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Corporate Profile

Orbital Engine Corporation Limited (Orbital) is a leading developer of engine technologies using direct injection, lean burn combustion and control systems. These technologies are collectively called the Orbital Combustion Process or OCP Technology.

Our goal is to rapidly commercialise innovative OCP products and technologies into global markets to create significant economic and environmental value for our shareholders, customers, employees, and the community.

Orbital strives to build value through the development and marketing of innovative technical solutions that create significant new market opportunities. Orbital's strategy is to actively participate in the commercialisation process to reduce risks and advance the rate of adoption of OCP technology. Strategic alliances with key established industrial groups are an important part of this strategy.

The Orbital group earns income from the sale of rights to its intellectual property (patents and know-how) to major vehicle, engine and component manufacturers through licence and engineering service agreements. These agreements grant the licensee certain rights to manufacture, use and sell products utilising OCP Technology.

Orbital's income stream also extends to profits from the sale of fuel systems and other components made by Orbital through joint ventures and fees for the provision of consulting and engineering services to a growing worldwide customer base.

Orbital currently has 15 agreements which grant licence rights and a customer base that coversapplications in the automotive, marine, recreational, and motorcycle markets.



Orbital has licence agreements with the following:
  • Ford Motor Company
  • General Motors Corporation
  • Fiat Auto Company
  • Brunswick Corporation (parent of Mercury Marine)
  • Outboard Marine Corporation
  • Tohatsu Corporation
  • Bombardier-Rotax GmbH
  • Bajaj Auto Limited
  • Piaggio V.E.S.p.A
  • Asian motorcycle manufacturer
  • Meteor (joint venture with Brunswick Corporation)
  • Synerject (joint venture with Siemens Automotive Corporation)
  • Genesis R&D Syndicate
  • OCP 4-stroke R&D Syndicate
  • Deutsche Morgan Grenfell Technology Investment Transactions

In addition to strategic alliances with Brunswick Corporation, Siemens Automotive Corporation and Lotus Engineering, Orbital has close affiliations with Motorola and Johnson Matthey.

Chairman & CEO's Report

In our 25th year of corporate existence, Orbital has successfully delivered the two key financial objectives set in the 1997 Annual Report. The goals of becoming cash positive and achieving a modest operating profit before tax and abnormal items are key indicators of the transition of Orbital's technology into the com-mercialisation and production phase. During the 1997/98 financial year Orbital's cash balance increased by $6.463 million and the group achieved an operating profit before tax and abnormal items of $6.279 million. We believe this is an excellent result and is a credit to all employees in the group.

Across the Corporation the focus has clearly moved to the application in production of our patented OCP technology. A culture of commerciality and cost consciousness has further developed inside the group. In addition to the financial achievements, a number of important milestones were achieved by our four business units in 1997/98.

The Automotive Direct Injection 4-stroke business unit was able to exploit the continually growing global interest in greenhouse gases, fuel economy and emissions control that is driving the introduction of direct fuel injection technology. Orbital's unique reservoir of know-how, experience and patents that has built up over 25 years of work in direct injection has been combined with the injection manufacturing capability of Siemens. This places Orbital in a market leadership position with this technology. Led by Daimler-Benz, OCP technology is under evaluation throughout the automotive world.

As announced in June this year, we have been working with Daimler-Benz in conjunction with Siemens Automotive for over two years to apply our fuel system to Mercedes engines. Direct injection allows manufacturers to preserve their enormous investments in 4-stroke gasoline engine plants while evolving this engine to the next level of efficiency.

The Marine and Recreation business unit concluded two landmark supply agreements with the two largest and most important manufacturers in this segment. In April 1998 an agreement was signed with Bombardier-Rotax covering their "Sea-Doo" personal watercraft range, while a similar agreement was signed in June 1998 with Mercury Marine regarding outboard engines. These supply agreements establish OCP technology as the industry's low emissions solution well into the next millennium.

The Motorcycle business unit significantly advanced the production programs they have in place with manufacturers in both Europe and Asia. The successful conclusion of these programs will see production scooters incorporating OCP technology entering this huge global market during 1999.

The Automotive 2-stroke business unit's Maleo project was an unfortunate casualty of the Asian economic crisis. A comprehensive marketing effort has demonstrated that significant potential remains for this technology in emerging markets, city cars and electric hybrids. Orbital's Genesis program has ensured that this technology is now fully mature and requires no further development expenditure. This group is now fully focused on establishing and building a market for this powerplant.

Alliances
The alliances Orbital has established have made a significant contribution to the progress of the business units during the year. The industrialisation skills of Siemens Automotive provide our customers with confidence their componentry can be supplied at high volume whilst retaining the requisite standard of quality. The joint venture, Synerject is now fully operational at Siemens' high volume manufacturing facility at Newport News, Virginia, and is manufacturing fuel rail assemblies for Orbital's marine customers.

The Siemens relationship was expanded in February 1998 to create an alliance that facilitates the supply of complete integrated systems incorporating OCP technology to automotive customers. This capability is essential in order to penetrate the automotive industry, as manufacturers are continuing to reduce the number of suppliers and rely more heavily on a few established systems integrators such as Siemens Automotive. The systems integrator sources, validates, and coordinates the supply of the components of a system including the fuel rail assembly, electronic control unit, compressor, fuel pump and wiring harnesses. The system is then sold to the manufacturer as a complete unit. This expansion in the relationship is an essential pre-requisite for, and primary indicator of, commercial volume production.

The continued growth of the alliance with Siemens, and the establishment of Synerject as a quality injector supplier in the marine industry, has opened the door for Siemens and Orbital to further their relationship in the non-automotive industry. At the same time Brunswick (Mercury Marine's parent) can now step back from the Meteor relationship, because Mercury Marine has a guaranteed high quality, low cost supplier and they have developed the necessary long term supply contract. Orbital is therefore currently negotiating to ensure that a suitable systems supply relationship is firmly in place to enable rapid growth of the technology in the motorcycle, marine and recreational segments.

During February 1998 an alliance was also established with Lotus Engineering. The alliance enables the two companies to take advantage of each others extensive facilities, but more importantly equips Lotus with the capability to offer engineering expertise related to OCP technology. We view this alliance as an additional enabling device for our technology to enter the market.

Financial
For the twelve months ended 30 June 1998, Orbital recorded an operating profit before abnormal items and income tax of $6.279 million, compared to a loss of $26.179 million for the 1997 financial year.

Consolidated operating revenue for the twelve months to 30 June 1998 increased by 145% to $62.093 million from $25.303 million in 1997. The substantial increase in revenue from trading operations (1998: $52.592 million compared to 1997: $22.376 million) is attributed to income earned from automotive 4-stroke customers, growth in earnings from the supply of fuel systems to marine and recreation production customers, and income associated with the Deutsche Morgan Grenfell (DMG) transactions discussed below.

Consolidated operating expenditure increased by 8% to $55.814 million from $51.482 million in 1997. The 1998 expenditure includes $5.294 million in relation to the written down value of assets sold. Excluding this item, 1998 operating expenditure is $50.520 million, a reduction of $0.962 million compared to 1997. The reduction in expenditure is noteworthy given the substantial increase in revenue from trading operations.

Orbital's result after abnormal items continues to be impacted by significant amortisation charges as we progress the alignment of our financial reporting under Australian and United States Generally Accepted Accounting Principles (AUS GAAP and US GAAP). These intangibles are not recognised under US GAAP. Abnormal expenses totalling $85.426 million were recorded in relation to amortisation of cash expenditures on Patents, Licenses and Technologies ($32.974 million) and Patents, Licenses and Technologies arising from corporate restructurings ($52.452 million). Orbital's intangibles balance at 30 June 1998 is $84.069 million. This balance will be fully eliminated through amortisation charges over the course of the 1999 financial year.

Orbital recorded an income tax expense of $9.603 million incorporating an income tax credit of $21.952 million and abnormal tax expenses of $16.114 million arising from the DMG transactions and $1.584 million from withholding tax payable. This was offset by the recoupment of foreign tax credits of $5.060 million which would have expired in June 1998. In addition, an abnormal tax expense of $18.883 million was recorded in relation to the non-deductible amortisation of Patents, Licenses and Technologies arising from corporate restructurings.
The operating loss after abnormal items and income tax was $88.750 million for the twelve months ended 30 June 1998 (1997: $144.094 million).

Cash Position
Orbital's consolidated cash position improved over the last twelve months following operating receipts from a number of customers and the DMG transactions. As at 30 June 1998, Orbital's cash balance was $27.789 million compared to $21.326 million at 30 June 1997. Orbital's cash and receivables total for 1998 improved by 49% from $32.385 million to $48.276 million.
Orbital's cash balance as at the date of this report is in excess of $50 million.

Convertible Debenture
In July 1998, Orbital announced it had signed an agreement with an institutional investor to raise US$20 million for the provision of working capital. These funds will be raised through the private placement of a 3% redeemable subordinated convertible debenture. This debenture will be issued in two tranches of US$10 million each and is convertible into shares at any time within three years. The first tranche was received in August 1998.

The conversion price of the first tranche, if converted within the first six months of issue, is $0.94 if converted into ordinary shares and US$4.50 if converted into ADRs. If converted after six months, the conversion price is at market prices. The second tranche will be issued when a pre-determined share price has been achieved, or by mutual agreement of both parties. The conversion price of the second tranche, if converted within the first six months of issue, is $1.38 if converted into ordinary shares and US$6.60 if converted into ADRs. If converted after six months, the conversion price is at market prices.

The provision of these funds will ensure that Orbital can respond to all the opportunities that have recently emerged and provide funding for future expansion as production increases.

DMG Transactions
Orbital's working capital reserves received a $14.817 million injection during the year as a result of a strategic investment program undertaken by Deutsche Morgan Grenfell (DMG), part of the global Deutsche Bank group. Under the terms of these transactions, DMG will provide a further $3.680 million during the 1999 financial year. The funds will be directed at increasing the prospect, rate and timing of widespread adoption of OCP technology in the non-automotive sectors. The net impact of these transactions on Orbital's 1998 profit before tax and abnormals is approximately $12 million.

Under the terms of this arrangement, Orbital was not required to establish or increase loan facilities or issue any new equities. DMG will earn a return on its investment through partial access to non-automotive royalty streams and profits generated from the sale of fuel systems to these markets. Management believes the ultimate return to shareholders will be enhanced via this investment as injection of funds at the current stage of the development process will not only bring forward revenue streams but also increase the prospect of total revenue to be earned in these markets.

Patents
Orbital continues to actively investigate new technologies whilst also improving on and enhancing existing technology through continued research and development and product refinement, particularly in regard to OCP related technology. Orbital believes that patent protection of its technologies and processes is critical to its financial performance, including the longevity of its royalty streams, and that its success depends upon its ability to protect its proprietary products and technology under United States, European and other foreign patent laws and intellectual property laws.

Accordingly, Orbital has been and will continue to be active in securing and policing intellectual property rights for its proprietary products and technology. As a direct consequence, Orbital continues to maintain and enhance its comprehensive patent and patent application portfolio. At July 1998, Orbital had over 117 individual patent families with a total in excess of 1020 patents and patent applications worldwide. In this regard, Orbital currently has granted patents and/or patent applications pending in over 30 countries around the world including the United States of America, Australia, Japan, China, Germany, Italy, France, Taiwan, and many more. In particular, Orbital presently holds no fewer than 80 granted US patents. Of course, some inventions, ideas and know-how, although valuable from a technical point of view, are either not patentable or are better served by protection as trade secrets. Orbital therefore also maintains high standards of confidentiality to safeguard such inventions, ideas and know-how.

Investor Relations
The developments in our relationships with Siemens Automotive and Daimler-Benz created enormous interest in the German financial markets. The interest led local market makers to list Orbital on German "over the counter" markets. Orbital's ordinary shares are now traded on the Frankfurt Stock Exchange and ADRs traded on the Berlin Stock Exchange.

On 21 July 1998, Orbital's largest shareholder, BHP sold a significant portion of their holding as part of their $3 billion sale of non-core assets. Whilst BHP remain our largest shareholder with approximately 9.5% of the Company, we would like to take this opportunity to thank them for their support over the Company's twenty-five year history.

As at 28 August 1998 approximately 54% of the Company's stock was held through ADRs. A large number of ordinary shares are also held by investors in the US and Germany. Orbital's market trading activity has become truly global.

Acknowledgement
Mr Ian Egan resigned as a Director of Orbital in August 1998. Orbital would like to take this opportunity to thank Mr Egan for his significant contributions as a Director since April 1996 and to wish him well for the future.

Automotive

4-Stroke
The automotive industry's evolution towards direct fuel injection gained significant momentum during the last year. The combination of improved fuel economy and performance whilst demonstrating the capability to meet the next generation of emissions regulations has proved compelling for the industry.

Direct fuel injection technology is seen as the next evolutionary step of the continually improving automotive gasoline 4-stroke engine. By minimising the changes required to the base automotive power-plant, the addition of a direct fuel injection system to existing engines minimises the capital costs, and risks, of making performance improvements to the engine.
Orbital has emerged as a leader in this development in the market place with a fuel economy and emissions capability second to none. Furthermore, Orbital's extensive combustion system expertise is complemented by the high volume industrialisation and systems integration skills of Siemens Automotive. The number of high volume manufacturers involved in engineering programs is a testament to the commercial viability of the application of OCP technology to the conventional 4-stroke automotive engine.

In June 1998, we were pleased to announce our lead customer in the automotive arena is Daimler-Benz. Orbital has been working in conjunction with Daimler-Benz and Siemens for over 2 years on the application of OCP technology to Mercedes engines.

Daimler-Benz status as a technical leader within the automotive industry has undoubtedly been a catalyst for further engineering programs commenced this year. Whilst unable to name our customers for competitive reasons, we can confirm eleven programs are underway worldwide. These engineering programs involve conversion of the manufacturers' existing engines to OCP direct injection, for the purposes of demonstrating the technical capability of our system. Demonstration and testing takes place at Orbital's Balcatta facilities, as well as the customer's premises.

Siemens has an active involvement to ensure commercial viability of the system through the provision of systems integration functions and the supply of the engine management system. The Orbital group is responsible for the combustion and fuel and air system technology as well as providing engineering application expertise. Synerject, Orbital's joint venture with Siemens, supplies the fuel rail assembly components.

The majority of these manufacturers have internal plans regarding the timing of release of production models with direct injection. Whilst some manufacturers may initially release product incorporating competing direct injection systems, Orbital has programs in place with those manufacturers that could displace those technologies for following model years. From a market status perspective, manufacturers want to remain competitive by releasing the technology early.
OCP's excellent technical results, particularly in the area of exhaust gas emission control, has lead to the commencement of a number engineering programs with Orbital, even where manufacturers are already working with competing systems.

One of the key potential advantages of OCP is the simplification of the exhaust catalytic converter. In order to meet the European Stage 3 emissions standards, due in the year 2000, test cell results indicate that existing three way catalysts could be used rather than the new, more expensive and higher risk, lean NOx catalysts. This could provide both a very significant cost and time advantage to those manufacturers looking for an early release of direct injection systems.
A summary of Orbital's fuel economy and emissions results compared with a baseline mutli-point injected engine are set out in the above table. These results are the untreated pre-catalyst emissions produced by the engine.

European market interest is such that we have relocated the head of our Automotive 4-stroke Business Unit and our Director of Patents and Licensing to Europe.

Throughout the two primary markets of Europe and North America external drivers are forcing the market towards direct fuel injection. The European industry is driven by a combination of economic and political commitment to reduce fuel consumption and exhaust pollutants, and competitive pressure from Japanese manufacturers Mitsubishi, Toyota and Nissan who have already released vehicles incorporating direct injection. The Japanese are understood to be releasing their direct injection vehicles into Europe in the near future. Due to the relatively high price of gasoline, the European consumer is receptive to technologies that produce a tangible saving in fuel consumption.

Orbital's US customers are being influenced by the Corporate Average Fuel Economy (CAFE) legislation which mandates an average fuel economy requirement over the fleet of vehicles sold. This legislation imposes severe fines for non-compliance. Due to the popularity of large engine capacity light-duty trucks, US manufacturers are faced with difficulties in meeting the average fuel economy requirement. Direct injection is the logical solution to this situation, as it allows the manufacturers to continue selling current volumes of these light trucks which are a significant contributor to the profitability of US manufacturers.

The external drivers outlined above create the potential for direct injection to achieve rapid widespread penetration of the global automotive industry. As a result, Orbital is currently dedicating more than half of its resources to this business unit to ensure we capture the maximum market share possible. The clear focus of the business unit is to convert customer engineering programs into license agreements (where they are not already in place) and then firm pro-duction commitments.

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2-Stroke
The 2-stroke technology Orbital has developed now enables us to present to customers various ways to utilise Orbital's direct injection and combustion technology. Customers can either apply this technology to existing 4-stroke engine designs or alternatively they can elect to reap the size, weight and cost benefits of 2-stroke by investing in a totally new engine design.

In the wake of the turmoil in Indonesia and resulting suspension of activity supporting the Maleo "National Car" project, Orbital embarked on a new initiative to promote the maturity of the OCP 2-stroke engine to the world automotive industry.

The platform for a renewed push to existing and new customers was the highly successful Genesis market trial. This market trial has demonstrated, over a 2 year period and in excess of 3.5 million kilometres, that 2-stroke automotive engines are reliable and provide significant benefits to both consumers and automotive producers.

This initiative involved presentations around the globe to various automotive companies and trade journals and included comprehensive vehicle appraisals.

Orbital's Genesis program has achieved all of the goals set for it providing extensive in-field data on the 100 vehicles distributed to a wide range of users in various climatic conditions. From the harsh environment of a rental car fleet in outback Australia to the chilly winters of the US mid-west these vehicles have performed meritoriously. The outback rental car operator, Nifty Rent-a-Car recently doubled the size of their fleet to 40 as a result of customer demand for the vehicles. The additional vehicles became available after the expiry of leases with the Australian Federal Government fleet manager. Overall there has been no major engine failures and a low incidence of in-field faults which have been confined to ancillary components. This market trial is ongoing and fleet data is continuing to be collected. The Genesis vehicles in total are accumulating up to 11,000 kilometres per day.

Further exposure to the technology was also gained by the use of Orbital's i6 2-stroke engine in the aXcess australia car which is being promoted globally as a showcase of innovative Australian automotive technology.

Several distinct opportunities have emerged from the extensive industry promotion of the OCP 2-stroke technology. These can be categorised in three areas: low cost high efficiency engines for city car applications; high technology yet low cost engines for emerging car markets in Eastern Europe, India and Asia; and compact, clean engines for hybrid electric vehicles.

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Motorcycle & Scooter

Emissions legislation continues to act as the primary market driver for direct fuel injection technology in the motorcycle industry. The industry itself is estimated to produce in excess of 19 million units annually with strong annual growth expected to continue. Production has been historically dominated by small capacity 2-stroke engines using a carburetor, however impending emissions legislation has forced manufacturers to plan for alternatives.

4-stroke engines have achieved a level of market penetration, however due to consumer requirements to maintain current performance levels, 4-stroke engines have not been viable alternatives for the smaller capacity (50cc) scooters. Accordingly, 2-stroke engines are estimated to retain a 60-70% market share of the motorcycle industry. Direct fuel injection is a cost effective means of reducing emissions by up to 80%, while maintaining size, weight, cost and power advantages of the 2-stroke engine.

Europe and Taiwan are leading the introduction of motorcycle emissions legislation, and therefore direct fuel injection technology. Orbital's strategy has been to identify key participants in these markets and work closely with those customers to achieve production release of OCP technology. Orbital has production intent programs underway with its lead customers in the both the European and Taiwanese markets. These programs cover multiple models with various engine displacements. The first program targets a 1999 release with new models following in subsequent years.

Technology demonstration vehicles delivered to customers meet their emissions and performance targets, while producing a significant improvement in fuel economy. Due to the low retail price of a small capacity scooter, manufacturers are particularly sensitive to cost issues. Orbital has therefore designed the system to ensure it is as simple as possible while utilising components existing across the Orbital group. The motorcycle industry volumes can generate significant unit cost advantages for Synerject which in turn benefits Orbital's various business units.

In addition to the various production programs with our lead customers, an in depth feasibility assessment is currently underway in China. Scooters converted to OCP technology have been delivered to a customer and satisfactorily met all technical targets. Whilst Chinese emissions regulations require further development, the volume and growth potential in the market create significant potential. Orbital also has active engineering programs underway with customers in Europe, Taiwan, Japan and India.

The Motorcycle business unit has customer interest in engineering programs and fuel systems supply with more customers than ever before. The impending introduction of emissions legislation has created a sense of urgency throughout the industry. The maturity of Orbital's fuel system has allowed us to capitalise on this momentum. The primary challenge for the group is to introduce product to market as soon as possible, which is expected to stimulate the advancement of existing programs with other customers.

Marine & Recreation

OCP technology has emerged as the preferred low emissions technology in the marine and recreation industry. The industry incorporates products such as marine propulsion (outboard, stern drive, and direct drive), personal watercraft (PWC), snowmobiles, all-terrain vehicles and other engines. The industry is estimated to produce up to 2 million units of these products annually. The 2-stroke dominated industry is responding to demanding US emissions standards set down by the Environmental Protection Authority calling for a 75% reduction in emissions from marine and PWC engines by the year 2006. Currently, the regulations require a staged reduction each year leading up to the 2006 legislated level. However speculation suggests the timeframe may move forward to as early as 2001.

During the financial year, the world's largest manufacturers in both the outboard and PWC markets, Mercury Marine and Bombardier-Rotax, signed long term supply agreements with Orbital. These agreements represent strong commitments towards the commercial use of Orbital's mature direct fuel injection technology for many years. As the volume of engines incorporating OCP technology expands, the systems cost and capability will improve further.

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Mercury Marine currently market OCP technology under the "Optimax" brand name. The technology is available on 225, 200, 150 and 135 horsepower models. Customer response to the technology has been excellent and Mercury has increased production plans for the forthcoming year by 50%. The Optimax engines further proved their outstanding reliability in the 1998 BASS Masters Classic with no engine failures over the prestigious three-day event.

The 135 and 150 horsepower models are now available in Australia, representing the first commercial availability of OCP technology in Orbital's home market. The technology produces an average fuel saving of 40% over a full cycle of operating conditions, and up to 80% under certain operating conditions. The significant fuel economy improvements, combined with smooth running quality and the elimination of exhaust fumes have provided Mercury customers with increased boating pleasure. The fuel systems used in these production engines are manufactured by Synerject, Orbital's joint venture with Siemens Automotive.

Orbital's lead recreational product customer, Bombardier-Rotax, are leaders in the PWC, snowmobile and jet boat markets. The long term supply agreement signed with Bombardier-Rotax relates to the supply of direct injection systems for PWCs. Confirmation of the fuel systems supply arrangement follows a period of extensive testing by Bombardier and will assist them to meet forthcoming emissions in the United States and Europe. Bombardier market their PWCs under the "Sea-Doo" brand name which accounts for approximately 50% of PWC sales.

Orbital believes the announcement of the supply agreement has the potential to attract additional PWC customers to OCP technology.

The majority of world wide marine and recreational product sales occur in North America. As a result, Orbital has relocated its marine and recreation base to the USA to deal directly with our North American customers. This base enables swift assistance for in-field issues and also provides rapid technical and production information flow to Orbital.

Orbital's Japanese outboard engine customers, including Tohatsu Corporation, are maintained from the Balcatta facilities with frequent customer communication and on-site visits. Tohatsu are actively industrialising the "TLDi" engine which has now been displayed at major international marine trade shows and exhibitions.

The focus of the resource effort for this business unit is industrialisation, system refinement, and cost reduction. Orbital continues to develop an extensive supplier base to ensure the fuel system components are sourced at the lowest possible price, while maintaining the required quality requirements.

Synerject designs and supplies the fuel rail assembly and works closely with the marine and recreation group to integrate this core assembly in the total system for each customer program.

 
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Orbital Corporation Limited, 4 Whipple Street, Balcatta, Western Australia 6021.
Phone: +618 9441 2311    Fax: +618 9441 2133    Email: info@orbitalcorp.com.au