pricing power, our cost-cutting measures, the market for our non-graphite product lines, our forecasting ability and internal controls and corporate compliance, and our restructuring activities and charges. The proposed class consists of all persons who purchased our securities during the period from November 3, 2005 until February 8, 2006. The complaint seeks, among other things, to recover damages resulting from such alleged violations. Our analysis and investigation relating to this lawsuit is in its earliest stages, and, as a result, we are not able to assess the likelihood of loss, if any, or the amount thereof. We have not yet filed a response to the complaint. We intend to vigorously defend against this lawsuit.

 

 

162

 

 

 

Item 9.  Changes in and Disagreements with Accountants on Accounting and Financial Disclosure

None.

Item 9A.  Controls and Procedures

Evaluation of Disclosure Controls and Procedures

Management is responsible for establishing and maintaining adequate disclosure controls and procedures at the reasonable assurance level. Disclosure controls and procedures are designed to ensure that information required to be disclosed by a reporting company in the reports that it files or submits under the Exchange Act is recorded, processed, summarized and reported within the time periods specified in the SEC’s rules and forms. Disclosure controls and procedures include, without limitation, controls and procedures designed to ensure that information required to be disclosed by it in the reports that it files under the Exchange Act is accumulated and communicated to management, including the chief executive officer and chief financial officer, as appropriate to allow timely decisions regarding required disclosure.

Under the supervision and with the participation of our management, including our Chief Executive Officer and interim Chief Financial Officer, we have evaluated the effectiveness of the design and operation of our disclosure controls and procedures as of December 31, 2005, and based on that evaluation, our Chief Executive Officer and interim Chief Financial Officer has concluded that these controls and procedures are effective at the reasonable assurance level as of December 31, 2005.

Changes in Internal Controls over Financial Reporting

During the 2005 third quarter, we announced the relocation of our principal executive office from Wilmington, Delaware to Parma, Ohio, the relocation of various business transaction processing and accounting functions from our offices in Clarkesville, Tennessee to Parma, and the relocation of certain management, accounting and treasury functions from our offices in Etoy, Switzerland to Parma. A significant number of our corporate employees (including employees involved in our control environment) have elected not to relocate and will leave the employment of the Company following a period during which their functions were or are being transitioned to other employees (including new employees hired or being hired in Parma). During the 2005 fourth quarter, we announced the termination of our business process services (“BPS”) agreement with CGI. Under this agreement, CGI managed certain of our accounting and finance functions and played a role in performing certain internal control functions. We no longer rely on the provider to perform these functions. The agreement’s effective termination date was February 28, 2006.

During the 2005 fourth quarter, we also announced the resignation of our Chief Financial Officer. Our Chief Financial Officer was also our principal accounting officer and was a key component of our overall control environment. In conjunction with his resignation, we named our Chief Executive Officer as our interim Chief Financial Officer.

Beginning in the 2005 fourth quarter, we have engaged in activities designed to ensure a smooth transition in connection with, and mitigate any material disruption to our business or our

 

163

 

 

control environment resulting from these events. As of December 31, 2005 and for the year-end closing and reporting processes, we believe that these events have not had a material adverse effect on our business and have not had a material adverse effect on our control environment.

Except as described above, there has been no change in our internal controls over financial reporting that occurred during the 2005 fourth quarter that materially affected or is reasonably likely to materially affect our internal controls over financial reporting.

Management’s Report on Internal Control over Financial Reporting

See Item 8 of this Report for “Management’s Report on Internal Control Over Financial Reporting.”

Limitations on Control Systems

A control system (including both disclosure controls and procedures and internal controls over financial reporting) is subject to inherent limitations. As a result, a control system can provide only reasonable, not absolute, assurance that the system’s objectives will be achieved. In the first instance, the design of a control system must reflect the fact that there are resource constraints and that the benefits of controls must be considered relative to their costs. Further, decision-making in connection with system design or operation can be faulty, and breakdowns can occur because of simple error or mistake as well as fraud. Also, projections of any evaluation of effectiveness to future periods are subject to the risk that controls become inadequate because of change in conditions or because the level of compliance with the policies and procedures may deteriorate.

Item 9B.  Other Information

Not Applicable.

 

 

 

164

 

 

 

PART III

Items 10 to 14 (inclusive).

Except as set forth below, the information required by Items 10, 11, 12, 13 and 14 will appear in the GrafTech International Ltd. Proxy Statement for the Annual Meeting of Stockholders to be held on May 24, 2006, which will be filed pursuant to Regulation 14A under the Securities Exchange Act of 1934 and is incorporated by reference in this Report pursuant to General Instruction G(3) of Form 10-K (other than the portions thereof not deemed to be “filed” for the purpose of Section 18 of the Securities Exchange Act of 1934).

Executive Officers and Directors

The information set forth below is provided as required by Item 10 and the listing standards of the NYSE.

The following table sets forth information with respect to our current executive officers and directors, including their ages, as of March 1, 2006. There are no family relationships between any of our executive officers.

Name
Age
Position
Craig S. Shular       53   Chief Executive Officer, President, Interim Chief Financial Officer and Director    
John J. Wetula    47   Vice President and President, Natural Graphite  
Petrus J. Barnard    56   Vice President and President, Graphite Electrodes  
Luiz A. Freitas    55   General Manager, Advanced Graphite Material  
Hermanus L. Pretorius    55   General Manager, Cathodes  
Karen G. Narwold    46   Vice President, General Counsel, Human Resources and Secretary  
R. Eugene Cartledge    76   Chairman of the Board  
Mary B. Cranston    58   Director  
John R. Hall    73   Director  
Harold E. Layman    59   Director  
Ferrell P. McClean    59   Director  
Michael C. Nahl    63   Director  
Frank A. Riddick, III    49   Director  

Executive Officers

Craig S. Shular became Chief Executive Officer and a director in January 2003 and has served as President since May 2002. From May 2002 through December 2002, he also served as Chief Operating Officer. From August 2001 to May 2002, he served as Executive Vice President of our former Graphite Power Systems Division. He served as Vice President and Chief Financial Officer from January 1999, with the additional duties of Executive Vice President, Electrode Sales and Marketing from February 2000, to August 2001. From 1976 through 1998, he held various financial, production and business management positions at Union Carbide, including the Carbon Products Division, from 1976 to 1979. We are the successor to the Carbon Products Division of Union Carbide. With the resignation of our Chief Financial Officer effective

 

165

 

 

December 12, 2005, Mr. Shular was also appointed as our interim Chief Financial Officer and Principal Accounting Officer.

Petrus J. Barnard became Vice President and President, Graphite Electrodes, in April 2005. From April 2003 to March 2005 he served as President, Advanced Carbon Materials. He served as Executive Vice President, Graphite Power Systems, from March 2000 to March 2003. He began his career with us in 1972 when he joined our South Africa subsidiary. He is a graduate of University of Potchefstroom - South Africa with a B.S. Sciences degree and an MBA.

Luiz A. Freitas became General Manager, Advanced Graphite Materials, in September 2005. He was Director, Operations – AET, from January 2002 to September 2005. He served as Director of Operations, Advanced Graphite Materials, from March 2000 to December 2001. He was Director of Worldwide Engineering from February 1999 to March 2000. He joined our Brazilian subsidiary in 1975 after graduating from Federal University of the State of Bahia, Brazil with a B.S. degree in Mechanical Engineering.

 

Hermanus L. Pretorius became General Manager, Cathodes, in September 2005. He served as Director Worldwide Operations and Engineering, Graphite Electrodes, from January 2003 to September 2005. From August 2001 to January 2003, he held various operations and supply chain positions for Europe, Asia and Africa. He began his career with us in Meyerton, South Africa in August 1977 before transferring to UCAR S.A. in Switzerland in March 1998. He is a graduate of University of Potchefstroom - South Africa with a B.S. Sciences degree and an MBA.

John J. Wetula became President of our natural graphite business, AET, in January 2003. From July 1999 to December 2002, he served as President of GrafTech Inc. From July 1998 to June 1999, he served as our Director of Export Sales. From October 1996 to June 1998, he was General Manager of our GRAFOIL® product line. He is a chemical engineer and MBA graduate of Cleveland State University.

Karen G. Narwold became Vice President, General Counsel and Secretary in September 1999 and also assumed responsibility for the human resources department effective January 2002. She joined our Law Department in July 1990 and served as Assistant General Counsel from June 1995 to January 1999 and Deputy General Counsel from January 1999 to September 1999. She was an associate with Cummings & Lockwood from 1986 to 1990.

 

Directors

R. Eugene Cartledge has been a director since 1996 and has served as Chairman of the Board since February 2005. From 1986 until his retirement in 1994, Mr. Cartledge was the Chairman of the Board and Chief Executive Officer of Union Camp Corporation. Mr. Cartledge retired as Chairman of the Board of Savannah Foods & Industries Inc. in December 1997; retired as a director of Chase Industries, Inc. in 2001; retired as a director of Delta Airlines, Inc. and Sun Company, Inc. in May 2002; and retired as a director of Formica Corporation in April 2005. He is currently a director of Blount International, Inc.

 

 

166

 

 

 

Mary B. Cranston has been a director since 2000. Ms. Cranston is a partner and has served since 1999 as Chair of Pillsbury Winthrop Shaw Pittman LLP, an international law firm. Ms. Cranston is based in San Francisco, California. Ms. Cranston has been practicing complex litigation, including antitrust, telecommunications and securities litigation, with Pillsbury Winthrop Shaw Pittman LLP since 1975. She is a trustee of Stanford University and the San Francisco Ballet and a director of the Bay Area Council, the Commonwealth Club of California, the Episcopal Charities, and the San Francisco Museum of Women.

                John R. Hall has been a director since 1995. Mr. Hall was Chairman of the Board and Chief Executive Officer of Ashland Inc. from 1981 until his retirement in January 1997 and September 1996, respectively. Mr. Hall had served in various engineering and managerial capacities at Ashland Inc. since 1957. He served as a director of Reynolds Metals Company from 1985 to 2000. He retired as Chairman of Arch Coal Inc. in 1998; retired as a director of CSX Corp. in May 2003; retired as a director of Canada Life in June 2003; and retired as a director of Bank One Corporation in May 2004. Mr. Hall currently serves as a member of the Boards of Humana Inc. and USEC Inc. Mr. Hall graduated from Vanderbilt University in 1955 with a degree in Chemical Engineering and later served as Vanderbilt’s Board Chairman from 1995 to 1999. Mr. Hall also serves as Chairman of the Blue Grass Community Foundation and the Commonwealth Fund for Kentucky Educational Television, and as President of the Markey Cancer Center Foundation.

Harold E. Layman has been a director since 2003. From 2001 until his retirement in 2002, Mr. Layman was President and Chief Executive Officer of Blount International, Inc. Prior thereto, Mr. Layman served in other capacities with Blount International, including President and Chief Operating Officer from 1999 to 2001, Executive Vice President and Chief Financial Officer from 1997 to 2000, and Senior Vice President and Chief Financial Officer from 1993 to 1997. From 1981 through 1992, he held various financial management positions with VME Group/Volvo AB. From 1970 to 1980, Mr. Layman held various operations and financial management positions with Ford Motor Company. He is currently a director of Blount International, Grant Prideco, Inc. and Infinity Property and Casualty Corporation.

Ferrell P. McClean has been a director since 2002. Ms. McClean was a Managing Director and Senior Advisor to the head of the Global Oil & Gas Group in Investment Banking at J.P. Morgan Chase & Co. from 2000 through the end of 2001. She joined J.P. Morgan & Co. Incorporated in 1969 and founded the Leveraged Buyout and Restructuring Group within the Mergers & Acquisitions Group in 1986. From 1991 until 2000, Ms. McClean was a Managing Director and co-headed the Global Energy Group within the Investment Banking Group at J.P. Morgan & Co. Ms. McClean is currently a director of El Paso Corporation. She retired as a director of Unocal Corporation in 2005.

Michael C. Nahl has been a director since 1999. Mr. Nahl has been Executive Vice President and Chief Financial Officer of Albany International Corp., a manufacturer of paper machine clothing, which are the belts of fabric that carry paper stock through the paper production process, since April 2005. Mr. Nahl joined Albany International Corp. in 1981 as Group Vice President, Corporate, and, prior to appointment to his present position, he was Senior Vice President and Chief Financial Officer. Mr. Nahl is currently a director of Lindsay Manufacturing Co. and a member of JPMorgan Chase & Company's Regional Advisory Board.

 

Frank A. Riddick, III became a director in September 2004. Mr. Riddick has served as President and Chief Executive Officer of Formica Corporation, a manufacturer of surfacing

 

167

 

 

materials used in countertops, cabinets, and flooring, since January 2002. Mr. Riddick was instrumental in assisting Formica to emerge from Chapter 11 bankruptcy proceedings in June 2004. He served as President and Chief Operating Officer of Armstrong Holdings, Inc. from August 2000 to December 2001 and in various other executive capacities at Armstrong and its subsidiaries from 1995 to 2000. In December 2000, Armstrong's principal operating subsidiary, Armstrong World Industries, Inc., filed for Chapter 11 bankruptcy protection as a result of Armstrong’s legacy asbestos liabilities. Prior to joining Armstrong, he held a number of financial managerial positions with FMC Corporation, General Motors Corporation and Merrill Lynch & Co., Inc.

NYSE Certification

Mr. Shular, Chief Executive Officer and President, has certified to the NYSE, pursuant to Section 303A.12 of the NYSE’s listing standards, that he is unaware of any violation by us of the NYSE’s corporate governance listing standards.

PART IV

Item 15.  Exhibits and Financial Statement Schedules

 

(a)(1)      Financial Statements

 

 

 

See Index to Consolidated Financial Statements at page 97 of this Report.

 

(2)          Financial Statement Schedules

 

 

 

None.

(b)           Exhibits

 

 

 

The exhibits listed in the following table have been filed with this Report.

Exhibit Number
Description of Exhibit
2.1.0(1) Recapitalization and Stock Purchase and Sale Agreement dated as of November 14, 1994 among Union Carbide Corporation, Mitsubishi Corporation, GrafTech International Ltd. and GrafTech International Acquisition Inc. and Guaranty made by Blackstone Capital Partners II Merchant Banking Fund L.P. and Blackstone Offshore Capital Partners II L.P.
2.2.0 Intentionally Omitted.
2.3.0 Intentionally Omitted.
2.4.0(1) Stock Purchase and Sale Agreement dated as of November 9, 1990 among Mitsubishi Corporation, Union Carbide Corporation and UCAR Carbon Company Inc.
2.5.0 Intentionally Omitted.
2.6.0 Intentionally Omitted.

 

168

 

Exhibit Number
Description of Exhibit
2.7.0(1) Transfer Agreement dated January 1, 1989 between Union Carbide Corporation and UCAR Carbon Company Inc.
2.7.1(1) Amendment No. 1 to Transfer Agreement dated December 31, 1989.
2.7.2(1) Amendment No. 2 to Transfer Agreement dated July 2, 1990.
2.7.3(1) Amendment No. 3 to Transfer Agreement dated as of February 25, 1991.
2.8.0(1) Amended and Restated Realignment Indemnification Agreement dated as of June 4, 1992 among Union Carbide Corporation, Union Carbide Chemicals and Plastics Company Inc., Union Carbide Industrial Gases Inc., UCAR Carbon Company Inc. and Union Carbide Coatings Service Corporation.
2.9.0(1) Environmental Management Services and Liabilities Allocation Agreement dated as of January 1, 1990 among Union Carbide Corporation, Union Carbide Chemicals and Plastics Company Inc., UCAR Carbon Company Inc., Union Carbide Industrial Gases Inc. and Union Carbide Coatings Service Corporation.
2.9.1(1) Amendment No. 1 to Environmental Management Services and Liabilities Allocation Agreement dated as of June 4, 1992.
2.10.0(4) Trade Name and Trademark License Agreement dated March 1, 1996 between Union Carbide Corporation and UCAR Carbon Technology Corporation.
2.11.0(1) Employee Benefit Services and Liabilities Agreement dated January 1, 1990 between Union Carbide Corporation and UCAR Carbon Company Inc.
2.11.1(1) Amendment to Employee Benefit Services and Liabilities Agreement dated January 15, 1991.
2.11.2(1) Supplemental Agreement to Employee Benefit Services and Liabilities Agreement dated February 25, 1991.
2.12.0(1) Letter Agreement dated December 31, 1990 among Union Carbide Chemicals and Plastics Company Inc., UCAR Carbon Company Inc., Union Carbide Grafito, Inc. and Union Carbide Corporation.
3.1.0(3) Amended and Restated Certificate of Incorporation of GrafTech International Ltd.
3.1.1(9) Certificate of Designations of Series A Junior Participating Preferred Stock of GrafTech International Ltd.
3.1.2(15) Certificate of Amendment to the Amended and Restated Certificate of Incorporation of GrafTech International Ltd.
3.1.3(19) Certificate of Amendment to the Amended and Restated Certificate of Incorporation of GrafTech International Ltd.
3.2.0(17) Amended and Restated By-Laws of GrafTech International Ltd. dated December 13, 2002.

 

 

 

169

 

Exhibit Number
Description of Exhibit
4.1.0(14) Indenture dated as of February 15, 2002 among GrafTech Finance Inc., GrafTech International Ltd., GrafTech Global Enterprises Inc., UCAR Carbon Company Inc., and the Subsidiary Guarantors from time to time party thereto and State Street Bank and Trust Company, as Trustee.
4.1.1(19) First Supplemental Indenture, dated as of April 30, 2002, among GrafTech Finance Inc., GrafTech International Ltd., GrafTech Global Enterprises Inc., UCAR Carbon Company Inc., UCAR Holdings V. Inc., UCAR Carbon Technology LLC, UCAR Holdings III Inc. and UCAR International Trading Inc. and State Street Bank and Trust Company.
4.2.0 Intentionally Omitted.
4.2.1 Intentionally Omitted.
4.3.0(20) Indenture dated as of January 22, 2004 among GrafTech International Ltd., GrafTech Finance Inc., GrafTech Global Enterprises Inc., UCAR Carbon Company Inc., UCAR International Trading Inc. and UCAR Carbon Technology LLC and U.S. Bank National Association.
4.3.1(2) Supplemental Indenture, dated as of February 7, 2005, among UCAR Holdings V Inc., GrafTech International Ltd., GrafTech Finance Inc., Graftech Global Enterprises Inc., UCAR Carbon Company Inc., UCAR International Trading Inc. and UCAR Carbon Technology LLC and U.S. Bank National Association.
4.4.0(9) Rights Agreement dated as of August 7, 1998 between GrafTech International Ltd. and The Bank of New York, as Rights Agent.
4.4.1(14) Amendment No. 1 to Rights Agreement dated as of November 1, 2000.
4.4.2(20) Amendment No. 2 to Rights Agreement dated as of May 21, 2002.
4.5.0 Intentionally Omitted.
10.1.0(2) Amended and Restated Credit Agreement dated as of February 8, 2005 among GrafTech International Ltd. GrafTech Global Enterprises Inc., GrafTech Finance Inc., the LC Subsidiaries from time to time party thereto, the Lenders from time to time party thereto, and JPMorgan Chase Bank, N.A., as Administrative Agent.
10.1.1(2) Amendment and Restatement Agreement dated as of February 8, 2005 among GrafTech International Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc., the LC Subsidiaries from time to time party thereto; the Lenders from time to time party thereto, and JPMorgan Chase Bank, N.A., as Administrative Agents.
10.1.2(2) Amended and Restated Guarantee Agreement dated as of February 8, 2005 made by GrafTech International Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc. and each Domestic Subsidiary party thereto in favor of JPMorgan Chase Bank, N.A., as Collateral Agent for the Secured Parties.

 

 

 

170

 

Exhibit Number
Description of Exhibit
10.1.3(2) Amended and Restated Security Agreement dated as of February 8, 2005 made by GrafTech International Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc. and the subsidiaries of GrafTech from time to time party thereto, in favor of JP Morgan Chase Bank, N.A., as Collateral Agent for the Secured Parties.
10.1.4(2) Amended and Restated Indemnity, Subrogation and Contribution Agreement dated as of February 8, 2005 among GrafTech International Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc., each of the Domestic Subsidiaries party thereto and JP Morgan Chase Bank, N.A., as Collateral Agent for the Secured Parties.
10.1.5(2) Amended and Restated Domestic Pledge Agreement dated as of February 8, 2005 by GrafTech International Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc. and the direct and indirect subsidiaries of GrafTech that are signatories thereto in favor of JPMorgan Chase Bank, N.A., as Collateral Agent for the Secured Parties.
10.1.6(2) Amended and Restated Intellectual Property Security Agreement dated as of February 8, 2005 made by GrafTech International Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc. and the subsidiaries of GrafTech from time to time party thereto in favor of JPMorgan Chase Bank, N.A., as Collateral Agent for the Secured Parties (schedules omitted).
10.1.7 (11) First Amendment, dated as of May 25, 2005, to the Amended and Restated Credit Agreement, dated as of February 8, 2005, among GrafTech International, Ltd., GrafTech Global Enterprises Inc., GrafTech Finance Inc., the LC Subsidiaries from time to time party thereto and JPMorgan Chase Bank, N.A., as Administrative Agent.
10.2.0 Intentionally Omitted.
10.2.1 Intentionally Omitted.
10.2.2 Intentionally Omitted.
10.2.3 Intentionally Omitted.
10.2.4 Intentionally Omitted.
10.2.5 Intentionally Omitted.
10.2.6 Intentionally Omitted.
10.2.7 Intentionally Omitted.
10.2.8 Intentionally Omitted.
10.2.9 Intentionally Omitted.
10.2.10* Form of Restricted Stock Unit Agreement.
10.8.0(18) GrafTech International Ltd. Management Stock Incentive Plan (Original Version) as amended and restated through July 31, 2003.
10.9.0* Form of Restricted Stock Agreement (2005 LTIP Version).
10.10.0(18) GrafTech International Ltd. Management Stock Incentive Plan (Senior Version) as amended and restated through July 31, 2003.
10.11.0(8) Form of Restricted Stock Agreement (Standard Form).

 

 

 

171

 

Exhibit Number
Description of Exhibit
10.12.0(18) GrafTech International Ltd. Management Stock Incentive Plan (Mid-Management Version) as amended and restated through July 31, 2003.
10.13.0(18) GrafTech International Ltd. 1995 Equity Incentive Plan as amended and restated through July 31, 2003.
10.14.0(18) GrafTech International Ltd. 1996 Mid-Management Equity Incentive Plan as amended and restated through July 31, 2003.
10.15.0(20) UCAR Carbon Company Inc. Compensation Deferral Program effective March 31, 2003.
10.15.1(2) First Amendment to the UCAR Carbon Compensation Deferral Plan dated as of October 7, 2004.
10.15.2(2) Second Amendment to the UCAR Carbon Compensation Deferral Plan effective as of January 1, 2005.
10.15.3* Third Amendment to the UCAR Carbon Compensation Deferral Plan effective as of November 1, 2005.
10.16.0(8) GrafTech International Ltd. 2005 Equity Incentive Plan.
10.17.0* Form of Severance Compensation Agreement for senior management (U.S. 2.0 Version).
10.17.1* Form of Severance Compensation Agreement for senior management (International 2.0 Version).
10.17.2* Form of Severance Compensation Agreement for senior management (U.S. 2.99 Version).
10.17.3* Form of Severance Compensation Agreement for senior management (International 2.99 Version).
10.18.0(20) UCAR Carbon Company Inc. Equalization Benefit Plan amended and restated as of March 31, 2003.
10.19.0(20) UCAR Carbon Company Inc. Supplemental Retirement Income Plan amended and restated as of March 31, 2003.
10.20.0(20) UCAR Carbon Company Inc. Enhanced Retirement Income Plan amended and restated as of March 31, 2003.
10.21.0(20) UCAR Carbon Company Inc. Benefits Protection Trust amended and restated as of August 1, 2003.
10.22.0(12) Separation Agreement between GrafTech International Ltd. and Scott C. Mason, dated November 15, 2005.
10.22.1 Intentionally Omitted.
10.22.2 Intentionally Omitted.
10.22.3 Intentionally Omitted.
10.23.0(7) Plea Agreement between the United States of America and GrafTech International Ltd. executed April 7, 1998.
10.24.0(13) Outsourcing Services Agreement, dated as of March 30, 2001, effective April 2001, between CGI Information Systems and Management Consultants, Inc. and GrafTech International Ltd. (Confidential treatment requested as to certain portions.)

 

 

 

172

 

Exhibit Number
Description of Exhibit
10.24.1* Memorandum of Agreement, dated as of November 14, 2005, between CGI Information Systems and Management Consultants, Inc. and GrafTech International Ltd.
10.25.0(13) Joint Development and Collaboration Agreement, effective June 5, 2001, among UCAR Carbon Company Inc., Advanced Energy Technology Inc., and Ballard Power Systems Inc. (Confidential treatment requested as to certain portions.)
10.26.0(13) Master Supply Agreement, effective June 5, 2001 between UCAR Carbon Company Inc. and Ballard Power Systems Inc. (Confidential treatment requested as to certain portions.)
10.27.0(13) Agreement, effective as of January 1, 2001, between ConocoPhillips (U.K.) Limited f/k/a Conoco (U.K.) Limited and UCAR S.A. (confidential treatment requested as to certain portions.)
10.27.1(2) Amendment to Agreement, effective as of January 1, 2005, between ConocoPhillips (U.K.) Limited and UCAR S.A. (confidential treatment requested as to certain portions)
10.27.2* Amendment No. 3 to Agreement, effective as of January 1, 2006, between ConocoPhillips (U.K.) Limited and UCAR S.A. (confidential treatment requested as to certain portions)
10.28.0(13) Agreement, effective as of January 1, 2001, between ConocoPhillips Company, UCAR Carbon Company Inc. and UCAR S.A. (Confidential treatment requested as to certain portions.)
10.28.1(2) Amendment to Agreement, effective as of January 1, 2005, among ConocoPhillips Company, UCAR Carbon Company Inc. and UCAR S.A. (confidential treatment requested as to certain portions.)
10.28.2* Amendment No. 3 to Agreement, effective as of January 1, 2006, among ConocoPhillips Company, UCAR Carbon Company Inc. and UCAR S.A. (confidential treatment requested as to certain portions.)
10.29.0* Form of Terms and Conditions of Sale to standard graphite electrode contract of sale (revision of September 8, 2004)
21.1.0* List of subsidiaries of GrafTech International Ltd.
23.1.0* Consent of PricewaterhouseCoopers LLP.
23.2.0* Consent of Deloitte & Touche LLP.
24.1.0* Powers of Attorney (included on signature pages).
31.1.0* Certification pursuant to Rule 13a-14(a) under the Exchange Act by Craig S. Shular, Chief Executive Officer and President.
31.2.0* Certification pursuant to Rule 13a-14(a) under the Exchange Act by Craig S. Shular, Interim Chief Financial Officer.
32.1.0* Certification pursuant to Section 906 of the Sarbanes-Oxley Act of 2002, by Craig S. Shular, Chief Executive Officer and President.
32.2.0* Certification pursuant to Section 906 of the Sarbanes-Oxley Act of 2002, by Craig S. Shular, Interim Chief Financial Officer.

 

 

*    Filed herewith.

 

 

173

 

 

 

(1)

Incorporated by reference to the Registration Statement of GrafTech International Ltd. and GrafTech Global Enterprises Inc. on Form S-1 (Registration No. 33-84850).

(2)

Incorporated by reference to the Annual Report of the registrant on Form 10-K for the year ended December 31, 2004 (File No. 1-13888).

(3)

Incorporated by reference to the Registration Statement of the registrant on Form S-1 (Registration No. 33-94698).

(4)

Incorporated by reference to the Quarterly Report of the registrant on Form l0-Q for the quarter ended March 31, 1996 (File No. 1-13888).

(5)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended June 30, 1996 (File No. 1-13888).

(6)

Incorporated by reference to the Quarterly Report of the registrant on Form l0-Q for the quarter ended September 30, 1997 (File No. 1-13888).

(7)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended March 31, 1998 (File No. 1-13888).

(8)

Incorporated by reference to the Current Report of the registrant on Form 8-K filed on September 6, 2005 (File No. 1-13888).

(9)

Incorporated by reference to the Annual Report of the registrant on Form 10-K for the year ended December 31, 1998 (File No. 1-13888).

(10)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended September 30, 1999 (File No. 1-13888).

(11)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended September 30, 2005 (File No. 1-13888).

(12)

Incorporated by reference to the Current Report of the registrant on Form 8-K filed on November 15, 2005 (File No. 1-13888).

(13)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended June 30, 2001 (File No. 1-13888).

(14)

Incorporated by reference to the Annual Report of the registrant on Form 10-K for the year ended December 31, 2001 (File No. 1-3888).

(15)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended March 31, 2002 (File No. 1-13888).

(16)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended June 30, 2002 (File No. 1-13888).

(17)

Incorporated by reference to the Annual Report of the registrant on Form 10-K for the year ended December 31, 2002 (File No. 1-13888).

(18)

Incorporated by reference to the Registration Statement of the registrant on Form S-3 (Registration No. 333-108039).

(19)

Incorporated by reference to the Quarterly Report of the registrant on Form 10-Q for the quarter ended June 30, 2003 (File No. 1-13888).

(20)

Incorporated by reference to the Annual Report of the registrant on Form 10-K for the year ended December 31, 2003 (File No. 1-13888).

 

 

174

 

 

 

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.

GRAFTECH INTERNATIONAL LTD.

March 15, 2006

By:            /s/ Craig S. Shular          

Craig S. Shular
Title:  Chief Executive Officer, President,
            Interim Chief Financial Officer
            and Director

 

KNOW ALL MEN BY THESE PRESENTS, that each individual whose signature appears below hereby constitutes and appoints Craig S. Shular and Karen G. Narwold, and each of them individually, his or her true and lawful agent, proxy and attorney-in-fact, with full power of substitution and resubstitution, for him or her and in his or her name, place and stead, in any and all capacities, to (i) act on, sign and file with the Securities and Exchange Commission any and all amendments to this Report together with all schedules and exhibits thereto, (ii) act on, sign and file with the Securities and Exchange Commission any and all exhibits to this Report and any and all exhibits and schedules thereto, (iii) act on, sign and file any and all such certificates, notices, communications, reports, instruments, agreements and other documents as may be necessary or appropriate in connection therewith and (iv) take any and all such actions which may be necessary or appropriate in connection therewith, granting unto such agents, proxies and attorneys-in-fact, and each of them individually, full power and authority to do and perform each and every act and thing necessary or appropriate to be done, as fully for all intents and purposes as he or she might or could do in person, and hereby approving, ratifying and confirming all that such agents, proxies and attorneys-in-fact, any of them or any of his, her or their substitute or substitutes, may lawfully do or cause to be done by virtue hereof.

 

175

 

 

 

Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed below by the following persons on behalf of the registrant and in the capacities and on the dates indicated.

Signatures

Title

Date

 

 

 

/s/ Craig S. Shular

Craig S. Shular

Chief Executive Officer, President, Interim Chief Financial Officer and Director (Principal Executive Officer and Principal Accounting Officer)

March 15, 2006

 

 

 

/s/ R. Eugene Cartledge

Director

March 15, 2006

R. Eugene Cartledge

 

 

 

 

 

/s/ Mary B. Cranston

Mary B. Cranston

Director

March 15, 2006

 

 

 

/s/ John R. Hall

John R. Hall

Director

March 15, 2006

 

 

 

/s/ Harold E. Layman

Harold E. Layman

Director

March 15, 2006

 

 

 

/s/ Ferrell P. McClean

Ferrell P. McClean

Director

March 15, 2006

 

 

 

/s/ Michael C. Nahl

Michael C. Nahl

Director

March 15, 2006

 

 

 

/s/ Frank A. Riddick, III

Frank A. Riddick, III

Director

March 15, 2006

 

 

 

176

 

 

 

EXHIBIT INDEX

 

Exhibit Number
Description of Exhibit
10.2.10 Form of Restricted Stock Unit Agreement.
10.9.0 Form of Restricted Stock Agreement (2005 LTIP Version).
10.15.3 Third Amendment to the UCAR Carbon Compensation Deferral Plan effective as of November 1, 2005.
10.17.0 Form of Severance Compensation Agreement for senior management (U.S. 2.0 Version).
10.17.1 Form of Severance Compensation Agreement for senior management (International 2.0 Version).
10.17.2 Form of Severance Compensation Agreement for senior management (U.S. 2.99 Version).
10.17.3 Form of Severance Compensation Agreement for senior management (International 2.99 Version).
10.24.1 Memorandum of Agreement, dated as of November 14, 2005, between CGI Information Systems and Management Consultants, Inc. and GrafTech International Ltd.
10.27.2 Amendment No. 3 to Agreement, effective as of January 1, 2006, between ConocoPhillips (U.K.) Limited and UCAR S.A. (confidential treatment requested as to certain portions)
10.28.2 Amendment No. 3 to Agreement, effective as of January 1, 2006, among ConocoPhillips Company, UCAR Carbon Company Inc. and UCAR S.A. (confidential treatment requested as to certain portions.)
10.29.0 Form of Terms and Conditions of Sale to standard graphite electrode contract of sale (revision of September 8, 2004)
21.1.0 List of subsidiaries of GrafTech International Ltd.
23.1.0 Consent of PricewaterhouseCoopers LLP.
23.2.0 Consent of Deloitte & Touche LLP.
24.1.0 Powers of Attorney (included on signature pages).
31.1.0 Certification pursuant to Rule 13a-14(a) under the Exchange Act by Craig S. Shular, Chief Executive Officer and President.
31.2.0 Certification pursuant to Rule 13a-14(a) under the Exchange Act by Craig S. Shular, Interim Chief Financial Officer.
32.1.0 Certification pursuant to Section 906 of the Sarbanes-Oxley Act of 2002, by Craig S. Shular, Chief Executive Officer and President.
32.2.0 Certification pursuant to Section 906 of the Sarbanes-Oxley Act of 2002, by Craig S. Shular, Interim Chief Financial Officer.


177