Initial Public Offering (IPO): Registration Statement (General Form) — Form S-1 Filing Table of Contents
Document/ExhibitDescriptionPagesSize 1: S-1 Registration Statement (General Form) HTML 2.08M
2: EX-3.1.1 Articles of Incorporation/Organization or By-Laws HTML 110K
3: EX-3.3 Articles of Incorporation/Organization or By-Laws HTML 65K
4: EX-4.2 Instrument Defining the Rights of Security Holders HTML 81K
5: EX-4.3 Instrument Defining the Rights of Security Holders HTML 83K
6: EX-4.4 Instrument Defining the Rights of Security Holders HTML 51K
7: EX-4.5 Instrument Defining the Rights of Security Holders HTML 47K
8: EX-4.6 Instrument Defining the Rights of Security Holders HTML 52K
9: EX-10.1.1 Material Contract HTML 58K
10: EX-10.1.2 Material Contract HTML 57K
11: EX-10.1.3 Material Contract HTML 52K
15: EX-10.13 Material Contract HTML 13K
16: EX-10.15 Material Contract HTML 231K
12: EX-10.3 Material Contract HTML 242K
13: EX-10.4 Material Contract HTML 248K
14: EX-10.5 Material Contract HTML 15K
17: EX-21.1 Subsidiaries of the Registrant HTML 7K
18: EX-23.1 Consent of Experts or Counsel HTML 8K
(Address, including zip code,
and telephone number, including area code, of Registrant’s
principal executive offices)
Donald R. Young
President and Chief Executive Officer
Aspen Aerogels, Inc.
30 Forbes Road, Building B Northborough, Massachusetts01532
(508) 691-1111
(Name, address, including zip
code, and telephone number, including area code, of agent for
service)
Copies to:
Sahir Surmeli, Esq.
Jonathan L. Kravetz, Esq.
Thomas R. Burton, III, Esq.
Mintz, Levin, Cohn, Ferris, Glovsky and Popeo, P.C.
One Financial Center Boston, Massachusetts02111
(617) 542-6000
Vincent Pagano, Jr., Esq.
Simpson Thacher & Bartlett LLP
425 Lexington Avenue New York, New York10017
(212) 455-2000
Approximate date of commencement of proposed sale to the
public: As soon as practicable after this
registration statement becomes effective.
If any of the securities being registered on this form are to be
offered on a delayed or continuous basis pursuant to
Rule 415 under the Securities Act of 1933 as amended (the
“Securities Act”), check the following
box. o
If this form is filed to register additional securities for an
offering pursuant to Rule 462(b) under the Securities Act,
check the following box and list the Securities Act registration
statement number of the earlier effective registration statement
for the same
offering. o
If this form is a post-effective amendment filed pursuant to
Rule 462(c) under the Securities Act, check the following
box and list the Securities Act registration statement number of
the earlier effective registration statement for the same
offering. o
If this form is a post-effective amendment filed pursuant to
Rule 462(d) under the Securities Act, check the following
box and list the Securities Act registration statement number of
the earlier effective registration statement for the same
offering. o
Indicate by check mark whether the registrant is a large
accelerated filer, an accelerated filer, a non-accelerated
filer, or a smaller reporting company. See the definitions of
“large accelerated filer,”“accelerated
filer” and “smaller reporting company” in
Rule 12b-2
of the Exchange Act. (Check one):
Large accelerated
filer o
Accelerated
filer o
Non-accelerated
filer þ
(Do not check if a smaller reporting company)
Smaller reporting
company o
CALCULATION OF
REGISTRATION FEE
Proposed
Maximum
Amount of
Title of Each Class of
Aggregate
Registration
Securities to be Registered
Offering Price(1)
Fee(2)
Common Stock, $0.001 par value per share
$
115,000,000
$
13,352
(1)
Estimated solely for the purpose of computing the amount of
the registration fee pursuant to Rule 457(o) under the
Securities Act of 1933, as amended. Includes the offering price
of additional shares that the underwriters have the option to
purchase.
(2)
Calculated pursuant to Rule 457(o) based on an estimate
of the proposed maximum aggregate offering price of the
securities registered hereunder to be sold by the Registrant.
The Registrant hereby amends this Registration Statement on
such date or dates as may be necessary to delay its effective
date until the Registrant shall file a further amendment which
specifically states that this Registration Statement shall
thereafter become effective in accordance with Section 8(a)
of the Securities Act of 1933 or until the Registration
Statement shall become effective on such date as the Securities
and Exchange Commission, acting pursuant to said
Section 8(a), may determine.
The
information in this preliminary prospectus is not complete and
may be changed. These securities may not be sold until the
registration statement filed with the Securities and Exchange
Commission is effective. This preliminary prospectus is not an
offer to sell nor does it seek an offer to buy these securities
in any jurisdiction where the offer or sale is not permitted.
This is an initial public offering of shares of common stock of
Aspen Aerogels, Inc.
We are
offering shares
of common stock to be sold in this offering. Prior to this
offering, there has been no public market for our common stock.
It is currently estimated that the initial public offering price
per share will be between $ and
$ . We intend to apply to list the
common stock on The New York Stock Exchange under the symbol
“ASPN.”
See “Risk Factors” on page 12 to read about
factors you should consider before buying shares of our common
stock.
Neither the Securities and Exchange Commission nor any other
regulatory body has approved or disapproved of these securities
or passed upon the accuracy or adequacy of this prospectus. Any
representation to the contrary is a criminal offense.
Per Share
Total
Initial public offering price
$
$
Underwriting discount
$
$
Proceeds, before expenses, to us
$
$
To the extent that the underwriters sell more
than shares
of common stock, the underwriters have the option to purchase up
to an
additional shares
from us at the initial public offering price less the
underwriting discount.
The underwriters expect to deliver the shares against payment in
New York, New York
on ,
2011.
No dealer, salesperson or other person is authorized to give any
information or to represent anything not contained in this
prospectus. You must not rely on any unauthorized information or
representations. This prospectus is an offer to sell only the
shares offered hereby, but only under circumstances and in
jurisdictions where it is lawful to do so. The information
contained in this prospectus is current only as of its date.
INDUSTRY AND
MARKET DATA
This prospectus contains market data and industry forecasts that
were obtained from industry publications, third party market
research and publicly available information. These publications
generally state that the information contained therein has been
obtained from sources believed to be reliable, but the accuracy
and completeness of such information is not guaranteed. While we
believe that the information from these publications is
reliable, we have not independently verified, and make no
representation as to the accuracy of, such information.
This prospectus also contains estimates and other statistical
data made by independent parties and by us relating to market
size and growth and other data about our industry. We obtained
the industry and market data in this prospectus from our own
research as well as from industry and general publications,
surveys and studies conducted by third parties, some of which
may not be publicly available. For example, this prospectus also
includes statistical data extracted from a market research
report by The Freedonia Group and a separate market research
report by Freedonia Custom Research, Inc., an independent
international market research firm, which was commissioned by us
and was issued in May 2011. Such data involves a number of
assumptions and limitations and contains projections and
estimates of the future performance of the industries in which
we operate that are subject to a high degree of uncertainty. We
caution you not to give undue weight to such projections,
assumptions and estimates. While we believe that these
publications, studies and surveys are reliable, we have not
independently verified the data contained in them.
The Freedonia Custom Research, Inc. Report, or the Freedonia
Report, represents data or viewpoints developed independently on
our behalf and does not constitute a specific guide to action.
In preparing the Freedonia Report, Freedonia Custom Research,
Inc. used various sources, including publically available third
party financial statements; government statistical reports;
press releases; industry magazines; and interviews with
manufacturers of related products (including us), manufacturers
of competitive products, distributors of related products and
government and trade associations. The Freedonia Report speaks
as of its final publication date (and not as of the date of this
prospectus).
TRADEMARKS, TRADE
NAMES AND SERVICE MARKS
“Aspen Aerogels,”“Cryogel,”“Pyrogel,”“Spaceloft,” the Aspen Aerogels
logo and other trademarks, service marks and trade names of
Aspen Aerogels appearing in this prospectus are the property of
Aspen Aerogels, Inc. Solely for convenience, the trademarks,
service marks and trade names referred to in this prospectus are
without the
®
and
tm
symbols, but such references are not intended to indicate, in
any way, that the owner thereof will not assert, to the fullest
extent under applicable law, such owner’s rights to these
trademarks, service marks and trade names. This prospectus
contains additional trade names, trademarks and service marks of
other companies, which, to our knowledge, are the property of
their respective owners.
This summary provides an overview of selected information
contained elsewhere in this prospectus and does not contain all
of the information you should consider before investing in our
common stock. You should carefully read this prospectus and the
registration statement of which this prospectus is a part in
their entirety before investing in our common stock, including
the information discussed under “Risk Factors” and our
consolidated financial statements and the related notes thereto
included elsewhere in this prospectus. Unless otherwise
indicated herein, the terms “we,”“our,”“us,” or “the Company” refer to Aspen
Aerogels, Inc. and its predecessor entity and unless otherwise
noted, their respective subsidiaries.
Overview
We are an energy efficiency company that designs, develops and
manufactures innovative, high-performance aerogel insulation. We
believe our aerogel blankets deliver the best thermal
performance of any widely used insulation products available on
the market today and provide a superior combination of
performance attributes unmatched by traditional insulation
materials. Our customers use our products to save money,
conserve energy, reduce
CO2
emissions and protect workers and assets.
Our technologically advanced products are targeted at the
estimated $32 billion annual global market for insulation
materials. Our insulation is principally used by industrial
companies, such as ExxonMobil and NextEra Energy, that operate
petrochemical, refinery, industrial and power generation
facilities. We are also working with BASF Construction Chemicals
and other leading companies to develop and commercialize
products for applications in the building and construction
market. We achieved a compound annual revenue growth rate of
46.7% from 2008 to 2010, with revenue reaching
$43.2 million in 2010. We believe demand for our
high-performance insulation products will increase significantly
to support widespread global efforts to cost-effectively improve
energy efficiency. To address capacity constraints caused by
growing demand, we began operating a second production line in
late March 2011 designed to double our production capacity at
our East Providence, Rhode Island facility.
We have grown our business by forming technical and commercial
relationships with industry-leading customers to optimize our
products to meet the particular demands of targeted market
sectors. In the industrial market, we have benefited from our
technical and commercial relationships with ExxonMobil in the
oil refinery and petrochemical sector, with Technip in the
offshore oil sector, and with NextEra Energy in the power
generation sector. In the building and construction market, we
have a joint development agreement with BASF Construction
Chemicals to develop products to meet increasingly stringent
building standards requiring improved thermal performance in
retrofit and new-build wall systems, particularly in Europe.
Our core aerogel technology and manufacturing processes are our
most significant assets. We currently employ 27 research
scientists and process engineers focused on advancing our
current aerogel technology and developing next generation
aerogel compositions, form factors and manufacturing
technologies. Our aerogels are complex structures in which 97%
of the volume consists of air trapped in nanopores between
intertwined clusters of amorphous silica solids. These extremely
low density solids provide superior insulating properties.
Although aerogels are usually fragile materials, we have
developed innovative and proprietary manufacturing processes
that enable us to produce industrially robust aerogel insulation
cost-effectively and at commercial scale.
Our aerogel products provide up to five times the thermal
performance of widely used traditional insulation in a thin,
easy-to-use blanket form. Our products enable compact design,
reduce installation time and costs, promote freight savings,
simplify logistics, reduce system weight and required storage
space and enhance job site safety. Our products provide
excellent compression resistance, are hydrophobic and reduce the
incidence of corrosion under insulation, a significant
operational cost and safety issue in industrial facilities. Our
products also offer strong fire protection, which is a critical
performance requirement in both the industrial and building and
construction markets. We believe our array of product attributes
provides strong competitive advantages over traditional
insulation. Although competing insulation materials may have one
or more comparable attributes, we believe that no single
insulation material currently available offers all of the
properties of our aerogel insulation.
We manufacture our products using our proprietary process
technology at our facility in East Providence, Rhode Island. We
have operated the East Providence facility at high volume and
high yield continuously since mid-2008. We successfully
commenced operation of our second production line at this
facility at the end of March 2011 and immediately began
producing commercial quality aerogel blankets. This line was
completed on time and on budget and is expected to double our
annual production capacity by the end of 2011 to 40 to
44 million square feet of aerogel blankets, depending on
product mix. We have begun the design and engineering phase of a
third production line and currently expect that this line will
be completed at our East Providence facility during 2012. We
also plan to construct a second manufacturing facility in the
United States or Europe, the location of which will be based on
factors including proximity to raw material suppliers, proximity
to customers, labor and construction costs and availability of
governmental incentives.
Pursuit of our capacity expansion plan requires us to raise
capital. During the past year, we have completed three
financings and established a line of credit. In late 2010, we
issued $21.4 million of convertible preferred stock to a
group of investors led by BASF Venture Capital and
$10.0 million of subordinated notes to a group of investors
led by affiliates of Piper Capital LLC. In the first half of
2011, we issued $30.0 million of convertible notes to
affiliates of Fidelity Investments and BASF Venture Capital and
established a $10.0 million revolving credit facility with
Silicon Valley Bank.
Our
Markets
Since 2008, our Cryogel and Pyrogel product lines have been used
by some of the world’s largest oil refiners and
petrochemical companies, including ExxonMobil, Petrobras, Shell
and Dow Chemical. These products are also used in applications
as diverse as liquefied natural gas facilities, food processing
facilities, oil sands extraction and electric power generation
facilities, with end-use customers such as Chevron, Archer
Daniels Midland, Suncor Energy, NextEra Energy and Exelon.
Insulation systems in these facilities are designed to maintain
hot and cold process piping and storage tanks at optimal process
temperatures, to protect plant and equipment from the elements
and from the risk of fire and to protect workers. Freedonia
Custom Research, Inc. has estimated that the worldwide
industrial insulation market totaled $4.5 billion in 2010.
Within the building and construction market, we are replicating
our strategy of working with industry leaders to seek to
penetrate critical market sectors. In addition to our
relationship with BASF Construction Chemicals, we are also
engaged in product development efforts in Europe and North
America with other industry leaders to target a wide variety of
applications. Our products also have been installed since 2006
in residential and commercial new-build and retrofit building
projects through the efforts of a small network of distribution
partners. Insulation systems in the building and construction
market are designed to isolate the interior of buildings from
external temperature variations and to reduce energy costs.
Freedonia Custom Research, Inc. has estimated that the worldwide
building and construction insulation market totaled
$22.7 billion in 2010.
In addition to our core markets, we also rely on a small number
of fabricators to supply fabricated insulation parts to original
equipment manufacturers, or OEMs. These global OEMs develop
products using our aerogels for applications as diverse as
military and commercial aircraft, trains, buses, appliances,
apparel, footwear and outdoor gear. While we do not currently
allocate significant resources to these markets, we believe
there are many future opportunities within these markets for our
aerogel technology based on its unique attributes. Freedonia
Custom Research, Inc. has estimated that the worldwide
transportation, appliance and apparel insulation markets totaled
$4.9 billion in 2010.
We believe our aerogel blankets deliver a superior combination
of performance attributes that provide cost-effective solutions
to address the demanding performance objectives of a wide range
of applications in our target markets, including:
•
Best Thermal Performance. Our aerogel
blankets provide the best thermal performance of any widely used
insulation products available on the market today and excel in
applications where available space is constrained or thermal
performance targets are aggressive.
•
Wide Temperature Range. We offer
insulation products that address the entire range of
applications within the cryogenic and sub-ambient
(−273oC
to 90oC),
ambient
(0oC to
40oC) and
hot process
(−25oC
to
650oC) temperature
ranges.
•
Ease of Installation. Our flexible
aerogel blankets install faster than rigid insulation materials
in the industrial market, which reduces labor costs and total
system costs.
•
Compact Design. Our aerogel blankets
reduce insulation system volume by 50% to 80% compared to
traditional insulation, enabling a reduction in the footprint,
size and structural costs of facilities, systems, vehicles and
buildings.
•
High Durability. Our aerogel blankets
offer excellent compression resistance, tensile strength and
vibration resiliency. Our products allow companies to
pre-insulate, stack and transport steel pipes destined for use
in harsh environments, which significantly reduces installation
labor costs in remote areas.
•
Strong Fire Protection. Our Pyrogel XT
and Spaceloft A2 product lines were specifically designed to
provide strong fire performance in applications within the
industrial and building and construction markets, qualifying our
products for use in a variety of applications in our target
markets.
•
Moisture Resistance. Our aerogel
blankets are durably hydrophobic. Our products offer improved
thermal performance in insulation systems exposed to the
elements or operating in humid environments compared to
traditional insulation.
•
Reduced Corrosion Under Insulation, or
CUI. Our Pyrogel XT product line is both
durably hydrophobic and vapor permeable. These attributes have
the potential to reduce the incidence of CUI in hot process
applications, which we believe provides our customers with a
significant reduction in long-term operating and capital costs.
•
Simplified Logistics. Our products
reduce the volume and weight of material purchased, inventoried,
transported and installed in the field. In addition, our
products reduce the number of stock-keeping units, or SKUs,
required to complete a project. Simplified logistics accelerate
project timelines, reduce installation costs and improve worker
safety.
We believe these performance attributes simplify logistics,
accelerate project timelines, reduce installation costs, improve
worker safety and significantly reduce long-term operating and
capital costs for our customers. In the industrial market, we
believe these characteristics enable our customers to meet their
insulation performance targets at lower total installed or
lifecycle costs versus traditional insulation in a growing
number of applications. In the building and construction market,
we believe the increasing thermal standards for retrofit and
new-build wall systems in Europe will become more difficult to
meet with traditional insulation materials due to space
constraints. We believe the thin form factor and strong fire
properties of our aerogel blankets will provide a cost-effective
and practical means to meet increasingly stringent building
standards in Europe.
We believe the following combination of capabilities
distinguishes us from our competitors and positions us to
compete effectively and benefit from the expected growth in the
market for energy efficiency solutions:
•
Superior product based on proven technology in commercial
production. Our aerogel products provide up
to five times the thermal performance of widely used traditional
insulation in a thin, easy-to-use blanket form. We believe our
array of product attributes provides strong competitive
advantages over traditional insulation and will enable us to
take a growing share of the existing market for insulation in
both the industrial and the building and construction markets.
Although competing insulation materials may have one or more
comparable attributes, we believe that no single insulation
material currently available offers all of the properties of our
aerogel insulation.
•
Proven and scalable proprietary manufacturing
process. Our manufacturing process is proven
and has been replicated to meet increasing demand. Our original
line in East Providence, Rhode Island, has operated continuously
since mid-2008. We successfully commenced operation of our
second production line at this facility in March 2011 and
immediately began producing commercial quality aerogel blankets.
We believe that our proven ability to produce product that meets
our clients’ specifications and our increased production
capacity will provide customers with the certainty of supply
that is required to expand their use of our products.
•
Strong relationships with industry
leaders. Through our relationships with
industry leading end-use customers, our products have undergone
rigorous testing and are now qualified for global usage in both
routine maintenance and in capital projects at some of the
largest industrial companies in the world. These relationships
have shortened the sales cycle with other customers within the
industrial market and have helped to facilitate our market
penetration. Within the building and construction market, we
have partnered with BASF Construction Chemicals to develop
products to meet increasingly stringent building standards for
thermal performance of retrofit and new-build wall systems. As
part of our relationship with BASF Construction Chemicals, we
have recently optimized a product, Spaceloft A2, that we believe
will have broad appeal across the building and construction
market.
•
Capital efficient business model. To
respond to increased demand for our products, we successfully
commenced operation in late March 2011 of a second production
line at our East Providence facility. The expansion is expected
to increase our annual production capacity by 20 to
22 million square feet of aerogel blankets at a total
construction cost of approximately $31.5 million. We
believe that our second production line, at full capacity and at
current prices, would be capable of producing in the range of
$50 million to $54 million in annual revenue of
aerogel blankets.
•
Experienced management and operations
team. Each of our executive officers has over
20 years of experience in global industrial companies,
specialty chemical companies or related materials science
research. This team has worked closely together at Aspen
Aerogels for nearly five years, and we believe our dedicated and
experienced workforce is an important competitive asset. As of
May 31, 2011, we employed 157 dedicated research
scientists, engineers, manufacturing line operators, sales and
administrative staff and management.
Our goal is to create shareholder value by becoming the leading
provider of high-performance aerogel products serving the global
energy efficiency market. We intend to achieve this goal by
pursuing the following strategies:
•
Expand our manufacturing capacity to meet market
demand. Demand for our aerogel products in
2010 grew by approximately 88% compared to 2009 and exceeded our
manufacturing capacity. In response, we constructed a second
production line at our East Providence facility designed to
double our manufacturing capacity. To meet anticipated future
growth in demand for our products, we are engaged in the design
and engineering of a third production line in our East
Providence facility and plan to construct a second manufacturing
facility in the United States or Europe.
•
Increase industrial insulation market
penetration. We plan to focus additional
resources to achieve a greater share of the industrial
insulation market, both through increased sales to our existing
customers and sales to new customers. In addition, we anticipate
that our growing maintenance-based business will lead to
increasing sales of our products into large capital projects,
including the construction of new refineries and petrochemical
facilities in emerging markets.
•
Leverage strategic relationships in the building and
construction market. We have a joint
development arrangement with BASF Construction Chemicals to
penetrate the market for energy efficient wall systems. We are
pursuing additional market opportunities with other leading
building materials manufacturers and distributors across
multiple regions to address the increasingly stringent
regulatory environment governing the thermal performance of
buildings. We believe this approach will enable us to leverage
their broad technical and distribution capabilities and
facilitate market penetration.
•
Expand our sales force, network of distributors and OEM
channels. We plan to expand our sales force
and distribution network to support growth in the industrial and
building and construction markets. We also intend to expand our
network of OEM fabricators to pursue opportunities in the
transportation, appliance and apparel markets.
•
Continue to develop advanced aerogel compositions,
applications and manufacturing
technologies. We believe that we are well
positioned to leverage a decade’s worth of research and
development to commercialize new products, applications and
advanced manufacturing technologies.
Risks Related to
Our Business
Investing in our common stock involves substantial risk. You
should carefully consider all of the information in this
prospectus prior to investing in our common stock. There are
several risks related to our business that are described under
“Risk Factors” elsewhere in this prospectus. Among
these important risks are the following:
•
We have incurred net losses since our inception, and we may
continue to incur net losses in the future and may never reach
profitability;
•
We have yet to achieve positive cash flow, and our ability to
generate positive cash flow is uncertain;
•
We have a limited operating history. This may make it difficult
to evaluate our business and prospects and may expose us to
increased risks and uncertainties;
•
The market for insulation products incorporating aerogel
blankets is relatively undeveloped, which makes it difficult to
forecast adoption rates and demand for our products;
We rely on sales to a limited number of distributors and
contractors for the substantial majority of our revenue, and the
loss of one or more significant distributors or several of our
smaller distributors could materially harm our business; and
•
Any significant disruption to our sole manufacturing facility or
the failure of our production lines to operate according to our
expectation could have a material adverse effect on our results
of operations.
Company
Information
Our predecessor company was incorporated in Delaware in May
2001. In June 2008, we completed a reorganization pursuant to
which our predecessor company merged with and into a newly
formed Delaware corporation, Aspen Merger Sub, Inc., a
wholly-owned subsidiary of our predecessor company formed for
the purpose of the reorganization. As the surviving entity to
the merger, we then changed our name from “Aspen Merger
Sub, Inc.” to “Aspen Aerogels, Inc.”
shares
(or shares
if the underwriters exercise their option to purchase additional
shares in full)
Common stock to be outstanding immediately after this offering
shares
(or shares
if the underwriters exercise their option to purchase additional
shares in full)
Use of proceeds
We estimate that the net proceeds to us from this offering,
after deducting estimated underwriting discounts and estimated
offering expenses payable by us, will be approximately
$ million (or approximately
$ million if the underwriters
exercise their option to purchase additional shares in full)
assuming an initial public offering price of
$ per share, which is the
mid-point of the estimated price range set forth on the cover
page of this prospectus. We intend to use the net proceeds from
this offering for general corporate purposes, including the
construction of additional manufacturing capacity. See “Use
of Proceeds” for more information.
Proposed NYSE symbol
“ASPN”
The number of shares of our common stock to be outstanding after
this offering is based on 94,960,028 shares of our common
stock outstanding as of March 31, 2011 after giving effect
to the automatic conversion of our outstanding Series A and
B redeemable convertible preferred stock, which we refer to
collectively as our preferred stock, into 68,853,493 shares
of our common stock immediately prior to the completion of this
offering and excludes the following:
•
12,832,208 shares of our common stock issuable upon the
exercise of stock options outstanding as of March 31, 2011
at a weighted-average exercise price of $0.46 per share;
•
shares
of our common stock that will be available for future issuance
under our 2011 equity incentive plan to be effective upon
completion of this offering; and
•
1,127,372 shares of common stock issuable upon the exercise
of warrants outstanding as of March 31, 2011 at a
weighted-average exercise price of $0.002 per share.
Except as otherwise noted, all information in this prospectus:
•
assumes the adoption of our restated certificate of
incorporation and restated by-laws in connection with the
consummation of the offering made hereby;
•
assumes that the closing of the offering made hereby occurs
on ,
2011 with an initial public offering price per share of
$ , the mid-point of the price
range set forth on the cover page of this prospectus;
•
gives effect to the automatic conversion of all outstanding
shares of our preferred stock into 68,853,493 shares of our
common stock on a 1-for-1 basis;
•
gives effect to the issuance
of shares
of common stock to the holders of our outstanding preferred
stock upon the closing of the offering made hereby in
satisfaction of accumulated dividends, as required by the terms
of the preferred stock;
•
gives effect to the issuance
of shares
of common stock issuable upon the automatic conversion of our
$30.0 million aggregate principal amount of
8.0% convertible subordinated notes due June 2014, which we
refer to as our convertible notes, together with accrued
interest thereon, upon the closing of the offering made hereby,
at a conversion price equal to 87.5% of the initial offering
price per share of the common stock offered hereby;
•
gives effect to
a
for
reverse split of our common stock, which will take place prior
to the closing of the offering made hereby; and
•
assumes no exercise by the underwriters of their option to
purchase additional shares.
See “Capitalization” for conversion adjustments with
respect to our preferred stock and our convertible notes that
may be applicable upon future events, such as the completion of
this offering.
We refer to the conversion of our preferred stock into shares of
common stock (including the conversion of accumulated dividends
on each series into shares of common stock) and the automatic
conversion of our convertible notes into shares of common stock
(including the conversion of the accrued interest into shares of
our common stock) herein, as the preferred stock and convertible
notes conversions.
The following tables present a summary of our consolidated
financial data for the periods, and as of the dates, indicated.
We derived the consolidated statement of operations data for the
years ended December 31, 2008, 2009 and 2010 from our
audited consolidated financial statements and the related notes
thereto included elsewhere in this prospectus. We derived the
consolidated statement of operations data for the three months
ended March 31, 2010 and 2011 and the consolidated balance
sheet data as of March 31, 2011 from our unaudited
consolidated financial statements and the related notes thereto
included elsewhere in this prospectus. The results of operations
for these interim periods are not necessarily indicative of the
results to be expected for a full year. Our unaudited
consolidated financial statements have been prepared on the same
basis as the audited consolidated financial statements and the
related notes thereto and, in the opinion of our management,
reflect all adjustments that are necessary for a fair
presentation in conformity with U.S. generally accepted
accounting principles, or GAAP. Our historical results for prior
periods are not necessarily indicative of results to be expected
for any future period. The summary unaudited pro forma balance
sheet information as of March 31, 2011 has been prepared to
give effect to this offering, our application of the proceeds
therefrom and the preferred stock and convertible notes
conversions as if they had occurred on March 31, 2011. The
summary unaudited pro forma balance sheet information is for
informational purposes only and does not purport to indicate
balance sheet information as of any future date.
You should read this summary consolidated financial data
together with our audited and unaudited consolidated financial
statements and the related notes thereto included elsewhere in
this prospectus and the information under “Selected
Consolidated Financial Data” and “Management’s
Discussion and Analysis of Financial Condition and Results of
Operations.”
Three Months Ended
Year Ended December 31
March 31
2008
2009
2010
2010
2011
($ in thousands, except share and per share data)
Consolidated statements of operations data:
Revenue:
Product
$
17,202
$
24,752
$
38,690
$
7,681
$
11,274
Research services
2,868
3,864
4,519
1,066
1,015
Total revenue
20,070
28,616
43,209
8,747
12,289
Cost of revenue:
Product
32,160
30,462
35,399
7,647
9,473
Research services
1,169
1,788
2,119
456
544
Impairment charge
2,524
—
—
—
—
Gross profit (loss)
(15,783
)
(3,634
)
5,691
644
2,272
Operating expenses:
Research and development
2,134
2,524
2,985
917
731
Sales and marketing
4,034
3,994
4,526
1,194
1,224
General and administrative
6,180
5,430
5,675
1,504
1,587
Total operating expenses
12,348
11,948
13,186
3,615
3,542
Income (loss) from operations
(28,131
)
(15,582
)
(7,495
)
(2,971
)
(1,270
)
Other income (expense):
Interest income
287
18
170
10
48
Interest expense
(7,400
)
(3,075
)
(2,585
)
(706
)
(499
)
Total other expense, net
(7,113
)
(3,057
)
(2,415
)
(696
)
(451
)
Net income (loss)
(35,244
)
(18,639
)
(9,910
)
(3,667
)
(1,721
)
Dividends and accretion on
redeemable convertible
preferred stock
(2,351
)
(2,984
)
(57,007
)
(608
)
(62,440
)
Net income (loss) attributable to
common stockholders
$
(37,595
)
$
(21,623
)
$
(66,917
)
$
(4,275
)
$
(64,161
)
Per share data:
Net income (loss) per share attributable
to common stockholders,
basic and diluted
Pro forma per share data will be
computed based upon the number of shares of common stock
outstanding immediately after consummation of this offering
applied to our historical net income (loss) amounts and will
give retroactive effect to the preferred stock and convertible
notes conversions and the issuance of the shares of our common
stock offered hereby.
The following table presents the
calculation of historical and pro forma basic and diluted net
income (loss) per share of common stock attributable to our
common stockholders:
Three Months Ended
Year Ended December 31
March 31
2008
2009
2010
2010
2011
($ in thousands, except share and per share data)
Net income (loss) attributable to common stockholders
$
(37,595
)
$
(21,623
)
$
(66,917
)
$
(4,275
)
$
(64,161
)
Dividends and accretion on redeemable convertible preferred stock
2,351
2,984
57,007
608
62,440
Interest expense
Discount on conversion of convertible notes
Pro forma net income (loss) attributable to common stockholders
Weighted-average common shares outstanding, basic and diluted
11,093
9,751,616
25,574,286
25,573,418
25,892,546
Common shares issued upon conversion of preferred stock and
accrued dividends
Common shares issued upon conversion of convertible notes and
interest thereon
Weighted-average common shares outstanding used in computing pro
forma net income (loss) per share, basic and diluted
Pro forma net income (loss) per share, basic and diluted
We price our products and measure
our product shipments in square feet. We believe the square foot
operating metric allows us and our investors to measure our
manufacturing output on a uniform and consistent basis.
(3)
We use Adjusted EBITDA, a non-GAAP
financial measure, as a means to assess our operating
performance. We define Adjusted EBITDA as income (loss) from
operations before depreciation and amortization expense,
share-based compensation expense and impairment charges.
Adjusted EBITDA is a supplemental measure of our performance
that is not required by, or presented in accordance with, GAAP.
Adjusted EBITDA should not be considered as an alternative to
income from operations or any other measure of financial
performance calculated and presented in accordance with GAAP. In
addition, our definition and presentation of Adjusted EBITDA may
not be comparable to similarly titled measures presented by
other companies.
We use Adjusted EBITDA as a measure
of operating performance, because it does not include the impact
of items that we do not consider indicative of our core
operating performance, for planning purposes, including the
preparation of our annual operating budget, to allocate
resources to enhance the financial performance of our business
and as a performance measure under our bonus plan. We also
believe that the presentation of Adjusted EBITDA provides useful
information to investors with respect to our results of
operations and in assessing the performance and value of our
business. Various measures of EBITDA are widely used by
investors to measure a company’s operating performance
without regard to items that can vary substantially from company
to company depending upon financing and accounting methods, book
values of assets, capital structures and the methods by which
assets were acquired.
We understand that, although
measures similar to Adjusted EBITDA are frequently used by
investors and securities analysts in their evaluation of
companies, Adjusted EBITDA has limitations as an analytical
tool, and you should not consider it in isolation or as a
substitute for GAAP income from operations or an analysis of our
results of operations as reported under GAAP. Some of these
limitations are:
• Adjusted EBITDA does
not reflect our historical cash expenditures or future
requirements for capital expenditures or other contractual
commitments;
• Adjusted EBITDA does
not reflect changes in, or cash requirements for, our working
capital needs;
• Adjusted EBITDA does
not reflect stock-based compensation expense;
• Adjusted EBITDA does
not reflect our tax expense or cash requirements to pay our
income taxes;
• Adjusted EBITDA does
not reflect our interest expense, or the cash requirements
necessary to service interest or principal payments on our debt;
• Although depreciation,
amortization and impairment are non-cash charges, the assets
being depreciated, amortized or impaired will often have to be
replaced in the future, and Adjusted EBITDA does not reflect any
cash requirements for these replacements; and
• Other companies in our
industry may calculate EBITDA or Adjusted EBITDA differently
than we do, limiting their usefulness as a comparative measure.
Because of these limitations, our
Adjusted EBITDA should not be considered as a measure of
discretionary cash available to us to reinvest in the growth of
our business or as a measure of cash available for us to meet
our obligations.
To properly and prudently evaluate
our business, we encourage you to review the GAAP financial
statements included elsewhere in this prospectus and not to rely
on any single financial measure to evaluate our business.
The following table presents a
reconciliation of income (loss) from operations, the most
directly comparable GAAP measure, to Adjusted EBITDA for the
periods presented:
Three Months
Year Ended December 31
Ended March 31
2008
2009
2010
2010
2011
($ in thousands)
Income (loss) from operations
$
(28,131
)
$
(15,582
)
$
(7,495
)
$
(2,971
)
$
(1,270
)
Depreciation and amortization
7,059
5,630
4,633
1,137
1,409
Stock-based compensation
927
831
468
96
190
Impairment charge
2,524
—
—
—
—
Adjusted EBITDA
$
(17,621
)
$
(9,121
)
$
(2,394
)
$
(1,738
)
$
329
(4)
Working capital means current
assets minus current liabilities.
Investing in our common stock involves a high degree of risk.
You should carefully consider the risks described below and all
of the other information set forth in this prospectus, including
our consolidated financial statements and the related notes
thereto, before deciding to invest in our common stock. If any
of the events or developments described below occurs, our
business, financial condition or results of operations could be
negatively affected. In that case, the market price of our
common stock could decline, and you could lose all or part of
your investment.
Risks Related to
Our Business and Strategy
We have
incurred net losses since our inception, and we may continue to
incur net losses in the future and may never reach
profitability.
We have a history of losses, and we may not ever achieve or
sustain profitability. We experienced net losses of
$35.2 million, $18.6 million and $9.9 million for
the years ended December 31, 2008, 2009 and 2010,
respectively, and $1.7 million for the three months ended
March 31, 2011. As of March 31, 2011, our accumulated
deficit was $197.9 million and total stockholders’
deficit was $122.1 million. We expect to continue to incur
operating losses as a result of expenses associated with the
continued development and expansion of our business. Our
expenses include sales and marketing, research and development,
and general and administrative costs. Furthermore, these
expenses are not the only factors that may contribute to our net
losses. For example, interest expense on our currently
outstanding debt and on any debt that we incur in the future
could contribute to our net losses. Any failure to increase
revenue or manage our cost structure as we implement initiatives
to grow our business could prevent us from achieving or
sustaining profitability. In addition, our ability to achieve
profitability is subject to a number of the risks and
uncertainties discussed below, many of which are beyond our
control. Failure to become and remain profitable may adversely
affect the market price of our common stock and our ability to
raise capital and continue operations.
We have yet to
achieve positive cash flow, and our ability to generate positive
cash flow is uncertain.
To rapidly develop and expand our business, we have made
significant up-front investments in our manufacturing capacity
and incurred research and development, sales and marketing and
general and administrative expenses. In addition, our growth has
required a significant investment in working capital over the
last several years. We have had negative cash flow before
investing and financing activities of $22.0 million,
$13.0 million and $15.1 million for the years ended
December 31, 2008, 2009 and 2010, respectively, and
$2.2 million for the three months ended March 31,2011. We anticipate that we will continue to have negative cash
flow for the foreseeable future as we continue to make
significant future capital expenditures to expand our
manufacturing capacity and incur increased research and
development, sales and marketing, and general and administrative
expenses. Our business will also require significant amounts of
working capital to support our growth and we will need to
increase our inventories of raw materials and our products as we
seek to grow our business. Therefore, we may need to raise
additional capital from investors to achieve our expected
growth, and we may not achieve sufficient revenue growth to
generate positive future cash flow. An inability to generate
positive cash flow for the foreseeable future or raise
additional capital on reasonable terms may decrease our
long-term viability.
We have a
limited operating history and the market for insulation products
incorporating aerogel blankets is relatively undeveloped. This
may make it difficult to evaluate our business and prospects,
and may expose us to increased risks and
uncertainties.
We began operating in May 2001 and, until 2004, when we first
began generating significant commercial revenues, we were
primarily focused on research and development. We did not begin
generating significant revenues from our current generation of
products until 2008. Accordingly, we have only a limited
operating history and an even more limited history of generating
revenues from our current generation of products. In addition,
the future revenue potential of our business in the emerging
market for high-performance insulation is uncertain. As a result
of our limited operating history, we have limited financial data
that can be used to evaluate our business, strategies,
performance and prospects or an investment in our common stock.
Any evaluation of our business and our prospects must be
considered in light of our limited operating history and the
risks and uncertainties encountered by companies at our stage of
development. To address these risks and uncertainties, we must
do the following:
•
maintain and expand our current relationships and develop new
relationships with direct and end-use customers;
•
increase our penetration of the industrial market and expand
into the building and construction market and other markets for
our products;
•
maintain and increase our manufacturing capacity to meet
existing and anticipated future demand for our products;
•
continue to develop our aerogel insulation products and increase
our research and development activities;
•
identify new partnership and market opportunities for our
products;
•
develop new applications for our products and our aerogel
technology;
•
execute our business and marketing strategies successfully;
•
respond to competitive developments; and
•
attract, integrate, retain and motivate qualified personnel.
We may be unable to accomplish one or more of these objectives,
which could cause our business to suffer. In addition, pursuing
many of these goals is expected to entail substantial expense,
which would adversely impact our operating results and financial
condition. Any predictions about our future operating results
may not be as accurate as they could be if we had a longer
operating history.
If we are
unable to maintain our technological advantage and expand market
acceptance of our products, our business may be adversely
affected. In addition, many factors outside of our control may
affect the demand for our insulation products.
We are researching, developing, manufacturing and selling
high-performance aerogel insulation products. The market for
aerogel insulation is at a relatively early stage of
development, and the extent to which our aerogel insulation will
be able to meet the requirements of our direct and end-use
customers and achieve significant market acceptance is
uncertain. Rapid and ongoing changes in technology and product
standards could quickly render our products less competitive, or
even obsolete, if we fail to continue to improve the performance
of our insulation products. We are currently developing new
applications for our existing products as well as new aerogel
technologies; however, we may not be successful in doing so and
new applications or technologies may not be commercially useful.
Other companies that are seeking to enhance traditional
insulation materials have recently introduced or are developing
other emerging and potential insulation technologies. These
competitors are engaged in significant development work on these
various insulation products. Competing technologies that
outperform our insulation in one or more performance attributes
could be developed and successfully introduced. We are also
aware of certain companies that have developed or are developing
products using aerogel technology similar to our technology and
these or other companies could introduce aerogel products that
compete directly with our products and outperform them in one or
more performance attributes. As a result of this competition and
potential competition, our products may not compete effectively
in our target markets.
In addition, we intend to expand our penetration of the building
and construction market, which we are targeting for our
products. However, historically, many of our potential end-users
in the building and construction market have been slow to adopt
new technology and incorporate new design and construction
techniques, which may delay or prevent the adoption of our
products. Our efforts to expand beyond our existing markets may
not be successful. Our products may never be accepted by those
new markets or result in the creation of additional revenue.
Additionally, we have been unable at times to produce sufficient
amounts of our product to meet demand from our customers, and we
may not be able to avoid capacity constraints in the future. If
we are unable to deliver our products within the timeframes
required by our direct and end-use customers, we may be at risk
of losing sales. Therefore, our recent historical growth
trajectory may not provide an accurate representation of the
market dynamics we may experience in the future, making it
difficult to evaluate our future prospects.
Our direct and end-use customers operate in extremely
competitive industries, and competition to supply their
insulation needs focuses on, among other factors, delivering
sufficient thermal performance in a cost-effective fashion. Many
other factors outside of our control may also affect the demand
for our insulation products and the viability of widespread
adoption of our aerogel blankets, including:
•
the price of our aerogel insulation compared to traditional
insulation materials, including the tendency of end-users in
some markets to opt for the frequently lower short-term costs of
traditional insulation materials even when the long-term and
overall costs of our products are lower and the performance
attributes of our products are superior;
•
the regulation of energy efficiency and building standards in
the industrial and the building and construction markets;
•
the availability of government funding and incentives to support
the use of high-performance insulation materials, such as our
aerogel blankets; and
•
fluctuations in economic and market conditions, including
changes in the cost of energy, the relative value of energy
efficiency measures, foreign exchange rates and the cost of the
raw materials for our products.
Any of these factors could make it more difficult for us to
attract and retain customers, cause us to lower our prices in
order to compete, or reduce our market share and revenues, any
of which could have a material adverse effect on our financial
condition and results of operations.
The market for
insulation products incorporating aerogel blankets is relatively
undeveloped and the sales cycles are long and unpredictable,
which make it difficult to forecast adoption rates and demand
for our products.
The market for insulation products utilizing aerogel blankets is
relatively undeveloped. Accordingly, our future financial
performance will depend in large part on our ability to
penetrate the worldwide insulation market. Our penetration of
this market is highly dependent on the acceptance of our
products by large, well-established end-users, contractors,
installers and distributors. The insulation market has
historically been slow to adopt new technologies and products.
Most insulation types currently in use in these markets have
been in use for over 50 years. If we fail to successfully
educate existing and potential industrial and building and
construction market end-users, installers, contractors and
distributors regarding the benefits of our aerogel products, or
if existing users of our products no longer rely on aerogel
insulation for their insulation needs, our ability to sell our
products and grow our business could be limited. Because we are
a new supplier to our end-use customers, we may face concerns
from these end-use customers about our reliability and our
ability to produce our products in a volume sufficient to meet
their supply needs. As a result, we may experience a reluctance
or unwillingness by existing end-use customers to expand their
use of our products and by potential end-use customers to begin
using our products. Our products may never reach mass adoption,
and changes or advances in technologies could adversely affect
the demand for our
products. A failure to increase, or a decrease in, demand for
aerogel insulation products caused by lack of end-user or
distribution channel acceptance, technological challenges,
competing technologies and products or otherwise would result in
a lower revenue growth rate or decreased revenue, either of
which could materially adversely affect our business and
operating results.
In addition, the sales cycles for our products are long and can
result in unpredictability in our revenues. We expect to have an
increasing percentage of our products sold for use in capital
projects, which orders tend to be larger and more sporadic, that
will further increase this unpredictability. Because of our
limited operating history and the difficulty in determining the
adoption rates for our products, we have no basis on which to
predict our quarterly revenue. These factors may result in a
high degree of variability in our revenue and will make it
difficult for us to accurately evaluate and plan based on our
future outlook and forecast quarterly or annual performance.
Any
significant disruption to our sole manufacturing facility or the
failure of our production lines to operate according to our
expectation could have a material adverse effect on our results
of operations.
We currently have only two production lines in one manufacturing
facility, which is located in East Providence, Rhode Island. Our
ability to meet the demands of our customers depends on
efficient, proper and uninterrupted operations at our
manufacturing facility. We only recently began operations on our
second production line and we have not yet achieved target
capacity on this line. We may not be able to do so. In addition,
in the event of a breakdown of one or more production lines, we
may not have sufficient inventory in stock to meet demand until
the production lines return to operation.
Power failures or disruptions, the breakdown, failure or
substandard performance of equipment, or the damage or
destruction of buildings and other facilities due to fire or
natural disasters could severely affect our ability to continue
our operations. In the event of such disruptions, we may not be
able to find suitable alternatives or make needed repairs on a
timely basis and at reasonable cost, which could have a material
adverse effect on our business and results of operations.
Particularly, our manufacturing processes include the use of
both high temperatures and the highly flammable chemical
ethanol, which subjects us to a significant risk of loss
resulting from fire. We had occasional incidences of fires at
our prototype facility, however, damage was immaterial. While
our manufacturing facilities are designed to limit any damage
resulting from a fire, this risk cannot be completely
eliminated. We maintain insurance policies to cover losses
caused by fire or natural disaster, including business
interruption insurance, however, such insurance may not
adequately compensate us for any such losses. If our
manufacturing facilities were to be damaged or cease operations,
and our insurance proves to be inadequate, it may reduce
revenue, cause us to lose customers and otherwise adversely
affect our business. If our sole manufacturing facility was
damaged or destroyed prior to completing construction of a
second facility, we would be unable to operate our business for
an extended period of time and may go out of business.
We operate in
highly competitive markets; if we are unable to compete
successfully, we may not be able to increase or maintain our
market share and revenues.
We face strong competition both from established manufacturers
of incumbent insulation materials and from other companies
producing aerogel-based products. Large producers of incumbent
insulation materials dominate the insulation market. In
addition, there are other companies seeking to develop
high-performance insulation materials, including aerogel
insulation. Many of our competitors are substantially larger and
better capitalized than we are and possess greater financial
resources. Cabot Corporation, or Cabot, is our primary
competitor in the market for aerogel insulation and is larger
and better capitalized than we are. Cabot manufactures and sells
a different form of aerogel insulation that is competitive with
our products in certain market sectors and for certain
applications based on price and form factor. Our competitors,
including Cabot, could focus their substantial financial
resources to develop new or additional competing products or
develop products that are more attractive to potential customers
than the products that we offer.
Because some insulation manufacturers are substantially larger
and better capitalized than we are, they may have the ability to
sell their products at substantially lower costs to a large,
existing customer base. While our products have superior
performance attributes and may sometimes have the lowest cost on
a fully-installed basis or offer life-cycle cost savings, our
competitors offer many incumbent insulation products that are
priced below our products. Our products are very expensive
relative to other insulation products and end-use customers may
not value our products’ superior performance attributes
sufficiently to pay their premium price. In addition, from time
to time we may increase the prices for our products and these
price increases may not be accepted by our end-use customers and
could result in a decreased demand for our products. Similarly,
we may make changes to our products in order to respond to
customer demand or to improve their performance attributes and
these changes may not be accepted by our end-use customers and
could result in a decrease in demand for our products. For
example, we currently plan on adding a coating to certain of our
products in order to reduce dustiness; however, this planned
coating may not achieve its aims, may not be valued by end-use
customers and may negatively impact our cost structure and
margins. Any of these competitive factors could make it more
difficult for us to attract and retain customers, cause us to
lower our prices in order to compete, and reduce our market
share and revenues, any of which could have a material adverse
effect on our financial condition and results of operations.
We rely on
sales to a limited number of distributors and contractors for
the substantial majority of our revenue, and the loss of one or
more significant distributors or contractors or several of our
smaller distributors or contractors could materially harm our
business. In addition, we understand from our distributors and
contractors that a substantial majority of their sales of our
products are to a small number of end-use customers and the loss
of one or more significant end-use customers or several of our
smaller end-use customers could materially harm our
business.
A substantial majority of our revenue is generated from sales to
a limited number of distributors and contractors. For the years
ended December 31, 2008, 2009 and 2010, and the three
months ended March 31, 2011, revenue from our top ten
distributors and contractors represented 51%, 47%, 53% and 70%
of our revenues, respectively. For the three months ended
March 31, 2010, one customer represented 36% of our total
revenue and for the three months ended March 31, 2011, two
customers represented 29% and 10%, respectively, of our total
revenue. In 2008, one customer represented 12% of our total
revenue; in 2009, no customers represented 10% or more of our
total revenue; and in 2010, one customer represented 14% of
total revenue. Although the composition of our significant
distributors and contractors will vary from period to period, we
expect that most of our revenues will continue, for the
foreseeable future, to come from sales to a relatively small
number of distributors and contractors. In addition, we
understand from our distributors and contractors that a
substantial majority of their sales of our products are to a
small number of end-use customers. Our contracts with our
distributors generally do not include long-term commitments or
minimum volumes that ensure future sales of our products and our
understanding is that our distributors’ and
contractors’ contracts with end-use customers also
generally do not include such commitments or minimums.
Consequently, our financial results may fluctuate significantly
from
period-to-period
based on the actions of one or more significant distributors,
contractors or end-use customers. A distributor or contractor
may take actions that affect us for reasons that we cannot
anticipate or control, such as reasons related to an end-use
customer’s financial condition, changes in business
strategy or operations, the introduction of alternative
competing products, or as the result of the perceived quality or
cost-effectiveness of our products. Our agreements with these
distributors and contractors may be cancelled if we fail to meet
certain product specifications or materially breach the
agreement or for other reasons outside of our control. In
addition, our distributors and contractors may seek to
renegotiate the terms of current agreements or renewals. The
loss of or a reduction in sales or anticipated sales to one or
more of our most significant distributors, contractors or
end-use customers or several of our smaller distributors,
contractors or end-use customers could have a material adverse
effect on our business, financial condition and results of
operations.
We understand
from our distributors that a substantial majority of their sales
of our products are to end-use customers in the oil and gas
industry, making us susceptible to prolonged negative trends
relating to this industry.
We understand from our distributors that a substantial majority
of their sales of our products are to end-use customers in the
oil and gas industry, making us susceptible to prolonged
negative trends relating to this industry. While we seek to
maintain a broad end-use customer base across several
industries, our end-use customers in the oil and gas industry
have accounted for a significant portion of our historical
revenues. Certain economic conditions, including low oil prices,
can result in slowdowns in the oil and gas industry, which in
turn can result in reduced demand for our products. If the oil
and gas industry were to suffer a prolonged or significant
downturn, our revenues, profits and cash flows may be reduced
significantly. While we also sell to other direct and end-use
customers in the industrial market and other markets, including
the building and construction industry, these markets are also
cyclical in nature and, as such, are subject to economic
downturns that could have a similar adverse effect on our
revenue, profits and cash flows.
Negative
perceptions regarding the safety or other attributes of our
products or a failure or a perceived failure of our products
could have a material adverse effect on our results of
operations and could make us unable to continue our
business.
Given the history of asbestos as an insulation material, we
believe that there is an elevated level of attention towards
perceived health and safety risks in the insulation industry. As
a consequence, it is essential to our existing business and to
our future growth that our products are considered safe. Even
modest perceptions by customers, potential customers and others
in the markets that we are targeting that our products are not
safe could have a critical impact on our ability to sell our
products and to continue as a business. In particular, the dust
produced by our products during their installation and use
increases the likelihood of such perceptions. While we believe
that the available scientific literature and our own testing
demonstrate the safety of our products, the scientific
literature may be incorrect and our testing may be inaccurate.
Our products are still not widely used and there is risk of an
actual or perceived failure of our products or other negative
perceptions regarding our products, such as perceived health
hazards. Such an event, or the perception of such an event,
could quickly result in our direct and end-use customers
replacing our products with traditional insulation materials
which, though they may provide inferior performance attributes
as compared to our aerogel blankets, still meet the technical
requirements of our direct and end-use customers.
Changes to
regional, national and local laws and regulations regarding
energy efficiency and building standards could materially
adversely affect our business and operating
results.
We believe that there has been a trend in certain countries,
especially within the European Union, for governments to mandate
increasingly stringent energy efficiency standards and building
standards for certain construction and renovation projects and
this trend has evidenced itself at various levels of government,
including regional, national and local. Our business is affected
by these laws and regulations. If this trend toward increasingly
stringent energy efficiency standards and building standards
were to lessen or cease or if there were to be a trend towards
weaker energy efficiency standards and building standards or
reduced enforcement of existing standards, then our business and
operating results could be materially adversely affected. In
addition, changes to the laws and regulations governing energy
efficiency and building standards in specific jurisdictions or
the enforcement of such laws, regulations or standards could
materially adversely impact our business and operating results
if we have significant sales of our products in that
jurisdiction or if we were targeting that jurisdiction for
expanded future sales.
In particular, our sales in the building and construction market
are driven substantially by government policies and legislation
in Europe that mandate high levels of energy efficiency in
buildings. The European Union’s directive on the energy
performance of buildings, Directive 2010/ 31/ EU, or
EPBD, requires EU member states to pass legislation or implement
regulations
requiring all new buildings as well as most major renovations to
achieve minimum energy performance requirements. The EPBD
significantly expands the scope of the original EU directive on
building energy performance adopted in 2002, Directive
2002/91/EC. While we believe the policies established under the
EPBD offer a significant opportunity for our products in the
European building and construction market, this opportunity is
largely dependent on faithful implementation of the directive by
EU member states and continued support for national and local
energy efficiency initiatives. Many EU member states have not
yet fully adopted legislation implementing the original 2002
directive and it is unclear when certain EU members will pass
legislation implementing the EPBD. In the event that the
European Union repeals or weakens the requirements of the EPBD
or that EU member states do not adopt or enforce national
legislation implementing the EPBD, our business and operating
results may be materially adversely impacted.
As a result of
becoming a public company, we will be obligated to develop and
maintain proper and effective internal control over financial
reporting. If our internal controls over financial reporting are
determined to be ineffective, or if our auditors are otherwise
unable to attest to their effectiveness when required, investor
confidence in our company, and our common stock price, may be
adversely affected.
We will be required, pursuant to Section 404 of the
Sarbanes-Oxley Act of 2002, or the Sarbanes-Oxley Act, to
furnish a report by management on, among other things, the
effectiveness of our internal control over financial reporting
for the first fiscal year beginning after the effective date of
this offering and in each year thereafter. Our auditors may also
need to attest to the effectiveness of our internal controls
over financial reporting. These assessments will need to include
disclosure of any material weaknesses identified by our
management in our internal control over financial reporting.
Although our independent registered public accounting firm did
not complete an audit of internal controls over financial
reporting as of December 31, 2010, two significant
deficiencies in internal controls were identified in connection
with the preparation of our financial statements and the audit
of our financial results for 2010. We determined that we had a
significant deficiency relating to our accounting resources and
financial information systems. In addition, we determined that
we had a significant deficiency relating to our information
technology and general controls.
We have taken actions to remediate both of these significant
deficiencies including instituting more detailed recording,
review and approval processes, establishing additional internal
controls, providing additional training and hiring additional
financial and accounting staff; however, we do not expect that
they will be remediated at the time of this offering.
We are in the very early stages of the costly and challenging
process of compiling our system of internal controls over
financial reporting and processing documentation necessary to
perform the evaluation needed to comply with Section 404.
We may discover, and not be able to remediate, future
significant deficiencies or material weaknesses, nor be able to
complete our evaluation, testing and any required remediation in
a timely fashion, any of which would make us less likely to
detect or prevent fraud. In addition, we may not be able to
remediate our current significant deficiencies. During the
evaluation and testing process, if we identify one or more
material weaknesses in our internal control over financial
reporting, we will be unable to assert that our internal
controls are effective. If we are unable to assert that our
internal controls over financial reporting are effective, or if
our auditors are unable to express an opinion on the
effectiveness of our internal controls, we could lose investor
confidence in the accuracy and completeness of our financial
reports or it could cause us to fail to meet our reporting
obligations, which could have a material adverse effect on the
price of our common stock. In addition, a delay in compliance
with Section 404 could subject us to a variety of
administrative sanctions, including Securities and Exchange
Commission, or SEC, action, ineligibility for short form resale
registration, the suspension or delisting of our common stock
from The New York Stock Exchange, or NYSE, and the inability of
registered broker-dealers to make a market in our common stock,
which would further reduce our stock price and could harm our
business.
We will incur
costs and demands upon management as a result of complying with
the laws and regulations affecting public companies in the
United States, which may adversely affect our operating
results.
After the consummation of this offering, we will be subject to
the reporting requirements of the Exchange Act that require us
to file, among other things, quarterly reports on
Form 10-Q
and annual reports on
Form 10-K.
Under Section 302 of the Sarbanes-Oxley Act, as a part of
each of these reports, our chief executive officer and chief
financial officer will be required to evaluate and report their
conclusions regarding the effectiveness of our disclosure
controls and procedures and to certify that they have done so.
This requirement will apply to our first
Form 10-Q
for the quarter following effectiveness of the registration
statement. Effective internal controls are necessary for us to
provide reliable financial reports and prevent fraud. In
addition, under Section 404 of the Sarbanes-Oxley Act, we
will be required to include a report of management on our
internal control over financial reporting in our
Form 10-K.
In addition, the independent registered public accounting firm
auditing our financial statements will be required to attest to
and report on the effectiveness of our internal control over
financial reporting. This requirement will first apply to our
Form 10-K
for our fiscal year ending December 31, 2012. The process
of improving our internal controls and complying with
Section 404 will be expensive and time consuming, and will
require significant attention of management.
Complying with these and other requirements applicable to public
companies may place a strain on our personnel, information
technology systems and resources and divert management’s
attention from other business concerns. We may need to hire
additional accounting and financial staff with appropriate
public company experience and technical accounting knowledge,
and we may not be able to do so without incurring material
costs. These and other requirements may also make it more
difficult or more costly for us to obtain certain types of
insurance, including directors’ and officers’
liability insurance. We, therefore, may be forced to accept
reduced policy limits and coverage or incur substantially higher
costs to obtain the same or similar coverage. The impact of
these events could also make it more difficult for us to attract
and retain qualified persons to serve on our board of directors,
our board committees or as executive officers. Any one of these
events could have a material adverse effect on our business,
financial condition and results of operations.
Our continued
growth requires that we expand our manufacturing facilities and
increase our production capacity.
We have begun the design and engineering phase of building a
third production line in our current manufacturing facility in
East Providence and also plan to construct a second
manufacturing facility located in either the United States or
Europe. If, for any reason, the third production line or the
second manufacturing facility should fail to be completed in a
timely fashion or any of the production lines in our current or
any future manufacturing facilities do not operate according to
our expectations, sales may be impeded, our growth may be
hindered and our business may be materially adversely affected.
Many factors could delay or prevent the addition of a third
production line or the construction of a second manufacturing
facility, including our inability to find financing on favorable
terms, or at all, design, engineering and construction
difficulties, interruptions in the supply of the necessary
construction materials or the increase in their price, and our
failure to obtain necessary legal, regulatory and other
approvals. Many factors could prevent the third production line
or the second manufacturing facility from producing at their
expected full capacity, including design and engineering
failures, inability to retain and train a skilled workforce,
improper operation of the manufacturing equipment and damage to
the manufacturing equipment due to design and engineering flaws
or operator error. Any such expansion will place a significant
strain on our senior management team and our financial and other
resources. The costs associated with our expansion could exceed
our expectations and result in a materially adverse impact on
our operating results.
Growth may
place significant demands on our management and our
infrastructure. If we fail to manage our growth effectively, we
may be unable to execute our business plan or address
competitive challenges adequately.
We expect to continue to expand our manufacturing, sales and
marketing, operations, engineering, research and development
capabilities and financial control and reporting systems, and as
a result, we may be unable to manage our growth. To manage our
anticipated future growth, we must continue to implement and
improve our managerial, operational, financial control and
reporting systems, expand our facilities and continue to recruit
and train additional qualified personnel. All of these measures
will require significant expenditures and will demand the
attention of management. Due to our limited resources, we may
not be able to effectively manage the expansion of our
operations or recruit and adequately train additional qualified
personnel. The physical expansion of our operations may lead to
significant costs and may divert our management and business
development resources. Any inability to manage growth could
delay the execution of our business plans or disrupt our
operations. If we fail to achieve the necessary level of
efficiency in our organization as it grows, our business,
results of operations and financial condition would be harmed.
We compete for personnel and advisors with other companies and
other organizations, many of which are larger and have greater
name recognition and financial and other resources than we do.
If we are not able to hire, train and retain the necessary
personnel, or if these managerial, operational, financial and
reporting improvements are not implemented successfully, we
could lose customers and revenues. We allocate our operations,
sales and marketing, research and development, general and
administrative and financial resources based on our business
plan, which includes assumptions about current and future orders
from industrial customers, building and construction customers
and original equipment manufacturers, or OEMs. However, these
factors are uncertain. If our assumptions regarding these
factors prove to be incorrect or if competing products gain
further acceptance, then actual demand for our aerogel products
could be significantly less than the demand we anticipate and we
may not be able to sustain our revenue growth or achieve
profitability.
Our financial
results may vary from
period-to-period
due to changes in the mix of our products that we sell during a
period and due to our expenses not corresponding with the timing
of our revenues, which may lead to volatility in our stock
price.
Our profitability from
period-to-period
may vary due to the mix of products that we sell in different
periods. While we have sold most of our products to date into
the industrial market, as we expand our business we expect to
sell an increasing amount of our aerogel insulation products
into the building and construction and OEM markets and for other
applications. Certain of the products aimed at these markets
have different cost profiles. In particular, Spaceloft and
Spaceloft A2, which are targeted at the building and
construction market, are relatively lower margin and lower
output as compared to our Pyrogel and Cryogel products, which
are targeted at the industrial and OEM markets. Consequently,
sales of individual products may not necessarily be consistent
across periods, which could affect product mix and cause our
gross profit, net income and cash flow to vary significantly. In
addition, most of our expenses are either relatively fixed in
the short-term or incurred in advance of sales. Moreover, our
spending levels are based in part on our expectations regarding
future revenues. As a result, if revenues for a particular
operating period are below expectations, we may not be able to
proportionately reduce expenses for that period. Therefore, we
believe that period-to-period comparisons of our operating
results may not necessarily be meaningful and that these
comparisons cannot be relied upon as indicators of future
performance. Moreover, our operating results may not meet
expectations of equity research analysts or investors. If this
occurs, the trading price of our common stock could fall
substantially either suddenly or over time.
The
qualification process for our products in the industrial,
building and construction and other markets can be lengthy and
unpredictable and can delay adoption of our products, leading to
uncertainty in our revenues. In addition, the insulation market
is generally characterized by
just-in-time
delivery, which limits our ability to predict future
sales.
Qualification of our products by many of our direct and end-use
customers in the industrial, building and construction and other
markets can be lengthy and unpredictable and many of these
direct and end-use customers have extended budgeting and
procurement processes. This extended sales process requires the
dedication of significant time by our personnel and our use of
significant financial resources, with no certainty of success or
recovery of our related expenses. Once the qualification process
is complete for a direct or end-use customer, the lead time
between order placement and product shipment is typically short
and the insulation market is generally characterized by
just-in-time
delivery. These factors limit our ability to predict future
sales. This limitation could result in our being unable to
reduce spending quickly enough to compensate for reductions in
sales. Additionally, we have been unable at times to produce
sufficient amounts of our products to meet demand from our
customers and we may not be able to avoid capacity constraints
in the future. If we are unable to deliver our products within
such short timeframes, we may be at risk of losing direct or
end-use customers. Accordingly, shortfalls in sales could
materially adversely affect our business and operating results.
Shortages of
the raw materials used in the production of our products,
increases in the cost of such materials or disruptions in our
supply chain could adversely impact our financial condition and
operating results.
The raw materials used in the production of our products consist
primarily of polyester and fiberglass battings, amorphous silica
and ethanol, which is used in the delivery of the amorphous
silica. Although we are not dependent on any one supplier, we
are dependent on the ability of our third-party suppliers to
supply such materials on a timely and consistent basis. While
these raw materials are available from numerous sources, they
may be subject to fluctuations in availability and price. Our
third-party suppliers may not dedicate sufficient resources to
meet our scheduled delivery requirements or our suppliers may
not have sufficient resources to satisfy our requirements during
any period of sustained demand. Failure of suppliers to supply,
delays in supplying, or disruptions in the supply chain for our
raw materials, or allocations in the supply of certain high
demand raw components, could materially adversely affect our
operations, our profitability and our ability to meet our
delivery schedules on a timely and competitive basis.
Fluctuations in the prices of these raw materials could have a
material adverse effect on results of operations. Our ability to
pass increases in raw material prices on to our customers is
limited due to competitive pricing pressure and the time lag
between increased costs and implementation of related price
increases. Although we are working with a number of amorphous
silica providers to plan for our potential future needs and to
develop processes to reduce our amorphous silica costs, we do
not yet have a secure, long-term supply of amorphous silica. We
may not be able to establish arrangements for secure, long-term
amorphous silica supplies at prices consistent with our current
costs or without incurring a delay in supply at prices
consistent with our current costs while we seek to identify
different sources. Any failure to establish a long-term supply
of amorphous silica at prices consistent with our current costs
would have a material adverse effect on our ability to increase
our sales and achieve profitability.
If we do not
continue to develop and maintain distribution channels for our
products or strategic relationships with industry leaders to
commercialize our products, our profitability could be
impaired.
For a significant portion of our revenues in the industrial and
OEM markets, we rely on sales to distributors who then sell our
products to end-users in those markets. Our success depends, in
part, on our maintaining satisfactory relationships with these
distributors. The majority of our sales to
distributors are effected on a purchase order basis that
requires us to meet expectations of delivery, quality and
pricing of our products, at both the distribution channel level
and at the level of the end-user of our products. If we fail to
meet expected standards, our revenues would decline and this
could materially adversely affect our business, results of
operations and financial condition.
Our business strategy requires us to align the design and
performance attributes of our products to the evolving needs of
the market. To facilitate this process, we have sought out
partnerships and relationships with industry leaders in order to
assist in the development and commercialization of our products.
We face competition from other manufacturers of insulation in
seeking out and entering into such partnerships and
relationships with industry leaders in our target markets and we
may therefore not be successful in establishing strategic
relationships in those markets. In the building and construction
market, we have entered into a joint development agreement with
BASF Construction Chemicals to develop products to meet
increasingly stringent building standards for thermal
performance of retrofit and new-build wall systems. In the event
that we are unable to develop products that meet market needs or
maintain our relationship with BASF Construction Chemicals, we
may be required to find less prominent partners in the building
and construction market and we may be less able or unable to
successfully penetrate that market. As a result, we may lose our
ability to grow our business in the building and construction
market, which could impair our profitability.
We may enter
into joint development agreements with industry leaders that may
limit our ability to broadly market our products or could
involve future obligations.
In order to develop and commercialize our products, we may enter
into joint development agreements with industry leaders, in
particular in the building and construction and OEM markets. We
cannot be certain that any products will be successfully
developed under any such agreement or, even if developed, that
they will be successfully produced or commercialized. These
agreements may contain exclusivity, ownership and other terms
that may limit our ability to commercialize any products or
technology developed under such joint development agreements,
including in ways that we do not envision at the time of
entering into the agreement. In addition, these agreements may
not obligate either party to make any purchases and may contain
technical specifications that must be achieved to the
satisfaction of our partner, which we cannot be certain we will
be able to achieve. If our ability to commercialize products or
technology developed under these joint development agreements is
limited or if we fail to achieve the technical specifications
that may be required, then our business, financial condition and
operating results could be materially adversely affected.
Our results of
operations could be adversely affected if our operating expenses
do not correspond with the timing of our revenues.
Most of our operating expenses, such as manufacturing facility
expenses, employee compensation and research expenses, are
either relatively fixed in the short-term or incurred in advance
of sales. Additionally, our spending levels are based in part on
our expectations regarding future revenues. As a result, if
revenues for a particular quarter are below expectations, we may
not be able to proportionately reduce operating expenses for
that quarter. For example, the time between our customers’
placing an order and delivery of our product is typically short,
which limits our ability to predict future sales. This
limitation could result in our being unable to reduce spending
quickly enough to compensate for reductions in sales and could
therefore adversely affect our operating results for any
particular operating period.
We are exposed
to the credit risk of some of our distributors and
contractors.
Although many of our end-use customers are larger,
well-capitalized industrial companies, we distribute our
products through a network of distributors and contractors that
may not be well-capitalized and may be of a lower credit
quality. This distributor and contractor network subjects us to
the risk of non-payment for our products. Although we have not
experienced a significant incidence of non-payment for our
products, such non-payments may occur in the future. In
addition, during periods
of economic downturn in the global economy, our exposure to
credit risks from our distributors and contractors may increase,
and our efforts to monitor and mitigate the associated risks may
not be effective. In the event of non-payment by one or more of
our distributors or contractors, our business, financial
condition and operating results could be materially adversely
affected.
Our working
capital requirements involve estimates based on demand and
production expectations and may decrease or increase beyond
those currently anticipated, which could harm our operating
results and financial condition.
In order to fulfill the product delivery requirements of our
direct and end-use customers, we plan for working capital needs
in advance of customer orders. As a result, we base our funding
and inventory decisions on estimates of future demand. If demand
for our products does not increase as quickly as we have
estimated or drops off sharply, our inventory and expenses could
rise, and our business and operating results could suffer.
Alternatively, if we experience sales in excess of our
estimates, our working capital needs may be higher than those
currently anticipated. Our ability to meet this excess customer
demand depends on our ability to arrange for additional
financing for any ongoing working capital shortages, since it is
likely that cash flow from sales will lag behind these
investment requirements. To meet any ongoing working capital
shortages, we may rely on our current loan and security
agreement with Silicon Valley Bank, which we refer to as our
revolving credit facility, under which we are entitled to borrow
up to $10.0 million. See “Management’s Discussion
and Analysis of Financial Condition and Results of
Operations — Liquidity and Capital Resources.” In
addition, we plan to increase our inventory in order to meet our
expected future demand. This would result in an increase in our
working capital requirements that could harm our operating
results and financial condition.
Our contracts
with U.S. government agencies may subject the company to audits,
criminal penalties, sanctions and other expenses and
fines.
U.S. government agencies, including the Defense Contract
Audit Agency and the Department of Labor, routinely audit
government contractors. These agencies review a
contractor’s compliance with contract terms and conditions,
performance under its contracts, cost structure and compliance
with applicable laws, regulations and standards. The
U.S. government also may review the adequacy of the
contractor’s systems and policies, including the
contractor’s purchasing, property, estimating, billing,
accounting, compensation and management information systems. Any
costs found to be overcharged or improperly allocated to a
specific contract or any amounts improperly billed or charged
for products or services will be subject to reimbursement to the
government. As a government contractor, we are required to
disclose credible evidence of certain violations of law and
contract overpayments to the U.S. government. If we are
found to have participated in improper or illegal activities, we
may be subject to civil and criminal penalties and
administrative sanctions, including termination of contracts,
forfeiture of profits, suspension of payments, fines and
suspension or prohibition from doing business with the
U.S. government. Any negative publicity related to such
contracts, regardless of the accuracy of such publicity, may
adversely affect the company’s business or reputation.
Our contracts
with U.S. government agencies may not be funded by future
appropriations and are subject to modification or termination at
any time prior to their completion.
Our contracts with U.S. government agencies are subject to
the availability of appropriated funds. The U.S. government
funds our contract research work through a variety of funding
programs that rely on monies appropriated by Congress. At any
point, the availability of funding could change, thus reducing
the opportunities for new or continued revenues to us from
government contract work. For example, we currently receive a
significant portion of our government contract revenues through
the Small Business Innovation Research program, or SBIR. SBIR
funding for our contracts with U.S. government agencies
could be reduced or eliminated for a number of reasons including
the
discontinuance of the program as a result of action or inaction
by Congress, a decrease in the portion of U.S. government
agencies’ budgets that are allocated to research and
development, or a reduction of the percentage of research and
development budgets that are allocated to SBIR. We expect that
our revenue under such contracts will continue to decline due to
the recent trend toward tightening of federal spending
guidelines and programs. Additionally, SBIR funding is currently
available only to companies with less than 500 employees.
In the event that our employee headcount equals or exceeds 500,
we would no longer be eligible to compete for and be awarded
contracts funded through SBIR. Any reduction in available
funding or inability to participate in the SBIR program may
adversely affect our revenues.
In addition, under our contracts, the U.S. government
generally has the right not to exercise options to extend or
expand our contracts and may modify, curtail or terminate the
contracts at its convenience. Our government customers may not
renew our existing contracts after the conclusion of their terms
and we may not be able to enter into new contracts with
U.S. government agencies. Any decision by the
U.S. government not to exercise contract options or to
modify, curtail or terminate our contracts or not to renew our
contracts or enter into new contracts with us would adversely
affect our revenues.
Loss of the
intellectual property rights that we license from Cabot
Corporation would have a material adverse impact on our
business.
We have licensed certain intellectual property rights from Cabot
under a cross license agreement. These intellectual property
rights have been and continue to be critical to the manufacture
of our existing products and may also be important to our
research, development and manufacture of new products. Any
termination or limitation of our cross license agreement with
Cabot, or any loss of the intellectual property rights granted
to us thereunder as a result of ineffective protection of such
rights by Cabot, a breach of or dispute under the cross license
agreement by either party or our inability to meet the payment
schedule set forth in the cross license agreement would have a
material adverse impact on our financial condition, results of
operations and growth prospects, and would prevent us from
continuing our business. Under the terms of the cross license
agreement, as amended, we are obligated, among other things, to
pay Cabot a nonrefundable fee of $38 million that is
amortized on a quarterly basis with the total amount to be paid
in full no later than December 2013. As of March 31, 2011,
$16.5 million remained outstanding to Cabot. For a more
detailed description of the cross license agreement with Cabot,
see “Business — Intellectual Property —
Cross License Agreement with Cabot Corporation” and
“Management’s Discussion and Analysis of Financial
Condition and Results of Operations — Contractual
Obligations and Commitments — Cross License
Agreement.”
Our inability
to protect our intellectual property rights could negatively
affect our business and results of operations.
Our ability to compete effectively depends in part upon
developing, maintaining
and/or
protecting intellectual property rights relevant to our aerogel
product forms, applications and manufacturing processes. We rely
principally on a combination of patent protection, trade secret
laws, confidentiality and nondisclosure agreements and licensing
arrangements to establish and protect the intellectual property
rights relevant to our business. However, these measures may not
be adequate in every given case to permit us to gain or keep any
competitive advantage, particularly in those countries where the
laws do not protect our proprietary rights as fully as in the
United States. In particular, since aerogels were developed
approximately 80 years ago, there has been a wide range of
research, development and publication related to aerogels, which
makes it difficult to establish intellectual property rights to
many key elements of aerogel technology and to obtain patent
protection. Accordingly, much of the critical technology that we
use in our manufacture of aerogel blankets is not protected by
patents.
Where we consider it appropriate, our strategy is to seek patent
protection in the United States and other countries on
technologies used in or relating to our aerogel product forms,
applications and manufacturing processes. As of May 31,2011, we had 17 issued U.S. patents and 13 issued foreign
patents, including one U.S. patent and one European patent
that we co-own with a third party. The issuance of a patent is
not conclusive as to its scope, validity and enforceability.
Thus, any patent held by us or to be issued to us from a pending
patent application, could be challenged, invalidated or held
unenforceable in litigation or proceedings before the
U.S. Patent and Trademark Office
and/or other
patent tribunals, or circumvented by others. No consistent
policy regarding the breadth of patent claims has emerged to
date in the United States and the landscape could become more
uncertain in view of future rule changes by the United States
Patent and Trademark Office, the introduction of patent reform
legislation and decisions in patent law cases by the federal
courts including the United States Supreme Court. The patent
landscape outside the United States is even less predictable. As
a result, the validity and enforceability of patents cannot be
predicted with certainty. In addition, we may fail to apply for
patents on important technologies or product candidates in a
timely fashion, if at all, and our existing and future patents
may not be sufficiently broad to prevent others from practicing
our technologies or from developing competing products or
technologies, in particular given the long history of aerogel
development.
As of May 31, 2011, we had 20 pending U.S. patent
applications and 34 pending foreign patent applications,
including one pending U.S. patent application that we
co-own with a third party and a family of pending foreign patent
applications that we co-own with another third party. Our
pending patent applications are directed to various enabling
technologies for the product forms, applications and
manufacturing processes that support our current business, as
well as aspects of products under development or contemplated
for the future. The issuance of patents from these applications
involves complex legal and factual questions and, thus, we
cannot assure you that any of our pending patent applications
will result in the issuance of patents to us. The
U.S. Patent and Trademark Office and relevant foreign
patent tribunals may deny or require significant narrowing of
claims in our pending patent applications. Patents issued as a
result of any of our pending patent applications may not cover
our enabling technology
and/or the
products or processes that support our current or future
business or afford us with significant commercial protection
against others with similar technology. Proceedings before the
U.S. Patent and Trademark Office could result in adverse
decisions as to the priority of our inventions and the narrowing
or invalidation of claims in issued patents. In addition, our
pending patent applications filed in foreign countries are
subject to laws, rules and procedures that differ from those of
the United States, and thus foreign patent applications may not
be granted even if counterpart United States patents are issued.
Moreover, others may independently develop and obtain patents
covering technologies that are similar or superior to the
product forms, applications or manufacturing processes that we
employ. If that happens, we may need to obtain licenses for
these technologies and may not be able to obtain licenses on
reasonable terms, if at all, which could limit our ability to
manufacture our current
and/or
future products and operate our business. Moreover, third
parties could practice our intellectual property rights in
territories where we do not have patent protection. Such third
parties may then try to import products made using our
intellectual property rights into the United States or other
countries.
Our contracts
with the U.S. government and other third parties could
negatively affect our intellectual property
rights.
To further our product development efforts, our scientists and
engineers work closely with customers, the U.S. government
and other third parties to research and develop advancements in
aerogel product forms, applications and manufacturing processes.
We have entered into agreements with private third parties and
have been awarded numerous research contracts with the U.S.
government to independently or jointly research, design and
develop new devices and systems that incorporate our aerogel
products. We also expect to enter into similar private
agreements and be awarded similar government contracts in the
future. In some instances, the research and development
activities that we conduct under contract with the
U.S. government
and/or with
private third parties may produce intellectual property to which
we may not have ownership or exclusive rights and will be unable
to protect or monetize. Moreover, when we develop new
technologies using U.S. government funding, the government may
obtain certain rights in any resulting patents, technical data
and/or other
confidential and proprietary information, generally including,
at a minimum, a non-exclusive license authorizing the U.S.
government to use the invention, technical data or software for
non-commercial purposes. This federal government funding may
limit when and how we can deploy our technology developed under
those contracts. In addition, the federal funding must be
disclosed in any resulting patent applications, and our rights
in such inventions will normally be subject to government
license rights, periodic post-contract utilization reporting,
foreign manufacturing restrictions and “march-in”
rights. March-in rights refer to the right of the U.S.
government to require us to grant a license to the technology to
a responsible applicant or, if we refuse, the government may
grant the license itself. The U.S. government may exercise its
march-in rights if it determines that action is necessary
because we fail to achieve practical application of any
technology developed under contract with the government or
because action is necessary to alleviate health or safety needs,
to meet requirements of federal regulations or to give
preference to United States industry. The U.S. government may
also have the right to disclose our confidential and proprietary
information to third parties.
Our U.S. government-sponsored research contracts are also
subject to audit and require that we provide regular written
technical updates on a monthly, quarterly or annual basis, and,
at the conclusion of the research contract, a final report on
the results of our technical research. Because these reports are
generally available to the public, third parties may obtain some
aspects of our confidential and proprietary information relating
to our product forms, applications
and/or
manufacturing processes. If we fail to provide these reports or
to provide accurate or complete reports, the U.S. government
could obtain rights to any intellectual property arising from
the related research.
Furthermore, there could be disputes between us and a private
third party as to the ownership rights to any inventions that we
develop in collaboration with such third party. Any such dispute
may cause us to incur substantial costs, and could place a
significant strain on our financial resources, divert the
attention of management from our core business and harm our
reputation.
We rely on
trade secrets to protect our technology, and our failure to
obtain or maintain trade secret protection could adversely
affect our competitive business position.
We rely in part on trade secret protection to protect
confidential and proprietary information relating to our
technology, particularly where we do not believe patent
protection is appropriate or obtainable. We continue to develop
and refine the manufacturing processes used to produce our
aerogel products and believe that we have already developed, and
will continue to develop, significant know-how related to these
processes. However, trade secrets can be difficult to protect.
We may not be able to maintain the secrecy of this know-how, and
competitors may develop or acquire equally or more valuable
know-how related to the manufacture of comparable aerogel
products. Our strategy for
scale-up of
commercial production will continue to require us to share
confidential and proprietary information with the U.S.
government and other third parties. While we take reasonable
efforts to protect our trade secrets, our employees,
consultants, contractors or scientific and other advisors, or
those of our business partners, may intentionally or
inadvertently disclose our confidential and proprietary
information to competitors. Any enforcement of claims by us that
a third party has obtained and is using our trade secrets is
expensive, time consuming and uncertain. In addition, foreign
courts are sometimes less willing than United States courts to
protect trade secrets.
We also require all employees and consultants to execute
confidentiality
and/or
nondisclosure agreements upon the commencement of an employment
or consulting arrangement with us, which agreements generally
require that all confidential and proprietary information
developed by the individual or made known to the individual by
us during the course of the individual’s relationship with
us be kept confidential and not disclosed to third parties.
These agreements further generally provide
that inventions conceived by the individual in the course of
rendering services to us will be our exclusive property.
Nevertheless, these agreements may not be honored and our
confidential and proprietary information may be disclosed, or
these agreements may be unenforceable or difficult to enforce.
We also require customers and vendors to execute confidentiality
and/or
nondisclosure agreements. However, we may not have obtained such
agreements from all of our customers and vendors. Moreover, some
of our customers may be subject to laws and regulations that
require them to disclose information that we would otherwise
seek to keep confidential. Our confidential and proprietary
information may be otherwise disclosed without our
authorization. For example, third parties could reverse engineer
our manufacturing processes, independently develop substantially
equivalent confidential and proprietary information or otherwise
gain access to our trade secrets. Failure to maintain trade
secret protection could enable others to produce competing
products and adversely affect our competitive business position.
We could
become subject to intellectual property litigation that could be
costly, limit or cancel our intellectual property rights, divert
time and efforts away from business operation, require us to pay
damages and/or otherwise have an adverse material impact on our
business.
The success of our business is highly dependent on protecting
our intellectual property rights. Unauthorized parties may
attempt to copy or otherwise obtain and use our products
and/or
enabling technology. Policing the unauthorized use of our
intellectual property rights is difficult and expensive, as is
enforcing these rights against unauthorized use by others.
Identifying unauthorized use of our intellectual property rights
is difficult because we may be unable to monitor the processes
and/or
materials being employed by other parties. The steps we have
taken may not prevent unauthorized use of our intellectual
property rights, particularly in foreign countries where
enforcement of intellectual property rights may be more
difficult than in the United States.
Our continued commercial success will also depend in part upon
not infringing the patents or violating other intellectual
property rights of third parties. We are aware of patents and
patent applications generally relating to aspects of our
technologies filed by, and issued to, third parties, and our
knowledge of the patent landscape with respect to the
technologies currently embodied within our aerogel products and
the processes that we practice in manufacturing those products
indicates that the third-party patent rights most relevant to
our business are those owned by Cabot and licensed to us under
the cross license agreement with Cabot. Nevertheless, we cannot
determine with certainty whether patents or patent applications
of other parties may materially affect our ability to conduct
our business. There may be existing patents of which we are
unaware that we may inadvertently infringe, resulting in claims
against us or our customers. In the event that the manufacture,
use and/or
sale of our products or processes is challenged, or if our
product forms or processes conflict with patent rights of
others, third parties could bring legal actions against us in
the United States, Europe or other countries, claiming damages
and seeking to enjoin the manufacturing
and/or
marketing of our products. Additionally, it is not possible to
predict with certainty what patent claims may issue from pending
patent applications. In the United States, for example, patent
prosecution can proceed in secret prior to issuance of a patent,
provided such application is not filed in a foreign
jurisdiction. For U.S. patent applications that are also
filed in foreign jurisdictions, such patent applications will
not be published until 18 months from the filing date of
the application. As a result, third parties may be able to
obtain patents with claims relating to our product forms,
applications
and/or
manufacturing processes which they could attempt to assert
against us.
In either case, litigation may be necessary to enforce, protect
or defend our intellectual property rights or to determine the
validity and scope of the intellectual property rights of
others. Any litigation could be unsuccessful, cause us to incur
substantial costs, divert resources and the efforts of our
personnel away from daily operations, harm our reputation
and/or
result in the impairment of our intellectual property rights. In
some cases, litigation may be threatened or brought by a patent
holding company or other adverse patent owner who has no
relevant product revenues and against which our patents may
provide little or no deterrence. If we are found to infringe any
patents, we could be
required to (1) pay substantial monetary damages, including
lost profits, reasonable royalties
and/or
treble damages if an infringement is found to be willful
and/or
(2) totally discontinue or substantially modify any
products or processes that are found to be in violation of
another party’s intellectual property rights. We also may
have to seek a license to continue making and selling our
products
and/or using
our manufacturing processes, which we may not be able to obtain
on reasonable terms, if at all, which could significantly
increase our operating expenses
and/or
decrease our revenue. If our competitors are able to use our
technology without payment to us, our ability to compete
effectively could be harmed. Our contracts generally indemnify
our customers for third-party claims of intellectual property
infringement related to our manufacture of a product up to the
amount of the purchase price paid for the product. The expense
of defending these claims may adversely affect our financial
results.
We may incur
significant costs complying with environmental laws, and failure
to comply with these laws and regulations could expose us to
significant liabilities, which could adversely affect our
operating results.
Costs of compliance with regional, national, state and local
existing and future environmental laws and regulations could
adversely affect our cash flow and profitability. We are
required to comply with numerous environmental laws and
regulations and to obtain numerous governmental permits in order
to operate our facilities and in connection with the design,
development, manufacture and transport of our products and the
storage, use, handling and disposal of hazardous substances,
including environmental laws, regulations and permits governing
air emissions. We may incur significant additional costs to
comply with these requirements. If we fail to comply with these
requirements, we could be subject to civil or criminal
liability, damages and fines, and our operations could be
curtailed or suspended. In addition, certain foreign laws and
regulations may affect our ability to export products outside of
the United States. Existing environmental laws and regulations
could be revised or reinterpreted and new laws and regulations
could be adopted or become applicable to us or our products, and
future changes in environmental laws and regulations could
occur. These factors may materially increase the amount we must
invest to bring our processes into compliance and impose
additional expense on our operations.
Among the changes to environmental laws and regulations that
could occur is the adoption of regulatory frameworks to reduce
greenhouse gas emissions, which a number of countries,
particularly in the European Union, have adopted, or are
considering adopting. These include adoption of cap and trade
regimes, carbon taxes, restrictive permitting, increased
efficiency standards, and incentives or mandates for renewable
energy, any of which could increase the costs of manufacturing
our products and increase our compliance costs, which could
materially adversely affect our business and operating results.
In addition, private lawsuits, including claims for remediation
of contamination, personal injury or property damage, or actions
by regional, national, state and local regulatory agencies,
including enforcement or cost-recovery actions, may materially
increase our costs. Certain environmental laws make us
potentially liable on a joint and several basis for the
remediation of contamination at or emanating from properties or
facilities we currently or formerly owned or operated or
properties to which we arranged for the disposal of hazardous
substances. Such liability is not limited to the cleanup of
contamination we actually caused. For example, the site of our
East Providence facility was associated with contamination
caused by prior activities on and near the site. While there is
currently in place a covenant not to sue from the state
environmental agency and a state-approved deed restriction
addressing contamination left in place by a previous owner, we
are required to comply with the deed restriction and the
accompanying soil management plan. We may incur additional costs
to comply with these requirements and failure to do so could
disrupt the operation of our manufacturing facility or could
subject us to liability for environmental remediation. We may
incur liability relating to the remediation of contamination,
including contamination we did not cause.
We may not be able to obtain or maintain, from time to time, all
required environmental regulatory approvals. A delay in
obtaining any required environmental regulatory approvals or
failure to obtain and comply with them could materially
adversely affect our business and operating results.
Our activities
and operations are subject to numerous health and safety laws
and regulations, and if we violate such regulations, we could
face penalties and fines.
We are subject to numerous health and safety laws and
regulations in each of the jurisdictions in which we operate,
including with regards to hazardous substances that we use in
our manufacturing process. These laws and regulations require us
to obtain and maintain permits and approvals and implement
health and safety programs and procedures to control risks
associated with our operations. Compliance with those laws and
regulations can require us to incur substantial costs. Moreover,
if our compliance programs are not successful, we could be
subject to penalties or to revocation of our permits, which may
require us to curtail or cease operations of the affected
facilities. Violations of laws, regulations and permit
requirements may also result in criminal sanctions or
injunctions. Manufacture of our products requires the use of
hazardous substances and our products contain these same
materials, including titanium dioxide and carbon black, which,
in certain forms and at certain levels, has been determined to
be possibly carcinogenic or otherwise harmful to humans. While
we use these hazardous substances, including titanium dioxide
and carbon black, in forms and at levels that comply with
current rules and regulations governing their use known to us,
such rules and regulations may become more stringent such that
we are required to modify our manufacturing process and such
that our customers’ use of our product may be impacted, or
we may inadvertently use such materials. In addition, our
production or manufacturing process may result in uses above
permitted levels. Such uses or changes in rules or regulations
could materially adversely affect our business, financial
condition and operating results. Health and safety laws,
regulations and permit requirements may change or become more
stringent. Any such changes could require us to incur materially
higher costs than we currently have. Our costs of complying with
current and future health and safety laws, regulations and
permit requirements, and any liabilities, fines or other
sanctions resulting from violations of them, could adversely
affect our business, financial condition and operating results.
We may face
certain product liability or warranty claims from our products,
including from improper installation of our products by third
parties. As a consequence, we could lose existing and future
business and our ability to develop, market and sell our
insulation could be harmed.
The design, development, production and sale of our products
involve an inherent risk of product liability claims and
associated adverse publicity. We may be named directly in
product liability suits relating to our products, even for
defects resulting from errors of our distributors, third-party
installers or end-use customers. These claims could be brought
by various parties, including distributors and other direct
customers who are purchasing products directly from us,
third-party installers who are contracted by our direct and
end-use customers to install our products, or end-use customers
who purchase our products from our distributors. We could also
be named as co-parties in product liability suits that are
brought against the distributors, third-party installers and
end-use customers of our products. Installation of our products
is handled by third parties over which we have no control and
errors or defects in their installation may also give rise to
claims against us, diminish our brand or divert our resources
from other purposes. The failure of our products to perform to
customer expectations, whether or not because of improper
installation, could give rise to warranty claims against us. Any
of these claims, even if without merit, could result in costly
litigation or divert management’s attention and resources.
In addition, many of our products are integrated into the final
products of our customers. The integration of our products may
entail the risk of product liability or warranty claims based on
malfunctions or hazards from both our products and the final
products of our customers.
A material product liability claim may seriously harm our
results of operations, as well as damage our customer
relationships and reputation. Although we carry general
liability insurance, our current insurance coverage could be
insufficient to protect us from all liability that may be
imposed under these types of claims. Insurance coverage is
expensive, may be difficult to obtain and may not be available
in the future on acceptable terms or at all. Our distributors,
third-party installers and end-use customers may not have
adequate insurance coverage to cover against potential claims.
This insurance may not provide adequate coverage against
potential losses, and if claims or losses exceed our liability
insurance coverage, we may go out of business. In addition,
insurance coverage may become more expensive, which would harm
our results of operations.
A majority of
our revenue comes from sales in foreign countries and we may
expand our operations outside of the United States, which
subjects us to increased economic, operational and political
risks that could increase our costs and make it difficult for us
to continue to operate profitably.
We conduct business across the globe, with a majority of our
sales outside the United States for each of the years ended
December 31, 2008, 2009 and 2010. In addition, we may
expand our operations outside of the United States. As a result,
we are subject to a number of risks, including, but not limited
to:
•
unexpected changes in regulatory requirements;
•
foreign currency fluctuations, which could result in reduced
revenue and increased operating expense;
•
potentially longer payment and sales cycles;
•
increased difficulty in collecting accounts receivable;
•
labor rules and collective bargaining arrangements in foreign
jurisdictions;
•
the effect of applicable foreign tax structures, including tax
rates that may be higher than tax rates in the United States or
taxes that may be duplicative of those imposed in the United
States;
•
tariffs and trade barriers;
•
general economic and political conditions in each country, which
may interfere with, among other things, our supply chain, our
customers and all of our activities in a particular location;
•
inadequate intellectual property protection in foreign countries;
•
the difficulties and increased expense in complying with a
variety of domestic and foreign laws, regulations and trade
standards, including the Foreign Corrupt Practices Act; and
•
terrorist activity and political unrest.
Our success will depend in large part on our ability to manage
the effects of continued global political
and/or
economic uncertainty, especially in our significant geographic
markets.
Our business
is affected by seasonal trends, and these trends could have an
adverse effect on our operating results.
We are subject to seasonal fluctuations that we believe are tied
to seasonal levels of industrial activity and the practices of
the worldwide insulation market. As a result, our revenue and
operating income in the fourth quarter is typically higher, and
our revenue and operating income in the first quarter is
typically lower, than in other quarters of the year. In
addition, if our products’ penetration of the building and
construction market grows, we may become subject to fluctuations
related to commercial and residential construction cycles. As a
result of these seasonal trends and fluctuations, we may
occasionally experience declines in revenue or earnings as
compared to the immediately
preceding quarter, and comparisons of our operating results on a
period-to-period
basis may not be meaningful. See “Management’s
Discussion and Analysis of Financial Condition and Results of
Operations — Quarterly Results of
Operations — Seasonality and Quarterly Results.”
We may require
significant additional capital to pursue our growth strategy,
but we may not be able to obtain additional financing on
acceptable terms or at all.
The growth of our business will depend on substantial amounts of
additional capital for construction of new production lines or
facilities, ongoing operating expenses and continued development
of our aerogel product lines. Our capital requirements will
depend on many factors, including the rate of our revenue
growth, our introduction of new products and enhancements to
existing products, and our expansion of sales and marketing and
product development activities. In addition, we may consider
strategic acquisitions of complementary businesses or
technologies to grow our business, which could require
significant capital and could increase our capital expenditures
related to future operation of the acquired business or
technology. We may not be able to obtain loans or additional
capital on acceptable terms or at all. Moreover, our revolving
credit facility, our secured subordinated notes issued in
December 2010, which we refer to as the subordinated notes, our
convertible notes and our loan agreement with Massachusetts
Development Finance Agency contain restrictions on our ability
to incur additional indebtedness, which, if not waived, could
prevent us from obtaining needed capital. Any future credit
facilities or debt instruments would likely contain similar
restrictions. In the event additional funding is required, we
may not be able to obtain bank credit arrangements or effect an
equity or debt financing on terms acceptable to us or at all. A
failure to obtain additional financing when needed could
adversely affect our ability to maintain and grow our business.
Our credit
facilities and our debt instruments contain financial and
operating restrictions that may limit our access to credit. If
we fail to comply with covenants in our credit facilities or our
debt instruments, we may be required to repay our indebtedness
thereunder, which may have an adverse effect on our
liquidity.
Provisions in our revolving credit facility, our subordinated
notes, our convertible notes and our loan agreement with
Massachusetts Development Finance Agency each impose
restrictions on our ability to operate, including, for some of
the agreements and instruments, but not for others, our ability
to:
•
incur additional debt;
•
pay dividends and make distributions;
•
redeem or repurchase capital stock;
•
create liens;
•
enter into transactions with affiliates; and
•
merge or consolidate with or into other entities.
These credit facilities and debt instruments also contain other
customary covenants. We may not be able to comply with these
covenants in the future. Our failure to comply with these
covenants may result in the declaration of an event of default
and could cause us to be unable to borrow funds under our
revolving credit facility. In addition to preventing additional
borrowings under our revolving credit facility, an event of
default, if not cured or waived, may result in the acceleration
of the maturity of indebtedness outstanding under the revolving
credit facility and under our other debt instruments and credit
facility, which would require us to pay all amounts outstanding.
If an event of default occurs, we may not be able to cure it
within any applicable cure period, if at all. If the maturity of
our indebtedness is accelerated, we may not have sufficient
funds available for repayment or we may not have the ability to
borrow or obtain sufficient funds to replace the accelerated
indebtedness on terms
acceptable to us, or at all. See “Management’s
Discussion and Analysis of Financial Condition and Results of
Operations — Liquidity and Capital Resources.”
If we lose key
personnel upon whom we are dependent, or if we are unable to
successfully recruit and retain skilled employees, we may not be
able to manage our operations and meet our strategic
objectives.
Our continued success depends to a considerable degree upon the
continued services of a small number of our employees with
critical knowledge of our products, our manufacturing process,
our intellectual property, our customers and our global
operations. The loss or unavailability of any of these
individuals could harm our ability to execute our business plan,
maintain important business relationships and complete certain
product development initiatives, which could harm our business.
In the event that any of these key individuals leave their
employment with us or take new employment with a competitor, our
business and results of operation could be materially adversely
affected. In addition, our continued success depends upon the
availability, contributions, vision, skills, experience and
effort of our senior management, financial, sales and marketing,
engineering and production teams. We do not maintain “key
person” insurance on any of our employees. We have entered
into employment agreements with certain members of our senior
management team, but none of these agreements guarantees the
services of the individual for a specified period of time. All
of the agreements with members of our senior management team
provide that employment is at-will and may be terminated by the
employee at any time and without notice.
Although we do not have any reason to believe that we may lose
the services of any our employees with critical knowledge of our
products, our manufacturing processes, our customers and our
global operations or any of our senior management, financial,
sales and marketing, engineering and production teams in the
foreseeable future, the loss of the services of any of these
individuals might impede our operations or the achievement of
our strategic and financial objectives. The loss or interruption
of the service of any of these individuals or our inability to
attract or retain other qualified personnel or advisors could
have a material adverse effect on our business, financial
condition and results of operations and could significantly
reduce our ability to manage our operations and implement our
strategy.
Our ability to
use our net operating loss carryforwards will be subject to
limitation.
Generally, a change of more than 50% in the ownership of a
company’s stock, by value, over a three year period
constitutes an ownership change for U.S. federal income tax
purposes. An ownership change may limit a company’s ability
to use its net operating loss carryforwards attributable to the
period prior to such change. At December 31, 2010, we had
$112 million of net operating losses available to offset
future federal income, if any, which expire on various dates
through December 31, 2030; however, we expect
$30 million of our net operating losses will not be able to
be utilized after June 2013. We performed an analysis pursuant
to Internal Revenue Code Section 382, as well as similar
state provisions, in order to determine whether any limitations
might exist on the utilization of net operating losses and other
tax attributes. Based on this analysis, we determined that it is
more likely than not that an ownership change occurred on
June 10, 2008, resulting in an annual limitation on the use
of our net operating losses and other tax attributes as of such
date. We also determined that we had certain built-in gains at
the date of ownership change. Built-in gains increase the
limitation under the Internal Revenue Code Section 382 to
the extent triggered during the five year period subsequent to
the date of change. Absent the disposition of certain built-in
gain assets, which assets are critical to our business and are
unlikely to be disposed of, within the five year period
subsequent to the acquisition, approximately $30 million of
our net operating losses will not be able to be utilized after
June 2013.
There has been
no prior public market for our common stock and an active
trading market may not develop.
Prior to this offering, there has never been a public market for
our common stock. A liquid trading market for our common stock
may not develop. We cannot predict when or whether investor
interest in our common stock on the NYSE might lead to an
increase in market price or the development of a more active
trading market or how liquid that market might become. If an
active market for our securities does not develop, it may be
difficult to sell common stock you purchase in this offering. An
inactive market may also impair our ability to raise capital by
selling our common stock and may impair our ability to acquire
other companies, products or technologies by using our common
stock as consideration.
We expect that
the price of our common stock will fluctuate substantially and
you may not be able to sell your shares at or above the initial
public offering price.
The initial public offering price of our common stock sold in
this offering was determined by negotiation between the
representatives of the underwriters and us. This price may not
reflect the market price of our common stock that will prevail
in the trading market following this offering. You may not be
able to resell your shares at or above the initial public
offering price due to a number of factors, including those
listed in “— Risks Related to Our Business and
Strategy” and including the following, some of which are
beyond our control:
•
volume and timing of orders for our products;
•
quarterly and yearly variations in our or our competitors’
results of operations;
•
our announcement or our competitors’ announcements
regarding new products, product enhancements, significant
contracts, number of distributors, acquisitions or strategic
investments;
•
announcements of technological innovations relating to aerogels,
thermal management and energy conservation insulation;
•
results of operations that vary from the expectations of
securities analysts and investors;
•
the periodic nature of our sales cycles, in particular for
capital projects in the industrial market;
•
our ability to develop, obtain regulatory clearance or approval
for and market new and enhanced products on a timely basis;
•
future sales of our common stock, including sales by our
executive officers, directors and significant stockholders;
•
announcements by third parties of significant claims or
proceedings against us, including with regards to intellectual
property and product liability;
•
changes in accounting principles; and
•
general U.S. and global economic conditions and other
factors, including factors unrelated to our operating
performance or the operating performance of our competitors.
Furthermore, the U.S. stock market has at times experienced
extreme volatility that in some cases has been unrelated or
disproportionate to the operating performance of particular
companies. These broad market and industry fluctuations may
adversely affect the market price of our common stock,
regardless of our actual operating performance.
In the past, following periods of market volatility,
stockholders have instituted securities class action litigation.
If we were involved in securities litigation, it could have a
substantial cost and divert
resources and the attention of our senior management team from
our business regardless of the outcome of such litigation.
Securities
analysts may not initiate coverage of our common stock or may
issue negative reports, which may have a negative impact on the
market price of our common stock.
The trading market for our common stock will rely in part on the
research and reports that industry or financial analysts publish
about us or our business. Securities analysts may elect not to
provide research coverage of our common stock after the
completion of this offering. If securities analysts do not cover
our common stock after the completion of this offering, the lack
of research coverage may cause the market price of our common
stock to decline. If one or more of the analysts who elects to
cover us downgrades our stock, our stock price would likely
decline substantially. If one or more of these analysts ceases
coverage of us, we could lose visibility in the market, which in
turn could cause our stock price to decline. In addition, rules
mandated by the Sarbanes-Oxley Act and a global settlement
reached in 2003 between the SEC, other regulatory agencies and a
number of investment banks have led to a number of fundamental
changes in how analysts are reviewed and compensated. In
particular, many investment banking firms are required to
contract with independent financial analysts for their stock
research. It may be difficult for companies such as ours, with
smaller market capitalizations, to attract independent financial
analysts that will cover our common stock. This could have a
negative effect on the market price of our stock.
Our directors,
officers and principal stockholders have significant voting
power and may take actions that may not be in the best interests
of our other stockholders.
As of March 31, 2011, our officers, directors and principal
stockholders and their affiliates collectively controlled
approximately 81.3% of our outstanding common stock. After this
offering, assuming no exercise of the underwriters’ option
to purchase additional shares, our officers, directors and
principal stockholders and their affiliates collectively will
control approximately % of our
outstanding common stock. As a result, these stockholders, if
they act together, will be able to control the management and
affairs of our company and most matters requiring stockholder
approval, including the election of directors and approval of
significant corporate transactions. This concentration of
ownership may have the effect of delaying or preventing a change
of control and might adversely affect the market price of our
common stock. This concentration of ownership may not be in the
best interests of our other stockholders.
Our management
team may invest or spend the proceeds of this offering in ways
in which you may not agree or in ways that may not yield a
return.
We expect to use the net proceeds from this offering for general
corporate purposes, including the construction of additional
manufacturing capacity. Our management will have considerable
discretion in the application of the net proceeds of this
offering. Stockholders may not agree with such uses and the net
proceeds may be used for corporate purposes that do not increase
our operating results or market value. Until the net proceeds
are used, they may be placed in investments that do not produce
income or that lose value.
Anti-takeover
provisions in our restated certificate of incorporation and
restated by-laws, and Delaware law, could delay or discourage a
takeover.
Anti-takeover provisions in our restated certificate of
incorporation and restated by-laws and Delaware law may have the
effect of deterring or delaying attempts by our stockholders to
remove or replace management, engage in proxy contests and
effect changes in control. The provisions of our charter
documents include:
•
procedures for advance notification of stockholder nominations
and proposals;
the inability of our stockholders to call a special meeting of
the stockholders and the inability of our stockholders to act by
written consent;
•
the ability of our board of directors to create new
directorships and to fill any vacancies on the board of
directors;
•
the ability of our board of directors to amend our restated
by-laws without stockholder approval; and
•
the ability of our board of directors to issue up
to shares
of preferred stock without stockholder approval upon the terms
and conditions and with the rights, privileges and preferences
as our board of directors may determine.
In addition, as a Delaware corporation, we are subject to
Delaware law, including Section 203 of the Delaware General
Corporation Law. In general, Section 203 prohibits a
Delaware corporation from engaging in any business combination
with any interested stockholder for a period of three years
following the date that the stockholder became an interested
stockholder unless certain specific requirements are met as set
forth in Section 203. These provisions, alone or together,
could have the effect of deterring or delaying changes in
incumbent management, proxy contests or changes in control. See
“Description of Capital Stock.”
Future sales
of our common stock or the possibility or perception of such
future sales may depress our stock price and impair our ability
to raise future capital through the sale of our equity
securities.
Upon completion of the offering, our current stockholders will
hold a substantial number of shares of our common stock that
they will be able to sell in the public market in the near
future. A significant portion of these shares will be held by a
small number of stockholders. Sales by our current stockholders
of a substantial number of shares after this offering, or the
perception that these sales could occur, could significantly
reduce the market price of our common stock. All the shares sold
in this offering will be freely tradable. Substantially all of
the remaining shares of our common stock are available for
resale in the public market, subject to the restrictions on sale
or transfer during the
180-day
lockup period after the date of this prospectus that is
described in “Shares Eligible for Future Sale.”
Registration of the sale of these shares of our common stock
would permit their sale into the market immediately. As
restrictions on resale end or upon registration of any of these
shares for resale, the market price of our common stock could
drop significantly if the holders of these shares sell them or
are perceived by the market as intending to sell them. These
sales could also impede our ability to raise future capital.
Moreover, following the completion of this offering and
including (i) any shares issued in satisfaction of any
accrued but unpaid dividends on our preferred stock and
(ii) any shares of common stock issuable upon the automatic
conversion of all principal and accrued but unpaid interest on
our convertible notes, each of which would occur upon the
closing of the offering made hereby, the holders of
approximately shares
of common stock, as well as approximately 1.0 million
shares underlying certain outstanding warrants to purchase our
common stock, will have rights, subject to some conditions, to
require us to include their shares in registration statements
that we may file for ourselves or other stockholders.
The million shares represent
approximately % of the total number
of shares of our common stock to be outstanding immediately
after this offering, assuming no exercise of the
underwriters’ option to purchase additional shares. See
“Description of Capital Stock — Registration
Rights” for a description of the registration rights of
these stockholders. By exercising their registration rights and
selling a large number of shares, these holders could cause the
prevailing market price of our common stock to decline.
As a new
investor, you will experience immediate and substantial dilution
in the net tangible book value of the shares you purchase in
this offering.
The initial public offering price is substantially higher than
the net tangible book value per share prior to the completion of
this offering. Assuming an initial public offering price of our
common stock of $ per share, the
mid-point of the initial public offering price range set forth
on the cover page of this prospectus, you will incur immediate
dilution in net tangible book value per share of
$ . This dilution is due in large
part to earlier investors in our company having paid
substantially less than the initial public offering price when
they purchased their shares. Additionally, new investors in this
offering will have contributed % of
our total equity as
of ,
2011, but will own only % of our
outstanding shares upon completion of this offering.
Since we may require additional funds to develop new products
and continue to expand our business, we may conduct substantial
future offerings of equity securities. Future equity issuances,
including future public offerings or future private placements
of equity securities and any additional shares issued in
connection with acquisitions, will result in further dilution to
investors.
We do not
intend to pay cash dividends in the foreseeable future and,
consequently, your ability to achieve a return on your
investment will depend on appreciation in the price of our
common stock.
We have never declared or paid cash dividends on our common
stock and we do not intend to pay any cash dividends on our
common stock in the foreseeable future. We currently expect to
retain all available funds and any future earnings for use in
the operation and expansion of our business. In addition, the
terms of our revolving credit facility, our subordinated notes,
our convertible notes and our cross license agreement with Cabot
restrict our ability to pay dividends and any future credit
facilities, loan agreements, debt instruments or license
agreement may further restrict our ability to pay dividends.
Payments of future dividends, if any, will be at the discretion
of our board of directors after taking into account various
factors, including our business, operating results and financial
condition, current and anticipated cash needs, plans for
expansion and any legal or contractual limitations on our
ability to pay dividends. As a result, capital appreciation, if
any, of our common stock will be your sole source of potential
gain for the foreseeable future.
This prospectus contains forward-looking statements. All
statements other than statements of historical facts contained
in this prospectus, including statements regarding our strategy,
future operations, future financial position, future revenue,
projected costs, prospects, plans, objectives of management and
expected market growth are forward-looking statements. These
statements involve known and unknown risks, uncertainties and
other important factors that may cause our actual results,
performance or achievements to be materially different from any
future results, performance or achievements expressed or implied
by the forward-looking statements.
The words “anticipate,”“believe,”“could,”“estimate,”“expect,”“intend,”“may,” “plan,’’
“potential,”“predict,”“project,”“should,”“target,”“will,”“would” and similar expressions are intended to
identify forward-looking statements, although not all
forward-looking statements contain these identifying words.
These forward-looking statements include, among other things,
statements about:
•
our expectations as to the future growth of our business;
•
the expected future growth of the market for aerogel insulation,
insulation generally, and energy efficiency solutions;
•
our belief that our products provide strong competitive
advantages over traditional insulation materials;
•
our expectations that our second production line will be capable
of operating at full capacity by the end of 2011 and that our
first two production lines will then be capable of an annual
production capacity of 40 to 44 million square feet of
aerogel blankets, depending on product mix;
•
our ability to produce $50 to $54 million in annual revenue
of aerogel blankets at current prices on our second production
line when operating at full capacity;
•
our expectation that the construction of our third production
line will be completed during 2012;
•
our plans to construct a second manufacturing facility in the
United States or Europe, based on proximity to raw material
suppliers, proximity to customers, labor and construction costs
and available governmental incentives;
•
the expected energy and cost savings of our products; and
•
the expected future development of new aerogel technologies.
These forward looking statements are only predictions and we may
not actually achieve the plans, intentions or expectations
disclosed in our forward-looking statements, so you should not
place undue reliance on our forward-looking statements. Actual
results or events could differ materially from the plans,
intentions and expectations disclosed in the forward-looking
statements we make. We have based these forward-looking
statements largely on our current expectations and projections
about future events and trends that we believe may affect our
business, financial condition and operating results. We have
included important factors in the cautionary statements included
in this prospectus, particularly in the “Risk Factors”
section, that could cause actual future results or events to
differ materially from the forward-looking statements that we
make. Our forward-looking statements do not reflect the
potential impact of any future acquisitions, mergers,
dispositions, joint ventures or investments we may make.
Our forward-looking statements in this prospectus represent our
views only as of the date of this prospectus. We disclaim any
intent or obligation to update “forward-looking
statements” made in this prospectus to reflect changed
assumptions, the occurrence of unanticipated events or changes
to future operating results over time. You should, therefore,
not rely on these forward-looking statements as representing our
views as of any date subsequent to the date of this prospectus.
We estimate that we will receive net proceeds from this offering
of approximately $ million,
or approximately $ million if
the underwriters exercise their option to purchase additional
shares in full, based on an assumed initial public offering
price of $ per share, which is the
mid-point of the estimated price range set forth on the cover
page of this prospectus, after deducting estimated underwriting
discounts and estimated offering expenses payable by us.
A $1.00 increase (decrease) in the assumed initial public
offering price of $ per share
would increase (decrease) the net proceeds to us from this
offering by $ million,
assuming the number of shares offered by us, as set forth on the
cover page of this prospectus, remains the same and after
deducting estimated underwriting discounts and estimated
offering expenses payable by us. An increase (decrease) of
1,000,000 shares from the expected number of shares to be
sold in this offering, assuming no change in the assumed initial
public offering price per share, would increase (decrease) our
net proceeds from this offering by
$ million.
We intend to use the net proceeds we receive from this offering
for general corporate purposes, including the construction of
additional manufacturing capacity. Pending specific utilization
of the net proceeds as described above, we intend to invest the
net proceeds of the offering in short-term investment grade and
U.S. government securities.
We have never declared or paid any dividends on our common
stock. We currently intend to retain future earnings, if any, to
finance our research and development efforts and for use in the
operation and expansion of our business and do not anticipate
declaring or paying cash dividends in the foreseeable future.
The convertible note purchase agreement related to the
convertible notes, the revolving credit facility, the note
purchase agreement related to the subordinated notes and the
cross license agreement with Cabot all contain restrictive
covenants that restrict our ability to pay any dividends or make
any distributions or payment on, or redeem, retire or
repurchase, any capital stock. Any future determination to pay
dividends will be at the discretion of our board of directors
and will depend upon a number of factors, including our results
of operations, financial condition, future prospects,
contractual restrictions, restrictions imposed by applicable law
and other factors our board of directors deems relevant.
The following table sets forth our cash and cash equivalents and
capitalization as of March 31, 2011:
•
on an actual basis;
•
on an unaudited pro forma basis to give effect upon the
completion of this offering to (i) the automatic conversion
of all shares of our preferred stock into shares of our common
stock and the issuance of shares of common stock in satisfaction
of accumulated dividends on such preferred stock; (ii) the
receipt in June 2011 of gross proceeds of $30.0 million
from the sale of our convertible notes and the automatic
conversion of the convertible notes and all accrued but unpaid
interest thereon into shares of our common stock; and
(iii) the sale
of shares
of our common stock offered by us in this offering at an assumed
initial public offering price of $
per share, the mid-point of the price range set forth on the
cover page of this prospectus, after deducting estimated
underwriting discounts and estimated offering expenses payable
by us.
You should read this table together with our consolidated
financial statements and the related notes thereto, as well as
the information under “Selected Consolidated Financial
Data” and “Management’s Discussion and Analysis
of Financial Condition and Results of Operations.” The
unaudited pro forma information below is prepared for
illustrative purposes only and our capitalization following the
completion of this offering will be adjusted based on the actual
initial public offering price, the closing of the offering made
hereby and other terms of the offering determined at pricing.
Series B redeemable convertible preferred stock,
$0.001 par value; 17,000,000 shares authorized,
16,010,292 shares issued and outstanding, actual; no shares
authorized, issued or outstanding, pro forma(3)
41,094
Series A redeemable convertible preferred stock,
$0.001 par value, 52,843,201 shares authorized, issued
and outstanding, actual; no shares authorized, issued or
outstanding, pro forma(3)
131,132
Stockholders’ (deficit) equity:
Common stock, $0.001 par value; 114,000,000 shares
authorized, 26,106,535 shares issued and outstanding,
actual;
and shares
issued and outstanding, pro forma(1)(2)(3)
26
Additional paid-in capital(1)
75,788
Accumulated deficit
(197,896
)
Total stockholders’ (deficit) equity(1)
$
(122,082
)
$
Total capitalization(1)
$
58,224
$
(1)
To the extent we change the number
of shares of common stock sold by us in this offering from the
shares we expect to sell or we change the initial public
offering price from the $ per
share assumed initial public offering price, representing the
mid-point of the estimated price range set forth on the cover
page of this prospectus, or any combination of these events
occurs, the net proceeds to us from this offering and
consequently the cash and cash equivalents and each of
additional paid-in capital, total
stockholders’ equity and total capitalization may increase
or decrease. A $1.00 increase (decrease) in the assumed initial
public offering price per share of the common stock would
increase (decrease) the net proceeds that we receive in this
offering and each of our unaudited pro forma cash and cash
equivalents, additional paid-in capital, total
stockholders’ equity and total capitalization by
approximately $ million,
assuming that the number of shares offered by us under this
prospectus remains the same. An increase (decrease) of
1,000,000 shares in the expected number of shares to be
sold in the offering, assuming no change in the assumed initial
public offering price per share, would increase (decrease) our
net proceeds from this offering and consequently the cash and
cash equivalents and each of additional paid-in capital, total
stockholders’ equity and total capitalization by
approximately $ million.
(2)
The unpaid principal amount of the
convertible notes, together with any accrued but unpaid interest
thereon, will be automatically converted into common stock upon
the closing of the offering made hereby at a conversion price
equal to 87.5% of the initial offering price per share to the
public in this offering.
A $1.00 increase from the assumed
initial public offering price of $
per share would decrease the number of shares of common stock
issuable upon the conversion of the convertible notes
by
shares and $1.00 decrease from the assumed initial public
offering price of $ per share
would increase the number of shares of common stock issuable
upon the conversion of the convertible notes
by shares,
in each case, assuming a ,
2011 closing date of the offering. For each day after the
assumed , 2011 closing date,
the number of shares of common stock issuable upon the
convertible notes would increase
by shares,
assuming an initial offering price of
$ per share. The actual number of
shares of common stock to be issued upon the conversion of the
convertible notes will be based on the amount of accrued but
unpaid interest then outstanding and the actual initial public
offering price.
(3)
Each series of our preferred stock
will convert upon the completion of this offering on a
1-for-1
basis. The terms of our existing preferred stock require us,
upon the closing of the offering made hereby, to issue
additional shares of common stock to the holders of such
preferred stock in satisfaction of accumulated dividends on such
preferred stock. The accumulated dividends were approximately
$4.8 million at March 31, 2011 and accumulate at the
rate of approximately $11,000 per day thereafter. The common
stock issued in satisfaction of those dividends will be valued
at the public offering price per share in this offering.
A $1.00 increase from the assumed
initial public offering price of $
per share would decrease the number of shares of common stock to
be issued to the holders of preferred stock in satisfaction of
accumulated dividends on such preferred stock by
approximately
shares and a $1.00 decrease from the assumed initial public
offering price of $ per share
would increase the number of shares of common stock to be issued
to the holders of our preferred stock in satisfaction of
accumulated dividends on such preferred stock by
approximately
shares, in each case, assuming the closing date of the offering
hereby occurs
on ,
2011. For each day after the
assumed , 2011
closing date, the number of shares of common stock issuable to
the holders of preferred stock in satisfaction of accumulated
dividends on such preferred stock would increase
by shares,
assuming an initial offering price of
$ per share. The actual number of
shares of common stock to be issued to the holders of our
preferred stock will be based on the amount of accrued dividends
then outstanding and the actual initial public offering price.
If you invest in our common stock, your interest in our net
tangible book value will be diluted to the extent of the
difference between the initial public offering price and the net
tangible book value per share of our common stock immediately
after the completion of this offering. Dilution results from the
fact that the initial public offering price is substantially in
excess of the book value per share attributable to the existing
stockholders for the presently outstanding stock.
As of March 31, 2011, our net tangible book value was
approximately $ , or approximately
$ per share of common stock. Net
tangible book value per share represents the amount of our total
tangible assets less total liabilities and preferred stock,
divided by 26,106,535, the number of common shares outstanding
on March 31, 2011. Our pro forma net tangible book value as
of March 31, 2011 was $ , or
$ per share of common stock. Pro
forma net tangible book value per share represents the amount of
our total tangible assets less our total liabilities, divided by
the number of shares of our common stock outstanding, as of
March 31, 2011, after giving effect to (i) the
automatic conversion of all shares of our preferred stock into
68,853,493 shares of our common stock; (ii) the
issuance
of
shares of common stock upon the closing of the offering made
hereby in satisfaction of accumulated dividends on our preferred
stock, assuming an initial public offering price of
$ per share, the mid-point of the
price range set forth on the cover page of this prospectus, and
the closing of the offering made hereby occurs
on ,
2011; and (iii) the automatic conversion of
$30.0 million aggregate principal amount and all accrued
but unpaid interest on our convertible notes upon the closing of
the offering made hereby into an aggregate
of
shares of our common stock, at a conversion price equal to 87.5%
of the initial offering price, assuming an initial public
offering price of $ per share, the
mid-point of the price range set forth on the cover page of this
prospectus, and that the closing of the offering made hereby
occurs
on ,
2011.
After giving effect to the sale by us of shares of our common
stock in the offering at the assumed initial public offering
price of $ , the mid-point of the
price range set forth on the cover page of this prospectus, and
after deducting estimated underwriting discounts and estimated
offering expenses payable by us, our pro forma as adjusted net
tangible book value as of March 31, 2011 would have been
approximately $ , or approximately
$ per share. This amount
represents an immediate increase in pro forma as adjusted net
tangible book value of $ per share
to our existing stockholders and an immediate dilution in pro
forma as adjusted net tangible book value of approximately
$ per share to new investors
purchasing shares of our common stock in this offering. We
determine dilution by subtracting the pro forma as adjusted net
tangible book value per share after the offering from the amount
of cash that a new investor paid for a share of common stock.
The following table illustrates this dilution on a per share
basis:
Assumed initial public offering price per share
$
Pro forma net tangible book value per share as of March 31,2011
Increase per share attributable to cash payments by new
investors in this offering
Pro forma as adjusted net tangible book value per share after
this offering
Dilution in pro forma net tangible book value per share to new
investors
$
If the underwriters exercise their option to purchase additional
shares in full, the pro forma as adjusted net tangible book
value per share after giving effect to the offering would be
$ per share. This represents an
increase in pro forma as adjusted net tangible book value of
$ per share to existing
stockholders and dilution in pro forma as adjusted net tangible
book value of $ per share to new
investors.
A $1.00 increase (decrease) in the assumed initial public
offering price of $ , the mid-point
of the price range set forth on the cover page of this
prospectus, would increase (decrease) our pro forma as adjusted
net tangible book value after this offering by
$ million and the pro forma
as
adjusted net tangible book value per share after this offering
by $ per share and would increase
(decrease) the dilution per share to new investors in this
offering by $ per share, in each
case, assuming the number of shares offered by us, as set forth
on the cover page of this prospectus, remains the same and
assuming the closing of the offering made hereby occurs
on ,
2011. The information discussed above is illustrative only and
will adjust based on the actual initial public offering price
and other terms of the offering determined at pricing.
The following table shows, as
of ,
2011, the differences between the number of shares purchased
from us, the total consideration paid to us and the average
price per share that existing stockholders and new investors
paid.
Shares Purchased
Total Consideration
Average Price
Number
Percentage
Amount
Percentage
per Share
Existing stockholders
%
$
%
$
New investors
Total
%
$
%
$
A $1.00 increase (decrease) in the assumed initial public
offering price of $ per share, the
mid-point of the price range set forth on the cover page of this
prospectus, would increase (decrease) total consideration paid
by new investors, total consideration paid by all stockholders
and the average price per share paid by all stockholders by
$ , $
and $ , respectively, after
deducting estimated underwriting discounts and estimated
offering expenses payable by us, and assuming the number of
shares offered by us, as set forth on the cover page of this
prospectus, remains the same and assuming the closing of the
offering made hereby occurs
on ,
2011.
The discussion and tables above assume no exercise of the
underwriters’ option to purchase additional shares. If the
underwriters’ option to purchase additional shares is
exercised in full, the number of shares of our common stock held
by existing stockholders will be further reduced
to % of the total number of shares
of our common stock to be outstanding after the offering, and
the number of shares of our common stock held by investors
participating in the offering will be further increased
to % of the total number of shares
of our common stock to be outstanding after the offering.
In addition, except as noted, the above discussion and table
assume no exercise of stock options or warrants to purchase
common stock after March 31, 2011. As of March 31,2011, we had outstanding options to purchase a total of
12,832,208 shares of our common stock at a weighted-average
exercise price of $0.46 per share and 1,127,372 shares of
common stock reserved for issuance upon the exercise of
outstanding warrants at a weighted-average exercise price of
$0.002 per share. If all such options and warrants had been
exercised as of March 31, 2011, pro forma as adjusted net
tangible book value per share would be
$ per share and dilution to new
investors would be $ per share. To
the extent we grant options to our employees in the future and
those options are exercised or other issuances of common stock
are made, there will be further dilution to new investors.
The following table sets forth our selected consolidated
financial data for the periods, and as of the dates, indicated.
You should read the following selected consolidated financial
data in conjunction with our audited and unaudited consolidated
financial statements and the related notes thereto included
elsewhere in this prospectus and the “Management’s
Discussion and Analysis of Financial Condition and Results of
Operations” section of this prospectus.
We derived the consolidated statement of operations data for the
years ended December 31, 2008, 2009 and 2010, and the
consolidated balance sheet data as of December 31, 2009 and
2010, from our audited consolidated financial statements and the
related notes thereto included elsewhere in this prospectus. We
derived the consolidated statement of operations data for the
fiscal years ended December 31, 2006 and 2007, and the
consolidated balance sheet data as of December 31, 2006,
2007 and 2008, from our audited consolidated financial
statements and the related notes thereto that are not included
in this prospectus. We derived the consolidated statement of
operations data for the three months ended March 31, 2010
and 2011, and the consolidated balance sheet data as of
March 31, 2011, from our unaudited consolidated financial
statements and the related notes thereto included elsewhere in
this prospectus. The results of operations for these interim
periods are not necessarily indicative of the results to be
expected for a full year. Our unaudited consolidated financial
statements have been prepared on the same basis as the audited
consolidated financial statements and the related notes thereto
and, in the opinion of our management, reflect all adjustments
that are necessary for a fair presentation in conformity with
GAAP. Our historical results for prior periods are not
necessarily indicative of results to be expected for any future
period.
Dividends and accretion on redeemable convertible
preferred stock
(1,812
)
(1,812
)
(2,351
)
(2,984
)
(57,007
)
(608
)
(62,440
)
Net income (loss) attributable to common stockholders
$
(38,552
)
$
(30,841
)
$
(37,595
)
$
(21,623
)
$
(66,917
)
$
(4,275
)
$
(64,161
)
Per share data:
Net income (loss) per share attributable to common stockholders,
basic and diluted
$
(4,163.04
)
$
(3,289.81
)
$
(3,389.12
)
$
(2.21
)
$
(2.62
)
$
(0.17
)
$
(2.48
)
Weighted-average common shares outstanding, basic and diluted
9,261
9,375
11,093
9,751,616
25,574,286
25,573,418
25,892,546
Pro forma net income (loss) per share, basic and diluted(1)
Weighted-average common shares outstanding used in computing pro
forma net income (loss) per share, basic and diluted(1)
Three Months
Years Ended December 31
Ended March 31
2006
2007
2008
2009
2010
2011
($ in thousands)
Consolidated balance sheet data:
Cash and cash equivalents
$
5,839
$
794
$
11,988
$
27,502
$
26,800
$
16,379
Working capital(2)
(34,593
)
(55,213
)
9,404
21,766
24,723
10,607
Total assets
61,273
49,296
54,624
64,735
88,795
85,696
Total debt
26,502
29,195
755
509
8,067
8,080
Preferred stock
61,051
62,863
184,269
31,681
109,786
172,226
Total stockholders’ (deficit) equity
(93,185
)
(123,055
)
(159,655
)
6,153
(58,103
)
(122,082
)
(1)
Pro forma per share data will be
computed based upon the number of shares of common stock
outstanding immediately after consummation of this offering
applied to our historical net income (loss) amounts and will
give retroactive effect to the preferred stock and convertible
notes conversions and the issuance of the shares of our common
stock offered hereby.
The following table presents the calculation of historical and
pro forma basic and diluted net income (loss) per share of
common stock attributable to our common stockholders:
Three Months
Year Ended December 31
Ended March 31
2006
2007
2008
2009
2010
2010
2011
($ in thousands, except share and per share data)
Net income (loss) attributable to common stockholders
$
(38,552
)
$
(30,841
)
$
(37,595
)
$
(21,623
)
$
(66,917
)
$
(4,275
)
$
(64,161
)
Dividends and accretion on redeemable convertible preferred stock
1,812
1,812
2,351
2,984
57,007
608
62,440
Interest expense
Discount on conversion of convertible notes
Pro forma net income (loss) attributable to common stockholders
Weighted-average common shares outstanding, basic and diluted
9,261
9,375
11,093
9,751,616
25,574,286
25,573,418
25,892,546
Common shares issued upon conversion of preferred stock and
accrued dividends
Common shares issued upon conversion of convertible notes and
interest thereon
Weighted-average common shares outstanding used in computing pro
forma net income (loss) per share, basic and diluted
Pro forma net income (loss) per share, basic and diluted
(2)
Working capital means current
assets minus current liabilities.
You should read the following in conjunction with the
“Selected Consolidated Financial Data” and our
consolidated financial statements and the related notes thereto
included elsewhere in this prospectus. In addition to historical
information, the following discussion and analysis includes
forward looking information that involves risks, uncertainties
and assumptions. Our actual results and the timing of events
could differ materially from those anticipated by these forward
looking statements as a result of many factors, including those
discussed under “Risk Factors” elsewhere in this
prospectus. See also “Special Note Regarding Forward
Looking Statements” included elsewhere in this
prospectus.
Overview
We design, develop and manufacture innovative, high-performance
aerogel insulation. We believe our aerogel blankets deliver the
best thermal performance of any widely used insulation products
available on the market today and provide a superior combination
of performance attributes unmatched by traditional insulation
materials. Our customers use our products to save money,
conserve energy, reduce
CO2 emissions
and protect workers and assets.
Our products are targeted at the estimated $32 billion
annual global market for insulation materials. Our insulation is
principally used by industrial companies that operate
petrochemical, refinery, industrial and power generation
facilities. We are working with leading building materials
manufacturers to develop and further commercialize our products
for applications in the building and construction market. We
also rely on a small number of fabricators and OEMs to develop
and sell products for applications as diverse as military and
commercial aircraft, trains, buses, appliances, apparel,
footwear and outdoor gear.
We generate product revenue through the sale of our line of
aerogel blankets. We market and sell our products primarily
through a direct sales force based in North America, Europe and
Asia. The efforts of our sales force are supported by a small
number of sales consultants with extensive knowledge of a
particular market or region. Our sales force is required to
establish and maintain customer and partner relationships, to
deliver highly technical information, and to ensure high quality
customer service.
In the industrial market, we rely on an existing and
well-established channel of distributors and contractors to
distribute products to our end-use customers. In the building
and construction market, we believe that our relationships with
leading building materials manufacturers with established
distribution networks will facilitate our penetration of the
market on a cost-effective basis. In the transportation,
appliance and apparel markets, our current plan is to rely on
the efforts of OEMs to develop opportunities within and provide
access to the markets.
We also perform research services under contracts with various
agencies of the U.S. government, including the Department
of Defense and the Department of Energy, and other institutions.
Research performed under contract with government agencies and
other institutions enables us to develop and leverage
technologies into broader commercial applications.
We manufacture our products using our proprietary, high-volume
process technology at our facility in East Providence, Rhode
Island. We have operated the East Providence facility since
mid-2008 and commenced operation of a second production line at
this facility at the end of March 2011. We expect our annual
production capacity by the end of 2011 to reach 40 to
44 million square feet of aerogel blankets, depending on
product mix.
Our core aerogel technology and manufacturing processes are our
most significant assets. As of May 31, 2011, we employed
27 research scientists and process engineers focused on
developing next generation aerogel compositions, form factors
and manufacturing technologies. Since inception
through March 31, 2011, we have invested $24.8 million
into our research and development activities and have delivered
$35.0 million in research services revenue.
Our predecessor company was incorporated in 2001 and spun off
from Aspen Systems, Inc., of Marlborough, Massachusetts, to
focus on the development and commercialization of aerogel
technology. We began selling our first products commercially in
the second quarter of 2001. Since inception through
March 31, 2011, we have generated $152.0 million in
revenue consisting of $117.0 million in product revenue and
$35.0 million in research services revenue. As of
May 31, 2011, we had 157 employees principally located
at two sites in the United States.
Our total revenue has grown from $11.4 million for the year
ended December 31, 2006 to $43.2 million for the year
ended December 31, 2010. For the year ended
December 31, 2010, our revenue grew 51% to
$43.2 million from $28.6 million in 2009. For the
three months ended March 31, 2011, our revenue grew 41% to
$12.3 million from $8.7 million in the comparable
period in 2010. Our revenue growth was constrained by capacity
limitations during 2010 and the first quarter of 2011.
We have experienced significant losses since inception, have an
accumulated deficit of $197.9 million at March 31,2011, and have significant ongoing cash flow commitments. We
have invested significant resources to commercialize aerogel
technology and to build a manufacturing infrastructure capable
of supplying aerogel products at the volumes and costs required
by our customers. We currently market a set of commercially
viable products, serve a growing base of customers and are
experiencing rapid growth.
Factors Affecting
Our Performance
Revenue
Growth
The key driver to improve our financial performance will be
continued revenue growth. We believe demand for our products
will increase significantly to support widespread global efforts
to improve energy efficiency. We plan to add resources to gain
share of the industrial insulation market by increasing revenue
from existing and new end-use customers. We also anticipate that
our growing revenue base associated with maintenance programs
will lead to increasing revenue associated with large capital
projects, including the construction of new refineries and
petrochemical facilities in emerging markets. We expect that
this increased revenue will drive incremental improvement in
gross profit, operating income and net income, and will lead to
higher levels of cash flow from operations. Our ability to
achieve sufficient revenue to generate net income and to fully
fund operations will require continued near-term investments in
manufacturing facilities, capital equipment, technology and
personnel. We expect these investments to negatively impact
current net income and cash balances, but to also set the
framework for improving financial performance in the long-term.
Manufacturing
Capacity
Demand for our aerogel products in 2010 increased by 88% from
2009 and exceeded our manufacturing capacity. In response to
growing demand, we constructed a second production line in our
East Providence facility designed to double our manufacturing
capacity. We plan to continue to expand capacity to meet
increased demand for our products. We have begun the design and
engineering phase for a third production line in the East
Providence facility and currently expect that this line will be
completed during 2012. We also plan to construct a second
manufacturing facility in either the United States or Europe and
to commence operations at the facility in the second half of
2013. Our ability to successfully bring this capacity online
when and as planned will have a significant impact on our
financial condition and results of operations.
Organizational
Resources
We plan to expand our sales force globally to support
anticipated growth in customers and demand for our products. We
also intend to increase personnel, funding and capital equipment
devoted to the research and development of new and advanced
technologies. In addition, we plan to increase staff to support
the expansion of our East Providence facility during 2012 and
multi-facility manufacturing operations during the second half
of 2013. These plans will require a significant investment in
managerial talent, human resources, information systems,
processes and controls to ensure maintenance of efficient and
economic operations. These investments are critical to our
ability to increase revenue, to generate net income and to fully
fund operations.
Reliance on
Partners
Our ability to initiate, maintain and manage relationships and
strategic arrangements has been fundamental to the success of
our business. We plan to leverage our relationships with leading
building materials manufacturers and OEMs to facilitate
penetration of the building and construction, transportation,
appliance and apparel markets. These relationships are critical
to our ability to penetrate these new markets on a cost
effective basis and are critical to our ability to sustain high
levels of revenue growth, to generate net income and to fully
fund operations.
Components of Our
Results of Operations
Revenue
We recognize product revenue from the sale of our line of
aerogel products and research services revenue from the
provision of services under contracts with various agencies of
the U.S. government and other institutions. The following
table sets forth the total revenue for the periods presented:
Three Months Ended
Year Ended December 31
March 31
2006
2007
2008
2009
2010
2010
2011
($ in thousands)
Revenue:
Product
$
5,571
$
9,075
$
17,202
$
24,752
$
38,690
$
7,681
$
11,274
Research services
5,806
4,743
2,868
3,864
4,519
1,066
1,015
Total revenue
$
11,377
$
13,818
$
20,070
$
28,616
$
43,209
$
8,747
$
12,289
We expect continued growth in product revenue due to increasing
market acceptance of our line of aerogel blankets and increasing
demand for energy efficiency products to reduce energy
consumption and
CO2
emissions. We expect that research services revenue will decline
due to the recent trend toward tightening of federal spending
guidelines and programs.
Product revenue accounted for 88% and 92% of total revenue for
the three months ended March 31, 2010 and 2011,
respectively, and 86%, 86% and 90% for the years ended
December 31, 2008, 2009 and 2010, respectively. We expect
that product revenue will continue to increase as a percentage
of our total revenue due to the anticipated strong growth in
product revenue in combination with the expected decline in
research services revenue.
A significant portion of our revenue is generated from a limited
number of customers, principally our distributors and
contractors. Our 10 largest customers accounted for
approximately 70% of our total revenue during the three months
ended March 31, 2011, and we expect that most of our
revenue will continue to come from a relatively small number of
customers for the foreseeable future. For the three months ended
March 31, 2010, one customer represented 36% of our total
revenue and for the three months ended March 31, 2011, two
customers represented 29% and 10%, respectively, of our total
revenue. In 2008, one customer represented 12% of our total
revenue; in 2009, no customers represented 10% or more of our
total revenue; and in 2010, one customer represented 14% of
total revenue.
Cost of revenue for our product revenue consists primarily of
raw materials, direct labor and manufacturing overhead. Cost of
product revenue is recorded when the related product revenue is
recognized. Cost of product revenue also includes stock-based
compensation and costs of shipping.
Raw material is our most significant component of cost of
product revenue and includes fibrous batting, silica materials
and additives. Raw material costs have declined as a percentage
of revenue during the past three years due principally to
purchasing efficiencies and manufacturing yield improvements.
Raw material costs as a percentage of product revenue vary from
product to product due to differences in average selling prices,
material requirements, blanket thickness and manufacturing
yields. As a result, raw material costs as a percentage of
revenue will vary from period to period due to changes in the
mix of aerogel products sold. However, in general, we expect raw
material costs in the aggregate to decline modestly as a
percentage of revenue as we seek to achieve continued sourcing
improvements and yield enhancements.
Manufacturing expense, including direct labor and manufacturing
overhead, is also a significant component of cost of revenue. We
expect to incur a significant increase in manufacturing expense
associated with the start up and operation of our second
production line in the East Providence facility. These costs are
principally fixed in nature and will be underabsorbed during the
period in which we ramp the production line to full capacity.
These underabsorbed manufacturing costs will increase the cost
of product revenue as a percentage of revenue in the near term,
but we expect these costs to decrease as a percentage of revenue
as a result of revenue growth supported by the increase in
manufacturing capacity.
Cost of revenue for our research services revenue consists
primarily of direct labor costs of research personnel committed
to funded research and development contracts, as well as
third-party consulting, and associated direct material costs.
Cost of revenue also includes overhead expenses associated with
project resources, engineering tools and supplies. Research
services cost of revenue is recorded when the related research
services revenue is recognized.
Gross
Profit
Our gross profit as a percentage of revenue is affected by a
number of factors, including the mix between product revenue and
research services revenue, the mix of aerogel products sold,
average selling prices, average material costs, our actual
manufacturing costs and the costs associated with expansions and
start-up of
production capacity. As we continue to grow our base of product
revenue and to build out our manufacturing capacity, we expect
increased manufacturing expenses will periodically have a
negative impact on gross profit, but will set the framework for
improved gross profit moving forward. Accordingly, we expect
that our gross profit in absolute dollars and as a percentage of
revenue to vary from period to period as we expand our
manufacturing capacity. However, in general, we expect gross
profit to improve as a percentage of revenue in the long-term
due to increases in manufacturing productivity, increased
production volumes, improved manufacturing yields and material
purchasing efficiencies.
Operating
Expenses
Operating expenses consist of research and development, sales
and marketing, and general and administrative expenses. The
largest component of our operating expenses is personnel costs,
consisting of salaries, benefits, incentive compensation and
stock-based compensation. We expect to continue to hire a
significant number of new employees in order to support our
anticipated growth. In any particular period, the timing of
additional hires could materially affect our operating expenses,
both in absolute dollars and as a percentage of revenue.
Operating expenses are reported net of any funding received
under contracts that are considered to be cost-sharing
arrangements with no contractually committed deliverable. We
have
entered into several cost-sharing arrangements with various
agencies of the U.S. government. Funds paid to us under
these agreements are not reported as revenue but are used to
directly offset our cost of revenue, research and development,
sales and marketing and general and administrative expenses in
support of our product revenue. Costs incurred and cost of
revenue, research and development, sales and marketing and
general and administrative expenditures offset by cost sharing
funding received under these contracts are as follows:
Three Months Ended
Year Ended December 31
March 31
2008
2009
2010
2010
2011
($ in thousands)
Total costs incurred
$
3,193
$
1,672
$
2,005
$
12
$
181
Expenditures offset by cost sharing funding received:
Cost of revenue:
Product
$
43
$
20
$
33
$
—
$
8
Research services
1,227
637
1,124
5
54
Operating expenses:
Research and development
1,214
620
475
4
83
Sales and marketing
342
193
170
1
16
General and administrative
367
202
203
2
20
Total expenditures offset by cost sharing
$
3,193
$
1,672
$
2,005
$
12
$
181
We do not expect to receive any additional funds under
cost-sharing arrangements in the near term due to the recent
trend toward tightening of federal spending guidelines and
programs.
Research and
Development Expenses
Research and development expenses consist primarily of expenses
for personnel engaged in the development of next generation
aerogel compositions, form factors and manufacturing
technologies. These expenses also include testing services,
prototype expenses, consulting services, equipment depreciation,
facilities costs and related overhead. We expense research and
development costs as incurred. We expect to continue to devote
substantial resources to the development of new aerogel
technology. We believe that these investments are necessary to
maintain and improve our competitive position. We expect that
our research and development expenses will continue to increase
as we continue to invest in additional research and engineering
personnel and the infrastructure required in support of their
efforts. Accordingly, we expect that our research and
development expenses will continue to increase in absolute
dollars but decrease as a percentage of revenue in the long-term.
Sales and
Marketing Expenses
Sales and marketing expenses consist primarily of
personnel-related costs, incentive compensation, marketing
programs, travel and entertainment costs, consulting expenses
and facilities-related costs. We plan to expand our sales force
and sales consultants globally to support anticipated growth in
customers and demand for our products. We expect that sales and
marketing expenses will continue to increase in absolute dollars
but decrease as a percentage of revenue in the long-term.
General and
Administrative Expenses
General and administrative expenses consist primarily of
personnel costs, legal expenses, consulting and professional
services, tax and audit costs, and expenses for our executive,
finance, human resources and information technology
organizations. We expect general and administrative expenses to
increase as we incur additional costs related to operating as a
publicly-traded company,
including costs of compliance with securities, corporate
governance and related regulations, investor relations expenses,
increased insurance premiums, including director and officer
insurance, and increased audit and legal fees. In addition, we
expect to add general and administrative personnel to support
the anticipated growth of our business and continued expansion
of our manufacturing operations. We expect that general and
administrative expenses will continue to increase in absolute
dollars but decrease as a percentage of revenue in the long-term.
Other Income
(Expense)
Other income (expense) consists primarily of imputed interest
expense on our cross license agreement with Cabot Corporation,
and interest expense on our term loans and notes payable and is
presented net of other income, which is primarily interest
income.
Provision for
Income Taxes
We have incurred net losses since inception and have not
recorded benefit provisions for U.S. federal income taxes
or state income taxes since the tax benefits of our net losses
have been offset by valuation allowances.
Key Metrics and
Non-GAAP Financial Measures
We regularly review a number of metrics, including the following
key metrics, to evaluate our business, measure our performance,
identify trends affecting our business, formulate financial
projections and make strategic decisions.
Square Foot
Operating Metric
We price our product and measure our product shipments in square
feet. We have produced in excess of 38 million square feet
of aerogel blankets in the East Providence facility since
mid-2008. Our annual manufacturing capacity is a function of
product mix. We expect our annual production capacity by the end
of 2011 to reach 40 million to 44 million square feet
of aerogel blankets, depending on product mix. We believe the
square foot operating metric allows us and our investors to
measure our manufacturing capacity and shipments on a uniform
and consistent basis. The following chart sets forth product
shipments in square feet for the periods presented:
Three Months Ended
Year Ended December 31
March 31
2008
2009
2010
2010
2011
Product shipments in square feet (in thousands)
6,909
10,525
16,443
3,480
5,110
Adjusted
EBITDA
We use Adjusted EBITDA, a non-GAAP financial measure, as a means
to assess our operating performance. We define Adjusted EBITDA
as income from operations before depreciation and amortization
expense, share-based compensation expense, and impairment
charges. Adjusted EBITDA is a supplemental measure of our
performance that is not required by, or presented in accordance
with, GAAP. Adjusted EBITDA should not be considered as an
alternative to income from operations or any other measure of
financial performance calculated and presented in accordance
with GAAP. In addition, our definition and presentation of
Adjusted EBITDA may not be comparable to similarly titled
measures presented by other companies.
We use Adjusted EBITDA as a measure of operating performance,
because it does not include the impact of items that we do not
consider indicative of our core operating performance, for
planning purposes, including the preparation of our annual
operating budget, to allocate resources to enhance the financial
performance of our business and as a performance measure used
under our bonus plan.
We also believe that the presentation of Adjusted EBITDA
provides useful information to investors with respect to our
results of operations and in assessing the performance and value
of our business. Various measures of EBITDA are widely used by
investors to measure a company’s operating performance
without regard to items that can vary substantially from company
to company depending upon financing and accounting methods, book
values of assets, capital structures and the methods by which
assets were acquired. See footnote (3) under “Summary
Consolidated Financial Data.”
To properly and prudently evaluate our business, we encourage
you to review the GAAP financial statements included elsewhere
in this prospectus, and not to rely on any single financial
measure to evaluate our business.
The following table presents a reconciliation of income (loss)
from operations, the most directly comparable GAAP measure, to
Adjusted EBITDA for the periods presented:
Year Ended December 31
2008
2009
2010
($ in thousands)
Income (loss) from operations
$
(28,131
)
$
(15,582
)
$
(7,495
)
Depreciation and amortization
7,059
5,630
4,633
Stock-based compensation(1)
927
831
468
Impairment charge
2,524
—
—
Adjusted EBITDA
$
(17,621
)
$
(9,121
)
$
(2,394
)
(1)
Represents non-cash stock-based
compensation related to stock option grants.
Three Months Ended
2009
2010
2011
March 31
June 30
Sept. 30
Dec. 31
March 31
June 30
Sept. 30
Dec. 31
March 31
($ In thousands)
Income (loss) from operations
$
(4,418
)
$
(5,119
)
$
(3,116
)
$
(2,929
)
$
(2,971
)
$
(2,752
)
$
(731
)
$
(1,041
)
$
(1,270
)
Depreciation and amortization
1,393
1,379
1,580
1,278
1,137
1,124
1,137
1,235
1,409
Stock-based compensation(1)
99
91
125
516
96
105
122
145
190
Impairment charge
—
—
—
—
—
—
—
—
—
Adjusted EBITDA
$
(2,926
)
$
(3,649
)
$
(1,411
)
$
(1,135
)
$
(1,738
)
$
(1,523
)
$
528
$
339
$
329
(1)
Represents non-cash stock-based
compensation related to stock option grants.
Our Adjusted EBITDA has improved significantly over the nine
quarters ending March 31, 2011. We achieved positive
Adjusted EBITDA for the first time in the three months ended
September 30,
2010, and have sustained a positive, quarterly Adjusted EBITDA
since that time.
Total revenue increased $3.5 million, or 40%, to
$12.3 million for the three months ended March 31,2011, from $8.7 million in the comparable quarter in 2010.
The increase was primarily the result of continued strong growth
in product revenue due to increasing market acceptance of our
products in the oil and gas sector of the industrial market.
Product revenue increased $3.6 million, or 47%, to
$11.3 million for the three months ended March 31,2011, from $7.7 million in the comparable quarter in 2010.
During the three months ended March 31, 2011,
$3.5 million of product revenue was associated with a
capital project in the Canadian oil-sands. In terms of volume,
product shipments increased 1.6 million square feet, or
47%, to 5.1 million square feet of aerogel products, as
compared to 3.5 million square feet in the comparable
quarter in 2010. We did not increase the prices of our products
during the periods presented. Product revenue as a percentage of
total revenue for the three months ended March 31, 2011
increased to 92% of total revenue from 88% of total revenue in
the comparable quarter in 2010. We expect that product revenue
will continue to increase as a percentage of total revenue in
the long-term.
Research services revenue decreased $0.1 million, or 5%, to
$1.0 million for the three months ended March 31, 2011
from $1.1 million in the comparable quarter in 2010. This
decrease in revenue is principally the result of a recent trend
toward tightening of federal spending guidelines and programs.
Research services revenue as a percentage of total revenue
decreased to 8% of total revenue for the three months ended
March 31, 2011 from 12% of total revenue in the comparable
quarter of 2010. We expect that research services revenue will
continue to decrease as a percentage of total revenue in the
long-term due to projected strong growth in product revenue.
Cost of
Revenue
Three Months Ended March 31
2010
2011
Percentage
Percentage
Percentage
Percentage
of Related
of Total
of Related
of Total
Change
Amount
Revenue
Revenue
Amount
Revenue
Revenue
Amount
Percentage
($ in thousands)
Cost of revenue:
Product
$
7,647
100
%
87
%
$
9,473
84
%
77
%
$
1,826
24
%
Research services
456
43
%
5
%
544
54
%
4
%
88
19
%
Total cost of revenue
$
8,103
93
%
93
%
$
10,017
82
%
82
%
$
1,914
24
%
Total cost of revenue increased $1.9 million, or 24%, to
$10.0 million for the three months ended March 31,2011 from $8.1 million in the comparable quarter in 2010.
The increase in total cost of revenue was the result of an
increase in raw material used to support increased output, in
combination with an increase in overhead expense to support the
planned increase in manufacturing capacity at our East
Providence facility. Product cost of revenue as a percentage of
product revenue decreased to 84% for the three months ended
March 31, 2011 from 100% in the comparable quarter in 2010,
primarily due to economies of scale related to the increase in
manufacturing output at the East Providence facility. We expect
to incur a significant increase in manufacturing costs beginning
in the three months ending June 30, 2011, primarily
associated with the start up and operation of our second
production line in the East Providence facility.
Research services cost of revenue as a percentage of research
services revenue increased to 54% for the three months ended
March 31, 2011 from 43% in the comparable quarter in 2010.
This increase was the result of a change in the mix of labor and
expenses required to perform the contracted research.
Gross profit increased $1.6 million, or 253%, to
$2.3 million for the three months ended March 31, 2011
from $0.6 million in the comparable quarter in 2010. This
increase in gross profit was principally the result of the
increase in product revenue, a reduction in material costs as a
percentage of product revenue and economies of scale related to
the increase in manufacturing output at our East Providence
facility. Gross profit as a percentage of total revenue
increased to 18% for the three months ended March 31, 2011
from 7% of total revenue in the comparable quarter in 2010. We
expect to experience a reduction in gross profit as a percentage
of total revenue during the three months ending June 30,2011, due to the increase in manufacturing costs associated with
the start up and operation of our second production line in our
East Providence facility. We expect gross profit as a percentage
of total revenue to increase in the long-term due to projected
growth in product revenue supported by the increase in
manufacturing capacity.
Research and
Development, or R&D, Expenses
Three Months Ended March 31
2010
2011
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
R&D expenses
$
917
10
%
$
731
6
%
$
(186
)
(20
)%
R&D expenses decreased $0.2 million, or 20%, to
$0.7 million for the three months ended March 31, 2011
from $0.9 million in the comparable quarter in 2010. This
decrease was principally the result of an increase in labor
allocated to research services and capitalization of plant
engineering costs related to the construction of our second
production line at our East Providence facility. R&D
expenses as a percentage of total revenue decreased to 6% for
the three months ended March 31, 2011 from 10% in the
comparable period in 2010. This decrease was principally the
result of the significant increase in total revenue for the
three months ended March 31, 2011 from the comparable
period in 2010. We expect that our research and development
expenses will increase as we invest in additional research and
engineering personnel and the infrastructure required in support
of their efforts. However, we expect that research and
development expenses will decline as a percentage of total
revenue in the long-term due to projected strong growth in
product revenue.
Sales and
Marketing Expenses
Three Months Ended March 31
2010
2011
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Sales and marketing expenses
$
1,194
14
%
$
1,224
10
%
$
30
3
%
Sales and marketing expenses increased by 3% to
$1.2 million for the three months ended March 31, 2011
from the comparable quarter in 2010. An increase in expense
associated with
additional sales and marketing personnel was offset by a
decrease in incentive compensation during the period. Sales and
marketing expenses as a percentage of total revenue decreased to
10% for the three months ended March 31, 2011 from 14% in
the comparable period in 2010. This decrease was principally
driven by the increase in total revenue for the three months
ended March 31, 2011, from the comparable period in 2010.
We plan to expand our sales force and sales consultants globally
to support anticipated growth in customers and demand for our
products. However, we expect that sales and marketing expenses
will continue to decline as a percentage of total revenue in the
long-term due to projected strong growth in product revenue.
General and
Administrative, or G&A, Expenses
Three Months Ended March 31
2010
2011
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
G&A expenses
$
1,504
17
%
$
1,587
13
%
$
83
6
%
G&A expenses increased $0.1 million, or 6%, to
$1.6 million for the three months ended March 31, 2011
from $1.5 million in the comparable quarter in 2010. This
modest increase was primarily the result of costs associated
with an increase in finance and human resource personnel in
preparation for operating as a public company. G&A expenses
as a percentage of total revenue decreased to 13% for the three
months ended March 31, 2011 from 17% in the comparable
period in 2010. This decrease was principally driven by the
increase in total revenue for the three months ended
March 31, 2011 from the comparable period in 2010. We
expect G&A expenses to increase as we incur additional
costs related to operating as a publicly traded company,
including costs of compliance with securities, corporate
governance and related regulations, investor relations expenses,
increased insurance premiums, including director and officer
insurance, ongoing listing fees, increased staff to comply with
public company requirements and increased legal and audit fees.
In addition, we expect to add general and administrative
personnel to support the anticipated growth of our business and
continued expansion of our manufacturing operations. However, we
expect that G&A expenses will decline as a percentage of
total revenue in the long-term due to projected strong growth in
product revenue.
Other Income
(Expense)
Three Months Ended March 31
2010
2011
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Other income (expense):
Interest income
$
10
0
%
$
48
0
%
$
38
380
%
Interest expense
(706
)
(8
)%
(499
)
(4
)%
207
29
%
Total other expense, net
$
(696
)
(8
)%
$
(451
)
(4
)%
$
245
35
%
Other expense, net of other income, decreased $0.2 million,
or 35%, to $0.5 million, for the three months ended
March 31, 2011 from $0.7 million in the comparable
quarter in 2010. This decrease was primarily the result of a
decrease in imputed interest expense associated with our cross
license agreement with Cabot. The decrease in imputed interest
expense was driven by payment of $7.5 million of this
obligation during the 12 months ending March 31, 2011,
which resulted in a corresponding reduction in imputed interest
expense during the period.
The following tables set forth our results of operations for the
periods presented:
Year Ended December 31
Year Ended December 31
2009
2010
$ Change
% Change
2009
2010
(Percentage of total revenue)
($ in thousands)
Revenue:
Product
$
24,752
$
38,690
$
13,938
56
%
86
%
90
%
Research services
3,864
4,519
655
17
%
14
%
10
%
Total revenue
28,616
43,209
14,593
51
%
100
%
100
%
Cost of revenue:
Product
30,462
35,399
4,937
16
%
106
%
82
%
Research services
1,788
2,119
331
19
%
6
%
5
%
Gross profit (loss)
(3,634
)
5,691
9,325
257
%
(13
)%
13
%
Operating expenses:
Research and development
2,524
2,985
461
18
%
9
%
7
%
Sales and marketing
3,994
4,526
532
13
%
14
%
10
%
General and administrative
5,430
5,675
245
5
%
19
%
13
%
Total operating expenses
11,948
13,186
1,238
10
%
42
%
31
%
Income (loss) from operations
(15,582
)
(7,495
)
8,087
52
%
(54
)%
(17
)%
Other income (expense):
Interest income
18
170
152
844
%
0
%
0
%
Interest expense
(3,075
)
(2,585
)
490
16
%
(11
)%
(6
)%
Total other expense, net
(3,057
)
(2,415
)
642
21
%
(11
)%
(6
)%
Net income (loss)
$
(18,639
)
$
(9,910
)
$
8,729
47
%
(65
)%
(23
)%
Revenue
Year Ended December 31
2009
2010
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Revenue:
Product
$
24,752
86
%
$
38,690
90
%
$
13,938
56
%
Research services
3,864
14
%
4,519
10
%
655
17
%
Total revenue
$
28,616
100
%
$
43,209
100
%
$
14,593
51
%
The following chart sets forth product shipments in square feet
for the periods presented:
Year Ended
December 31
Change
2009
2010
Amount
Percentage
Product shipments in square feet (in thousands)
10,525
16,443
5,918
56
%
Total revenue increased $14.6 million, or 51%, in 2010 to
$43.2 million from $28.6 million in 2009 primarily as
a result of an increase in product revenue. Product revenue
increased $13.9 million, or 56%, to $38.7 million in
2010 from $24.8 million in 2009. This increase was
principally the result of an increase in demand for our aerogel
products in the oil and gas sector of the industrial market in
2010 including the receipt of several large scale orders in the
offshore oil market and the Canadian oil sands. In volume terms,
product shipments increased 5.9 million square feet, or
56%, to 16.4 million square feet of aerogel products, as
compared to 10.5 million square feet in 2009. We did not
increase the prices of our products during the periods
presented. Research services revenue increased
$0.7 million, or 17%, to $4.5 million in 2010 from
$3.9 million in 2009 primarily due to revenue generated
under a significant contract with the Department of Energy.
Product revenue as a percentage of total revenue increased to
90% of total revenue in 2010, from 86% of total revenue in 2009.
Research services revenue decreased to 10% of total revenue in
2010 from 14% of total revenue in 2009. Moving forward, we
expect product revenue to continue to increase as a percentage
of total revenue, and research services revenue to continue to
decrease as a percentage of total revenue.
Cost of
Revenue
Year Ended December 31
2009
2010
Percentage
Percentage
Percentage
Percentage
of Related
of Total
of Related
of Total
Change
Amount
Revenue
Revenue
Amount
of Revenue
Revenue
Amount
Percentage
($ in thousands)
Cost of revenue:
Product
$
30,462
123
%
106
%
$
35,399
91
%
82
%
$
4,937
16
%
Research services
1,788
46
%
6
%
2,119
47
%
5
%
331
19
%
Total cost of revenue
$
32,250
113
%
113
%
$
37,518
87
%
87
%
$
5,268
16
%
Total cost of revenue increased $5.3 million, or 16%, to
$37.5 million in 2010 from $32.3 million in 2009. The
increase in total cost of revenue was the result of an increase
in raw material costs to support increased product revenue,
offset, in part, by a decrease in manufacturing expense due to
improved manufacturing productivity. Product cost of revenue as
a percentage of product revenue decreased to 91% during 2010
from 123% in 2009 due to the decrease in manufacturing costs, a
reduction in material costs as a percentage of product revenue,
and increased production volume during the year. The reduction
in material costs as a percentage of product revenue, in turn,
was the result of improved manufacturing yields and purchasing
efficiency during 2010. We expect to incur a significant
increase in manufacturing costs included in cost of revenue
during 2011 primarily associated with the start up and operation
of our second production line in the East Providence facility.
Research services cost of revenue increased $0.3 million,
or 19%, to $2.1 million during 2010 from $1.8 million
during 2009. The increase was due to the increase in research
services provided during 2010 and an unfavorable mix of labor
and expense associated with the contracts. Research services
cost of revenue as a percentage of research services revenue
increased to 47% during 2010 from 46% in 2009 principally due to
the mix of labor and expense required to perform the contracted
research, each of which carries a different rate of
reimbursement.
Gross profit increased $9.3 million, or 257%, to
$5.7 million in 2010 from a gross loss of $3.6 million
in 2009. This increase in gross profit was the result of
economies of scale associated with increased product revenue, a
reduction in material costs as a percentage of product revenue
due to improved manufacturing yields and purchasing efficiency
and a decrease in manufacturing expenses due to increased
productivity at our East Providence facility. Gross profit as a
percentage of total revenue increased to 13% of total revenue in
2010 from a gross loss of 13% of total revenue in 2009. We
expect gross profit as a percentage of total revenue to decrease
from 2010 levels in the near term due to the increase in
manufacturing expense associated with the start up and operation
of our second production line in the East Providence facility.
We expect gross profit as a percentage of total revenue to
increase in the long-term due to projected growth in product
revenue supported by the increase in manufacturing capacity.
R&D
Expenses
Year Ended December 31
2009
2010
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
R&D expenses
$
2,524
9
%
$
2,985
7
%
$
461
18
%
R&D expenses increased $0.5 million, or 18%, to
$3.0 million in 2010 from $2.5 million in 2009. This
increase was principally the result of an increase in
engineering personnel to support the operation of our East
Providence facility. R&D costs as a percentage of total
revenue decreased to 7% during 2010 from 9% during 2009. This
decrease was the result of strong growth in product revenue
during 2010. We expect that our research and development
expenses will continue to increase as we invest in additional
research and engineering personnel and the infrastructure
required in support of their efforts. However, we expect that
research and development expenses will decline as a percentage
of total revenue due to projected strong growth in product
revenue.
Sales and
Marketing Expenses
Year Ended December 31
2009
2010
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Sales and marketing expenses
$
3,994
14
%
$
4,526
10
%
$
532
13
%
Sales and marketing expenses increased $0.5 million, or
13%, to $4.5 million during 2010 from $4.0 million
during 2009. The increase in expense was driven by an increase
in sales personnel and an increase in incentive compensation
associated with the 56% increase in product revenue during 2010.
Sales and marketing expenses as a percentage of total revenue
decreased to 10% during 2010 from 14% in 2009. This decrease was
the result of the growth in total revenue during 2010. We plan
to continue to expand our sales force and sales consultants
globally during 2011 to support anticipated growth in customers
and demand for our products. We expect that sales and marketing
expenses will increase in absolute dollars but decrease as a
percentage of total revenue in the long-term.
G&A expenses increased $0.2 million, or 5%, to
$5.7 million in 2010 from $5.4 million in 2009. This
increase was primarily the result of an increase in finance and
human resource personnel. G&A expenses as a percentage of
total revenue decreased to 13% for 2010 from 19% in 2009. This
decrease was principally driven by the increase in total revenue
during the year. We expect G&A expenses to increase as we
incur additional costs related to operating as a publicly traded
company, including costs of compliance with securities,
corporate governance and related regulations, investor relations
expenses, increased insurance premiums, including director and
officer insurance, and increased legal and audit fees. In
addition, we expect to add general and administrative personnel
to support the anticipated growth of our business and continued
expansion of our manufacturing operations. As a result, we
expect that G&A expenses will increase in absolute dollars
but decrease as a percentage of total revenue in the long-term.
Other Income
(Expense)
Year Ended December 31
2009
2010
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Other income (expense):
Interest income
$
18
0
%
$
170
0
%
$
152
844
%
Interest expense
(3,075
)
(11
)%
(2,585
)
(6
)%
490
16
%
Total other expense, net
$
(3,057
)
(11
)%
$
(2,415
)
(6
)%
$
642
21
%
Other expense, net of other income, decreased $0.6 million,
or 21%, to $2.4 million in 2010 from $3.1 million in
2009. This decrease was primarily the result of a decrease in
imputed interest expense associated with our cross license
agreement with Cabot. The decrease in imputed interest expense
was driven by the payment of $7.4 million of this
obligation during the year ended December 31, 2010, which
resulted in a corresponding reduction in imputed interest
expense for the period.
The following chart depicts product shipments in square feet for
the periods presented:
Year Ended December 31
Change
2008
2009
Amount
Percentage
Product shipments in square feet (in thousands)
6,909
10,525
3,616
52
%
Total revenue increased $8.5 million, or 43%, in 2009 to
$28.6 million from $20.1 million in 2008 primarily as
a result of an increase in product revenue. Product revenue
increased $7.6 million, or 44%, to $24.8 million in
2009 from $17.2 million in 2008. This increase was
principally the result of a broad based increase in global
demand for our line of aerogel products in the oil and gas
sector of the industrial market. Product revenue during 2009 was
also supported by an expansion of our global insulation
distributor network. In addition, 2009 marked the first full
year of revenue of our Pyrogel XT and Cryogel Z product lines.
In volume terms, product shipments increased 3.6 million
square feet, or 52%, to 10.5 million square feet of aerogel
products in 2009, as compared to 6.9 million square feet in
2008. We did not increase the prices of our products during the
periods presented. Accordingly, the difference between revenue
growth and volume growth was the result of a change in mix of
products sold. Research services revenue increased
$1.0 million, or 35%, to $3.9 million in 2009 from
$2.9 million in 2008 primarily due to a number of
significant research contract awards.
Product revenue as a percentage of total revenue of 86% and
research services revenue of 14% during 2009 remained unchanged
from 2008.
Cost of
Revenue
Year Ended December 31
2008
2009
Percentage
Percentage
Percentage
Percentage
of Related
of Total
of Related
of Total
Change
Amount
Revenue
Revenue
Amount
Revenue
Revenue
Amount
Percentage
($ in thousands)
Cost of revenue:
Product
$
32,160
187
%
160
%
$
30,462
123
%
106
%
$
(1,698
)
(5
)%
Research services
1,169
41
%
6
%
1,788
46
%
6
%
619
53
%
Impairment charge
2,524
13
%
13
%
—
0
%
0
%
(2,524
)
(100
)%
Total cost of revenue
$
35,853
179
%
179
%
$
32,250
113
%
113
%
$
(3,603
)
(10
)%
Total cost of revenue decreased $3.6 million, or 10%, to
$32.3 million in 2009 from $35.9 million in 2008. The
decrease in total cost of revenue was the result of the shutdown
of our Northborough, Massachusetts prototype facility and
consolidation of manufacturing operations into our East
Providence facility. The shutdown resulted in a decrease in
manufacturing and overhead expenses. In addition, despite
significant growth in product revenue, material costs declined
in absolute dollars due to improved manufacturing yields and
purchasing efficiency. As a result, product cost of revenue as a
percentage of product revenue decreased to 123% during 2009 from
187% in 2008.
Research services cost of revenue increased $0.6 million,
or 53%, to $1.8 million during 2009 from $1.2 million
during 2008. The increase was due to the increase in research
services revenue during 2009 and an unfavorable mix of labor and
expense associated with the contracts. Research services cost of
revenue as a percentage of research services revenue increased
to 46% during 2009 from 41% in 2008 principally due to the mix
of labor and expense required to perform the contracted
research, each of which carries a different rate of
reimbursement.
In addition, total cost of revenue in 2008 included an
impairment charge of $2.5 million related to the shutdown
of our Northborough facility.
Gross loss decreased $12.1 million to $3.6 million in
2009 from a gross loss of $15.8 million in 2008. This
decrease in gross loss was the result of economies of scale
associated with increased product revenue, a reduction in
material costs as a percentage of product revenue due to
improved manufacturing yields and purchasing efficiency, and an
absolute dollar decrease in manufacturing expenses due the
shutdown of our Northborough facility. In addition, total cost
of revenue in 2008 included an impairment charge of
$2.5 million related to the shutdown of the Northborough
facility. Gross loss as a percentage of total revenue decreased
to 13% of total revenue in 2009 from a gross loss of 79% of
total revenue in 2008.
R&D
Expenses
Year Ended December 31
2008
2009
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
R&D expenses
$
2,134
11
%
$
2,524
9
%
$
390
18
%
R&D expenses increased $0.4 million, or 18%, to
$2.5 million in 2009, from $2.1 million in 2008. This
increase was principally the result of an increase in research
personnel devoted to product development and a reduction in
proceeds from cost-sharing arrangements. R&D costs as a
percentage of total revenue decreased to 9% during 2009 from 11%
during 2008. This decrease was the result of the growth in total
revenue during 2009.
Sales and
Marketing Expenses
Year Ended December 31
2008
2009
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Sales and marketing expenses
$
4,034
20
%
$
3,994
14
%
$
(40
)
(1
)%
Sales and marketing expenses remained relatively unchanged from
the 2008 levels. A reduction in expense associated with a
reduction in sales personnel was offset by expense related to a
non-compete agreement during 2009. Sales and marketing expenses
as a percentage of total revenue decreased to 14% during 2009
from 20% in 2008. This decrease was primarily the result of the
growth in total revenue during 2009.
G&A expenses decreased $0.8 million, or 12%, to
$5.4 million in 2009 from $6.2 million in 2008. This
decrease was the result of a decrease in depreciation of assets
in our Northborough facility and a reduction in legal and
professional fees. G&A expenses as a percentage of total
revenue decreased to 19% during 2009 from 31% during 2008. This
decrease was principally driven by the reduction in G&A
expenses and the increase in total revenue during the year.
Other Income
(Expense)
Year Ended December 31
2008
2009
Percentage
Percentage
Change
Amount
of Revenue
Amount
of Revenue
Amount
Percentage
($ in thousands)
Other income (expense):
Interest income
$
287
1
%
$
18
0
%
$
(269
)
(94
)%
Interest expense
(7,400
)
(37
)%
(3,075
)
(11
)%
4,325
58
%
Total other expense, net
$
(7,113
)
(35
)%
$
(3,057
)
(11
)%
$
4,056
57
%
Other expense, net of other income, decreased $4.1 million,
or 57%, to $3.1 million in 2009 from $7.1 million in
2008. This decrease was primarily due to a decrease in interest
expense following the conversion of our 14% promissory notes due
2010 and demand notes into several classes of preferred stock on
June 10, 2008. In addition, imputed interest expense
decreased due to the repayment of $4.4 million of our
obligation under our cross license agreement with Cabot during
2009.
Quarterly Results
of Operations
The unaudited consolidated financial statements for each of the
quarters presented were prepared on a basis consistent with our
audited consolidated financial statements and include all
adjustments, consisting of normal and recurring adjustments,
that our management considers necessary for a fair presentation
of the financial position and results of operations as of and
for such periods. You should review our quarterly operating
results in conjunction with our consolidated financial
statements and the related notes located elsewhere in this
prospectus. The results of operations for any quarter are not
necessarily indicative of the results of operations for any
future periods.
Seasonality
and Quarterly Results
Our operating results may fluctuate for a variety of reasons
outside of our control, including seasonal factors that
influence our customers and our markets. Historically, we have
experienced a relatively high level of revenue in the quarter
ended December 31 of each year and a relatively low level of
revenue in the quarter ending March 31 of each year. As a
result, comparing our operating results on a
period-to-period
basis may not be meaningful and historical results may not be
indicative
of future performance. The following table sets forth the
unaudited quarterly consolidated results of operations data for
each of the quarters presented:
Three Months Ended
2009
2010
2011
March 31
June 30
Sept. 30
Dec. 31
March 31
June 30
Sept. 30
Dec. 31
March 31
($ in thousands)
Revenue:
Product
$
3,886
$
5,949
$
5,967
$
8,950
$
7,681
$
8,327
$
10,187
$
12,495
$
11,274
Research services
879
866
1,076
1,043
1,066
1,172
1,059
1,222
1,015
Total revenue
4,765
6,815
7,043
9,993
8,747
9,499
11,246
13,717
12,289
Cost of revenue:
Product
6,064
8,426
6,860
9,112
7,647
8,467
8,567
10,718
9,473
Research services
346
418
498
526
456
549
508
606
544
Gross profit (loss)
(1,645
)
(2,029
)
(315
)
355
644
483
2,171
2,393
2,272
Operating expenses:
Research and development
614
601
538
771
917
802
535
731
731
Sales and marketing
749
1,276
892
1,077
1,194
1,124
1,007
1,201
1,224
General and administrative
1,410
1,213
1,371
1,436
1,504
1,309
1,360
1,502
1,587
Total operating expenses
2,773
3,090
2,801
3,284
3,615
3,235
2,902
3,434
3,542
Income (loss) from operations
(4,418
)
(5,119
)
(3,116
)
(2,929
)
(2,971
)
(2,752
)
(731
)
(1,041
)
(1,270
)
Other income (expense):
Interest income
6
—
14
(2
)
10
27
1
133
48
Interest expense
(818
)
(773
)
(764
)
(720
)
(706
)
(698
)
(607
)
(574
)
(499
)
Total other expense, net
(812
)
(773
)
(750
)
(722
)
(696
)
(671
)
(606
)
(441
)
(451
)
Net income (loss)
$
(5,230
)
$
(5,892
)
$
(3,866
)
$
(3,651
)
$
(3,667
)
$
(3,423
)
$
(1,337
)
$
(1,482
)
$
(1,721
)
Our Adjusted EBITDA has improved dramatically over the nine
quarters ending March 31, 2011. We achieved positive
Adjusted EBITDA for the first time in the three months ended
September 30, 2010, and have sustained a positive,
quarterly Adjusted EBITDA since that time. The following table
sets forth a reconciliation of income (loss) from operations to
Adjusted EBITDA for the periods presented:
Three Months Ended
2009
2010
2011
March 31
June 30
Sept. 30
Dec. 31
March 31
June 30
Sept. 30
Dec. 31
March 31
($ in thousands)
Income (loss) from operations
$
(4,418
)
$
(5,119
)
$
(3,116
)
$
(2,929
)
$
(2,971
)
$
(2,752
)
$
(731
)
$
(1,041
)
$
(1,270
)
Depreciation and amortization
1,393
1,379
1,580
1,278
1,137
1,124
1,137
1,235
1,409
Stock-based compensation
99
91
125
516
96
105
122
145
190
Impairment charge
—
—
—
—
—
—
—
—
—
Adjusted EBITDA
$
(2,926
)
$
(3,649
)
$
(1,411
)
$
(1,135
)
$
(1,738
)
$
(1,523
)
$
528
$
339
$
329
Liquidity and
Capital Resources
Overview
We have experienced significant losses since inception, have an
accumulated deficit of $197.9 million as of March 31,2011 and have significant ongoing cash flow commitments. We have
invested significant resources to commercialize aerogel
technology and to build a manufacturing infrastructure capable
of supplying aerogel products at the volumes and costs required
by our customers. We currently market a set of commercially
viable products, serve a growing base of customers and are
experiencing rapid growth.
Our financial forecast anticipates increasing revenue, improving
levels of profitability and improving cash flow from operations
supported by capacity expansions and related capital
investments. Based on this forecast, we believe that our
existing cash, cash equivalents, marketable securities,
available credit, and proceeds under recent debt financings will
be sufficient to satisfy anticipated cash requirements during
the next 12 months. However, if our operating performance
falls short of forecast and deteriorates from levels achieved
during 2010, we could conceivably experience a decrease in
liquidity and a deterioration of our ability to continue as a
going concern. Accordingly, we will continue to seek new sources
of debt and equity financing, including funds generated through
this offering, to expand our cash balances, financial resources
and available credit to ensure our ability to meet commitments
and to fully fund our operational plans.
Primary
Sources of Liquidity
As of March 31, 2011, we had $16.4 million of cash and
cash equivalents.
In December 2010, we entered into a subordinated note and
warrant purchase agreement with affiliates of Piper Capital LLC
and other investors and issued an aggregate of
$10.0 million principal amount of secured subordinated
promissory notes, which we refer to as our subordinated notes.
The subordinated notes bear interest at the rate of 12% annually
and are required to be repaid upon the earlier of:
(i) March 2, 2014, (ii) the first anniversary of
the completion of this offering or (iii) the last business
day prior to the date that any of our preferred stock is
redeemed. See “Description of Certain Indebtedness.”
In March 2011, we entered into a $10.0 million revolving
credit facility with Silicon Valley Bank, which we refer to as
our revolving credit facility, under which we could have drawn
$8.0 million as of March 31, 2011 due to borrowing
base limitations. Interest on extensions of credit under the
revolving credit facility is equal to the prime rate which at
March 31, 2011 was 4.0% per annum, plus 1.0% per annum,
provided that if we are at or above a certain liquidity
threshold, interest on extensions of credit under the revolving
credit facility is equal to the prime rate plus 0.5% per annum.
In addition, we are required to pay a quarterly unused revolving
line facility fee of 0.5% per annum of the average unused
portion of the revolving credit facility. The revolving credit
facility will mature on March 31, 2013. As of
March 31, 2011, there were no amounts outstanding under the
revolving credit facility. See “Description of Certain
Indebtedness.”
In June 2011, we entered into a note purchase agreement with
certain affiliates of Fidelity Investments and BASF Venture
Capital and issued $30.0 million aggregate principal amount
of unsecured convertible notes, which we refer to as our
convertible notes, with a maturity date of June 1, 2014.
Interest on the convertible notes accrues at the rate of 8.0%
per year. The unpaid principal amount of the convertible notes,
together with any interest accrued but unpaid thereon, will be
automatically converted into common stock upon the closing of
the offering made hereby at a conversion price equal to 87.5% of
the price to the public in this offering. See “Description
of Certain Indebtedness.”
We are currently in the due diligence phase of the application
process for a loan guarantee with the Department of Energy under
Section 1703 of Title XVII of the Energy Policy Act of
2005 for a term loan in the amount of approximately
$70 million to be used in the financing of the expansion of
our East Providence facility. Our continued expansion of our
East Providence facility is not dependent upon obtaining this
guarantee. If awarded, we will assess the opportunity to obtain
a loan guaranteed under this program.
The following table summarizes our cash flows for the periods
indicated:
Three Months Ended
Year Ended December 31
March 31
2008
2009
2010
2010
2011
($ in thousands)
Net cash (used in) provided by:
Operating activities
$
(21,973
)
$
(12,972
)
$
(15,126
)
$
(4,692
)
$
(2,221
)
Investing activities
(952
)
(1,783
)
(15,707
)
(391
)
(7,849
)
Financing activities
34,119
30,269
30,131
(188
)
(351
)
Net increase (decrease) in cash
11,194
15,514
(702
)
(5,271
)
(10,421
)
Cash and cash equivalents, beginning of period
794
11,988
27,502
27,502
26,800
Cash and cash equivalents, end of period
$
11,988
$
27,502
$
26,800
$
22,231
$
16,379
Net Cash Used in
Operating Activities
Our net cash used in operating activities for the three months
ended March 31, 2011 was $2.2 million and was
primarily due to our net loss of $1.7 million adjusted for
non-cash items of $2.1 million (including depreciation and
amortization of $1.4 million, imputed interest of
$0.5 million and stock compensation expense and other items
of $0.2 million) and the net decrease in cash due to
changes in operating assets and liabilities of
$2.6 million. This decrease in cash from changes in
operating assets and liabilities is primarily due to the
payments made pursuant to our cross license agreement with Cabot.
Our net cash used in operating activities in 2010 was
$15.1 million and was primarily due to our net loss of
$9.9 million adjusted for non-cash items of
$7.5 million (including depreciation and amortization of
$4.6 million, imputed interest of $2.4 million, and
stock compensation expense of $0.5 million) and a net
decrease in cash due to changes in operating assets and
liabilities of $12.8 million. The net decrease in cash due
to changes in operating assets and liabilities was primarily the
result of increases in accounts receivable of $6.0 million,
inventories of $0.7 million, other current assets of
$0.3 million, and a decrease in other long-term liabilities
of $7.4 million and deferred revenue of $0.2 million
slightly offset by an increase in accrued expenses of
$1.6 million. The increases in accounts receivable and
inventory balances are primarily the result of the increase in
revenue and the decrease in other long-term liabilities is due
to the payments made pursuant to our cross license agreement
with Cabot.
Our net cash used in operating activities in 2009 was
$13.0 million and was primarily due to our net loss of
$18.6 million adjusted for non-cash items of
$9.5 million (including depreciation and amortization of
$5.6 million, imputed interest of $3.0 million, and
stock compensation expense of $0.8 million) and a net
decrease in cash due to changes in operating assets and
liabilities of $3.8 million, primarily due to a decrease in
other long-term liabilities of $4.4 million and a decrease
in accounts payable of $1.3 million slightly offset by
decreases in inventories of $1.6 million and accounts
receivable of $0.2 million. The decrease in other long-term
liabilities is due to the payments made pursuant to our cross
license agreement with Cabot.
Our net cash used in operating activities in 2008 was
$22.0 million and was primarily due to our net loss of
$35.2 million adjusted for non-cash items of
$17.6 million (including depreciation and amortization of
$7.1 million, an asset impairment charge of
$2.5 million, imputed interest of $3.5 million,
paid-in-kind
interest of $3.4 million, stock compensation expense of
$0.9 million and other items of $0.2 million) and a
net decrease in cash due to changes in operating assets and
liabilities of $4.4 million, primarily due to increases in
accounts receivable of $1.1 million, inventories of
$1.8 million and a decrease in long-term liabilities of
$4.0 million, slightly offset by increases in
accounts payable of $1.9 million and deferred revenue of
$0.5 million. The decrease in other long-term liabilities
is due to the payments made pursuant to our cross license
agreement with Cabot.
Net Cash Used in
Investing Activities
Net cash used in investing activities primarily related to
capital expenditures to support our growth. For the year ended
December 31, 2010, and the three months ended
March 31, 2011, investing activities also include
purchases, sales and maturities of our marketable securities.
Net cash used in investing activities for the three months ended
March 31, 2011 totaled $7.8 million and included
capital expenditures of $11.9 million for machinery and
equipment, primarily related to the build-out of our second
manufacturing line at our East Providence facility, offset, in
part, by net proceeds from the sale of marketable securities of
$4.0 million.
Net cash used in investing activities for 2010 totaled
$15.7 million and included capital expenditures of
$11.3 million for machinery and equipment, primarily
related to the build-out of our second manufacturing line at our
East Providence facility, an increase in our restricted cash
balance of $0.3 million, and net purchases of our
marketable securities of $4.1 million.
Net cash used in investing activities for 2009 totaled
$1.8 million and was principally related to capital
expenditures for machinery and equipment.
Net cash used in investing activities for 2008 totaled
$1.0 million and was principally related to capital
expenditures for machinery and equipment.
Net Cash Provided
by Financing Activities
Cash flows from financing activities primarily include net
proceeds from issuances of preferred stock and proceeds and
payments related to issuances of notes payable.
Net cash used by financing activities for the three months ended
March 31, 2011 totaled $0.4 million and included
payment of deferred financing costs of $0.3 million and
repayments of borrowings under long-term debt and capital lease
obligations of $0.1 million.
Net cash provided by financing activities in 2010 totaled
$30.1 million and included proceeds from the issuance of
preferred stock of $21.1 million and proceeds from the
issuance of debt of $10.0 million that were partially
offset by payment of deferred financing costs of
$0.7 million and repayments of borrowings under long-term
debt and capital lease obligations of $0.3 million.
Net cash provided by financing activities in 2009 totaled
$30.3 million and included proceeds from the issuance of
preferred stock of $30.5 million that were offset, in part,
by repayments of borrowings under long-term debt and capital
lease obligations of $0.3 million.
Net cash provided by financing activities in 2008 totaled
$34.1 million and included proceeds from the issuance of
preferred stock of $26.6 million and proceeds from the
issuance of debt of $8.0 million that were offset, in part,
by repayments of borrowings under long-term debt and capital
lease obligations of $0.5 million.
Future Capital
Requirements
We believe that our available cash, cash equivalents, marketable
securities and amounts available under the revolving credit
facility will be sufficient to fund our operations for at least
the next 12 months. Our future capital requirements will
depend on many factors, including our rate of revenue growth,
the expansion of our sales and marketing activities, extent of
spending to support technology development efforts, the
expansion of our manufacturing capacity, the timing of new
product introductions, investment in infrastructure to support
our growth, and the continued growth in market acceptance of our
products and services.
The following table summarizes our contractual obligations as of
March 31, 2011, under contracts that provide for fixed and
determinable payments over the periods indicated:
Less than
More than
Contractual
Obligations(1)
Total
1 Year
1-3 Years
3-5 Years
5 Years
($ in thousands)
Operating leases
$
2,091
$
617
$
1,250
$
120
$
104
Capital leases
174
44
110
20
—
6% Term Loan
179
179
—
—
—
Subordinated Notes(2)
14,556
—
14,556
—
—
Accrued ARO
1,033
—
1,033
—
—
Cross License Agreement
16,500
6,000
10,500
—
—
Purchase Commitment
5,259
3,189
2,070
—
—
Total
$
39,792
$
10,029
$
29,519
$
140
$
104
(1)
The contractual obligations table
excludes repayment of our convertible notes issued in June 2011,
all of which will be automatically converted into shares of our
common stock upon closing of the offering made hereby.
(2)
In connection with the issuance of
our convertible notes issued in June 2011, the holders of our
subordinated notes amended the terms of their original agreement
to require that the subordinated notes would become due
March 2, 2014, prior to the maturity of our convertible
notes. The new amount due has been retroactively presented as if
these terms were in place at March 31, 2011.
Operating and
Capital Leases
We lease our office space for our corporate offices in
Northborough, Massachusetts, which expires in 2013, and a
warehouse facility and land adjacent to our East Providence
facility, which expire at various dates from 2013 through 2021,
under non-cancelable operating lease agreements. See
“Business — Facilities.” We also lease
vehicles and equipment under non-cancelable capital leases that
expire at various dates.
6% Term
Loan
In January 2005, we executed a term loan with the Massachusetts
Development Finance Agency for $1.5 million. The proceeds
were used to build research and development lab space at our
Northborough facility. The term loan bears interest at 6% per
annum, is to be repaid in monthly installments of principal and
interest through January 2012, and is secured by certain
leasehold improvements and laboratory equipment.
Subordinated
Notes
On December 29, 2010, we issued secured subordinated
promissory notes for aggregate proceeds of $10.0 million.
The proceeds were used to fund, in part, the construction of a
second manufacturing line at our East Providence facility. The
notes are collateralized by certain of our assets at our East
Providence facility. The term notes bear interest at 12% per
annum, and all accrued interest on the notes is compounded by
adding it to the principal of the subordinated notes on a
semi-annual basis commencing on June 30, 2011 and
continuing until the last such date to occur prior to maturity.
The subordinated notes are required to be repaid upon the
earlier of: (i) March 2, 2014, (ii) the first
anniversary of the completion of this offering or (iii) the
last business day prior to the date that any of our preferred
stock is redeemed. The noted contractual obligation reflects the
balance of principal and accrued interest anticipated to be due
on March 2, 2014.
We have asset retirement obligations arising from requirements
to perform certain asset retirement activities at the
termination of our Northborough facility lease and upon disposal
of certain machinery and equipment. The liability was initially
measured at fair value and subsequently adjusted for accretion
expense and changes in the amount or timing of the estimated
cash flows. The corresponding asset retirement costs are
capitalized as part of the carrying amount of the related
long-lived asset and depreciated over the asset’s remaining
useful life. We maintain restricted cash balances of
$0.2 million to settle part of this liability.
Cross License
Agreement
We are obligated to make quarterly payments through December
2013 under the terms of our cross license agreement with Cabot.
As of March 31, 2011, our remaining payment obligation
under the cross license agreement totaled $16.5 million.
Purchase
Commitment
We have agreed to purchase at least 2.4 million pounds of
silica annually through 2012 at a fixed price per pound pursuant
to the terms of a supply agreement dated January 1, 2011.
The contractual obligation set forth in the table above assumes
that the price we pay per pound of silica remains fixed through
the term of the contract. As of March 31, 2011, we have
purchased 0.2 million pounds of silica and have a remaining
commitment in 2011 of 2.2 million pounds.
Off Balance Sheet
Arrangements
Since inception, we have not engaged in any off balance sheet
activities as defined in Item 303(a)(4) of
Regulation S-K.
Recent Accounting
Pronouncements
In October 2009, the Financial Accounting Standards Board, or
the FASB, issued Accounting Standards Update, or ASU,
No. 2009-13,
Multiple-Deliverable Revenue Arrangements, or ASU
2009-13. ASU
2009-13
supersedes certain guidance in FASB ASC Topic
605-25,
Multiple-Element Arrangements and requires an entity to
allocate arrangement consideration at the inception of an
arrangement to all of its deliverables based on their relative
selling prices (the relative-selling-price method). ASU
2009-13
eliminates the use of the residual method of allocation in which
the undelivered element is measured at its estimated selling
price and the delivered element is measured as the residual of
the arrangement consideration, and requires the
relative-selling-price method in all circumstances in which an
entity recognizes revenue for an arrangement with multiple
deliverables subject to ASU
2009-13. ASU
2009-13 must
be adopted no later than the beginning of the first fiscal year
beginning on or after June 15, 2010, with early adoption
permitted through either prospective application for revenue
arrangements entered into, or materially modified, after the
effective date or through retrospective application to all
revenue arrangements for all periods presented. We have adopted
ASU 2009-13
and determined that it does not have a material impact on our
consolidated financial statements.
Critical
Accounting Policies and Estimates
Our financial statements are prepared in accordance with
accounting principles generally accepted in the United States of
America. The preparation of our financial statements and related
disclosures requires us to make estimates, assumptions and
judgments that affect the reported amount of assets,
liabilities, revenue, costs and expenses and related
disclosures. We believe that the estimates, assumptions and
judgments involved in the accounting policies described below
have the greatest potential impact on our financial statements;
and therefore, we consider these to be our critical accounting
policies. Accordingly, we evaluate our estimates and assumptions
on an ongoing
basis. Our actual results may differ from these estimates under
different assumptions and conditions. See Note 2 to our
consolidated financial statements included elsewhere in this
prospectus for information about these critical accounting
policies, as well as a description of our other significant
accounting policies.
Revenue
Recognition
We recognize product revenue from the sale of our line of
aerogel products and research services revenue upon delivery of
research and development services, including under contracts
with various agencies of the U.S. government. Revenue is
recognized when all of the following criteria are met:
persuasive evidence of an arrangement exists, the price to the
buyer is fixed or determinable, delivery has occurred or
services have been provided and collectability is reasonably
assured. Product revenue is generally recognized upon transfer
of title and risk of loss, which is generally upon shipment or
delivery. In general, our customary shipping terms are FOB
shipping point. Products are typically delivered without
significant post-sale obligations to customers other than
standard warranty obligations for product defects. We provide
warranties for our products and record the estimated cost within
cost of sales in the period that the revenue is recorded. Our
standard warranty period extends one to two years from the date
of sale, depending on the type of product purchased. Our
warranties provide that our products will be free from defects
in material and workmanship, and will, under normal use, conform
to the specifications for the product. For the three months
ended March 31, 2011, and for the years ended
December 31, 2008, 2009 and 2010, warranty charges have
been insignificant.
We perform research services under contracts with various
government agencies and other institutions. We record revenue
earned on research services contracts using the
percentage-of-completion method in two ways: (1) for
firm-fixed-price contracts, we accrue that portion of the total
contract price that is allocable, on the basis of the our
estimates of costs incurred to date to total contract costs;
(2) for cost-plus-fixed-fee contracts, we record revenue
that is equal to total payroll cost incurred times a stated
factor plus reimbursable expenses, to a stated upper limit.
Revisions in cost estimates and fees during the course of the
contract are reflected in the accounting period in which the
facts that require the revisions become known.
Contract costs and rates used to allocate overhead to contracts
are subject to audit by the respective contracting government
agency. Adjustments to revenue as a result of audit are recorded
in the period they become known.
We maintain an equity incentive plan pursuant to which our board
of directors may grant qualified and nonqualified stock options
to officers, key employees, and others who provide or have
provided service to us. We recognize the costs associated with
stock option grants based on their estimated fair value at date
of grant amortized over the vesting period of the grant, which
is typically three to four years. Future expense amounts for any
particular quarterly or annual period could be affected by
changes in our assumptions or changes in market conditions.
Stock-based compensation is included in cost of revenue and
operating expenses as set forth below:
Year Ended December 31
Three Months Ended March 31
2008
2009
2010
2010
2011
($ in thousands)
Stock-based compensation:
Product cost of revenue
$
178
$
148
$
81
$
18
$
31
Operating expenses:
Research and development
67
96
57
13
20
Sales and marketing
136
157
87
21
28
General and administrative
546
430
243
44
111
Total
$
927
$
831
$
468
$
96
$
190
As of March 31, 2011, there was approximately
$2.1 million of total estimated unrecognized compensation
cost related to non-vested options under our equity incentive
plan, which will be recognized over a weighted-average period of
3.6 years.
We use the Black-Scholes option-pricing model to estimate the
fair value of stock-based awards. The determination of the
estimated fair value of stock-based awards is based on a number
of complex and subjective assumptions. These assumptions include
the determination of the estimated fair value of the underlying
security, the expected volatility of the underlying security, a
risk-free interest rate, the expected term of the option, and
the forfeiture rate for the award class. The following
assumptions were used to estimate the fair value of the option
awards:
Three Months
Year Ended December 31
Ended March 31
2008
2009
2010
2010
2011
Weighted-average assumptions:
Expected term (in years)
6.08
5.60
6.04
5.94
6.06
Expected volatility
33.00
%
57.00
%
49.75
%
49.95
%
50.73
%
Risk free rate
3.65
%
2.64
%
1.90
%
2.76
%
2.31
%
Expected dividend yield
0.00
%
0.00
%
0.00
%
0.00
%
0.00
%
•
The expected term represents the period that our stock-based
awards are expected to be outstanding and is determined using
the simplified method described in ASC 718 for all grants.
We believe this is a better representation of the estimated life
than our actual limited historical exercise behavior.
•
For the three months ended March 31, 2010 and 2011, and for
the years ended December 31, 2008, 2009, and 2010, the
expected volatility is based on the weighted-average volatility
of up to six companies within various industries that the we
believe are similar to our own.
•
The risk-free interest rate is based on U.S. Treasury
zero-coupon issues with a remaining term equal to the expected
life assumed at the date of grant.
We use an expected dividend yield of zero, since we do not
intend to pay cash dividends on our common stock in the
foreseeable future, nor have we paid dividends on our common
stock in the past.
As share-based compensation expense is recognized based on
awards ultimately expected to vest, it has been reduced for an
estimated forfeiture rate of 3% for the three months ended
March 31, 2010 and 2011, and the years ended
December 31, 2009 and 2010, and 7% for 2008. Forfeitures
are required to be estimated at the time of grant and revised,
if necessary, in subsequent periods, if actual forfeitures
differ from those estimates. Forfeitures were estimated based on
voluntary termination behavior as well as analysis of actual
option forfeitures.
The assumptions underlying these valuations represent
management’s estimates, which involve inherent
uncertainties and the application of management judgment. As a
result, if factors or expected outcomes change and we use
significantly different assumptions or estimates, our
stock-based compensation could be materially different. The most
significant input into the Black-Scholes option-pricing model
used to value our option grants is the estimated fair value of
the common stock. We considered a combination of valuation
methodologies, including market and transaction approaches.
Determination of
Fair Value
We believe we have used reasonable methodologies and assumptions
in determining the fair value of our common stock for financial
reporting purposes. Our board of directors has historically
estimated the fair value of our common stock. Because there has
been no public market for our shares, our board of directors
historically determined the fair value of our common stock based
on the market approach and the income approach to estimate the
enterprise value of the business under various liquidity event
scenarios, including an initial public offering by the company
and the sale of the company. To support the valuations, we
utilized a probability-weighted expected return under those
various liquidity scenarios, public guideline companies, our
cash flow projections, and other assumptions to derive the
enterprise value of the business. We then derived the estimated
fair value of each class of stock, taking into consideration the
rights and preferences of each instrument based on a
probability-weighted expected return.
The most significant factors considered in estimating the fair
value of our common stock were as follows:
•
current business conditions and projections;
•
the probability and value of future liquidity scenarios,
including an initial public offering by the company and the sale
of the company;
•
the market performance of comparable publicly traded
companies; and
•
U.S. and global capital conditions.
We believe consideration of these factors by our board of
directors was a reasonable approach to estimating the fair value
of our common stock for the periods considered. Estimating the
fair value of our stock requires complex and subjective
judgments, however, and there is inherent uncertainty in our
estimate of fair value.
Prior to this offering, we did not maintain a market for our
shares. In the absence of a public market for our common stock,
the fair value of our common stock underlying our stock options
has historically been determined by our board of directors using
methodologies consistent with the American Institute of
Certified Public Accountants Practice Guide, Valuation of
Privately-Held-Company Equity Securities Issued as Compensation.
In connection with making this determination, we have engaged
independent third-party valuation advisors to assist us. In each
case, our board of directors has made the ultimate determination
of fair value. While we have issued new equity to unrelated
third parties and we use such facts in the estimation of the
fair value of our shares, we
believe that the lack of a secondary market for our common stock
and our limited history issuing stock to unrelated parties makes
it impracticable to estimate the expected volatility of our
common stock. Therefore, it was not possible to reasonably
estimate the grant-date fair value of our options using our own
historical price data. Accordingly, we accounted for the share
options under the calculated value method.
The following table summarizes the number of stock options
granted from January 1, 2009, through May 31, 2011,
the average per share exercise price of the options, and the
estimated per share fair value of the options:
The fair value of our common stock
and the per share exercise price of options are determined by
our board of directors.
(2)
The per share fair value of the
options was estimated for the date of grant using the
Black-Scholes option pricing model. This model estimates the
fair value by applying a series of factors including the
exercise price of the option, a risk-free interest rate, the
expected term of the option, expected share price volatility of
the underlying common stock and expected dividends on the
underlying common stock. Additional information regarding our
common stock option awards is set forth in Note 9 to our
audited consolidated financial statements included elsewhere in
this prospectus.
The fair value of our common stock was estimated using the
probability-weighted expected return method, or PWERM, which
considers the value of preferred and common stock based upon
analysis of the future values for equity assuming various future
outcomes, including initial public offerings, merger or sale,
dissolutions, or continued operation as a private company.
Accordingly, share value is based upon the probability-weighted
present value of expected future net cash flows, considering
each of the possible future events, as well as the rights and
preferences of each share class. PWERM is complex as it requires
numerous assumptions relating to potential future outcomes of
equity, hence, the use of this method can be applied:
(i) when possible future outcomes can be predicted with
reasonable certainty; and (ii) when there is a complex
capital structure (i.e., several classes of preferred and common
stock).
Grants from March 27, 2009 through July 22,2009. On March 27, 2009, our board of
directors established the exercise price per share of common
stock at $0.33 per share determined by the PWERM method. Our
board of directors reaffirmed this exercise price on
May 27, 2009 and July 22, 2009 in connection with
option grants. The significant drivers and weightings for our
valuations during this period were: initial public offering,
10%; sale of our company/assets, 50%, remain private, 15%; and
dissolution, 25%. The estimated fair value of one share of
common stock
was estimated under each of the five scenarios and the
associated probabilities to arrive at a probability-weighted
value per share.
Grants from November 11, 2009 through March 17,2010. On November 11, 2009, our board of
directors established the exercise price per share of common
stock at $0.22 per share determined by the PWERM method. Our
board of directors reaffirmed this exercise price on
December 18, 2009, January 20, 2010 and March 17,2010 in connection with option grants. This valuation took into
consideration economic events including our arm’s length
sale of Series A redeemable convertible preferred stock, or
Series A preferred stock, in August 2009, which had been
sold at price per share that was less than prior sales of our
preferred stock due to the economic conditions at that time and
the difficulties in obtaining venture capital funding. The
significant drivers and weightings for our valuations during
this period were: initial public offering, 10%; sale of our
company/assets, 60%, remain private, 10%; and dissolution, 20%.
The estimated fair value of one share of common stock was
estimated under each of the five scenarios and the associated
probabilities to arrive at a probability-weighted value per
share.
Grants from July 21, 2010 through November 17,2010. On July 21, 2010, our board of
directors established the exercise price per share of common
stock at $1.30 per share determined by the PWERM method. Our
board of directors reaffirmed this exercise price on
September 15, 2010 and November 17, 2010 in connection
with option grants. This valuation took into consideration
economic events including our arm’s length sale of
Series B redeemable convertible preferred stock, or
Series B preferred stock, in September and October 2010 at
a price of $1.34 per share of Series B preferred stock. The
significant drivers and weightings for our valuations during
this period were: initial public offering, 60%; sale of our
company/assets, 20%, remain private, 15%; and dissolution, 5%.
The estimated fair value of one share of common stock was
estimated under each of the five scenarios and the associated
probabilities to arrive at a probability-weighted value per
share.
Grants from January 18, 2011 through March 16,2011. On January 18, 2011, our board of
directors established the exercise price per share of common
stock at $1.46 per share determined by the PWERM method. Our
board of directors reaffirmed this exercise price on
January 19, 2011 and March 16, 2011 in connection with
option grants. This valuation took into consideration market and
general economic events as well as our financial results and
other data available at that time. The significant drivers and
weightings for our valuations during this period were: initial
public offering, 60%; sale of our company/assets, 20%, remain
private, 15%; and dissolution, 5%. The estimated fair value of
one share of common stock was estimated under each of the five
scenarios and the associated probabilities to arrive at a
probability-weighted value per share.
Grants on May 18, 2011. On
May 9, 2011, our board of directors established the
exercise price per share of common stock at $2.44 per share
determined by the PWERM method. Our board of directors
reaffirmed this exercise price on May 18, 2011 in
connection with option grants. This valuation took into
consideration market and general economic events as well as our
financial results and other data available at that time. The
significant drivers and weightings for our valuations during
this period were: initial public offering, 70%; sale of our
company/assets 20%; remain private, 5%; and dissolution, 5%. The
estimated fair value of one share of common stock was estimated
under each of the five scenarios and the associated
probabilities to arrive at a probability-weighted value per
share.
Valuation models require the input of highly subjective
assumptions. There are significant judgments and estimates
inherent in the determination of these valuations. These
judgments and estimates include assumptions regarding our future
performance, the time to undertaking and completing an initial
public offering or other liquidity event, as well as
determinations of the appropriate valuation methods. If we had
made different assumptions, our stock-based compensation
expense, net income (loss) and net income (loss) per share could
have been significantly different. The foregoing valuation
methodologies are not the only valuation methodologies available
and will not
be used to value our common stock once this offering is
complete. We cannot make assurances regarding any particular
valuation of our common stock.
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 operating loss
and tax credit carryforwards. Deferred tax assets and
liabilities are measured using enacted tax rates expected to
apply to taxable income in the years in which those temporary
differences are expected to be recovered or settled. The effect
on deferred tax assets and liabilities of a change in tax rates
is recognized in income in the period that includes the
enactment date.
We recognize the effect of income tax positions only if those
positions are more likely than not of being sustained. We
account for uncertain tax positions using a recognition
threshold and measurement attribute for the financial statement
recognition and measurement of a tax position taken or expected
to be taken in a tax return. Differences between tax positions
taken in a tax return and amounts recognized in the financial
statements are recorded as adjustments to income taxes payable
or receivable, or adjustments to deferred taxes, or both.
Changes in recognition or measurement are reflected in the
period in which the change in judgment occurs. We recognize
penalties and interest related to recognized tax positions, if
any, as a component of income tax expense.
Management’s judgment and estimates are required in
determining our tax provision, deferred tax assets and
liabilities and any valuation allowance recorded against
deferred tax assets. We review the recoverability of deferred
tax assets during each reporting period by reviewing estimates
of future taxable income, future reversals of existing taxable
temporary differences, and tax planning strategies that would,
if necessary, be implemented to realize the benefit of a
deferred tax asset before expiration. We have recorded a full
valuation allowance against our deferred tax assets due to the
uncertainty associated with the utilization of the net operating
loss carryforwards. In assessing the realizability of deferred
tax assets, we consider all available evidence, historical and
prospective, with greater weight given to historical evidence,
in determining whether it is more likely than not that some
portion or all of the deferred tax assets will not be realized.
The ultimate realization of our deferred tax assets generally is
dependent upon generation of future taxable income.
Impairment of
Long-Lived Assets
Long-lived assets are reviewed for impairment whenever events or
changes in circumstances indicate that the carrying amount of an
asset may not be recoverable. Recoverability of assets to be
held and used is measured by a comparison of the carrying amount
of an asset to future undiscounted net cash flows expected to be
generated by the asset. If the carrying amount of an asset
exceeds its estimated undiscounted future cash flows, an
impairment charge is recognized for the amount by which the
carrying amount of the asset exceeds the fair value of the
asset. Fair value is determined through various valuation
techniques including discounted cash flows models, quoted market
values and third-party independent appraisals, as considered
necessary.
Redeemable
Convertible Preferred Stock
Our preferred stock is classified as temporary equity and shown
net of issuance costs. We recognize changes in the redemption
value immediately as they occur and adjust the carrying amount
of the preferred stock to equal the redemption value at the end
of each reporting period.
Qualitative and
Quantitative Disclosures about Market Risk
Market risk represents the risk of loss that may impact our
financial position due to adverse changes in financial market
prices and rates. Our market risk exposure results primarily
from
fluctuations in interest rates as well as from inflation. In the
normal course of business, we are exposed to market risks,
including changes in interest rates which affect our line of
credit under our revolving credit facility as well as cash
flows. We may also face additional exchange rate risk in the
future as we expand our business internationally.
Interest Rate
Risk
We are exposed to changes in interest rates in the normal course
of our business. At March 31, 2011, we had unrestricted
cash and cash equivalents of $16.4 million. These amounts
were held for working capital purposes and were invested
primarily in government-backed securities. Due to the short-term
nature of these investments, we believe that we do not have any
material exposure to changes in the fair value of our cash and
cash equivalents as a result of changes in interest rates.
As of March 31, 2011, our outstanding debt consisted of
capital leases and term loans that have fixed interest rates. In
March 2011 we entered into a two-year line of credit under our
revolving credit facility with a bank, to borrow up to
$10.0 million secured by our then outstanding accounts
receivable and inventory. Borrowings under this revolving credit
facility accrue interest at prime plus 0.5%. As of March 2011,
there were no borrowings outstanding under this revolving credit
facility.
Inflation
Risk
Although we expect that our operating results will be influenced
by general economic conditions, we do not believe that inflation
has had a material effect on our results of operations during
the periods presented. However, our business may be affected by
inflation in the future.
Foreign
Currency Exchange Risk
We are subject to inherent risks attributed to operating in a
global economy. Principally all of our revenue, receivables,
costs and our debts are denominated in U.S. dollars.
Although our international operations are currently not
significant compared to our operations in the United States, we
expect to expand our international operations in the long-term.
An expansion of our international operations will increase our
potential exposure to fluctuations in foreign currencies.
We are an energy efficiency company that designs, develops and
manufactures innovative, high-performance aerogel insulation. We
believe our aerogel blankets deliver the best thermal
performance of any widely used insulation products available on
the market today and provide a superior combination of
performance attributes unmatched by traditional insulation
materials. Our customers use our products to save money,
conserve energy, reduce
CO2
emissions and protect workers and assets.
Our technologically advanced products are targeted at the
estimated $32 billion annual global market for insulation
materials. Our insulation is principally used by industrial
companies, such as ExxonMobil and NextEra Energy, that operate
petrochemical, refinery, industrial and power generation
facilities. We are also working with BASF Construction Chemicals
and other leading companies to develop and commercialize
products for applications in the building and construction
market. We achieved a compound annual revenue growth rate of
46.7% from 2008 to 2010, with revenue reaching
$43.2 million in 2010. We believe demand for our
high-performance insulation products will increase significantly
to support widespread global efforts to cost-effectively improve
energy efficiency. To address capacity constraints caused by
growing demand, we began operating a second production line in
late March 2011 designed to double our production capacity
at our East Providence, Rhode Island facility.
We have grown our business by forming technical and commercial
relationships with industry-leading customers to optimize our
products to meet the particular demands of targeted market
sectors. In the industrial market, we have benefited from our
technical and commercial relationships with ExxonMobil in the
oil refinery and petrochemical sector, with Technip in the
offshore oil sector and with NextEra Energy in the power
generation sector. In the building and construction market, we
have a joint development agreement with BASF Construction
Chemicals to develop products to meet increasingly stringent
building standards requiring improved thermal performance in
retrofit and new-build wall systems, particularly in Europe. We
will continue our strategy of working with innovative companies
to target and penetrate new market opportunities.
Our core aerogel technology and manufacturing processes are our
most significant assets. We currently employ 27 research
scientists and process engineers focused on advancing our
current aerogel technology and developing next generation
aerogel compositions, form factors and manufacturing
technologies. Our aerogels are complex structures in which 97%
of the volume consists of air trapped in nanopores between
intertwined clusters of amorphous silica solids. These extremely
low density solids provide superior insulating properties.
Although aerogels are usually fragile materials, we have
developed innovative and proprietary manufacturing processes
that enable us to produce industrially robust aerogel insulation
cost-effectively and at commercial scale.
Our aerogel products provide up to five times the thermal
performance of widely used traditional insulation in a thin,
easy-to-use blanket form. Our products enable compact design,
reduce installation time and costs, promote freight savings,
simplify logistics, reduce system weight and required storage
space, and enhance job site safety. Our products provide
excellent compression resistance, are hydrophobic and reduce the
incidence of corrosion under insulation, a significant
operational cost and safety issue in industrial facilities. Our
products also offer strong fire protection which is a critical
performance requirement in both the industrial and building and
construction markets. We believe our array of product attributes
provides strong competitive advantages over traditional
insulation. Although competing insulation materials may have one
or more comparable attributes, we believe that no single
insulation material currently available offers all of the
properties of our aerogel insulation.
Since 2008, our Cryogel and Pyrogel product lines have been used
by some of the world’s largest oil refiners and
petrochemical companies, including ExxonMobil, Petrobras, Shell
and Dow Chemical. These products are also used in applications
as diverse as liquefied natural gas facilities, food processing
facilities, oil sands extraction and electric power generation
facilities, with end-use customers such as Chevron, Archer
Daniels Midland, Suncor Energy, NextEra Energy and Exelon.
Insulation systems in these facilities are designed to maintain
hot and cold process piping and storage tanks at optimal process
temperatures, to protect plant and equipment from the elements
and from the risk of fire, and to protect workers. Freedonia
Custom Research, Inc. has estimated that the industrial
insulation market totaled $4.5 billion in 2010.
Within the building and construction market, we are replicating
our strategy of working with industry leaders to seek to
penetrate critical market sectors. In addition to our
relationship with BASF Construction Chemicals, we are also
engaged in product development efforts in Europe and North
America with other industry leaders to target a wide variety of
applications. Our products also have been installed since 2006
in residential and commercial new-build and retrofit building
projects through the efforts of a small network of distribution
partners. Freedonia Custom Research, Inc. has estimated that the
building and construction insulation market totaled
$22.7 billion in 2010.
In addition to our core markets, we also rely on a small number
of fabricators to supply fabricated insulation parts to original
equipment manufacturers, or OEMs. These global OEMs develop
products using our aerogels for applications as diverse as
military and commercial aircraft, trains, buses, appliances,
apparel, footwear and outdoor gear. While we do not currently
allocate significant resources to these markets, we believe
there are many future opportunities within these markets for our
aerogel technology based on its unique attributes. Freedonia
Custom Research, Inc. has estimated that the transportation,
appliance and apparel insulation markets totaled
$4.9 billion in 2010.
We manufacture our products using our proprietary, high-volume
process technology at our facility in East Providence, Rhode
Island. We have operated the East Providence facility at high
volume and high yield continuously since mid-2008. We
successfully commenced operation of our second production line
at this facility in March 2011 and immediately began producing
commercial quality aerogel blankets. This line was completed on
time and on budget and is expected to double our annual
production capacity by the end of 2011 to 40 to 44 million
square feet of aerogel blankets, depending on product mix. We
have begun the design and engineering phase of a third
production line and currently expect that this line will be
completed at our East Providence facility during 2012. We also
plan to construct a second manufacturing facility in the United
States or Europe, the location of which will be based on factors
including proximity to raw material suppliers, proximity to
customers, labor and construction costs and availability of
governmental incentives.
Industry
Background
Global economic growth, continued geopolitical conflict in
oil-producing regions, and rising and volatile energy prices are
increasing demand for energy efficiency products to reduce
energy consumption, energy costs and dependence on oil.
Heightened concerns about global warming and climate change are
likewise increasing demand for energy efficiency products
targeting the reduction of
CO2
emissions.
Markets
Insulation is a material or combination of materials that slows
the transfer of heat and is used in a wide variety of
applications. According to Freedonia Custom Research, Inc., the
global market for insulation materials was estimated to be
$32 billion during 2010, and The Freedonia Group estimates
annual growth of 6.3% through 2014. There are a variety of
insulation materials available in the market, most of which have
been in use for over 50 years. Each insulation material has
a different set of performance attributes and the extent of its
use in a given market is based on the performance and cost
criteria applicable to that market.
industrial, including use as covering for pipes, valves and
storage tanks;
•
building and construction, in walls, floors and
ceilings; and
•
original equipment manufacture, including use in transportation,
appliances and apparel applications.
The industrial insulation market is global, well-established and
includes large and well-capitalized customers across a diverse
set of industries. Freedonia Custom Research, Inc. has estimated
that the industrial market for insulation totaled
$4.5 billion during 2010. This market includes companies
operating refinery, petrochemical, general manufacturing, food
processing and district energy operations. The market also
includes firms operating gas, coal, nuclear, hydro and solar
thermal power generating facilities. Insulation systems in the
industrial market are designed to maintain hot and cold process
piping and storage tanks at optimal temperatures, to protect
plant and equipment from the elements and from the risk of fire,
and to protect workers from burns. The industrial insulation
market is served by a well-organized, well-established,
worldwide network of distributors, contractors and engineers. We
believe that under ordinary economic circumstances,
approximately 70% of the annual demand for insulation in the
industrial market is generated by capital expansions and related
capital projects, while the remainder is associated with
routine, non-discretionary maintenance programs within existing
facilities. Capital expansions and related capital projects are
driven primarily by increased energy prices and overall economic
growth. Maintenance programs are essential to optimal operation
of processing equipment, to ensure worker safety and to minimize
the risk of a catastrophic loss. Accordingly, we believe that
demand for insulation for maintenance purposes in comparison to
capital projects is less affected by volatility associated with
economic cycles, the price of oil or similar macroeconomic
factors.
The building and construction insulation market is driven by
residential and commercial new-build and retrofit projects.
Freedonia Custom Research, Inc. has estimated that the building
and construction insulation market totaled $22.7 billion in
2010. Insulation systems in the building and construction market
are designed to isolate the interior of buildings from external
temperature variations and to reduce energy costs. These
insulation systems are used in wall systems, under traditional
and radiantly heated floors, in ceilings and roofs, in window
and door frames and in solar thermal panels and systems. Most
insulation products in the building and construction market are
manufactured or fabricated to meet industry-standard thicknesses
and dimensions. The building and construction market is
characterized by a fragmented distribution network and myriad
national, regional and local building codes, regulations and
standards. We believe there are important economic and
regulatory drivers supporting energy efficiency initiatives
globally in this market. First, commercial and residential
buildings currently account for approximately 40% of total
energy consumption in both the United States and the European
Union. For example, in the United States, buildings surpass both
the transportation and industrial sectors in terms of energy
consumption at 29% and 30%, respectively. According to
McKinsey & Company, governmental policies to
strengthen the thermal performance of commercial, residential
and governmental buildings are among the most cost-effective
means to improve energy efficiency and to reduce carbon
emissions. For example, The Better Buildings Initiative
announced by U.S. President Barack Obama in February 2011
estimates that U.S. companies and business owners can
reduce their energy bills by about $40 billion at
today’s energy prices by making buildings more energy
efficient, thus constituting a direct economic benefit.
Additionally, numerous European Union member states, in support
of their commitments under the Kyoto accord to reduce carbon
emissions, have enacted legislation that is increasing minimum
thermal standards for commercial and residential wall systems
through 2020. We believe that these increasing thermal standards
for retrofit and new-build wall systems in Europe are becoming
more difficult to meet with traditional insulation materials. We
also believe that strategic relationships with leading building
materials manufacturers with established distribution networks
are a critical
requirement for a new industry player to penetrate the building
and construction market in a rapid and cost-effective manner.
The transportation, appliance and apparel insulation markets are
global, diverse and fragmented. Freedonia Custom Research, Inc.
has estimated that these markets totaled $4.9 billion in
2010. The transportation market includes insulation of aircraft,
automobiles, ships and trains where we believe the key
performance criteria include thermal performance, a thin
profile, fire resistance and durability. The appliance market
includes insulation of commercial and residential refrigerators
and freezers, conventional and microwave ovens, dryers and water
heaters. The apparel market includes insulation of work boots,
outdoor gear and tents. Insulation applications across the
transportation, appliance and apparel markets commonly require
insulation to be fabricated into forms to meet design
specifications.
Insulation
System Design Considerations
Because insulation is used in a wide variety of demanding
applications, insulation materials must satisfy a wide range of
performance criteria on a cost-effective basis. The technical,
performance and economic challenges faced by insulation
materials in meeting the thermal management requirements of
applications in the industrial, building and construction and
other markets include:
•
Thermal Performance. Insulation must
deliver the required thermal performance within the space
allotted. Higher performance insulation is principally required
where space is at a premium.
•
Operating Temperature
Limitations. Insulation must be able to
perform safely and effectively in a system’s operating
temperature range. Insulation is commonly targeted and optimized
for applications within the cryogenic and
sub-ambient
(−273oC
to 90oC),
ambient
(0oC to
40oC) or
hot process
(−25oC
to
650oC) temperature
regimes.
•
Form Factor. Insulation must be
supplied in a form that meets system specifications. Common
insulation forms include flexible blankets, boards, loose fill,
rigid pipe covers, sprayed and shaped foam structures.
•
Speed of Installation. Insulation that
installs rapidly helps reduce total system costs. Labor costs
for on-site
installation are a significant component of an insulation
system’s total cost.
•
Volume and Weight. The volume and
weight of the insulation required to meet system specifications
impact capital and operating costs of a facility, system,
vehicle or building.
•
Durability. Insulation must meet
customer specifications for tensile strength, compressive
strength and resiliency. Under cryogenic conditions, insulation
should not crack, contract or degrade in response to freeze-thaw
cycles. In hot process applications, insulation should not
crack, crumble or sag.
•
Fire Resistance and
Protection. Insulation is commonly tested for
fire resistance and fire protection under industry-standard
protocols. These tests measure whether insulation contributes to
the spread of flame and smoke or acts as a passive fire barrier.
In industrial markets, minimum fire ratings are largely
determined by individual companies. In the building and
construction markets, minimum fire ratings are usually
determined by national, regional and local building practices
and codes.
•
Moisture Resistance. Insulation is
commonly tested for water absorption using industry-standard
protocols. Moisture reduces the thermal performance of
insulation. The resistance of insulation to moisture is critical
to the performance of systems exposed to the elements and
operating in humid climates.
•
Vapor Permeability. The rate of flow of
vapor through insulation layers is critical to the performance
of industrial systems. Insulation systems used in cryogenic
applications must be impermeable to water vapor to avoid
catastrophic system failures. Many cryogenic insulation
systems incorporate vapor barriers. Conversely, high vapor
permeability enables optimal system performance in hot process
applications.
•
Corrosion Under Insulation, or CUI. In
the industrial market, systems operating between
−4oC
and 175oC
are subject to CUI. Insulation materials can trap water and
exacerbate corrosion of the underlying metal surfaces. Corrosion
of process piping and storage tanks increases the risk of
catastrophic system failures. Preventative facility maintenance
and shutdowns are estimated to cost the petrochemical industry
billions of dollars per year. Insulation that is both
hydrophobic and vapor permeable has the potential to
significantly reduce the incidence of CUI.
•
Logistics. The logistics associated
with purchasing, storing, transporting and installing insulation
materials in facilities and on job sites can be complex and
costly. Improved logistics on job sites reduces operating costs
and enhances worker safety.
Within the industrial market, insulation systems are generally
designed to maintain hot and cold process piping and storage
tanks at optimal temperatures, to protect plant and equipment
from external elements and risk of fire, and to protect workers.
In this market, we believe that the performance attributes that
are most important are thermal performance, durability, ease of
installation, moisture resistance and vapor permeability. When
choosing products in the industrial market, we believe that
customers evaluate which insulation product enables them to meet
their performance targets with the lowest installed
and/or
lifecycle costs.
Within the building and construction market, insulation systems
are generally designed to isolate the interior of the building
from external temperature variations and to reduce energy costs.
In this market, we believe that the most important performance
attributes of insulation are thermal performance, form factor,
volume, weight and fire resistance. When choosing insulation in
the building and construction market, customers evaluate which
product provides the most cost-effective means to achieve their
performance targets within system design specifications.
Our
Solution
We believe that our aerogel technology has allowed us to create
superior insulation products for our core markets that will
allow us to continue to grow our market share. We believe that
the potential for significant technological innovation in
traditional insulation materials is limited and that new
high-performance materials will be required to meet evolving
market requirements for energy efficient insulation systems. Our
line of high-performance aerogel blankets is positioned to meet
these requirements. Our solution is driven by our innovative and
proprietary manufacturing processes that produce aerogels in a
flexible and industrially robust blanket form and is supported
by over ten years of research and development dedicated to new
aerogel compositions, form factors and manufacturing
technologies. We believe our aerogel blankets deliver a superior
combination of performance attributes that provide
cost-effective solutions to address the demanding performance
objectives of a wide range of applications in our target
markets, including:
•
Best Thermal Performance. Our aerogel
blankets provide the best thermal performance of any widely used
insulation products available on the market today. Our products
excel in applications where available space is constrained or
thermal performance targets are aggressive.
•
Wide Temperature Range. We offer
insulation products that address the entire range of
applications within the cryogenic and sub-ambient
(−273oC
to 90oC),
ambient
(0oC to
40oC) and
hot process
(−25oC
to
650oC) temperature
ranges.
•
Ease of Installation. Our flexible
aerogel blankets install faster than rigid insulation materials
in the industrial market, which reduces labor costs and total
system costs.
Compact Design. Our aerogel blankets
reduce insulation system volume by 50% to 80% compared to
traditional insulation. Our products allow for a reduction in
the footprint, size and structural costs of facilities, systems,
vehicles and buildings.
•
High Durability. Our aerogel blankets
offer excellent compression resistance, tensile strength and
vibration resiliency. The compression resistance of our products
allows companies to pre-insulate, stack and transport steel
pipes destined for use in harsh or remote environments.
Pre-insulation of pipes significantly reduces installation labor
costs in industrial applications in remote areas such as the oil
sands in Alberta, Canada.
•
Strong Fire Protection. Our Pyrogel XT
and Spaceloft A2 product lines were specifically designed to
provide strong fire performance in applications within the
industrial and building and construction markets. Strong fire
performance qualifies our products for use in a variety of
applications in our target markets.
•
Moisture Resistance. Our aerogel
blankets are durably hydrophobic. Our products offer improved
thermal performance in insulation systems exposed to the
elements or operating in humid environments compared to
traditional insulation.
•
Reduced Corrosion Under Insulation. Our
Pyrogel XT product line is both durably hydrophobic and vapor
permeable. These attributes have the potential to reduce the
incidence of CUI in hot process applications. We believe that a
reduction in CUI offers industrial customers a significant
reduction in long-term operating and capital costs.
•
Simplified Logistics. Our aerogel
blankets simplify job site logistics. Our products reduce the
volume and weight of material purchased, inventoried,
transported and installed in the field. In addition, our
products reduce the number of stock-keeping units, or SKUs,
required to complete a project. Simplified logistics accelerate
project timelines, reduce installation costs and improve worker
safety.
In the industrial market, we believe these characteristics
enable our customers to meet their insulation performance
targets at lower total installed or lifecycle costs versus
traditional insulation in a growing number of applications. In
the building and construction market, we believe the increasing
thermal standards for retrofit and new-build wall systems in
Europe will become more difficult to meet with traditional
insulation materials due to space constraints. We believe the
thin form factor and strong fire properties of our aerogel
blankets will provide a cost-effective and practical means to
meet increasingly stringent building standards in Europe.
Our Competitive
Strengths
We believe the following combination of capabilities
distinguishes us from our competitors and positions us to
compete effectively and benefit from the expected growth in the
market for energy efficiency solutions:
•
Superior product based on proven technology in commercial
production. Our aerogel products provide up
to five times the thermal performance of widely used insulation
in a thin, easy-to-use blanket form. Our products enable compact
design, reduce installation time and costs, promote freight
savings, simplify logistics, reduce system weight and required
storage space and enhance job site safety. Our products provide
excellent compression resistance, are hydrophobic and reduce the
incidence of corrosion under insulation, a significant
operational cost and safety issue in industrial facilities. Our
products also offer strong fire protection which is a critical
performance requirement in both the industrial and building and
construction markets. We believe our array of product attributes
provides strong competitive advantages over traditional
insulation and will enable us to take a growing share of the
existing market for insulation in both the industrial and the
building and construction markets. Although competing insulation
materials may have one or more comparable attributes, we believe
that no single insulation material currently available offers
all of the properties of our aerogel insulation.
Proven and scalable proprietary manufacturing
process. Our manufacturing process is proven
and has been replicated to meet increasing demand. Our original
line in East Providence, Rhode Island, has operated continuously
since mid-2008. From mid-2008 through March 31, 2011, we
have produced and sold in excess of 38 million square feet
of aerogel blankets. We successfully commenced operation of our
second production line at this facility in March 2011 and
immediately began producing commercial quality aerogel blankets.
This line was completed on time and on budget and is expected to
double our annual production capacity by the end of 2011 to 40
to 44 million square feet of aerogel blankets, depending on
product mix. We believe that our proven ability to produce
product that meets our clients’ specifications and our
increased production capacity will provide customers with the
certainty of supply that is required to expand their use of our
products.
•
Strong relationships with industry
leaders. We have a track record of working
with industry leading end-use customers, in order to achieve
in-depth knowledge of our target market and to optimize our
products to meet the challenges they face. With these
relationships, our products have undergone rigorous testing and
are now qualified for global usage in both routine maintenance
and in capital projects at some of the largest industrial
companies in the world. We believe these strong relationships
represent a competitive advantage, giving us both a significant
source of potential demand and a means of validating our
technology, products and value proposition. These relationships
have proven to shorten the sales cycle with other customers
within the industrial market and have helped to facilitate our
market penetration. Within the building and construction market,
we have partnered with BASF Construction Chemicals to develop
products to meet increasingly stringent building standards for
thermal performance of retrofit and new-build wall systems. As
part of our relationship with BASF Construction Chemicals, we
have recently optimized a product, Spaceloft A2, that we believe
will have broad appeal across the building and construction
market. BASF Venture Capital made strategic investments in us in
September 2010 and June 2011.
•
Capital efficient business model. To
respond to increased demand for our products, we successfully
commenced operation in late March 2011 of a second production
line at the East Providence facility. The expansion is expected
to increase our annual production capacity by 20 to
22 million square feet of aerogel blankets at a total
construction cost of approximately $31.5 million. We
believe that our second production line, at full capacity and at
current prices, would be capable of producing in the range of
$50 million to $54 million in annual revenue of
aerogel blankets. We expect to add production capacity in a
capital efficient manner through the planned expansion of our
East Providence facility and construction of a second
manufacturing facility in the United States or Europe.
•
Experienced management and operations
team. Each of our executive officers has over
20 years of experience in global industrial companies,
specialty chemical companies or related materials science
research. This team has worked closely together at Aspen
Aerogels for nearly five years and we believe our dedicated and
experienced workforce is an important competitive asset. As of
May 31, 2011, we employed 157 dedicated research
scientists, engineers, manufacturing line operators, sales and
administrative staff and management.
Our
Strategy
Our goal is to create shareholder value by becoming the leading
provider of high-performance aerogel products serving the global
energy efficiency market. We intend to achieve this goal by
pursuing the following strategies:
•
Expand our manufacturing capacity to meet market
demand. Demand for our aerogel products in
2010 grew by approximately 88% compared to 2009 and exceeded our
manufacturing capacity. In response, we constructed a second
production line in our East
Providence, Rhode Island, manufacturing facility designed to
double our manufacturing capacity. To meet anticipated future
growth in demand for our products, we are engaged in the design
and engineering of a third production line at our East
Providence facility and plan to construct a second manufacturing
facility in the United States or Europe. We believe an expanded
and geographically diversified manufacturing base will allow us
to satisfy increasing demand for our products and to eliminate
the risk associated with single site operations.
•
Increase industrial insulation market
penetration. We plan to focus additional
resources to achieve a greater share of the industrial
insulation market, both through increased sales to our existing
customers and sales to new customers. We are promoting greater
enterprise-wide utilization of our products by existing end-use
customers. We believe the validation of our products by these
technically sophisticated customers helps shorten the sales
cycle with new customers and facilitates market penetration. In
addition, we anticipate that our growing maintenance-based
business will lead to increasing sales of our products into
large capital projects, including the construction of new
refineries and petrochemical facilities in emerging markets.
•
Leverage strategic relationships in the building and
construction market. We believe the building
and construction market represents our largest target market
opportunity and is in the midst of a transformation that is
increasing demand for high-performance, energy-efficient
insulation systems. We have partnered with BASF Construction
Chemicals to penetrate the market for energy efficient wall
systems. We are pursuing additional market opportunities with
other leading building materials manufacturers and distributors
across multiple regions to address the increasingly stringent
regulatory environment governing the thermal performance of
buildings. We believe this approach will enable us to leverage
their broad technical and distribution capabilities and
facilitate market penetration.
•
Expand our sales force, network of distributors and OEM
channels. We plan to expand our sales force
and distribution network to support growth in the industrial and
building and construction markets. We have identified
distributors with proven records of success serving important
customers and intend to make selected additions to our existing
global distribution network. We also intend to expand our
network of OEM fabricators to pursue opportunities in the
transportation, appliance and apparel markets. We believe that a
strong, global and diverse network of distributors and OEMs will
support our goal to expand and further penetrate the global
markets for our products.
•
Continue to develop advanced aerogel compositions,
applications and manufacturing
technologies. We believe that we are well
positioned to leverage a decade’s worth of research and
development to commercialize new products, applications and
advanced manufacturing technologies. While we have not
formalized our intellectual property rights to all of these
potential new products, applications and advanced manufacturing
technologies, we have already obtained patents for a number of
these technologies in the United States and abroad. We also
maintain a significant portfolio of trade secrets and know-how
in areas of gel compositions, aerogel manufacturing and process
scalability. Examples of new technologies under development
include:
•
Refractory aerogel insulation compositions for use in
applications with temperatures as high as 1649°C including
advanced aerospace thermal protection, high temperature furnaces
and boilers and single crystal silicon manufacture.
•
Ultra-low dielectric aerogel films that are mechanically robust
and can be readily integrated into electronic devices including
circuit boards, cables, connectors and discrete components.
•
Aerogel solid sorbents that reversibly capture carbon dioxide
for future use in the power industry.
Highly durable and flexible aerogel composite insulation for use
in tents, outerwear and safety gear.
•
Advanced gel compositions designed to enable aerogels to be
processed rapidly and at ultra-high volumes.
•
Aerogel materials suitable for gas, liquid and solid filtration
and separation.
•
Electrically conductive aerogels suitable for power storage
applications.
We intend to increase personnel, funding and capital equipment
devoted to the research, development and protection of
intellectual property associated with new and advanced
technologies. We will also continue to seek opportunities to
leverage new and advanced technologies into broad commercial
opportunities.
Our
Products
Our aerogels consist of a complex structure of intertwined
clusters of very fine, lightweight, amorphous silica solids that
comprise 3% of the material by volume. The remaining volume of
the aerogel material is composed of air contained in nanopores.
Aerogels are a very low density solid and are usually extremely
fragile materials. However, our manufacturing processes produce
aerogels in a flexible, resilient, durable and easy-to-use
blanket form.
The core raw material in the production of our aerogel products
is a silica-rich stream of ethanol. Our manufacturing process
initially creates a semi-solid alcogel in which the nanopore
structure is filled with ethanol. We produce aerogel by means of
a supercritical extraction process that removes ethanol from the
gel and replaces it with air. Our process allows the liquid
ethanol to be extracted without causing the solid matrix in the
gel to collapse from capillary forces.
The nanoporous structure of our aerogel products minimizes the
three mechanisms of thermal transport:
•
Convection. Heat convection through the
gas in nanoporous structures is confined. The mean free path, or
average distance traveled, of gas molecules in aerogels is
significantly reduced. As a result, thermal convection is
severely restricted.
•
Conduction. Heat conduction is
correlated to material density. Aerogels are very low density
solids. As a result, thermal conductivity is extremely low.
Radiation. Radiation requires no medium
to transfer heat. Thermal radiation is partially absorbed by
aerogels. Our aerogel products also contain infrared absorbing
additives to significantly reduce radiant heat transfer.
We believe our aerogel products offer the lowest levels of
thermal conductivity, or best insulating performance, of any
widely used insulation available on the market today. Our
aerogel blankets are reinforced with non-woven fiber batting. We
manufacture and sell our blankets in 60 inch wide, three
foot diameter rolls with a range of thickness of 2 millimeters
to 10 millimeters. Our base products are all flexible,
hydrophobic yet breathable, compression resistant and able to be
cut with conventional cutting tools. We have specifically
developed our line of aerogel blankets to meet the requirements
of a broad set of applications within the industrial, building
and construction and OEM markets. The composition and attributes
of our aerogel blankets are as described below:
Industrial
•
Pyrogel XT. Pyrogel XT, our best
selling product, is reinforced with a glass-fiber batting and
has an upper use temperature of
650oC.
Pyrogel XT was initially designed for use in high temperature
systems in refineries and petrochemical facilities, and we
believe that it has wide applicability throughout the industrial
market, including the power generation and district heating
sectors. Pyrogel XT’s hydrophobicity and vapor permeability
reduce the risk of corrosion under insulation in high
temperature operating systems when compared to traditional
insulation.
•
Pyrogel XTF. Pyrogel XTF is similar in
thermal performance to Pyrogel XT, but is reinforced with a
glass- and silica-fiber batting. Pyrogel XTF is specially
formulated to provide strong protection against fire.
•
Cryogel Z. Cryogel Z is designed for
sub-ambient
and cryogenic applications in the industrial market. Cryogel Z
is reinforced with a glass- and polyester-fiber batting and is
produced with an integral vapor barrier. Cryogel Z is also
specially formulated to minimize the incidence of stress
corrosion cracking in stainless steel systems. We believe that
Cryogel Z’s combination of properties allow for simplified
designs and reduced installation costs in cold applications
throughout the industrial market when compared to traditional
insulation.
•
Spaceloft Subsea. Spaceloft Subsea is
reinforced with glass- and polyester-fiber batting and is
designed for use in
pipe-in-pipe
applications in offshore oil production. Spaceloft Subsea can be
fabricated and pre-packaged to permit faster installation.
Spaceloft Subsea allows for small profile carrier pipelines and
associated reductions in capital costs.
Building and
Construction
•
Spaceloft. Spaceloft is reinforced with
a glass- and polyester-fiber batting and is designed for use in
the building and construction market. Spaceloft is either
utilized in roll form by contractors in the field or fabricated
by OEMs into strips, panels and systems that meet industry
standards. Spaceloft is designed for use in solid wall buildings
and where space is at a premium.
•
Spaceloft A2. Spaceloft A2 is
reinforced with a glass-fiber batting and specifically designed
to meet Euroclass A2 standards for fire properties of building
and construction products. Spaceloft A2 was developed under a
joint development agreement with BASF Construction Chemicals.
Spaceloft A2 is designed for use in systems subject to European
fire performance standards, including hospitals, schools,
warehouses, factories, shopping centers and commercial buildings
over 15 meters high.
Pyrogel 2250. Pyrogel 2250 is
reinforced with carbon-fiber batting and has an upper use
temperature of
200oC.
Pyrogel 2250 is our thinnest and our highest tensile strength
product. Pyrogel 2250 is designed for use in applications where
space is limited. Pyrogel 2250 is targeted to OEMs that design,
produce and sell hot appliances, automotive systems and
electronic components.
•
Pyrogel 6650. Pyrogel 6650 is
reinforced with silica-fiber batting and has an upper use
temperature of
650oC.
Pyrogel 6650 is our lowest-density product and is designed for
use in applications where weight is critical. Pyrogel 6650 is
targeted to OEMs that design, produce and sell aerospace systems
and components.
•
Cryogel X201. Cryogel X201 is similar
in composition to Cryogel Z, but is produced without a vapor
barrier. Cryogel X201 is designed for use in cold system designs
where space is at a premium. Cryogel X201 is targeted to OEMs
that design, produce and sell refrigerated appliances, cold
storage equipment and aerospace systems.
The attributes of our aerogel blankets are as summarized in the
following table:
Nominal
Thermal
Maximum Use
Product
Thickness
Conductivity
Density
Temperature
Applications
Markets
mm
in
mW/
Btu-in/
g/cc
lb/ft3
°C
°F
m-K
hr-ft2-°F
Pyrogel XT
5.0
10.0
0.20
0.40
21.0
0.146
0.18
11.0
650°
1200°
High temperature steam pipes, vessels and equipment, and
aerospace and defense systems
Industrial
Pyrogel XTF
10.0
0.40
21.0
0.146
0.18
11.0
650°
1200°
High temperature steam pipes, vessels and equipment, aerospace
and defense systems, fire barriers and welding blankets
Industrial
Cryogel Z
5.0
10.0
0.20
0.40
15.0
0.104
0.13
8.0
90°
194°
Sub-ambient and cryogenic pipelines, vessels and equipment
Industrial
Spaceloft Subsea
5.0
0.20
13.9
0.096
0.13
8.0
200°
390°
Medium to high temperature offshore oil pipelines
Industrial
Spaceloft
5.0
10.0
0.20
0.40
14.0
0.097
0.15
9.4
200°
390°
Ambient temperature walls, floors and roofs in commercial,
residential and institutional buildings
Building and
Construction
Spaceloft A2
10.0
0.40
18.0
0.125
0.18
11.0
200°
390°
Ambient temperature walls, floors and roofs in commercial,
residential and institutional buildings; Euroclass A2 Fire Rated
Building and
Construction
Pyrogel 2250
2.0
0.08
15.5
0.107
0.17
10.7
200°
390°
Medium to high temperature appliances, transportation and
electronics
OEM
Pyrogel 6650
6.0
0.24
14.0
0.097
0.12
7.5
650°
1200°
High temperature aerospace and defense systems
OEM
Cryogel x201
5.0
10.0
0.20
0.40
15.0
0.104
0.13
8.0
200°
390°
Sub-ambient including refrigerated appliances, cold storage and
aerospace
Traditional and specialty insulation materials provide a range
of R-values. The following table provides the
R-value per
meter of thickness:
R-Values by
Material
R-Value
per meter of thickness
Material
Form
From
To
Aerogel
Blankets, Beads
66
100
Cellulose
Loose Fill
22
26
Expanded Clay
Loose Fill
4
4
Expanded Polystyrene (EPS)
Boardstock
26
31
Extruded Polystyrene (XPS)
Boardstock
35
40
Fiberglass
Blankets
22
28
Fiberglass
Loose Fill
20
20
Fiberglass
Pipe Covering
25
25
Foamed Glass
Boardstock
21
21
Mineral Wool
Blankets
22
26
Mineral Wool
Loose Fill
17
17
Mineral Wool
Pipe Covering
19
26
Perlite
Pipe Covering
17
17
Perlite
Loose Fill
17
21
Perlite
Board
17
19
Polyurethane
Spray On
44
44
Polyurethane
Rigid board
44
44
Polyisocyanurate
Rigid board
45
50
Vermiculite
Loose Fill
17
26
Sales and
Marketing
We market and sell our products primarily through a direct sales
force. Our salespeople are based in North America, Europe and
Asia and travel extensively to market and sell to new and
existing customers. The efforts of our sales force are supported
by a small number of sales consultants with extensive knowledge
of a particular market or region. Our sales force is required to
establish and maintain customer and partner relationships, to
deliver highly technical information and to provide first class
customer service. We have plans to expand our sales force
globally to support anticipated growth in customers and demand
for our products.
Our sales force calls on and maintains relationships with all
participants in the insulation industry supply chain. Our
salespeople have established and manage a network of insulation
distributors to ensure rapid delivery of our products in
critical regions. Our salespeople work to educate insulation
contractors about the technical and operating cost advantages of
aerogel blankets. Our sales force works with end users to
promote qualification and acceptance of our products. In
addition, our salespeople work with OEMs and development
partners to create new products and solutions to open new
markets.
In the industrial market, we rely heavily on the existing and
well-established channel of distributors and contractors to
distribute products to our customers. In the building and
construction market, we believe that our relationships with
leading building materials manufacturers with established
distribution networks are a critical requirement to our
penetration of the market on a cost effective basis. In the
transportation, appliance and apparel markets, our current plan
is to rely on the efforts of OEMs to develop opportunities
within and provide access to the markets.
The sales cycle for a new insulation material is typically
lengthy. Our sales cycle from initial customer trials to
widespread use can take from three to five years, although we
typically realize increasing revenue at each stage in the cycle.
Our relationships with technically sophisticated customers serve
to validate our technology, products and value proposition
within a target market. These relationships have proven to
shorten the sales cycle with other customers within specific
market segments and to facilitate market penetration.
We have focused our marketing efforts on developing technical
support materials, installation guides, case studies and general
awareness of the superior performance of our aerogel blankets.
We rely on our website, printed technical materials,
participation in industry conferences and tradeshows and
presentation of technical papers to communicate our message to
potential customers. We also receive strong
word-of-mouth
support from the growing network of distributors, contractors,
OEMs and end users that understand the benefits of our products.
As of May 31, 2011, we had 17 employees in our sales
and marketing organization worldwide. Their efforts were
supported by a team of eight sales consultants.
Customers,
Development Relationships and End Users
As described below, our primary customers are distributors,
contractors and OEMs that stock, install and fabricate
insulation products, components and systems for technically
sophisticated end users that require high-performance insulation.
•
Distributors: We are currently
operating under agreements with a network of over 40 insulation
distributors serving industrial and building and construction
markets across the globe. The agreements generally provide for
exclusivity by geography linked to annual purchase volume
minimums. In general, insulation distributors stock, sell and
distribute aerogel materials to insulation contractors and end
users. Outside of North America, insulation distributors often
will also proactively market and promote aerogel materials
across all markets. During 2010, our most significant
distributors by revenue were Thorpe Products and Distribution
International in the United States, Aerogel Korea Co, Ltd. in
Asia, Aktarus Group in Europe and Burnaby Insulation in Canada.
•
Contractors: We currently sell directly
to a number of insulation contractors under multi-year
agreements and under project specific contracts. Insulation
contractors generally perform insulation installation,
inspection and maintenance and project management for end users.
In addition, some insulation contractors provide end users with
project engineering and design services. Several of our
agreements with contractors provide for exclusivity by market
sector or geography linked to annual purchase volume minimums.
During 2010, our significant contractor customers included
Technip and Saint-Gobain Wanner.
•
OEMs: We currently sell directly to
more than ten OEMs that design, fabricate and manufacture
insulation components and systems for use in the industrial,
building and construction, transportation, appliance and apparel
markets. During 2010, our most significant OEM customers ranked
by revenue were Enershield, A. Proctor Group and Shenzhen Naneng
Technology Co., Ltd. Enershield manufactures and sells
pre-insulated pipes for use in the Canadian oil sands, A.
Proctor Group fabricates and sells aerogel insulated wall board
in the U.K. market, and Shenzhen Naneng Technology Co., Ltd.
supplies insulation systems for use in China’s national
high speed railway.
Our development partners are some of the most technically
sophisticated companies in our target markets. These
relationships have allowed us to seek to optimize our products
to meet the particular demands of targeted market sectors. In
the industrial market, we have benefited from our relationship
with ExxonMobil in the oil refinery and petrochemical sector,
with Technip in the offshore oil sector and with NextEra Energy
in the power generation sector. In the building and construction
market, we have a joint development agreement with BASF
Construction Chemicals to develop
products to meet increasingly stringent building standards
requiring improved thermal performance of retrofit and new-build
wall systems. We are also engaged in developmental relationships
in Europe and North America with other leading building
materials manufacturers to target a variety of applications
within the broader building and construction market. We also
rely on a small number of OEM partners to develop opportunities
in the transportation, appliance and apparel markets.
As described below, the end users of our aerogel blankets range
from individual homeowners to some of the largest and most well
capitalized companies in the world:
Industrial
•
Oil Refinery and Petrochemical: Our
aerogel blankets are in use at ExxonMobil, Citgo, Chevron, BP,
Valero, PPG Industries, PEMEX, Petrobras, ConocoPhillips, Shell,
Lyondell, China National Petroleum, Tupras, Ecopetrol and
Kuwaiti National Petroleum Group, among others. Over time, these
companies have used our products in an increasing range of
applications and throughout an increasing number of their
industrial facilities.
•
LNG Production and Storage: Our
products are in use in LNG facilities including Gate Import
Terminal in the Netherlands, Canaport LNG in Canada and Golden
Pass LNG in the United States, among others. These facilities
are owned and operated by Qatar Petroleum, Exxon