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UNITED STATES
SECURITIES AND EXCHANGE COMMISSION

WASHINGTON, D.C. 20549

FORM 10-Q

x QUARTERLY REPORT PURSUANT SECTION 13 OR 15(d) OF THE SECURITIES
EXCHANGE ACT OF 1934

For the quarterly period ended July 31, 2004

OR

o TRANSITION REPORT PURSUANT SECTION 13 OR 15(d) OF THE SECURITIES
EXCHANGE ACT OF 1934

Commission File Number: 333-73552

PLASTIPAK HOLDINGS, INC.


(Exact name of registrant as specified in its charter)
     
Michigan   52-2186087

 
(State or other jurisdiction of   (I.R.S. Employer
incorporation or organization)   Identification Number)

41605 Ann Arbor Road, Plymouth, Michigan 48170


(Address of principal executive offices)

(734) 455-3600


(Registrant’s telephone number, including area code)

(Former address: 9135 General Court, Plymouth, Michigan 48170)

Securities registered pursuant to Section 12(b) of the Act: None

Securities registered pursuant to Section 12(g) of the Act: None

Indicate by check mark 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 o

Indicate by check mark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Exchange Act) Yes o No x

The number of shares of the registrant’s common stock, $1.00 par value, outstanding as of July 31, 2004 was 28,316.

 


PLASTIPAK HOLDINGS, INC.
FORM 10-Q INDEX

         
    PAGE
    1  
    1  
    1  
    3  
    4  
    6  
    20  
    29  
    30  
    30  
    30  
    31  
    32  
    33  
 Certification of Principal Executive Officer to Section 302
 Certification of Principal Financial Officer to Section 302
 Certification of Chief Executive Officer to Section 906
 Certification of Chief Financial Officer to Section 906

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Table of Contents

PART I - FINANCIAL INFORMATION

ITEM 1. FINANCIAL STATEMENTS

Plastipak Holdings, Inc. and Subsidiaries

Consolidated Balance Sheets

                 
    July 31,   November 1,
ASSETS   2004
  2003
    (unaudited)        
Current Assets
               
Cash and cash equivalents
  $ 10,535,267     $ 37,278,406  
Accounts Receivable
               
Trade (net of allowance of $3,317,280 and $2,541,820 at July 31, 2004 and November 1, 2003)
    62,561,017       54,531,831  
Related parties
    8,435,071       7,202,753  
 
   
 
     
 
 
 
    70,996,088       61,734,584  
Inventories
    96,822,318       90,020,742  
Prepaid expenses
    16,079,465       13,039,269  
Prepaid federal income taxes
    2,545,164       2,793,980  
Deferred income taxes
    2,922,000       1,843,000  
Other current assets
    2,359,459       3,688,059  
 
   
 
     
 
 
Total Current Assets
    202,259,761       210,398,040  
Property, Plant & Equipment- Net
    416,131,982       366,920,226  
Other Assets
               
Cash surrender value of life insurance
    1,990,892       1,990,892  
Deposits
    11,184,966       10,716,360  
Capitalized loan costs (net of accumulated amortization of $4,739442 and $3,449,524 at July 31, 2004 and November 1, 2003)
    8,251,805       9,541,723  
Intangible assets (net of accumulated amortization of of $6,156,499 and $4,937,791 at July 31, 2004 and November 1, 2003)
    9,003,260       6,429,468  
Prepaids
    841,704       936,658  
Sundry
    298,400       266,645  
 
   
 
     
 
 
 
    31,571,027       29,881,746  
 
   
 
     
 
 
Total Assets
  $ 649,962,770     $ 607,200,012  
 
   
 
     
 
 

The accompanying notes are an integral part of these financial statements.

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Plastipak Holdings, Inc. and Subsidiaries

Consolidated Balance Sheets

                 
    July 31,   November 1,
LIABILITIES AND STOCKHOLDERS’ EQUITY   2004
  2003
    (unaudited)        
Current Liabilities
               
Accounts payable
  $ 120,934,240     $ 115,125,413  
Current portion of long term obligation
    4,674,821       3,823,347  
Accrued liabilities
               
Taxes other than income
    10,090,328       4,740,907  
Other accrued expenses
    40,370,267       29,309,529  
Income taxes
    1,345,241       1,363,371  
 
   
 
     
 
 
Total Current Liabilities
    177,414,897       154,362,567  
Senior Notes (net of unamortized premium and FV of swaps of $2,006,626 and ($4,711,202) at July 31, 2004 and $2,218,660 and ($4,748,452) at November 1, 2003)
    322,295,024       322,470,208  
Long-Term Obligations
    65,441,254       60,601,547  
Deferred Income Taxes
    23,261,000       16,483,000  
Other Non-Current Liabilities
    4,582,399       4,030,943  
Obligations Under Stock Bonus Plans
    10,484,727       8,306,882  
Stockholders’ Equity
               
Common stock, $1.00 par value, 60,000 shares authorized; 28,316 shares issued and outstanding
    28,316       28,316  
Retained earnings
    46,455,153       40,916,549  
 
   
 
     
 
 
Total Stockholders’ Equity
    46,483,469       40,944,865  
 
   
 
     
 
 
Total Liabilities and Stockholders’ Equity
  $ 649,962,770     $ 607,200,012  
 
   
 
     
 
 

The accompanying notes are an integral part of these financial statements.

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Plastipak Holdings, Inc. and Subsidiaries

Consolidated Statements of Earnings

                                 
    Three Months Ended
  Nine Months Ended
    July 31,   August 2,   July 31,   August 2,
    2004
  2003
  2004
  2003
    (unaudited)   (unaudited)   (unaudited)   (unaudited)
Revenues
  $ 261,559,078     $ 237,355,017     $ 738,738,884     $ 664,228,422  
Cost and expenses
    224,901,848       207,944,594       642,637,249       572,464,745  
 
   
 
     
 
     
 
     
 
 
Gross profit
    36,657,230       29,410,423       96,101,635       91,763,677  
Selling, general and administrative expenses
    20,182,832       18,693,366       59,653,060       55,556,230  
 
   
 
     
 
     
 
     
 
 
Operating profit
    16,474,398       10,717,057       36,448,575       36,207,447  
Other expense (income)
                               
Interest expense
    9,246,585       9,118,594       26,964,215       28,138,198  
Interest income
    (37,184 )     (208,947 )     (402,905 )     (768,149 )
Royalty income
    (62,734 )     (187,500 )     (439,780 )     (767,746 )
(Gain) loss on foreign currency translation
    (653,355 )     33,366       (640,951 )     819,791  
Sundry income
    (83,154 )     (57,106 )     (235,624 )     (91,691 )
 
   
 
     
 
     
 
     
 
 
 
    8,410,158       8,698,407       25,244,955       27,330,403  
 
   
 
     
 
     
 
     
 
 
Earnings before income taxes
    8,064,240       2,018,650       11,203,620       8,877,044  
Income tax expense (benefit)
                               
Current
    34,000       (2,878,000 )     (947,000 )     (1,177,000 )
Deferred
    3,313,000       4,486,000       5,699,000       5,043,000  
 
   
 
     
 
     
 
     
 
 
 
    3,347,000       1,608,000       4,752,000       3,866,000  
 
   
 
     
 
     
 
     
 
 
Net earnings
  $ 4,717,240     $ 410,650     $ 6,451,620     $ 5,011,044  
 
   
 
     
 
     
 
     
 
 

The accompanying notes are an integral part of these financial statements.

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Plastipak Holdings, Inc. and Subsidiaries

Consolidated Statements of Cash Flows

                 
    Nine Months Ended
    July 31,   August 2,
    2004
  2003
    (unaudited)   (unaudited)
Cash Flows from Operating Activities
               
Net Income
  $ 6,451,620     $ 5,011,044  
Adjustments to reconcile net income to net cash provided by operating activities:
               
Depreciation and amortization
    48,251,784       41,498,012  
Amortization of net premium on Senior Notes
    (212,425 )     (212,425 )
Bad debt expense
    893,078       783,388  
Deferred salaries
    618,675       290,700  
Gain on sale of equipment
    (55,182 )     (212,792 )
Deferred tax expense
    5,699,000       5,043,000  
Restricted stock option - compensation
    1,264,829       1,538,377  
Foreign currency translation (gain) loss
    (145,603 )     796,677  
Change in assets and liabilities:
               
Increase in accounts receivable
    (10,154,582 )     (4,828,791 )
Increase in inventories
    (6,801,576 )     (8,056,094 )
Increase in prepaid expenses and other current assets
    (2,048,642 )     (1,616,523 )
Decrease (increase) in prepaid federal income taxes
    248,816       (51,915 )
Increase in other liabilities
    16,379,880       11,966,463  
(Increase) decrease in deposits
    (468,606 )     4,032,320  
Increase (decrease) in accounts payable
    5,808,827       (6,865,648 )
Increase in sundry other assets
    (31,755 )     (235,503 )
Decrease in income taxes
    (18,130 )     (18,940 )
 
   
 
     
 
 
Net cash provided by operating activities
    65,680,008       48,861,350  
Cash Flows (Used In) Provided By Investing Activities
               
Acquisition of property and equipment
    (87,331,791 )     (72,010,775 )
Proceeds from sale of equipment
    1,394,367       629,559  
Acquisition of intangible assets
    (4,512,500 )     (775,000 )
 
   
 
     
 
 
Net cash used in investing activities
    (90,449,924 )     (72,156,216 )
Cash Flows Provided By (Used In) Financing Activities
               
Net borrowings under revolving credit facility
    1,961,472       1,052,982  
Principal payments on long-term obligations
    (4,552,733 )     (4,981,250 )
Proceeds from long-term obligations
    618,038       50,545  
 
   
 
     
 
 
Net cash used in financing activities
    (1,973,223 )     (3,877,723 )
 
   
 
     
 
 
Net decrease in cash and cash equivalents
    (26,743,139 )     (27,172,589 )
Cash and cash equivalents at beginning of the year
    37,278,406       66,196,262  
 
   
 
     
 
 
Cash and cash equivalents at end of the period
  $ 10,535,267     $ 39,023,673  
 
   
 
     
 
 

The accompanying notes are an integral part of these financial statements.

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Plastipak Holdings, Inc. and Subsidiaries

Consolidated Statements of Cash Flows - Continued

                 
    July 31,   August 2,
    2004
  2003
    (unaudited)   (unaudited)
Supplemental Cash Flow Information
               
Cash paid for interest
  $ 22,650,000     $ 22,387,000  
 
   
 
     
 
 
Cash paid for income taxes
  $     $ 723,000  
 
   
 
     
 
 
Supplemental Noncash Investing and Financing Activities
               
Acquisition of equipment through the assumption of long-term obligations
  $ 7,810,000     $ 5,317,000  
 
   
 
     
 
 
Increase in Obligation Under Stock Bonus Plan
  $ 913,000     $ 1,740,000  
 
   
 
     
 
 
Increase (decrease) in fair value of interest rate swaps
  $ 37,000     $ (6,910,000)  
 
   
 
     
 
 

The accompanying notes are an integral part of these financial statements.

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Plastipak Holdings, Inc. and Subsidiaries

Notes to the Consolidated Financial Statements (Unaudited)

Note A - Basis of Presentation, Nature of Operations and Summary of Accounting Policies

Organization and Basis of Presentation

     The accompanying unaudited condensed consolidated financial statements have been prepared pursuant to the rules of the Securities and Exchange Commission for quarterly reports on Form 10-Q. Accordingly, they do not include all of the information and footnotes required by generally accepted accounting principles for complete financial statements. In the opinion of management, all adjustments (consisting of normal recurring adjustments) considered necessary for a fair presentation have been included. Operating results for the nine months ended July 31, 2004 are not necessarily indicative of the results that may be expected for the year ending October 30, 2004.

     These financial statements should be read in conjunction with the Company’s audited consolidated financial statements and notes thereto included in the Company’s Form 10-K filed by Plastipak Holdings, Inc. (Plastipak) with the Securities and Exchange Commission on January 29, 2004.

Reclassifications

     Certain reclassifications have been made to the 2003 financial information in order for them to conform to the classifications at July 31, 2004.

Employee Compensation Plans

     The Company has two stock-based employee compensation plans. The Company accounts for these plans under the recognition and measurement principles of APB Opinion No. 25, Accounting for Stock Issued to Employees, and related interpretations. The plans are considered to be variable plans and therefore, stock-based employee compensation cost is reflected in net income as a component of general and administrative expenses, as all options granted under those plans had an exercise price less than the market value of the underlying common stock on the date of grant. Amounts expensed approximate that which would have been expensed had the value of the options granted been computed under provisions of FAS 123.

Note B - Fiscal Period

     Plastipak has elected a 52/53 week fiscal period for tax and financial reporting purposes. Plastipak’s fiscal period ends on the Saturday closest to October 31. The three month periods ended July 31, 2004 and August 2, 2003 contained 13 weeks. The nine-month periods ended July 31, 2004 and August 2, 2003 contained 39 weeks.

Note C - New Accounting Pronouncements

     In January 2003, the Financial Accounting Standards Board issued FASB Interpretation 46 (FIN 46), Consolidation of Variable Interest Entities. FIN 46 clarifies the applications of Accounting Research Bulletin 51, Consolidated Financial Statements, for certain entities that do not have sufficient equity at risk for the entity to finance its activities without additional subordinated financial support from other parties or in which equity investors do not have the characteristics of a controlling financial interest (“variable interest entities”). Variable interest entities within the scope of FIN 46 are required to be consolidated by their primary beneficiary. The primary beneficiary of a variable interest entity is determined to be the party that absorbs a majority of the entity’s expected losses, receives a majority of its expected returns, or both.

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Plastipak Holdings, Inc. and Subsidiaries

Notes to the Consolidated Financial Statements (Unaudited) - Continued

Note C - New Accounting Pronouncements – Continued

     In December 2003, the Financial Accounting Standards Board issued FASB Interpretation 46(R), Consolidation of Variable Interest Entities. FIN 46(R) replaces FIN 46 and clarifies the accounting for interests in variable interest entities. FIN 46(R) should be applied to entities considered to be Special Purpose Entities (SPE’s) no later than the end of the first reporting period after December 15, 2003 and by the end of the first reporting period that ends after March 15, 2004 to entities other than SPE’s. The adoption of this standard did not have an impact on the Company’s financial position or results of operations.

Note D - Inventories

     Inventories consisted of the following at:

                 
    July 31,   November 1,
    2004
  2003
Raw Materials
  $ 36,876,910     $ 34,835,429  
Finished Goods
    46,107,431       41,984,322  
Parts & Supplies
    13,837,977       13,200,991  
 
   
 
     
 
 
 
  $ 96,822,318     $ 90,020,742  
 
   
 
     
 
 

Note E - Legal Proceedings

     The Company is a party to various litigation matters arising in the ordinary course of business. The ultimate legal and financial liability of this litigation cannot be estimated with certainty, but management believes, based on their examination of these matters, experience to date and discussions with counsel, that the ultimate liability will not be material to the Company’s business, financial condition or results of operations.

Note F - Derivative Instruments and Hedging Activities

     Financial Accounting Standards Board Statement No. 133, “Accounting for Derivative Instruments and Hedging Activities,” as amended and clarified, requires companies to recognize all of their derivative instruments as either assets or liabilities at fair value in the statement of financial position. The accounting for changes in the fair value (i.e., gains or losses) of a derivative instrument depends on whether it has been designated and qualifies as part of a hedging relationship and further, on the type of hedging relationship. For those derivative instruments that are designated and qualify as hedging instruments, a company must designate the hedging instrument, based upon the exposure being hedged, as either a fair value hedge or a cash flow hedge.

     For derivative instruments that are designated and qualify as a fair value hedge (i.e., hedging the exposure to changes in the fair value of an asset or a liability or an identified portion thereof that is attributable to a particular risk), the gain or loss on the derivative instrument as well as the offsetting loss or gain on the hedged item attributable to the hedged risk are recognized in current earnings during the period of the change in fair values. For derivative instruments that are designated and qualify as a cash flow hedge (i.e., hedging the exposure to variability in expected future cash flows that is attributable to a particular risk), the effective portion of the gain or loss on the derivative instrument is reported as a component of other comprehensive income and reclassified into earnings in the same period or periods during which the hedged transaction affects earnings.

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Plastipak Holdings, Inc. and Subsidiaries

Notes to the Consolidated Financial Statements (Unaudited) - Continued

Note F - Derivative Instruments and Hedging Activities - Continued

For derivative instruments not designated as hedging instruments, the gain or loss is recognized in current earnings during the period of change. The Company currently uses only fair value hedge accounting.

     On March 11, 2003, the Company entered into two interest rate swap agreements. In connection with the Senior Notes, the Company exchanged fixed rate interest of 10.75% for variable rate interest. The interest rate swap agreements have notional amounts of $50,000,000 each. The variable rates are equal to six month LIBOR plus 6.46% and 6.66%, respectively, for an 8-year period ending September 1, 2011. As of July 31, 2004, the Company recorded an increase of $4,711,202 in other accrued expenses to recognize the fair value of the swap and a $4,711,202 decrease in the Senior Notes to recognize the difference between the carrying value and fair value of the related hedged liability.

Note G - Guarantor and Nonguarantor Financial Statements and Reportable Segments

     The Senior Notes are unsecured, and guaranteed by each of Plastipak’s current and future material domestic subsidiaries.

     The following condensed consolidating financial information presents:

(1)   Condensed consolidating balance sheets as of July 31, 2004 and November 1, 2003, statements of operations for the three months and nine months ended July 31, 2004 and August 2, 2003 and statements of cash flows for the nine months ended July 31, 2004 and August 2, 2003 of (a) Plastipak the parent; (b) the guarantor subsidiaries (North American Operating Segment); (c) the nonguarantor subsidiaries (South American Operating Segment and European Operating Segment); (d) Plastipak on a consolidated basis, and
 
(2)   Elimination entries necessary to consolidate Plastipak Holdings, Inc., the parent, with the guarantor (North American Operating Segment) and nonguarantor (South American Operating Segment and European Operating Segment) subsidiaries.

     Each subsidiary guarantor is wholly-owned by Plastipak, all guarantees are full and unconditional and all guarantees are joint and several.

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Plastipak Holdings, Inc. and Subsidiaries

Notes to the Consolidated Financial Statements (Unaudited)
 - Continued

Note G- Guarantor and Nonguarantor Financial Statements and Reportable Segments (Continued)

Condensed Consolidating Balance Sheet

As of July 31, 2004

                                         
    Parent   Guarantor   Nonguarantor           Consolidated
    Total
  Subsidiaries
  Subsidiaries
  Eliminations
  Total
Current Assets
                                       
Cash
  $ 1,652,849     $ 6,874,917     $ 2,007,501     $     $ 10,535,267  
Accounts receivable
    15,543,410       46,794,482       15,053,646       (6,395,450 )     70,996,088  
Inventories
          78,433,599       18,388,719             96,822,318  
Prepaid expenses
          9,747,760       6,331,705             16,079,465  
Prepaid federal income taxes
    1,953,000       498,234       93,930             2,545,164  
Deferred income taxes
    (2,600,000 )     2,997,000       2,525,000             2,922,000  
Other current assets
          1,548,077       811,382             2,359,459  
 
   
 
     
 
     
 
     
 
     
 
 
Total Current Assets
    16,549,259       146,894,069       45,211,883       (6,395,450 )     202,259,761  
Property, Plant & Equipment- Net
          368,442,595       47,789,387       (100,000 )     416,131,982  
Other Assets
                                       
Cash surrender value of life insurance
          1,990,892                     1,990,892  
Deposits
          12,460,305             (1,275,339 )     11,184,966  
Investment in and advances to affiliates
    373,252,767       (295,991,627 )             (77,261,140 )      
Capitalized loan costs
    926,786       7,325,019                   8,251,805  
Intangible assets
          7,022,851       1,980,409             9,003,260  
Deferred tax asset - -long term
    (429,556 )     429,556                    
Prepaids
          841,704                   841,704  
Sundry
          5,000,000       298,400       (5,000,000 )     298,400  
 
   
 
     
 
     
 
     
 
     
 
 
 
    373,749,997       (260,921,300 )     2,278,809       (83,536,479 )     31,571,027  
 
   
 
     
 
     
 
     
 
     
 
 
Total Assets
  $ 390,299,256     $ 254,415,364     $ 95,280,079     $ (90,031,929 )   $ 649,962,770  
 
   
 
     
 
     
 
     
 
     
 
 

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Plastipak Holdings, Inc. and Subsidiaries

Notes to the Consolidated Financial Statements (Unaudited) - Continued

Note G- Guarantor and Nonguarantor Financial Statements and Reportable Segments (Continued)

Condensed Consolidating Balance Sheet - Continued

As of July 31, 2004

                                         
    Parent   Guarantor   Nonguarantor           Consolidated
    Total
  Subsidiaries
  Subsidiaries
  Eliminations
  Total
Current Liabilities
                                       
Accounts payable
  $     $ 88,169,840     $ 39,141,020     $ (6,376,620 )   $ 120,934,240  
Current portion of long term obligation
          4,067,038       607,783             4,674,821  
Taxes other than income
          6,318,739       3,771,589             10,090,328  
Other accrued expenses
    18,757,374       20,516,338       2,390,723       (1,294,168 )     40,370,267  
Income taxes
    (168,440 )     1,513,681                   1,345,241  
 
   
 
     
 
     
 
     
 
     
 
 
Total Current Liabilities
    18,588,934       120,585,636       45,911,115       (7,670,788 )     177,414,897  
Senior Notes
    325,217,224       (2,922,200 )                 322,295,024  
Long-Term Obligations
          8,628,584       61,812,670       (5,000,000 )     65,441,254  
Deferred Income Taxes
    (10,475,098 )     31,211,097       2,525,000       1       23,261,000  
Other Non-Current Liabilities
          4,094,658       487,741             4,582,399  
Obligations Under Stock Bonus Plan
    10,484,727                         10,484,727  
Stockholders’ Equity (Deficit)
    46,483,469       92,817,589       (15,456,447 )     (77,361,142 )     46,483,469  
 
   
 
     
 
     
 
     
 
     
 
 
Total Liabilities and Stockholders’ Equity
  $ 390,299,256     $ 254,415,364     $ 95,280,079     $ (90,031,929 )   $ 649,962,770  
 
   
 
     
 
     
 
     
 
     
 
 

10


Table of Contents

Plastipak Holdings, Inc. and Subsidiaries

Notes to the Consolidated Financial Statements (Unaudited) - Continued

Note G - Guarantor and Nonguarantor Financial Statements and Reportable Segments (Continued)

Condensed Consolidating Balance Sheet

As of November 1, 2003

                                         
    Parent   Guarantor   Nonguarantor           Consolidated
    Total
  Subsidiaries
  Subsidiaries
  Eliminations
  Total
Current Assets
                                       
Cash
  $ 23,104,119     $ 12,750,772     $ 1,423,515     $     $ 37,278,406  
Accounts receivable
    9,090,858       47,835,342       11,085,537       (6,277,153 )     61,734,584  
Inventories
          71,520,128       18,500,614             90,020,742  
Prepaid expenses
          10,075,312       2,963,957             13,039,269  
Prepaid federal income taxes
    975,392       1,719,048       99,540             2,793,980  
Deferred income taxes
    (3,679,000 )     2,997,000       2,525,000             1,843,000  
Other current assets
          3,336,833       351,226             3,688,059  
 
   
 
     
 
     
 
     
 
     
 
 
Total Current Assets
    29,491,369       150,234,435       36,949,389       (6,277,153 )     210,398,040  
Pr