Dustin Olson
Analyst · Craig-Hallum. Your line is open
Thank you, Mike. Our first commercial facility in Ironton, Ohio is well underway and is expected to be operational in the fourth quarter of 2022. We have between 150 and 220 craftsmen on site daily working diligently to keep Ironton on schedule. Approximately 90% of the utility equipment is on site and we expect to energize the facility this month. With 65% of the PreP equipment also on site, we expect a soft startup for this pre-processing facility in August ahead of the purification facility. Currently, all 26 modules are on site at Gulfspan with construction pacing material deliveries. There are 60 to 90 craftsmen on this site daily, and we expect our first module delivery to Ironton in April. We have discussed how our partnerships with Koch Modular Process Solutions and Gulfspan allow PureCycle to build our facilities more safely and with more time and cost efficiencies. We estimate that between the KMPS Module Design and the Gulfspan construction capacity has eliminated 6 to 12 months of potential delays in Ironton. Our work with these strategic partners set the foundation to replicate construction of PureCycle's purification plants both domestically and internationally. While we do see continued pressure on cost and schedule we currently anticipate holding our project timeline despite the elevated risk of delayed equipment deliveries due to global supply chain disruptions. Moving to slide 6. In just two weeks on March 22, we will break ground in Augusta, Georgia for PureCycle's second purification facility. Our head start engineering plan is on track and the early phase procurement activities are completed. Our long lead purchases are awaiting final purchase order by the end of March. While all components have been evaluated, the initial key long lead critical items are rotating equipment, high pressure vessels and specialty valves and instrumentation. As with Ironton, we understand that supply chain disruptions may impact our building process. But we have a creative team and dedicated strategic supply partners trying to solve these problems every day. Augusta Phase 1 will include building two lines, each with a capacity of 130 million pounds per year and with a total capacity of 260 million pounds of capacity per year. We believe this strategy will create substantial construction, procurement and operational efficiencies. We anticipate these first two lines to be operational in Q4 of 2023. Our committed spend to-date is $29 million. As with Ironton and all future facilities, our copy/paste design should allow us to build our facilities faster. For Augusta, we expect to be able to build two lines every six months. Additionally, our engineering teams designed the infrastructure such that our space can support at least eight purification lines. This would create a multi line production facility capable of producing more than 1 billion pounds of ultra pure recycled resin at a single location. We are four months into our 24 month project schedule for phase one. We will continue to leverage Gulfspan to scale more efficiently and prior quarter releases we have discussed the concept of a second multi line facility and domestic U.S. with a primary target of a West Coast operation. This is still in our long term planning. But the facility supply chain economics would have to outweigh the scale economy efficiencies in Augusta. We remain firmly committed to being born digital and value our collaborative relationship with Emerson. This program should allow us to compress our commissioning timeline, enhance our training and ultimately streamline our global operations. When you build smart facilities on a technical infrastructure design for future improvements, all aspects of the operation can move faster and more efficiently. Lastly, like everyone else in the industry specific areas of CapEx forecasts are trending approximately 10% to 30% over estimates conceived two to three years ago. However, we believe our projects supply chain economics and our variable and fixed costs at Augusta will help us stay on track. Currently, Augusta variable and fixed costs are modeled at 15% to 30% below Ironton. Moving to slide 7. Last quarter we laid out the strategy behind our pre-processing facilities. We call them PrePs with two capital Ps. These regional facilities allow us to not only build strong regional relationships with feedstock suppliers and partners, but open up access to more feedstock and further reduce our own carbon footprint. Our Ironton PreP facility is co-located with our purification line and we anticipate a soft launch date in the third quarter of 2022. This facility will be dedicated to the Ironton purification operation. Our first regional facility located in Central Florida, which we expect to supply feedstock to Augusta is expected to start up in the third quarter of 2022 also. This central Florida facility will have the ability to advanced sort and wash at least 75 million pounds per year, and we expect to grow to more than 150 million pounds per year in the future. We are advancing our discussions with Titus in California. This facility will have the capacity to advanced sort 10 million pounds to 25 million pounds of feedstock. PureCycle will not actively operate this facility. But we will receive all the polyolefin feedstock and we intend to use this facility as a model for future West Coast feedstock development. We expect this facility will supplement feed and Augusta while building a supply source for a third U.S. location. Site selection for PreP facility Northeast is underway. We are working on identifying a location that would allow us the capacity to sort and wash between 75 million pounds and 150 million pounds of feedstock each year. This facility will be very similar to our facility in central Florida. These facilities will be used to capture the polypropylene volume from number one to seven bales number three to seven bales and also low quality number five bales. We will also plan to use these facilities to add incremental operations to enhance the processing of specialized feedstock opportunities. These facilities play a key role in our overall strategy and will ultimately serve to diversify our feed system. Moving to slide 8. Next, we would like to share with you our progress on securing feedstock for our business plan. We continue to strengthen our relationships in the marketplace and that has resulted in new Letters of Intent signed in the fourth quarter for an additional 60 million pounds per year of feedstock, bringing our total feedstock secured via contract or in Letters of Intent to an aggregate of 438 million pounds per year for Ironton and Augusta. We are executing against our strategy to secure feedstock from a diverse suppliers across United States and continue to identify feedstock from three diverse waste streams. As you can see on the slide, 60 million pounds of feedstock in the fourth quarter comes from post consumer non-curbside. The feedstock team is targeting both traditionally recycled feedstocks as well as more complex opportunities that based on our understanding, other recyclers are not targeting. We continue to show that our technology can purify polypropylene from a wider variety of feedstock, which allows us to access waste streams that were previously landfilled or incinerated. An example of this is with impact copolymer. In Q4 PureCycle was able to purify this feedstock into base components of PP homopolymer and EPR, a rubbery additive. While our technical evaluation of this polymer is still in development since this feedstock is extensively used in automotive applications, we intend to evaluate the use of automotive plastic residues as a potential feedstock source. Moving to slide 9. The commercial team continues to build our pipeline and active discussion accounts for 822 million pounds per year of our ultra pure recycled resin. We have grown our pipeline significantly from Q3 to Q4, with an increase of 80% increase in deals and negotiations with either term sheets or sales agreements. We continue to build our funnel with early discussion volume increasing 38% compared to last quarter. With our wind pack announcement, we have now expanded our converter network to include Aptar, Berry Global and Winpak. PureCycle is well positioned to connect brands with high quality resin to deliver products that are truly sustainable to their customers. We've already scratched the surface on what is out there and we believe we will continue to see increases each quarter. We know that our ultra pure recycled resin can be a game changer for companies looking to replace fossil fuel derivatives, fossil fuel derived resins and reduced their carbon footprint. We continue to execute the objectives we need to expand our pipeline and ultimately help companies achieve their highest sustainability goals. Moving to slide 10. The past five years have been remarkable across the board. We have experienced a global pandemic, a commodity boom and market volatility [add] inflation and instability overseas this created a volatile market and a volatile business environment. Amid supply chain disruptions and pandemic driven economic shutdowns PureCycle has built a resilient business model to help insulate our business from significant disruptions in the global markets and supply chain inefficiencies. As you can see from the slide, we have modeled multiple scenarios that have transpired across the last three years relative to our original business plan. There are two key takeaways. One, despite disruptions the previous unit EBITDA projections remain largely intact. And two, we believe the introduction of the feedstock plus pricing program has currently modeled reduces earnings volatility created between the virgin PP and number five feedstock spread. Moving to slide 11. I'm also pleased to provide you with the latest data from our third party independent lifecycle analysis. Their review was based on the final design of our Ironton, Ohio facility and resulted in 35% lower carbon emissions as compared to fossil fuel derived polypropylene. Nearly 80% lower energy usage and water consumption being on par with fossil fuel derived polypropylene. It's important to note that our carbon emissions are heavily impacted by the high concentration of coal in the Ohio grid compared to those and other regions in the country. This assessment was conducted to understand initial baseline environmental impact of our process, and we will update with operational data post startup. The third party preliminary LCA confirms that our purification technology not only creates a good outcome for our world, but also a strong value proposition for our customers. With this carbon footprint analysis estimated to be below virgin polypropylene production. We believe our product provides an alternative to the high cost carbon credit purchasing programs for our customers. We understand the complexity of this analysis and the nuances that can swing the numbers. Rest assured, however, PureCycle will continue to study alternatives to further improve our numbers through renewable energy supplies at both Ironton and Augusta. Moving to slide 12. We also want to provide you an update on our FDA letter of no objection. In September, we submitted our LNO request to the FDA and in January of this year, we received a follow up inquiry from the FDA in response to our submission. This is the first time we have engaged the FDA in discussions about our process, and it required substantial collaboration to create mutual understanding. We expect this to be the first of many submissions to the FDA as we find new feeds, new operating conditions and as we scale the technology. Through the discussions and in reply to the FDA, PureCycle revised and finalized our letter of no objection submission for categories C through G, which covers many of the products that consumers use on a regular basis. This is a good first step in the approval process. As always PureCycle will continue to optimize the process across new feeds, and process conditions and resubmit to the FDA periodically for use of purified resin in additional cases. I will now turn it over to our CFO, Larry Somma to provide details related to the private equity raise and our current liquidity position. Larry?