Carr’s UK agricultural activities (which include all its associates and JVs) encompass a broad range of services for farmers and other rural dwellers. This is complemented by an international business manufacturing and selling high added-value feed blocks in the US, UK, mainland Europe and New Zealand. Carr’s range of agricultural activities provides a level of protection against negative influences affecting one part of the agricultural sector. Within the Agriculture division, Carr’s frequently opts to form JVs with established industry partners in regions outside the UK, for example with Agravis in Germany, as this gives an accelerated market entry and reduces the risk associated with entering new territories.
Traditional agricultural supply merchants rely on selling high volumes of relatively low-value feed, fertiliser and other agricultural inputs. The cost of transporting these significant distances tends to limit geographic expansion. For Carr’s, the ability to offer high-margin feed blocks, boluses and other animal health products raises margins overall, provides the potential to develop overseas markets, and sustains long-term relationships with farmers by providing a complete nutritional package for livestock based on advice from agronomists.
Feed supplements: Adding value through IP
Feed blocks: Part of the shift to more professional farming practices
Carr’s molasses-based branded feed blocks are made in the UK, Germany and North America and sold throughout the UK, Europe, North America and New Zealand. Around 140–150 thousand tonnes of feed blocks are sold worldwide each year. The feed blocks are manufactured according to a patented process. The top layer of the block absorbs moisture from the atmosphere and is therefore removed when livestock lick it, but the underlying layers are too hard to be licked away. This regulates the amount that can be consumed by a single animal each day and thus the amount of nutrients taken up. The feed block formulation is adjusted for different animal species and specific life-stages such as pre-calving, post-calving or finishing lambs.
Consumption is linked to the adoption of more sophisticated farming practices where the calorific, protein, mineral and vitamin content of forage and feed are precisely controlled to maximise the return on investment. Many of the feed blocks are formulated to promote increased utilisation of forage, thus maximising the economic performance of an animal. The ability to quantify the economic benefit for farmers by providing results from locally based trials helps overcome their innate conservatism and supports a high margin.
Supplement portfolio broadened following Animax acquisition
The acquisition of Animax in September 2018 broadened the group’s existing range of animal health products and supplements, enabling farmers to administer trace elements via boluses rather than licks. Animax contributed £6.1m to revenues and £0.6m to adjusted EBIT during FY19. As planned, management has made significant investment in automation and management at Animax since the acquisition, supporting the development of product sales into the European and North American markets. Animax’s R&D facility will become the division’s Centre of Excellence for Innovation and New Product Development.
Expansion of feed block sales in new geographies
Carr’s completed its feed block platform in the US when its new low-moisture feed block plant in Tennessee became fully operational in January 2018, enabling it to sell low-moisture feed blocks to farmers in the eastern states of the US, which could not be accessed from existing operations. It has started to ship feed blocks from the South Dakota factory into Canada. The next step is opening feed block plants in other regions where cattle are reared on forage-based systems. The group continues to ship feed blocks to New Zealand with the intension of constructing a production facility in the country once volumes are sufficiently high. Our estimates assume that any extensive penetration of New Zealand will be beyond the period covered by our forecasts.
More professional farming methodologies promote demand for feed supplements
Demand for feed blocks in the US is primarily driven by beef cattle farmers and is linked to weather conditions, consumer demand for quality beef and cattle prices. Demand for feed blocks in the UK and Ireland is primarily from sheep farmers and is linked to weather conditions at lambing time. The division is reducing volume seasonality by promoting products for use by dairy farmers. Demand for feed blocks in continental Europe and New Zealand is primarily from dairy farmers and linked to the adoption of more sophisticated feeding regimens that deliver increased output from the same number of animals. Demand for supplements providing trace elements is likely to increase if there is a ban on routinely feeding animals antibiotics, as farmers will potentially turn to nutritional supplements to boost the resilience of their livestock to infection. Similarly, regulations introduced in Germany that ban debeaking of poultry promote the use of new blocks designed to give caged poultry something else to peck at rather than their companions. A new plant to manufacture these blocks in Germany is currently being commissioned.
Limited competition for feed supplements
There is limited competition for low-moisture feed blocks in the UK and New Zealand. New Zealand is a relatively new market where farmers are beginning to adopt the more sophisticated feed regimes common in the US. Ridley, which was acquired by animal nutrition and health specialist Alltech in 2015, is the North American market leader, with an estimated 40% share, compared with Carr’s 26%. In the US, Carr’s competes through branding with its ‘Feed in a Drum’ and SmartLic supplements.
UK agriculture
Third-largest animal feed manufacturer in the UK
Carr’s manufactures around 500,000 tonnes of compound and blended feeds each year. These are sold to sheep, dairy and beef cattle farmers in the North of England, Scotland, Wales and the Midlands. The feed is manufactured by an associate company, Carrs Billington, at compound feed mills in Staffordshire, Lancashire and Cumbria, and at blends plants in Kirkbride, Cumbria, Lancaster and Staffordshire.
Carr’s is the third-largest manufacturer in the UK behind ForFarmers and NWF Group. There are numerous small feed suppliers in the area served by Carr’s as well. Underlying demand for dairy feed in the UK is linked to the volume of milk produced, which was 2% higher year-on-year during FY19 than FY18 (source: Agriculture and Horticulture Development Board, AHDB). The number of dairy farms, however, reduced by 0.4% between February and October 2019. The trend to larger herds and more intensive rearing regimens. favours a more technical approach to feeding cattle, which benefits larger operations such as Carr’s that can offer nutritional advice and specialised feed blocks as well as feed. This technical approach is important whether farmgate milk prices are high or low, as farmers are keen to investigate changes to feed regimens that can help improve either yield or profitability, depending on the economic environment. Demand for feed varies from year to year depending on weather conditions. Carr’s is less dependent on demand for dairy feed than NWF Group because it also sells substantial volumes of sheep and beef cattle feed.
Retail outlets dedicated to farmers and the broader rural community
Carr’s operates a chain of over 40 retail outlets in Scotland, the North of England, Staffordshire, Derbyshire and the Welsh borders. This includes seven machinery branches, making Carr’s one of the largest AgCo distributors (Massey Ferguson and Fendt equipment) in the UK. These stores specialise in products for farmers and the broader rural community including animal health products, agricultural sundries such as fencing and farm consumables, pet and equine products and rural clothing. The products offered vary between stores to reflect the type of farming in the area. Farmers are typically conservative and cautious about purchasing from brand-new outlets. Carr’s has therefore expanded its retail operations predominantly by purchasing smaller agricultural suppliers with a limited retail offer but a solid customer base. Post-acquisition it then broadens the product portfolio to appeal to both farmers and other rural dwellers and expands the retail space, relocating the premises if necessary.
A high proportion of sales at Carr’s Country Stores relates to non-discretionary farming expenditure, so underlying demand, especially for farm machinery, is linked to farm incomes. Carr’s has been able to grow sales independently of this by broadening the product offer to include higher-margin animal healthcare products. The retail outlets are typically situated at places convenient for farmers such as stock auction markets rather than on conventional retail parks.
Fuel distribution complements retail offer to farmers and rural dwellers
Carr’s operates eight fuel distribution depots, which service rural premises in Dumfries, Galloway, Cumbria and Lancashire. At around 115m litres per year, the operation is significantly smaller than that of NWF Group (552m litres in FY19), which is the third-largest oil distributor in the UK. However, unlike NWF, Carr’s is not intending to become a national player in the sector, but views this as a service within its agricultural supply offer. The operation is highly complementary to the feed and machinery sales operations, providing significant opportunities for cross-selling. Demand for heating oil is dependent on weather conditions. This dependence is reduced by selling tractor fuel as well. Demand for tractor fuel is typically higher over the summer, when demand for heating fuel is weaker.
Exhibit 3: Acquisitions within the Engineering division
Company |
Year |
Price |
Location |
Activity |
Bendalls |
1996 |
£3.5m |
Carlisle |
Specialist fabrications for nuclear, oil & gas, petrochemical industries |
Carr’s MSM |
2003 |
- |
Swindon |
Remote handling equipment for nuclear industry |
Wälischmiller Engineering |
2009 |
£4.9m |
Markdorf, Germany |
Remote handling equipment for nuclear industry |
Chirton Engineering |
2014 |
£2.9m |
Newcastle-on-Tyne |
Precision machining of components for the offshore oil & gas industry |
STABER |
2016 |
€7.85m |
Markdorf, Germany |
Robotics IP |
NuVision Engineering |
2017 |
<£15.4m |
Pittsburgh, PA and Charlotte, NC |
Specialist engineering for nuclear and waste remediation industry, including remote handling equipment |
NW Total Engineered Solutions |
2019 |
<£9.6m |
Barrow-on-Furness, UK |
Designs and manufactures bespoke process equipment packages and provides onsite technical support, installation and condition monitoring services to the nuclear defence, nuclear power generation and decommissioning markets |
The Engineering division designs, manufactures and services bespoke equipment supporting markets in the global nuclear commercial, nuclear defence and oil and gas industries. These capabilities are complemented by a portfolio of remote handling manipulators and robotics. The division serves customers in Europe, Russia, the Far East, Australia, South Africa, the US and Latin America. It has been built up through a sequence of acquisitions, (Exhibit 3). Management focus is on driving the synergies between the different businesses, fostering cross-selling and joint work on projects. This has already proved successful, with NuVision helping the German robotic business win a US$8.5m contract in the previously impenetrable US market, and the UK manufacturing business supplying a tank to Sellafield containing NuVision’s fluidics technology.
UK service and manufacturing
This part of the division primarily designs and manufactures bespoke steel fabrications such as pressure vessels up to 5.0m in diameter and 50m-long process columns, chemical reactors, tanks and tidal and wind turbines. These are typically sold to customers in the nuclear, oil and gas, petrochemical and process industries. Safety is critical in these sectors, so full material traceability along with radiographic weld testing, hydraulic testing and documentation packages are offered as standard. Customers include Aker Kvaerner, BP, Chevron Texaco, Chiyoda, Costain, KBR, Pfizer, Roche, Royal Dutch Shell and Sellafield. The division also offers precision machining services to customers in the offshore oil and gas and nuclear industries.
Exhibit 4: Steel fabrications
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Recently acquired NW Total designs and manufactures bespoke process equipment packages and provides onsite technical support, installation and condition monitoring services to the nuclear defence, nuclear power generation and decommissioning markets. The acquisition enhances the Engineering division’s offer for the nuclear industry, adding specialist services such as condition monitoring and staff authorised to work on highly regulated sites such as Sellafield. The deal extends the customer base in the UK and provides opportunities for cross-selling, with NW Total designing complex fabrications such as pressure vessels and heat exchangers and the existing UK businesses manufacturing them. The initial consideration payable was £6.0m, with a performance-related deferred consideration of up to £3.6m payable over the following three years. For the year ended March 2019, NW Total reported £9.1m revenues and £1.5m profit before tax. As with previous acquisitions, Carr’s intends to invest in the newly acquired business, recruiting staff to support business development and drive operating efficiency improvements. Despite the costs associated with the additional staff, management expects the acquisition to be earnings enhancing in its first full year of ownership.
Global Technical Services
NuVision Engineering designs and implements technically advanced engineering solutions that help extend the life and safe operation of power plants and enable the movement and management of radioactive waste. For example, its patented MSIP technology is a patented, permanent solution that has been accepted by the United States Nuclear Regulatory Commission as a technique for mitigating stress corrosion cracking in both boiling water reactor and pressurized water reactor plants. If not addressed, stress corrosion cracking can compromise nuclear plant safety and availability. NuVision also validates new plant designs and analyses existing systems to predict and proactively manage potential problems, in which capacity it has conducted more than 100 large-scale demonstration test programs for US Department of Energy (DOE) and UK customers. Its customers include the US and other governments, utilities, nuclear plant designers and OEMs. It has assisted with the clean-up of legacy waste in North America and the UK for more than 30 years, having developed, designed, built, tested and implemented waste management systems at key sites such as Oak Ridge, Los Alamos, Sellafield and Dounreay.
In 2018 NuVision was awarded US$3m funding from the US DOE to develop a small-scale working prototype of its passive cooling technology. This provides an engineered solution to mitigate the effects of loss of power to light water-based nuclear reactors (as happened in Fukushima) and to remove decay heat from the reactor core, mitigating losses due to random equipment failures and severe accidents. This potentially opens a new product area longer term.
This part of the division designs and manufactures remote handling equipment such as robotic arms and master-slave manipulator units. These devices are widely used in the nuclear industry in post-irradiation examination laboratories and fuel element reprocessing cells. The robotic arms incorporate specialist gearing systems that permit the very precise control of movement required for remote handling applications and are unusual in that they have no external cabling or hydraulic systems so there is no restriction on rotational movement. The robotic arms are typically customised for deployment in specific applications. For example, the V1000 power manipulator has a robotic arm mounted on crawlers to create a fully remote-controlled handling vehicle and has with radiation-proof components and easy-to-decontaminate surfaces for deployment in the nuclear industry. A single robotic arm sale may be around €1m. The division is one of the largest providers of highly specialist remote handling equipment for the nuclear industry globally and has the broadest product range.
Exhibit 5: Self-propelled robotic arm for nuclear waste clean-up operations
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Before the acquisition of NuVision, which has offered its own robotic arms for around 20 years, customers for these products were primarily engaged in the nuclear industry in France, Germany, the Far East and the UK, where the main customer is Sellafield. In calendar year 2012, the group was awarded a ‘life of plant’ contract with Sellafield, under which it supplies master-slave manipulator parts for the major operating plants at Sellafield. This contract extends until at least 2020 and generates revenues of over £2m each year. The acquisition of NuVision has created a route to market that overcomes the resistance in the US to purchasing from foreign suppliers that had been experienced previously.