SECURITIES AND EXCHANGE
COMMISSION
Washington, D. C. 20549
| [X] | ANNUAL
REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF
1934 For the fiscal year ended December 31, 2003 |
| [_] | TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 For the transition period from _________________ to __________________ |
| BADGER PAPER MILLS, INC. |
| (Exact name of registrant as specified in its charter) |
| 200 West Front Street | Wisconsin |
| P.O. Box 149 | (State of incorporation) |
| Peshtigo, Wisconsin 54157-0149 | 39-0143840 |
| (Address of principal executive office) | (I.R.S. Employer Identification Number) |
Registrant s telephone number, including area code: (715) 582-4551
Securities registered pursuant to Section 12(b) of the Act: None
Securities registered
pursuant to Section 12(g) of the Act:
Common Stock, Without Nominal or Par Value
Indicate by checkmark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports) and (2) has been subject to such filing requirements for the past 90 days. Yes |X| No ___
Indicate by checkmark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of the registrants knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this form 10-K. [_]
Indicate by checkmark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Act) Yes ___ No |X|
As of June 30, 2003 the aggregate market value of the common stock (based upon the closing sale price of the common stock as reported on the Nasdaq SmallCap Market) held by non-affiliates was approximately $11,142,533. Determination of stock ownership by non-affiliates was made solely for the purpose of responding to this requirement, and registrant is not bound by this determination for any other purpose.
As of December 31, 2003, 2,039,155 shares of common stock were outstanding.
The Companys Proxy Statement for its 2004 Annual Meeting of Shareholders to be filed with the Commission under Regulation 14A is incorporated by reference into Part III of this Form 10-K to the extent indicated in Part III hereof.
This Annual Report Form 10-K, each of Badger Paper Mills, Inc. s (the Company) annual reports to shareholders, Forms 8-K and 10-Q, definitive proxy statements, and any other written or oral statement made by or on behalf of the Company subsequent to the filing of this Annual Report on Form 10-K may include one or more forward-looking statements that may state the Companys or managements intentions, hopes, beliefs, expectations or predictions for the future. In the following discussion and elsewhere in this Annual Report on Form 10-K, statements containing words such as expect, anticipate, believe, estimate, goal, objective or similar words are intended to identify forward-looking statements. In making such forward-looking statements, the Company undertakes no obligation to publicly update or revise any such statements.
Forward-looking statements of the Company are based on information available to the Company as of the date of such statements and reflect the Companys expectations as of such date, but are subject to risks and uncertainties that may cause actual results to differ materially from those projected, expressed or implied by such forward-looking statements. In addition to specific factors, which may be described in connection with any of the Companys forward-looking statements, factors that could cause actual results to differ materially include:
| | Increased competition from domestic or foreign paper producers, or providers of alternatives to the Companys products, including increases in competitive production capacity and/or weakness in demand for paper products. As a paper manufacturer, the Company, if it wants to achieve acceptable production costs, must operate its paper mill at a relatively high percentage of its available production capacity. The Companys competitors face the same or similar situations. Therefore, when the overall market for paper products softens, the Company (and other paper manufacturers) will generally accept lower selling prices for its products in order to maintain acceptable production efficiencies and costs. |
| | Changes in the price of pulp, the Companys main raw material. The Company purchases all of its pulp on the open market and price changes for pulp have a significant impact on the Companys costs. Pulp price changes can occur due to changes in worldwide consumption of pulp, pulp capacity additions, expansions or curtailments affecting the supply of pulp, inventory building or depletion at pulp consumer levels which affect short-term demand, and pulp producer cost changes related to wood availability, environmental issues and other variables. During 2003, the market price for pulp increased. The Company anticipates that the market price for pulp will continue to increase into 2004. |
| | Interruptions in the supply of, or increases and/or changes in the price of energy (principally natural gas and electricity) that the Company needs to run manufacturing operations. During the latter part of 2002 and early in 2003, energy prices rose significantly. The current market price of natural gas has stabilized at historically high levels. Future energy costs are uncertain. |
| | Changes in demand for the Companys products due to overall economic activity affecting the rate of consumption of the Companys paper products, growth rates of the end markets for the Companys products, technological or consumer preference changes and acceptance of the Companys products by the markets it serves. |
| | Unforeseen operational problems at any of the Companys facilities causing significant lost production and/or higher operating costs. |
| | Changes in laws or regulations affecting the Company, particularly environmental laws and regulations affecting air quality and wastewater discharges. |
| | The Companys profitability may be adversely affected by increases in interest rates because a significant portion of the Companys debt bears interest at variable interest rates. |
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| Year ended December 31, | |||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| 2003 |
2002 |
2001 |
2000 |
1999 | |||||||||||||
| Operations (dollars in thousands): | |||||||||||||||||
Net sales | $ | 71,691 | $ | 73,772 | $ | 76,305 | $ | 76,137 | $ | 69,231 | |||||||
| Cost of sales | 70,472 | 65,943 | 66,463 | 73,451 | 62,478 | ||||||||||||
| Gross profit | 1,219 | 7,829 | 9,842 | 2,686 | 6,753 | ||||||||||||
| Selling and administrative expenses | 5,097 | 5,779 | 5,559 | 5,128 | 4,890 | ||||||||||||
| Loss on write-off of trade credits | -- | -- | -- | 440 | -- | ||||||||||||
| Loss on disposal of property, plant and equipment | -- | -- | 8 | 22 | -- | ||||||||||||
| Operating income (loss) | (3,878 | ) | 2,050 | 4,283 | (2,882 | ) | 1,863 | ||||||||||
| Other income | 24 | 51 | 237 | 175 | 617 | ||||||||||||
| Gain on sale of non-core assets | -- | 1,125 | 1,627 | -- | -- | ||||||||||||
| Interest expense | 440 | 402 | 927 | 1,250 | 1,064 | ||||||||||||
| Income (loss) before income taxes * | (4,294 | ) | 2,824 | 5,220 | (3,957 | ) | 1,416 | ||||||||||
| Provision (benefit) for income taxes | (1,203 | ) | 925 | 1,374 | (891 | ) | 279 | ||||||||||
| Net income (loss) * | (3,091 | ) | 1,899 | 3,846 | (3,066 | ) | 1,137 | ||||||||||
Common Stock: | |||||||||||||||||
Number of shareholders of record | 307 | 337 | 380 | 392 | 434 | ||||||||||||
| Weighted average of shares outstanding | 2,033,391 | 2,026,299 | 2,004,664 | 1,981,716 | 1,966,111 | ||||||||||||
| Net earnings (loss) per share basic | $ | (1.52 | ) | $ | 0.94 | $ | 1.92 | $ | (1.55 | ) | $ | 0.58 | |||||
| Net earnings (loss) per share diluted | $ | (1.52 | ) | $ | 0.91 | $ | 1.89 | $ | (1.55 | ) | $ | 0.58 | |||||
| Book value per share | $ | 9.52 | $ | 11.05 | $ | 10.19 | $ | 8.32 | $ | 9.91 | |||||||
Financial Position (dollars in thousands): | |||||||||||||||||
Working capital | $ | 5,132 | $ | 6,457 | $ | 6,717 | $ | (9,950 | ) | $ | 8,259 | ||||||
| Capital expenditures | 730 | 3,165 | 1,439 | 2,265 | 2,815 | ||||||||||||
| Total assets | 38,478 | 41,808 | 40,280 | 43,357 | 46,894 | ||||||||||||
| Long-term debt | 10,637 | 7,377 | 9,794 | 1,310 | 15,705 | ||||||||||||
| Shareholders' equity | 19,349 | 22,392 | 20,445 | 16,482 | 19,484 | ||||||||||||
| * | Includes the gain on the sale of non-core assets of $1,125,000 in 2002 and $1,627,000 in 2001. |
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Badger Paper Mills, Inc. (Badger or the Company) has been producing paper and paper products in Wisconsin since it was incorporated under the laws of the State of Wisconsin in 1929.
The Company has two operating facilities. In Peshtigo, Wisconsin and adjacent to the Companys principal executive offices, the Company manufactures paper on two paper machines (a Yankee paper machine and a Fourdrinier paper machine). The Company also performs certain converting operations in Peshtigo. The Companys physical facilities in Peshtigo are sometimes collectively referred to in this Annual Report as the Peshtigo Facilities.
The Company also has production facilities in Oconto Falls, Wisconsin (approximately 30 miles from Peshtigo, Wisconsin), which consist of a Company-owned manufacturing facility and certain leased warehouse space. The Companys owned and leased facilities in Oconto Falls are sometimes collectively referred to in this Annual Report as the Oconto Falls Facilities.
At the Peshtigo Facilities, the Company manufactures paper on its Yankee paper machine and its Fourdrinier paper machine, and converts paper in accordance with customer specifications. Converting operations include punching, sheeting, trimming, sealing, perforating, rewinding, waxing and drilling of paper for uses in several applications.
Products produced on the Yankee paper machine include converted printed and unprinted waxed papers for quick service restaurants, grades used in laminating applications, colored papers, specialty-coated papers and papers used in applications where twisting is required to seal product. The Companys sales personnel and commissioned brokers sell these products to manufacturers and converters.
The Fourdrinier paper machine produces fine paper grades utilizing fiber purchased on the open market, including pre- and post-consumer recycled fibers. Papers produced on the Fourdrinier paper machine are used in several applications including business papers, printing, high quality writing papers, book publishing stock, reply card, watermarked, industrial and consumer papers that require water-oil-grease resistant attributes, copier papers and specialty papers. The Company offers a wide range of colored papers and specializes in color matching. A portion of the products produced by the Company are sold under certain trademarks and trade names, including Ta-Non-Ka®, Copyrite®, ENVIROGRAPHIC®, Northern Brights®, Artopaque®, Marks of Distinction® and DuraEdge®. Other products are sold through paper merchants, brokers and value-added converters who, in turn, sell to other value-adding entities or direct to the consumer.
The Companys two paper machines produce papers that have different features. Paper produced on the Yankee paper machine has a very smooth surface on one side of the paper, which is referred to as machine glazed (MG). The smooth finish on MG paper allows the paper to work well in certain coating and printing applications.
Paper produced on the Fourdrinier paper machine does not have a glazed finish, rather it is machine finished (MF). MF paper works well in a broad range of applications including publishing, writing paper and certain printing applications.
Products produced at the Oconto Falls manufacturing facility complement the Companys overall product offerings by adding value to certain paper grades through printing and converting of paper and plastic substrates. At this facility, the Company produces a variety of printed products on paper and plastic substrates and manufactures polyethylene bags.
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Badger sells its products produced at each facility to a wide range of converting companies throughout the United States. These sales are conducted through the Companys sales personnel. The largest concentration of the Companys customers can be found in the Midwestern states including Wisconsin, Illinois, Michigan and Ohio. However, as a result of expanded national sales efforts, the Company has made significant progress toward expanding its customer base into other regions of the United States.
The Companys foreign net sales are immaterial to its operations.
Badgers products are sensitive to competition from numerous sources, including other paper products and products of other composition. Product quality, price, volume and service are all competitive factors. Badgers paper production represents less than 1% of the production capacity in the United States for these products. Competition for all grades of paper manufactured by the Company includes International Paper Company, Georgia-Pacific Corporation, Domtar, Inc., Wausau-Mosinee Paper Corporation and smaller, non-integrated paper companies. Many of the Companys larger competitors have greater financial, technical, marketing and public relation resources, larger client bases and greater brand or name recognition than Badger.
The principal raw material used by the Company is pulp. Badger utilizes a variety of fibers to meet the formulation requirements of the papers it produces. Northern and southern softwood and hardwood pulps, pre-consumer and post-consumer recycled pulps, and hard white rolls make up the total fiber requirements. Badger purchases all its fiber requirements on the open market. Other raw materials used in the manufacturing process include inks and polyethylene substrates. Other raw materials are purchased directly from manufacturers and distributors.
Badger has at least two sources of supply for major items. Shortages of pulp or certain chemicals (including petrochemicals) could have an adverse effect on Badgers ability to manufacture its products, and could adversely affect product mix. Although Badger does not anticipate shortages of raw materials, it is anticipated that there will be near-term increases in pulp prices and the cost of polyethylene.
Badger is a large consumer of energy, including electricity and natural gas. In 2003, 9.7% of Badgers cost of sales represented energy costs compared to 7.8% of Badgers cost of sales in 2002. Badger purchases electricity from local public utilities, and it purchases natural gas from various sources in the United States and Canada. Two dual-fueled boilers capable of burning natural gas or fuel oil and one natural gas boiler supply the Peshtigo Facilities heating and manufacturing requirements. During 2002, the Company removed its fuel oil storage tanks at its Peshtigo Facilities. As a result, the Company will not have the flexibility to switch between natural gas and fuel oil as a source of fuel.
Although Badger experienced temporary interruptions of electrical service in the summer of 2002 due to regional shortages of electricity during peak demand periods, the Company believes that current sources of electricity and natural gas are adequate to meet its needs. Such interruptions caused the Company to temporarily stop the manufacture of paper. There is no damage to equipment during these temporary power interruptions. Badger could experience similar interruptions in the future.
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The market price for natural gas stabilized at historically high levels during the second half of 2003. In order to reduce the risk of fluctuating market prices for natural gas, the Company has purchased a significant portion of its natural gas requirements for the first half of 2004 at a fixed price.
The Company possesses certain patents and licenses used in connection with its business, none of which individually, or in the aggregate, are material.
The Company maintains a dedicated technical staff of employees charged with the responsibility of researching and developing new products. The Company also relies on outside consultants from time to time for special research and development projects. The Companys technical staff also refines and improves existing products in response to customer requirements and market demands. The Company spent $673,000 in 2003, $769,000 in 2002 and $469,000 in 2001 on product research and development activities.
A significant percentage of the Companys research and development costs are spent working on concepts and designs for new and/or improved paper products for customers. Since many of the Companys customers for paper products are converters, these customers need trial production runs of paper products to evaluate how the Companys new or modified paper products perform in actual use on the customers paper converting machinery and equipment. If such trial production runs are unsuccessful, the Company charges the associated costs to research and development. If such trial production runs are successful, the Company sells the product to the customers. Revenues from successful trial production runs are included in sales and the associated costs are accounted for in cost of sales.
As of December 31, 2003, the value of the Companys order backlog was approximately $2,221,000 as compared to $1,270,000 and $2,837,000 at December 31, 2002 and 2001, respectively.
In 2003, 2002 and 2001, no customer represented over 10% of Badgers net sales.
In 2000, the Company received final regulatory approval from the Wisconsin Department of Natural Resources (WDNR) of its Title V air operating permit for its Peshtigo Facilities. The permit does not require the Company to install new or additional pollution control equipment, and as such, the Company is responsible for the costs associated with routine monitoring, record keeping and reporting requirements. These costs are minimal.
Prior to January 30, 2002, effluent flow from Badgers Peshtigo Facilities was directed into a joint municipal wastewater treatment plant, which Badger operated under contract with the City of Peshtigo, Wisconsin. Effective January 30, 2002, Badger sold this wastewater treatment plant to the City of Peshtigo for approximately $1,250,000; however, Badger continues to operate this wastewater treatment plant under contract with the City of Peshtigo. Management believes that this wastewater treatment plant continues to meet or exceed all currently applicable environmental requirements and that Badgers use of the treatment plant is in compliance with all regulatory requirements. In 2000, Badger renewed its wastewater discharge permit for this wastewater treatment plant.
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In January 2000, the WDNR approved a final closure report filed by the Company with respect to its former Harbor Road Landfill. The WDNR will continue to review the effectiveness of this closure. If the WDNR subsequently determines that the closure was ineffective, then the WDNR may require the Company to undertake further remedial actions. Based on the Companys consultants report (dated April 1999), the Company estimated that the potential future cost of such future environmental remedial efforts (assuming that the WDNR determines that the closure was ineffective) was approximately $300,000. The Company has not subsequently updated this consultants report. Management believes that the Company is in compliance with all WDNR Net Worth Financial Responsibility Tests as of December 31, 2003.
Soil contamination was identified at the Companys French Street location in Peshtigo during the removal of four above ground storage tanks. The Company performed site investigation work and in October 2003, requested that the case be transferred from the WDNR to the Wisconsin Department of Commerce (Commerce) for case closure with a soil Geographic Information System Registry and a Wisconsin Administrative Code Chapter NR 140 Preventative Action Limit exemption. Commerce requested additional information in February 2004. The requested documents and information were provided to Commerce. As of the filing of this Annual Report on Form 10-K, the Company has not received a response regarding closure from Commerce. It is not possible to determine the costs, if any, that may be incurred in completing any additional investigation or required remediation.
The Companys Peshtigo Facilities are located near the Lower Fox River/Green Bay Area of Concern (AOC). Pursuant to the Great Lakes Water Quality Agreement, 43 AOCs have been identified and re-located throughout the Great Lakes Basin. The Company has not been identified by WDNR or the United States Environmental Protection Agency (EPA) as responsible for the environmental problems within the Lower Fox/Green Bay AOC.
The Company does not anticipate any material capital expenditures for pollution control equipment during the next two fiscal years.
The Company holds an air-operating permit by the WDNR for its Oconto Falls Facilities. The permit expires on January 29, 2006. The permit limits emissions so that the facility is considered a synthetic minor under the EPAs Title V air permit program. The permit authorizes the operation of the flexographic printing process at the Oconto Falls Facilities.
Badger believes it has in force all of the necessary environmental permits from Federal, state and local authorities to continue production of current business activities. The Company began production on new foil laminating equipment in late 2003, which requires a permit for additional volatile organic compounds emissions. The Company is currently operating its laminating equipment under the construction permit it received in 2003. The construction permit will expire in January 2005.
As of December 31, 2003, the Company had 292 employees, including 183 employees at the Peshtigo Facilities covered by three-year collective bargaining agreements running through May 2005. The Company has begun a process to redesign workflow in order to reduce the number employees necessary to produce its products. Teams comprised of management and union employees are working to redesign workflow with the objective of improving efficiency and quality. Another result will be fewer employees required to meet manufacturing requirements. It is anticipated that workforce reductions will begin during the second quarter of 2004.
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The Company maintains a website with the address www.badgerpaper.com. Additional information regarding the Company can be found on this website. The Company is not including the information contained in the Companys website as a part of, or incorporating it by reference into, this Form 10-K.
| Properties |
|||
| Location | Owned or Leased | Approximate Floor Area in Square Feet |
Principal Uses |
Peshtigo, WI |
Owned (1) | 3,750 | Principal executive offices |
| Peshtigo, WI | Owned (1) | 88,500 | Manufacture and Converting of Paper |
| Oconto Falls, WI | Owned | 40,000 | Printing and Converting |
| Oconto Falls, WI | Leased (2) | 20,300 | Warehouse space |
| (1) | As a result of the November 2001 refinancing of its revolving and long-term debt, two of the Companys lenders hold mortgages on the Peshtigo Facilities. |
| (2) | The lease for the warehouse space is a five-year lease (triple net lease basis) which commenced on October 1, 2000. The current base rent is approximately $54,000 per year, increasing incrementally to $56,000 per year in the final year of the lease. |
| * | The Company leases equipment. Information related to these leases can be found in Note L to the Companys 2003 audited financial statements. |
The Company does not have any material legal proceedings pending, and does not have any litigation or governmental proceedings with respect to environmental matters pending (except to the extent identified under the Environmental Matters caption in Item 1 of Part I of this Annual Report on Form 10-K).
No matters were submitted to a vote of the Companys shareholders in the fourth quarter of 2003.
The following table sets forth certain information as of December 31, 2003 concerning the Companys executive officers.
| Name |
Age |
Office |
Period Served In This Office |
|---|---|---|---|
Ronald E. Swanson |
54 | President and Chief Executive Officer | 2003 - Present |
| of the Company, Director | |||
| Senior Vice President - SENA Magazine Papers | 2000-2002 | ||
| Stora Enso North America | |||
| Senior Vice President | 1997-2000 | ||
| Consolidated Papers, Inc. |
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| Name |
Age |
Office |
Period Served In This Office |
|---|---|---|---|
William H. Peters |
45 | Vice President, Chief Financial Officer, Secretary, | |
| and Treasurer | 2001-Present | ||
| of the Company | |||
| Executive Vice President and Treasurer, | |||
| North Shore Capital | 1996-2001 | ||
| (small market venture capital firm) | |||
J. Glenn Davis |
46 | Vice President-Sales and Marketing | |
| of the Company | 2002-Present | ||
| Business Manager, | |||
| International Papers (specialty papers) | 2000-2001 | ||
| President, | |||
| JND Company, Inc. (food processing) | 1998-2000 | ||
| Director, Specialty Products | |||
| Appleton Papers (carbonless papers) | 1998 | ||
Robert J. Spannuth |
56 | Vice President, Operations | 2003-Present |
| of the Company | |||
| Director - Source & Support | 2001-2002 | ||
| Mead Westvaco | |||
| Vice President & Mill Manager | 1999-2001 | ||
| Fraser Papers |
Officers are elected to hold office until the next annual meeting of the Board of Directors following the annual meeting of shareholders or until their successors are elected and qualified. There is no arrangement or understanding among any of the above officers or any other person pursuant to which such officer was selected for the office held. No family relationship of any kind exists between the officers.
The Companys Common Stock trades on the Nasdaq SmallCap Market under the symbol BPMI. As of December 31, 2003, the Company had 307 shareholders of record. Information about the trading prices for shares of the Companys Common Stock and dividends on the Common Stock is included in this Annual Report on Form 10-K under the caption Stock Price and Dividend Information. Information about equity compensation plans is included in this Annual Report on Form 10-K under Item 12.
Selected Company financial data is presented in this Annual Report on Form 10-K under the caption Five-Year Comparison of Selected Financial Data.
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The Company saw a decline in net sales during 2003 as a result of decreased shipment volume. Reduced shipment volume can be attributed to declining market demand for certain products manufactured by the Company. The Company also realized increases in costs for pulp and natural gas in 2003 as compared to 2002.
The combination of reduced shipment volume and higher manufacturing costs resulted in a decrease in gross profit. In 2003, gross profit was $1,219,000 and 1.7% of net sales, compared to $7,829,000 and 10.6% in 2002. As a result of lower gross profit, the Company generated a net loss for 2003 of $3,091,000 as compared to net earnings of $1,899,000 in the previous year. The results for 2002 include a pretax gain of $1,125,000 (after tax gain of $747,000) from the sale of non-core assets. The Company did not have a similar gain in 2003.
The increases in the cost of pulp and natural gas are driven by market conditions outside of the Companys control. In order to reduce internal costs, the Company has begun a process to redesign workflow. Teams comprised of management and union employees are redesigning workflow with the objective of improving efficiency and quality. Another result will be fewer employees required to meet manufacturing requirements. The teams began meeting in the first quarter of 2004. It is anticipated that workforce reductions will begin during the second quarter of 2004.
Net sales in 2003 were $71,691,000 compared to $73,772,000 in 2002, a decrease of $2,081,000 and 2.8%. The reduction in net sales can be attributed to decreased shipment volume of paper products combined with increased sales of printed products. The shipment volume of paper products in 2003 as compared to 2002 declined by 5.3% while the average price for paper products increased 0.8%. The Company realized an increase in the sales of printed and converted products of $1,487,000 in 2003 as compared to 2002.
The decrease in shipment volume in 2003 as compared to 2002 can be directly related to the Companys decline in sales of fine paper products. Net sales in 2003 of fine paper products declined 19.6% when measured in sales dollars, and declined 22.0% when measured in tons shipped when compared to 2002. The reduction in fine paper volume resulted in increased downtime on the Fourdrinier paper machine in 2003 as compared to 2002. The decline in fine paper business can be attributed to difficult market conditions resulting in lower pricing in the market.
Cost of sales in 2003 was $70,472,000 and 98.3% of net sales compared to $65,943,000 and 89.4% of net sales in 2002. During 2003 the market price for pulp increased resulting in higher pulp costs for the Company. The Company also incurred significantly higher costs for natural gas in 2003 as compared to 2002. The increases in the cost of pulp and natural gas combined with the inability to increase prices due to difficult market conditions resulted in higher cost of sales when measured as a percentage of sales.
The Companys overall cost for pulp increased $594,000 and 2.7% in 2003 as compared to 2002 on 6.7% lower production volume. The disproportionate increase in pulp costs is a result of higher market prices for pulp.
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The Company anticipates that the market price of pulp will continue to increase into 2004. The Company has entered into contracts with pulp suppliers to purchase a portion of its pulp requirements at a fixed price. The Company anticipates that approximately half of its pulp requirements in 2004 will be purchased under these agreements.
During the first quarter of 2003, the market price for natural gas increased significantly. The market price for natural gas stabilized at historically high levels during the second half of 2003. Because of the increases in the market price of natural gas, the Companys cost for natural gas in 2003 increased $1,649,000 and 57.3% from 2002. In order to reduce the risk of fluctuating market prices for natural gas, the Company has purchased a significant portion of its natural gas requirements for the first half of 2004 at a fixed price.
Gross profit in 2003 was $1,219,000 and 1.7% of net sales compared to $7,829,000 and 10.6% of net sales in 2002. The decrease in gross profit is the result of higher costs for pulp and natural gas combined with the Companys inability to increase pricing on fine paper products due to difficult market conditions.
Selling and administrative expenses in 2003 were $5,097,000 and 7.1% of net sales compared to $5,779,000 and 7.8% in 2002. The reduction in selling and administrative expenses is the result of lower employment related costs and reduced spending on outside professional services.
In 2003, the Company had an income tax benefit of $1,203,000 and 28% of the loss before income taxes compared to income tax expense of $925,000 and 32.8% of income before taxes in 2002. The differences between statutory rates and the Companys effective rate are a largely the result of increases in the valuation allowance.
During 2003 other income and expense was a $416,000 expense compared to a $774,000 net income in 2002. In 2002, the Company recognized a gain on the sale of a wastewater treatment facility of $1,125,000. The Company did not have a similar gain in 2003.
Net sales in 2002 were $73,772,000 compared to $76,305,000 in 2001, a decrease of $2,533,000 and 3.3%. The reduction in net sales can be attributed to volume and pricing. The sale of paper in 2002 as compared to 2001 increased by 4.5% while average pricing decreased by 3.7%. The Company also realized a decrease of $3,050,000 in the shipment of printed products in 2002 versus 2001.
Net sales volume as measured in weight increased on each paper machine, while total average pricing decreased. The decrease in average pricing was driven entirely by pricing on machine finished (MF) paper grades. The average selling price of machine glazed (MG) products increased an average of 1.7%. The increase in the average price of MG products is a result of shifting the product offering to specialty markets.
The decrease in net sales of printed products is a result of losing business from a number of customers through competitive bidding processes.
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The cost of sales for 2002 was $65,943,000 and 89.4% of net sales compared to $66,463,000 and 87.1% in 2001. During 2002, the production volume of printed products declined when compared to the previous year. This decline in business resulted in a portion of the decline in the cost of sales as measured in dollars. The increase in cost of sales relative to sales is driven primarily by the decrease in the average selling prices while, at the same time, maintaining a relatively flat cost for pulp.
During 2002, production activity on the Companys two paper machines increased 4.2% compared to 2001. Total cost for pulp in 2002 increased 5.1% when compared to 2001. The disproportionate increase in pulp cost when compared to production activity is the combined effect of the average cost for fiber and the utilization efficiency.
Gross profit during 2002 was $7,829,000 and 10.6% of net sales compared to $9,842,000 and 12.9% of net sales in 2001. The decrease in gross profit is the combined result of the decrease in net sales as it relates to pricing, while at the same time holding certain production costs consistent with the previous year. The overall average selling price during 2002 decreased 3.7% when compared to 2001. The reduction in average pricing is the result of pricing pressure on certain commodity grades still manufactured by the Company.
In 2002, selling and administrative expenses were $5,779,000 and 7.8% of net sales compared to $5,559,000 and 7.3% in 2001. The increase in selling and administrative expenses is a result of cost associated with additional resources necessary to develop and market products for specialty markets that are consistent with the Companys strategy to move from commodity grades to specialty paper markets. During 2002, the Company incurred $252,000 associated with management restructuring costs. Had the Company not incurred management restructuring costs, selling and administrative expenses would have been $5,527,000 in 2002 compared to $5,559,000 the previous year.
Income taxes in 2002 were $925,000 and 32.8% of income before taxes and reflect the statutory tax rates.
Income taxes in 2001 were $1,374,000 and 26.3% of income before taxes. The difference between statutory tax rates and the Companys effective tax rate is the realization of the benefits related to the Federal net operating loss carryforward utilized in 2001.
During 2002, the Company realized a gain of $1,125,000 on the sale of a wastewater treatment facility. The Company continues to manage the facility under an operating agreement with the City of Peshtigo.
During 2001, the Company realized $1,627,000 in gains from the sale of timberland that was not used in the day-to-day operations of the business since the Company closed its pulp mill several years ago.
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Capital expenditures in 2003 were $1,880,000 ($1,150,000 of which were financed through a capital lease) compared to $3,165,000 in 2002. The largest project in 2003 was the purchase of foil laminating equipment. The total cost of the project was $1,257,000. In 2002, the Company purchased waxer / winder equipment with a total estimated cost of $2,822,000. As of December 31, 2003, the Company had invested $2,319,000 into this equipment. The Company will continue to purchase interchangeable components as necessary to keep the equipment operating on a continuous basis.
The Company anticipates that total capital expenditures in 2004 will not exceed $2,000,000.
In November 2001, the Company obtained a revolving credit agreement with a commercial bank providing for asset-based financing which was scheduled to expire in November 2004. In November 2003, the Company received a two-year extension of the revolving credit agreement. The financing is now scheduled to expire in November 2006. The line of credit provides for maximum borrowings of $15,000,000, limited to certain percentages of receivables and inventory, and reduced by outstanding letters of credit. The line of credit bears interest at a variable rate based on alternative interest rate bases at the Companys option (4.50% at December 31, 2003). A facility fee of 0.25% is payable for unused amounts. The line of credit is collateralized by accounts receivable and inventory.
As of December 31, 2003, the Companys capital resources included $656,000 in cash and the Companys $15,000,000 revolving credit facility. Borrowings under this facility totaled $2,756,000 as of December 31, 2003. Based on the balances in inventory and accounts receivable, the Company had $4,555,000 of availability under the revolving credit facility at December 31, 2004.
At December 31, 2003, the revolving line of credit required, among other items, the Company to maintain $3,500,000 in unused availability and a minimum tangible net worth. Capital expenditures are limited to $3,000,000 in 2003 and each subsequent year while the revolving line of credit is in effect.
The Company obtained a variable rate term loan in November 2001. The agreement provides for monthly payments of principal and interest, with interest at prime plus 0.25%. Borrowings are collateralized by certain property, plant and equipment.
The Urban Development Action Grant debt, including additional funding obtained in November 2001, is due in monthly installments of $17,931, including interest at 5.0%, through maturity in November 2011. This loan is collateralized by certain property.
The Company obtained a variable rate loan in September 2002 to finance capital expenditures. This agreement provides for up to $2,000,000 in borrowings and was due in January 2004. In May 2003, the Company refinanced this loan with variable rate term debt. The long-term debt agreement provides for monthly payments of $17,336, including interest at 4.25% through maturity in November 2015.
During 2003, the Company violated the fixed charge coverage ratio covenant contained in the credit facility and the debt service coverage ratio included in the Companys long-term debt agreement. As of December 31, 2003, the Company has obtained waivers for these violations. The Company has also received waiver for the possible violation of the fixed charge coverage ratio and the minimum tangible net worth covenants contained in its credit facility for the first quarter of 2004. The Company believes that cash provided by operations and its revolving credit facility are sufficient to meet its current and anticipated working capital needs as well as to fund its planned capital expenditures.
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In November 2003, the Company entered into a lease purchase agreement for $1,150,000 to finance the purchase of certain converting equipment. The monthly lease payments are $14,913, including interest at an effective rate of 5.9% with a purchase option in December 2010.
Net cash required to support operations in 2003 was $2,110,000 compared to cash generated by operations of $4,306,000 in 2002. The reduction of cash flow during 2003 relative to 2002 is the result of reduced profitability and reductions in accounts payable and accrued liabilities.
Net cash used in investing activities in 2003 was $730,000 compared to $1,627,000 in 2002. During 2002, the Company realized proceeds from the sale of non-core assets of $1,374,000, which it used to pay down debt. The Company did not have a similar gain in 2003. The Company invested $730,000 in fixed assets in 2003 compared to $3,165,000 in 2002.
Cash flow generated from financing activities in 2003 was $2,394,000 compared to using $2,241,000 for financing activities in 2002. The increase in cash provided by financing activities is the combined result of reduced cash flow from operations and investments in property, plant and equipment.
In November of 2003 the Company borrowed $1,150,000 under the terms of a lease purchase agreement to finance the purchase of foil laminating equipment.
During the first quarter of 2002, the Company sold its wastewater treatment facility. Proceeds from the sale were used to reduce the outstanding advances under its revolving credit facility.
The Company believes that its cash flow from operations, together with available borrowings, will be sufficient to allow the Company to meet its obligations in 2004.
The following table of certain material contractual obligations at December 31, 2003 summarizes the effect that these obligations are expected to have on the Companys cash flow in future periods set forth below:
| Payments due by period | |||||
|---|---|---|---|---|---|
| Contractual Obligations |
Total |
Less than 1 year |
1-3 years |
3-5 years |
More than 5 years |
| Long-Term Debt | $10,395,000 | $ 727,000 | $5,074,000 | $2,210,000 | $2,384,000 |
| Capital Lease Obligations | 1,116,000 | 147,000 | |||