In Paper Machine Clothing (PMC):
• All three of our Asian plant expansions were successfully completed. The greenfield plant in Hangzhou, China, started up in October 2008, and should be at full production by mid-2009. In our view, the Hangzhou plant, and the expanded plants in Chungju, Korea, and Panyu, China, are the best-equipped plants of their kind in the world. These will play a critical role in our global PMC business as we eliminate exports from Europe to Asia, supply products to emerging markets outside of Asia that had been served by our European plants, and of course, once Asian economies begin to grow again, meet the growing demand locally.
• The critical contract negotiations with the two largest papermakers in Europe were successfully completed.In both instances, we gained a significantly higher share of volume, and just as importantly, strengthened our long-term relationships.
• In each of our major product lines, market trials of major new products were successfully completed. In every case, the products being tested offer better performance to our customers.
• And as the year progressed, and restructuring, process improvement, and shared services started to take hold, gross margins improved even while revenue declined, and selling, technical, general, and research expenses declined. These trends should continue through 2009.
In Albany Doors Systems, progress in 2008 and early 2009 came on three fronts, each of which also improves our prospects for coming out of 2009 in strong shape with good cash flow:
• The 24% growth in sales in 2008 compared to 2007 was fueled in large measure by new product introductions, particularly in the machine protection market, as well as the full-year effect of the July 2007 R-Bac acquisition. Late in 2008, we completed the acquisition of Aktor GmbH, a producer of low-cost high-performance doors for the food market. While we expect overall product sales to be down sharply in 2009 because of the recession, we do expect sales from our Aktor line to grow rapidly through the recession.
• We continued to expand our aftermarket presence, with aftermarket sales growing 19% in 2008 compared to 2007. Aftermarket sales should continue to grow during the recession, and will help to offset the likely decline in product sales.
• A number of process-simplification and cost-reduction activities were initiated during 2008, and these should begin to contribute to profitability as 2009 progresses.
Turning to Composites, 2008 was a disappointing year because of the failure of our largest source of near-term revenue, Eclipse Aviation. And results for 2009 are also likely to be soft, because of the impact of the recession on several of our other customers, who have ramped down production of their engines and aircraft. But underlying the weak sales picture is a strengthening prospect of new business development and of the long-term annuity-like streams of revenue associated with such development. Both 2008 and early 2009 were marked by the expansion of our portfolio of development projects. We are now working on or exploring a broader array of engine parts for a broader array of new engines, a growing number of applications for a growing number of new airframes,
and a small but significant number of new projects in the defense sector.
As I discussed in our Q4 2008 earnings release, Engineered Fabrics (EF) had a disappointing 2008. Sales were flat for the year, dragged down by a very weak fourth quarter. But more importantly, profitability was down sharply for the year, and the business lost money in Q4. The weak performance triggered an extensive restructuring of the business in late 2008 and early 2009; the goal of these efforts is to bring about improvement in the profitability of this business to levels above historical margins. And as with our other businesses, while the restructuring is underway, we continue to pursue our strategic initiatives, which in the case of EF, focus on new product development and geographic expansion into emerging markets.
As for the PrimaLoft® Products segment, it had a strong 2008, growing by 24% to $21 million in sales. Profitability was ahead of expectations, but margins eroded as the year progressed and the recession deepened. And so, as with all of our businesses, in Q4 2008, we began to restructure our manufacturing operations and reduce fixed costs, in anticipation of a long and deep recession.