General
Digital Power
Corporation designs, develops, manufactures, markets, and sells switching power
supplies to industrial, telecommunication, data communication, medical, and
military industries. We are a California corporation originally formed in
1969. Our corporate office, which contains our administrative, sales, and
engineering functions, is located in Fremont, California. In addition, the
Company has a wholly-owned subsidiary, Digital Power Limited (DPL),
located in Salisbury, England, which designs, manufactures, and sells products
for the European marketplace, including power conversion products for naval and
military applications and DC/AC inverters for the telecommunications industry,
under the label Gresham Power Electronics.
We primarily sell
our switching power supplies to industrial, telecommunication, data
communication, medical, and military industries both in North America and
Europe. These industries have experienced pricing pressure that has
adversely affected our operations and financial condition. As a result, we
incurred an operating loss during the first half of the year ended December 31,
2005. The Company moved all its production to a Chinese subcontractor
offering lower prices with shorter lead-times, and to Telkoor Telecom Ltd.
(Telkoor), an Israeli Manufacturer and a major shareholder holding
43% of the outstanding shares of DPC. Telkoor manufactures at longer lead
times and at higher total costs in comparison to the Chinese
manufacturing partners.
Power supplies are
critical components of electronic equipment that supply, convert, distribute,
and regulate electrical power. The various subsystems within electronic
equipment require a steady supply of direct current (DC) electrical power,
usually at different voltage levels from the other subsystems within the
equipment. In addition, the electronic components and subsystems require
protection from the harmful surges and drops in electrical power that commonly
occur over power lines.
Power supplies
satisfy these issues of allocation and protection by (i) converting alternating
current (AC) electricity into direct current (DC); (ii) dividing a single input
voltage into distinct and isolated output voltages; and (iii) regulating and
maintaining such output voltages within a narrow range of values.
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Products, which
convert AC from a primary power source into DC, are generally referred to as
power supplies and commonly referred to as AC/DC power
supplies. Products, which convert one level of DC voltage into a higher or
lower level of DC voltage, are generally referred to as DC/DC
converters. Switching power supplies are distinguished
from linear power supplies by the manner and efficiency with which
the power supplies step down voltage levels. A linear power
supply converts an unregulated DC voltage to a lower regulated voltage by
throwing away the difference between the two voltages as heat.
Consequently, the linear power supply is inherently inefficient
typically, only 45% efficient for a 5V output regulator. By contrast, a
switching power supply converts an unregulated DC voltage to a lower regulated
voltage by storing the voltage difference in a magnetic field. When the
magnetic field grows to a pre-determined level, the unregulated DC is switched
off and the output power is provided by the energy stored in the magnetic
field. When the field is sufficiently depleted, the unregulated DC is
switched on again to deliver power to the output, while the excess voltage is
again stored in the magnetic field. As a result, the switching power
supply is more efficient than the linear power supply typically, 75%
efficient for a 5V output regulator.
One of the great
advantages of switching power supplies and our designs, which we secure through
Telkoor, in addition to their higher efficiency, is their high power density, or
power-to-volume ratio, making them smaller than those of our
competitors.
Another advantage of
our power supply products is the flexibility of design. We have designed
the base model power supply products so that they can be quickly and
economically modified and adapted to the specific power supply needs of any
OEM. This flexibility approach has allowed us to provide
samples of modified power supplies to OEM customers in only a few days after
initial consultation, an important capability given the emphasis placed by OEMs
on time to market. This flexibility approach also
results in very low non-recurring engineering (NRE) expenses. Because of
reduced NRE expenses, we do not generally charge our original equipment
manufacturer (OEM) customers for NRE related to tailoring a power
supply to a customers specific requirements. This gives us an
advantage over our competitors, many of whom do charge their customers for NRE
expenses. Our marketing strategy is to exploit this combination of high
power density, design flexibility, and short time-to-market to win an increasing
share of the power supply market.
In addition to the
line of proprietary products offered, and in response to requests from OEMs, we
also provide value-added services. The term value-added
services refers to our incorporation of an OEMs selected electronic
components, enclosures, and cable assemblies with our power supply products to
produce a power subassembly that is compatible with the OEMs own
equipment, and specifically tailored to meet the OEMs needs. We
purchase parts and components that the OEM itself would otherwise attach to, or
integrate with, our power supply, and we provide the OEM with that integration
and installation service, thus saving the OEM time and money. We believe
that this value-added service is well suited to those OEMs who wish to reduce
their vendor base, and minimize their investment in manufacturing that leads to
increased fixed costs. Based on the value-added services, the OEMs do not
need to build assembly facilities to manufacture their own power subassemblies
and thus are not required to purchase individual parts from many
vendors.
Historically, as a
result of our strategic collaboration with Telkoor, we were awarded an initial
$1.6 million contract in 2004 for a military avionics application. The majority
of the revenue generated from this contract was recognized in 2005 and will be
completed in the first quarter of 2006.
Telkoor Telecom Ltd.
Telkoor is a
corporation organized and headquartered in Israel. It is primarily engaged
in developing; marketing, and selling power supplies and power systems for the
Commercial and Military Markets. Consistent with our total cost reduction
efforts, and taking advantage of Telkoors strong engineering team, we have
and will continue to utilize Telkoor to assist us in new product
development. Further, during the year ended December 31, 2005, we made
significant progress in penetrating the United States and European markets with
Telkoors products. This effort generated sales of approximately 36%
of our revenues for 2005. We intend to continue to sell Telkoors
products in the future to supplement our line of products.
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In April 2005, the
Company granted 70,000 options to Telkoors employees. The Company had
accounted for its options to Telkoors employees under the fair value
method of SFAS No. 123 and EITF 96-18. Those options vest primarily over four
years. The fair value for these options was estimated using a Black-Scholes
option-pricing model with the following weighted average assumptions for 2005:
risk-free interest rates of 4.4%, dividend yields of 0%, volatility of 103.4%,
and the contractual life of the options of 9.67 years. Compensation expenses of
approximately $ 8,000 were recognized during the year ended December 31,
2005.
Digital Power Limited
Digital Power
Limited organized and headquartered in Salisbury, England, designs,
manufactures, and distributes switching power supplies, uninterruptible power
supplies, and power conversion and distribution equipment frequency converters
for the commercial and military markets, under the name Gresham Power
Electronics. Uninterruptible power supplies (UPS) are devices
that are inserted between a primary power source and the primary power input of
the electronic equipment to be protected for the purpose of eliminating the
effects of transient power anomalies or temporary outages. A UPS consists
of an inverter powered by a battery that is kept trickle-charged by rectified AC
from an incoming power line. In the event of a power interruption, the
battery takes over without the loss of even a fraction of a cycle in the AC
output of the UPS. Frequency converters manufactured by DPL are used to
convert a warships generated 60-cycle electricity supply to 400
cycles. This 400-cycle supply is used to power critical equipment such as
the ships gyro, compass, and weapons systems. DPL also designs and
manufactures Transformer Rectifiers for Naval use. Typically, these
provide battery supported back up for critical DC systems such as machinery and
communications. In addition, higher power rectifiers are used for
helicopters on naval vessels. DPL products, add diversity to our product
line, provide greater access to the United Kingdom and European markets, and
strengthen our engineering and technical resources. For the year ended
December 31, 2005, DPL contributed approximately 54% to our gross
revenues.
The Market
Geographically, we serve primarily the North American power electronics market with individual AC/DC power supplies and DC/DC converters ranging from 50 watts to 1200 watts of total output power. DPL serves the United Kingdom and the European marketplace with AC/DC power supplies, uninterruptible power supplies, and frequency inverters.
Customers
Our products are sold in North America through a network of manufacturers representatives and distributors. Our customers can generally be grouped into five broad industries, consisting of the industrial, telecommunication, data communication, medical, and the military. We have a current base of approximately 400 active customers, some of which are served through our distributors.
DPL products are sold primarily in the UK and in Europe. The Company has been particularly successful in securing an export market in Spain for its defense products. In the UK, our main customers include the UK Ministry of Defense, BAE Systems, Babcock Defense, and Ultra Electronics. In Mainland Europe, we sell directly to Navantia in Spain, Martin Lighting in Denmark and Elma in Germany. We sell power supplies through European distributors with our greatest strength lying with Germany and Scandinavia.
Strategy
Our strategy is to be the supplier of choice to OEMs requiring high-quality power solutions where power density (size), rapid modification, and time-to-market are critical to business success. Target market segments include the industrial, telecommunication, and data communication, medical, and military industries. While many of these segments would be characterized as computer-related, we do not participate in the personal computer (PC) power supply market because of the low margins arising out of the high volume and extremely competitive nature of that market.
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We intend to
continue our sales primarily to existing customers while simultaneously
targeting sales to new customers. We believe that our flexibility
and high density power supplies allow customers a more effective choice
between our products and products offered by other power supply
competitors. Our flexibility and high density series is
designed around a standardized power platform, but allows the customer to
specify output voltages tailored to its exact requirements within specific
parameters. Furthermore, OEMs are seeking power supplies with greater
power density and higher efficiency. Digital Powers strategy in
responding to this demand has been to offer increasingly smaller power supply
units or packages. OEMs typically had to settle for a standard power
supply product with output voltages and other features predetermined by the
manufacturer. Alternatively, if the OEMs product required a
different set of power supply parameters, the OEM was forced to design this
modification in-house, or pay a power supply manufacturer for a custom
product. Because custom-designed power supplies are development-intensive
and require a great deal of time to design, develop, and manufacture, typically
only OEMs with significant volume requirements can economically justify the
expense and delay associated with in-house production. Furthermore, since
virtually every power conversion product intended for use in commercial
applications requires certain independent safety agency testing at considerable
expense, such as by Underwriters Laboratories, an additional barrier is
presented to the smaller OEM. By offering OEM customers a new choice with
Digital Powers flexibility and high density power supplies, we
believe we have an advantage over our competitors.
Products and Products Strategy
We have eleven
series of base designs from which thousands of individual models can be
produced. Each series has its own printed circuit board (PCB) layout that
is common to all models within the series, regardless of the number of output
voltages (typically one to four) or the rating of the individual output
voltages. Simply changing the power transformer construction and a small
number of output components can produce a broad range of output ratings, from
2.0 volts to 48 volts. Designers of electronic systems can determine their
total power requirements only after they have designed the systems
electronic circuitry and selected the components to be used in the system.
Because the designer has a finite amount of space for the system and may be
under competitive pressure to further reduce its size, a burden is placed on the
power supply manufacturer to maximize the power density of the power
supply. A typical power supply consists of a PCB, electronic components, a
power transformer and other electromagnetic components, and a sheet metal
chassis. The larger components are typically installed on the PCB by means
of pin-through-hole assembly where the components are inserted into pre-drilled
holes and soldered to electrical circuits on the PCB. Other components can
be attached to the PCB by surface mount interconnection technology (SMT), which
allows for a reduction in board size because the holes are eliminated and
components can be placed on both sides of the board. Our US100 series is
an example of a product using this manufacturing technology.
Digital Powers
flexibility and high density concept applies to all of our
EF175/200, EF300/400, cpci, Strongbox, US, UP/SP, DP, and UPF product
series. Generally a common printed circuit board is usually shared by each
model in a particular family, resulting in a reduction in parts inventory while
allowing for rapid modifiability into thousands of output combinations.
The following is a description of our primary products.
Four of our product
offerings resulting from our strategic relationship with Telkoor is: the
eFs series, CPCIs series, Strong Box series, and custom
products.
The new 3.6KW
Strongbox® is a single output front end with I 2 C data bus. It
features 3 x 1200 watt cassettes. The Strongbox is available in 24V and
48V outputs with active power factor correction.
The EF series are
high-density open frame power supplies, which most commonly come in 12,24 and 48
volt options with power factor correction.
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The CPCI series are
high-density enclosed central power supplies, which most commonly come in 5, 12,
24, and 48-volt options with power factor correction.
The US50 series of
power supplies consists of compact, economical, high efficiency, open frame
switchers that deliver up to 50 watts of continuous power, or 60 watts of peak
power, from one to four outputs. The 90-264 VAC universal inputs allow
them to be used worldwide without jumper selection. Flexibility options
include power good signal, an isolated V4 output, and UL544 (2 nd Ed.)
safety approval. All US50 series units are also available in 24VDC, or
48VDC inputs. This optional DC input unit (DP50 series) maintains the same
pin-out, size, and mounting as the US50 series.
The US70 series of
power supplies is similar to the US50 series, a compact, economical, highly
efficient, open frame switcher that delivers up to 65 watts with a 70-watt
peak. This unit is offered with one to four outputs, a universal input
rated from 90 to 264 VAC, and is only slightly larger than the US50
series. The US70 series is differentiated from competitive offerings by
virtue of its smaller size, providing up to four outputs while competitors
typically are limited to three outputs. Flexibility options include cover,
power good signal, an isolated V4 output, and UL544 (2 nd Ed.) medical
safety approval. The DP70 is the same as the US70 except the input is 48
volts DC. We also offer 24VDC input on this series where the model series
changes to a DM. This type of product is ideal for low profile systems,
with the power supply measuring 3.2 x 5 x 1.5.
The US100/DP100 was
the industrys smallest 100-watt switcher when originally introduced.
Measuring only 5 x 3.3 x 1.5, this series delivers up to 100
watts of continuous power, or 120 watt peak power, from one to four
outputs. The 90-264VAC universal input allows them to be used
worldwide. This product is ideal in applications where OEMs have upgraded
their systems, requiring an additional 30-40 watts of output power, but being
unable to accommodate a larger unit. The US100 fits in the same form
factor and does not require any tooling or mechanical changes by the OEM.
Flexibility options include a cover and adjustable post regulators on V3 and/or
V4 outputs and UL2601-1 (2 nd Ed.) medical safety approval.
Fully customized models are also available. All US100 series units are
also available with 12VDC, 24VDC, or 48 VDC inputs. This optional DC input
unit (DP100) maintains the same pin-out, size, and mounting as the US100
series.
The US250 series
consists of economical, high efficiency, open frame switchers that deliver up to
250 watts of continuous power, or 300 watts of peak power, from one to four
outputs. The 115/230VAC auto-selectable input allows them to be used
worldwide. Flexibility options include cover, power fail/power good
signal, enable/inhibit, and an isolated V3 output. All US250 series units
are also available with 12VDC, 24VDC, or 48VDC inputs. This optional DC
input unit (DP250) maintains the same pin-out, size, and mounting as the US250
series.
The UP300 series
consists of economical, high efficiency, open frame switchers that deliver up to
300 watts of continuous, or 325 watts of peak power, from one or two
outputs. The 115/230VAC auto-selectable input allows them to be used
worldwide. On-board EMI filtering is a standard feature. Flexibility
options include a cover, power fail/power good signal, and an isolated 2nd
output. This product can be used in network switching systems or other
electronic systems where a lot of single output current, such as 5, 12, 24, or
48 volt current might be required.
The UPF150/DP150
series is an open-frame switcher that delivers up to 150 watts of continuous
power from one to four outputs. In response to market condition for more
functionality, the UPF 150 has both power factor correction and a Class B EMI
filter as standard features. All UPF150 series units are available with
24VDC, or 48VDC inputs. This optional DC input unit (DP150) maintains the
same pin-out, size, and mounting as the UPF150 series.
The UPF 300 watts
delivers up to 300 watts from one or two outputs and also includes power factor
correction and measures 8 x 4.5 x 2.
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DPL Products
Gresham designs and manufactures a wide range of products for Naval applications. These include:
Static Frequency Converters typically converts ships supply from 50/60Hz to 400Hz for gyros and weapons systems. Power range is from 1kVA to 35kVA.
DC Systems converts main ships supply to 24VDC. These systems normally supported by battery backup provide the vessels emergency DC supplies for machinery, communications, and other essential services.
Transformer Rectifiers 28V to 400A. Ratings of 10 and 15kVA provide DC power to enable the ship to start and service helicopters. Greshams Transformers are in service with a number of Navys, including the Royal Navy, and are designated by Westland Helicopters in support of the Super Lynx.
Inverters 1kVA to 3.6 kVA typically convert DC to 440V 3phase 60 Hz for communications and emergency services.
Circuit breaker monitoring and controls modular system of controls for main circuit breakers based upon digital circuitry. Modules available include over current, short circuit, low voltage, over and under frequency and an indicator module. Many are used in submarine service.
Intelligent switch mode DC/DC power supplies in support of inboard submarine sonar.
Filter boxes for secure communications.
Navigation and signal panels for the control and dimming of ships external navigation lights.
DPL also manufactures a range of commercial inverters of its own design for telecoms applications. Rated at 250VA, 500VA, and 1kVA, these convert either 24V or 48V DC to AC.
In addition to Digital Power and Telkoor products, DPL distributes a wide range of commercial uninterruptible power supplies. Power ratings range from 500VA to 6kVA in a modular configurable range. The Company also provides turnkey high power solutions for major business users. Typically configured with generators for the support of substantial institutional systems, power ratings can extend to 300kVA
Manufacturing Strategy
Consistent with our
product flexibility strategy, we aim to maintain a high degree of flexibility in
our manufacturing strategy through the use of strategically focused contract
manufactures. It is our belief that strategically focused contract
manufacturers will meet our near term cost, delivery, and quality goals, while
providing synergistic concepts. In addition, we believe these
relationships will eventually give us access to new markets and cross licensing
arrangements that may be beneficial. The competitive nature of the power
supply industry has also placed continual downward pressure on selling
prices. In order to achieve our low cost manufacturing goals with labor
intensive product, we also plan on continually increasing our supply base
through the use of contract manufacturers in the Far East. At present, our
principal source in the Far East is Winco Power Technology (Winco). In
coordination with Telkoor, we are launching two additional contract
manufacturers in China. We are no longer subcontracting to a manufacturer
located in Guadalajara, Mexico.
We have contract manufacturing relationships with Winco to manufacture our products at facilities located in China on a turnkey basis. Purchases from Winco are made pursuant to purchase orders. For the year ended December 31, 2005, Digital Power purchased approximately 28% of its power supply requirements through Winco. Our products are meeting the certification standards according to independent safety agency requirements.
- 7 -
Regulatory Requirements
Digital Power and its manufacturing partners are required to meet applicable regulatory, environmental, emissions, safety or other requirements where specified by the customer and accepted by Digital Power or as required by local regulatory or legal requirements. In July of 2006, the industry will be phasing in RoHs and Weee requirements in most geographical markets with specific emphasis on consumer based products. These requirements may require the use of new components or finish goods to be built with RoHs and Wee compliant components potentially rendering existing or down revision finish goods inventory and component inventory to risk of obsolescence. In addition, there is some speculation that RoHs and Wee compliant components may be subject to longer lead-times and higher prices in the near term as the industry transitions to these new requirements
Digital Power Limited Manufacturing
DPL operates from a 25,000 sq. ft leased facility located in Salisbury U.K. The equipment designed and manufactured in Salisbury is different from the power supplies produced in China. Full assembly, test, and quality assurance take place in-house.
Sales and service support staff for the European network of distributors for Digital Power products are located within the building together with other functions, such as Engineering and Administration.
Sales and Marketing
Digital Power markets its products through a network of independent manufacturers representatives and distributors. Each representative organization is responsible for managing sales in a particular geographic territory. Generally, the representative has exclusive access to all potential customers in the assigned territory and is compensated by commissions at 5% of net sales after the product is shipped, received, and paid for by the customer. Typically, either the representative organization or we may terminate the agreement with 30 days written notice.
In certain
territories, we have entered into agreements with distributors who buy and
resell our products. For the fiscal years ended December 31, 2005 and
2004, U.S. distributor sales accounted for 18.95% and 20.43%, respectively, of
our total sales. Over this same period, one distributor accounted for
13.01%, and 16.85%, respectively, of total sales. In general, the
agreements with distributors are subject to annual renewal and may be terminated
upon 90 days written notice. Although either party may terminate these
agreements, in the event a distributor decides to terminate his agreement with
us, we believe that we would be able to continue the sale of our products
through direct sales to the customers of that distributor. Usually the
Company does not grant a right of return. Revenues subject to certain
stock rotation are deferred until the products are sold to the end customer or
until the rotation rights expire. Certain distributors are allowed, in the
sixth month after the initial stock purchase, to rotate stock that has not been
sold for other products. This may be repeated each sixth month thereafter
for 18 months, at no more than 25% of the distributors purchase during the
previous six months. For the past three years, stock rotations have not
exceeded one percent of total sales.
Our promotional efforts to date have included product data sheets, trade shows, and Internet Web sites. Our future promotional activities will likely include space advertising in industry-specific publications, application notes, and enhancements to our existing Web sites.
Our products are warranted to be free of defects for approximately twelve months from date of shipment. As of December 31, 2005, our warranty reserve was $73,000.
- 8 -
Competition
The merchant power
supply manufacturing industry is highly fragmented and characterized by intense
competition. Our competition includes hundreds of companies located
throughout the world, some of whom have advantages over us in terms of labor and
component costs, and some of who may offer products comparable in quality to
ours. Many of our competitors, including Power One, Artesyn (Emerson)
Technologies, Inc., ASTEC (Emerson) America, Lambda Electronics, and Meanwell
Power Supplies have substantially greater fiscal and marketing resources and
geographic presence than we do. If we are successful in increasing our
revenues, competitors may notice and increase competition with our
customers. We also face competition from current and prospective customers
who may decide to design and manufacture internally power supplies needed for
their products. Furthermore, certain larger OEMs tend to contract only
with larger power supply manufacturers. This factor could become more
problematic to us if consolidation trends in the electronics industry continue
and some of the OEMs to whom we sell our products are acquired by larger
OEMs. To remain competitive, management believes that we must continue to
compete favorably on the basis of value by providing reliable manufacturing,
offering customer service and design engineering services, continuously
improving quality and reliability levels, and offering flexible and reliable
delivery schedules. We believe we have a competitive position with our
targeted customers who need a high-quality, compact product, which can be
readily modified to meet the customers unique requirements. However,
there can be no assurance that we will continue to compete successfully in the
power supply market.
Engineering and Product Development
Our engineering and product development efforts are primarily directed toward modification of our standard power supply to provide a broad array of individual models. Improvements are constantly sought in power density, adaptability, and efficiency, while we attempt to anticipate changing market demands for increased functionality, such as PFC and improved EMI filtering.
Historically, the Company has utilized Telkoor consultants and contract engineering for the majority of its new product developments, supported by the internal engineering staff for product engineering. The Company intends to continue this strategy for engineering and development.
Employees
As of December 31, 2005, Digital Power had 32 employees located in the United States and the United Kingdom.
Foreign Currency Fluctuations
DPL conducts its financial operation using the United Kingdom pound sterling. Therefore, we are subject to monetary fluctuations between the U.S. dollar and United Kingdom pound sterling. For the years ended December 31, 2005, and 2004, we recorded a foreign currency translation loss adjustment of $132,000 and $81,000 respectively.
Raw Materials
The raw materials for power supplies principally consist of electronic components. These raw materials are available from a variety of sources and we are not dependent on any one supplier. We generally allow our subcontractors to purchase components based on orders received or forecast to minimize our risk of unusable inventory. To the extent necessary we may allow them to procure materials prior to orders received to obtain shorter lead times and to achieve quantity discounts following a risk assessment. (see regulatory requirements).
- 9 -
Intellectual Property
We rely upon a combination of trade secrets, industry expertise, confidential procedures, and contractual provisions to protect our intellectual property. We believe that because our products are continually updated and revised, obtaining patents would be costly and not beneficial.
On July 8, 2004, our trademark, DP Digital Power Powering our technologies, was registered with the United States Patent and Trademark Office.
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