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SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549
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FORM 10-K
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(MARK ONE)
[X] ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE
SECURITIES EXCHANGE ACT OF 1934
FOR THE FISCAL YEAR ENDED DECEMBER 31, 2001
OR
[ ] TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE
SECURITIES EXCHANGE ACT OF 1934
FOR THE TRANSITION PERIOD FROM ____________ TO____________
COMMISSION FILE NUMBER 0-20646
CARAUSTAR INDUSTRIES, INC.
(Exact name of registrant as specified in its charter)
NORTH CAROLINA 581388387
(State or other jurisdiction of (I.R.S. Employer
incorporation or organization) Identification No.)
3100 JOE JERKINS BLVD. 30106
AUSTELL, GEORGIA (Zip Code)
(Address of principal executive
offices)
(770) 948-3101
(Registrant's telephone number, including area code)
SECURITIES REGISTERED PURSUANT TO SECTION 12(b) OF THE ACT:
NONE
SECURITIES REGISTERED PURSUANT TO SECTION 12(g) OF THE ACT:
COMMON STOCK, $.10 PAR VALUE
(Title of Class)
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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 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 check mark 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 registrant's 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. [X]
The aggregate market value of voting stock held by non-affiliates of the
registrant as of March 15, 2002, computed by reference to the closing sale price
on such date, was $280,553,772. For purposes of calculating this amount only,
all directors and executive officers are treated as affiliates. This
determination of affiliate status shall not be deemed conclusive for other
purposes. As of the same date, 27,855,488 shares of Common Stock, $.10 par
value, were outstanding.
DOCUMENTS INCORPORATED BY REFERENCE
The Registrant's definitive Proxy Statement pertaining to the 2002 Annual
Meeting of Shareholders ("the Proxy Statement") and filed pursuant to Regulation
14A is incorporated herein by reference into Part III.
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INTRODUCTION
Caraustar Industries, Inc. operates its business through 19 subsidiaries
across the United States and in Mexico and the United Kingdom. As used herein,
"we," "our," "us," (or similar terms), the "Company" or "Caraustar" includes
Caraustar Industries, Inc. and its subsidiaries, except that when used with
reference to common shares or other securities described herein and in
describing the positions held by management of the Company, the term includes
only Caraustar Industries, Inc.
FORWARD-LOOKING INFORMATION
This Annual Report on Form 10-K, including "Management's Discussion and
Analysis of Financial Condition and Results of Operations," may contain various
"forward-looking statements," within the meaning of Section 21E of the
Securities Exchange Act of 1934, that are based on our beliefs and assumptions,
as well as information currently available to us. When used in this document,
the words "believe," "anticipate," "estimate," "expect," "intend," "should,"
"would," "could," or "may" and similar expressions may identify forward-looking
statements. These statements involve risks and uncertainties that could cause
our actual results to differ materially depending on a variety of important
factors, including, but not limited to, those identified under the caption "Risk
Factors" in Part I, Item 1 of this Report and other factors discussed elsewhere
in this Report and the Company's other filings with the Securities and Exchange
Commission. These documents are available from us, and also may be examined at
public reference facilities maintained by the Securities and Exchange Commission
or, to the extent filed via EDGAR, accessed through the Web Site of the
Securities and Exchange Commission (http://www.sec.gov). We do not undertake any
obligation to update any forward-looking statements we make.
PART I
ITEM 1. DESCRIPTION OF BUSINESS
Overview
We are a major manufacturer of 100% recycled paperboard and converted
paperboard products. We manufacture products primarily from recovered fiber,
which is derived from recycled paper. We operate in three business segments:
- - Paperboard
- - Tube, core and composite container
- - Carton and custom packaging
We report certain financial information by segment in Note 11 to the
consolidated financial statements included in Part II, Item 8 of this Report.
Operations and Products
Paperboard. Our principal manufacturing activity is the production of
uncoated and clay-coated recycled paperboard. In this manufacturing process, we
reduce paperstock to pulp, clean and refine it and then process it into various
grades of paperboard for internal consumption by our converting facilities or
sale in the following four end-use markets:
- - Tube, core and composite containers
- - Folding cartons
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- - Gypsum wallboard facing paper
- - Other specialty products
We currently operate a total of 15 paperboard mills, including one owned in
a joint venture. These mills are located in the following states: Connecticut,
Georgia, Indiana, Iowa, New York, North Carolina, Ohio, Pennsylvania, South
Carolina, Tennessee and Virginia. We ceased operations at two paperboard mills
during 2000: the Baltimore, Maryland mill in February 2000 and the Camden, New
Jersey mill in September 2000. Our Chicago, Illinois paperboard mill ceased
operations in January 2001.
In 2001, approximately 38% of the recycled paperboard sold by our
paperboard mills was consumed internally by our converting facilities; the
remaining 62% was sold to external customers. Sales of unconverted paperboard to
external customers as a percentage of total sales by end-use market were as
follows (excludes sales from the 50%-owned Premier Boxboard mill):
YEARS ENDED DECEMBER 31,
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END-USE MARKET 1999 2000 2001
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Tube, core and composite containers......................... 1.8% 1.7% 1.6%
Folding cartons............................................. 12.1% 12.6% 11.5%
Gypsum wallboard facing paper............................... 13.8% 10.2% 7.9%
Other specialty products(1)................................. 10.5% 11.0% 10.7%
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(1) Includes sales of unconverted paperboard and certain specialty converted
products.
Three of our paperboard mills operate specialty converting facilities that
supply other specialty converted and laminated products to the bookbinding,
game, puzzleboard, printing and furniture industries. We also operate two
specialty converting facilities that supply die cut and foam laminated products
and manufacture jigsaw puzzles, coin folders and other specialty products.
Each of our paperboard mills and most of our converting plants have onsite
recovered fiber facilities that collect and bale recycled paperstock. In
addition, we operate 8 stand-alone paperstock recycling and brokerage facilities
that collect, sale and broker recovered fiber to external customers and to our
own mills. Sales of paperstock to external customers accounted for 4.0%, 5.6%
and 5.2% of our total sales in 2001, 2000 and 1999, respectively.
Tube, Core and Composite Container. Our largest converting operation is
the production of tubes and cores. The principal applications of these products
are cloth cores, paper mill cores, yarn carriers, carpet cores and film, foil
and metal cores. Our 30 tube and core converting plants obtain approximately 88%
of their paperboard needs from our paperboard mills and the remaining 12% from
other manufacturers. Paper tubes are designed to provide specific physical
strength properties, resistance to moisture and abrasion, and resistance to
delamination at extremely high rotational speeds. Because of the relatively high
cost of shipping tubes and cores, tube and core converting facilities generally
serve customers within a relatively small geographic area. Accordingly, most of
our tube and core converting plants are located close to concentrations of
customers.
We are seeking to expand our presence in the markets for more sophisticated
tubes and cores, which require stronger paper grades, higher skill and new
converting technology. These markets include the yarn carrier and plastic film
markets, as well as the market for cores used in certain segments of the paper
industry. We believe these markets offer significant growth potential, as well
as potentially higher operating margins.
In addition to tube and core converting facilities, our tube, core and
composite container division operates four facilities that produce specialty
converted products used in industrial packaging protection applications (edge
protectors). Our tube, core and related sales to external customers accounted
for 22.1%, 21.3% and 21.8% of our total sales to external customers in 2001,
2000 and 1999, respectively.
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Our tube, core and composite container division also produces composite
containers used in the adhesive, sealant, food and food service markets, as well
as grease cans, tubes, cartridges and other components. The group has three
composite container plants located in Stevens Point, Wisconsin, Saint Paris,
Ohio and Orrville, Ohio and a transportation operation in Ohio. Composite
container sales accounted for 4.4%, 3.9% and 4.3% of our total sales to external
customers in 2001, 2000 and 1999, respectively.
We manufacture injection-molded and extruded plastic products, including
plastic cores for the textile industry, plastic cores for the film, paper and
other industries and other specialized products. These plastic products are, to
a large extent, complementary to our tube and core products. We have an 80%
equity interest in a plant in Union, South Carolina that produces such plastic
products. Some of this plant's customers also purchase our tubes and cores. This
plant currently has six plastic extrusion lines and 24 injection-molding
machines, using the latest available process control technology. We also produce
injection-molded plastic parts at our facility in Georgetown, Kentucky. These
parts are primarily used as components in the manufacture of our composite
containers. We produce plastic cartridges at a facility located in New Smyrna
Beach, Florida. Plastic product and related sales to external customers
accounted for 2.1%, 2.3% and 2.5% of our total sales to external customers in
2001, 2000 and 1999, respectively.
Carton and Custom Packaging. Our other converting operations produce
folding cartons and rigid set-up boxes at 16 plants. These plants obtain
approximately 48% of their paperboard needs from our paperboard mills and the
remaining 52% from other manufacturers. Our boxes and cartons are used
principally as containers for hosiery, hardware, candy, sports-related items,
cosmetics, dry food, film and various other industrial applications, including
textile and apparel applications.
We operate eight specialty packaging facilities: four in Ohio, two in New
Jersey and one each in Massachusetts and North Carolina. These facilities
perform contract manufacturing and custom contract packaging for a variety of
consumer product companies. Additionally, we operate a digital imaging facility
in Ohio and a prepress reproduction facility in Connecticut.
Carton and custom packaging sales accounted for 35.6% of our total sales to
external customers in 2001, 31.4% in 2000 and 28.2% in 1999.
Our consolidated sales for the twelve months ended December 31, 2001 were
$913.7 million. We estimate that our three business segments accounted for the
following percentages of sales for the twelve months ended December 31, 2001:
- - Paperboard -- 36%
- - Tube, core and composite container -- 28%
- - Carton and custom packaging -- 36%
Joint Ventures. We also operate two joint ventures with Temple-Inland,
Inc., in which we own 50% interests. One of the joint ventures, Premier Boxboard
Limited LLC, formed in 1999, produces a new, lightweight gypsum facing paper
along with other containerboard grades. We believe that Premier is the lowest
cost mill in the industry. The other joint venture, Standard Gypsum, L.P.,
formed in 1996, manufactures gypsum wallboard. We manage the day-to-day
operations of our Premier Boxboard joint venture, and Temple-Inland manages the
day-to-day operations at our Standard Gypsum joint venture.
We also have an equity interest as the nonoperating partner in two tube
plants. One of the tube plants is located in Tacoma, Washington and manufactures
spiral-wound tubes and edge protectors. The other tube plant is located in
Scarborough, Ontario, Canada and manufactures spiral- and convolute-wound tubes.
Raw Materials. Recovered fiber derived from recycled paperstock is the
only significant raw material we use in our mill operations. We purchase
approximately 69% of our paperstock requirements from independent sources, such
as major retail stores, distribution centers and manufacturing plants. We obtain
the balance from a combination of other sources. We collect some paperstock from
small collectors and waste collection businesses. Our paperstock recycling and
processing facilities sort and bale this paperstock and then either transfer it
to our mills for processing or sell it to third parties. We also obtain
paperstock from customers of our converting operations and from waste handlers
and collectors who deliver loose paperstock to our mill sites for
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direct use without baling. We obtain another portion of our requirements from
our small baler program, in which we lease, sell or furnish small baling
machines to businesses that bale their own paperstock for our periodic
collection.
We closely monitor our recovered fiber costs, which can fluctuate
significantly. We also intend to further increase our unbaled paperstock
purchases as a percentage of our total recovered fiber needs and to increase our
reliance on purchases from our small baler program.
Energy Costs. Excluding labor, energy is our most significant
manufacturing cost. We use energy, including electricity, natural gas, fuel oil
and coal, to generate steam used in the paper making process and to operate our
paperboard machines and our other converting machinery. We purchase energy from
local suppliers at market rates.
Product Distribution. Each of our manufacturing and converting facilities
has its own sales staff and maintains direct sales relationships with its
customers. We also employ divisional and corporate level sales personnel who
support and coordinate the sales activities of individual facilities. Divisional
and corporate sales personnel also provide sales management, marketing and
product development assistance in markets where customers are served by more
than one of our facilities. Approximately 200 of our employees are devoted
exclusively to sales and customer service activities, although many other
employees participate generally in sales efforts. We generally do not sell our
products through independent sales representatives. Our advertising is limited
to trade publications.
Customers. We manufacture most of our converted products pursuant to
customers' orders. We do, however, maintain minimal inventory levels of certain
products. Our business generally is not dependent on any single customer or upon
a small number of major customers. However, in 2000, Georgia-Pacific, formerly
our largest gypsum facing paper customer, refused to continue purchasing its
requirements of gypsum facing paper for certain plants pursuant to the terms of
a long-term supply contract. Our operating results and financial condition have
been materially and adversely affected by the loss of contract volume from
Georgia-Pacific. Other than the loss of Georgia-Pacific, we do not believe that
the loss of any one customer would have a material adverse effect on our
financial condition or results of operations.
Competition. Although we compete with numerous other manufacturers and
converters, our competitive position varies greatly by geographic area and
within the various product markets of the recycled paperboard industry. In most
of our markets, our competitors are capable of supplying products that would
meet customer needs. Some of our competitors have greater financial resources
than we do. We compete in our markets on the basis of price, quality and
service. We believe that it is important in all of our markets to work closely
with our customers to develop or adapt products to meet customers' specialized
needs. We also believe that we compete favorably on the basis of all of the
above factors.
Tube, core and composite containers. In the southeastern United States,
where we historically have marketed our tubes and cores, we believe that we and
Sonoco Products Company are the major competitors. On a national level, Sonoco
is our dominant competitor in the tube and core market. According to industry
data, Sonoco had more than 50% of the total tube and core market in the United
States in 2001. We also compete with several regional companies and numerous
small local companies in the tube and core market.
Carton and custom packaging. The folding carton and custom packaging
market in the United States is served by several large national and regional
companies and numerous small local companies. Nationally, none of the major
competitors is dominant, although certain competitors may be dominant in
particular geographic areas or market niches. In the markets served by our
carton plants, the dominant competitors are Rock-Tenn Company, Smurfit-Stone
Container Corporation and Graphic Packaging, Inc.
Gypsum wallboard facing paper. The gypsum wallboard industry is divided
into independent gypsum wallboard manufacturers, which either do not produce
their own gypsum wallboard facing paper or cannot fill all of their needs
internally, and integrated wallboard manufacturers, which supply all of their
own gypsum wallboard facing paper requirements internally. We believe that the
two largest integrated gypsum wallboard manufacturers, USG Corporation and
National Gypsum Company, do not have significant sales of gypsum wallboard
facing paper to the independent gypsum wallboard manufacturers. We believe that
we have the
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largest market share of the supply of gypsum wallboard facing paper to
independent wallboard manufacturers in North America.
We also compete in the gypsum wallboard industry through our joint venture
with Temple-Inland. Our joint venture, Standard Gypsum, competes with larger
integrated wallboard manufacturers such as USG Corporation and National Gypsum,
who have greater financial resources and superior marketing strength due to
their greater number of locations and national presence. Standard Gypsum
competes primarily on the basis of product quality, dependability, timeliness of
delivery and price.
Other specialty products. In our sales of specialty products and in sales
of recycled paperboard to other manufacturers for the production of tubes, cores
and composite containers, folding cartons and boxes and miscellaneous converted
products (other than gypsum wallboard facing paper), we compete with a number of
recycled paperboard manufacturers, including Rock-Tenn, Smurfit-Stone Container
Corporation and The Newark Group, Inc. We believe that none of our competitors
is dominant in any of these markets.
Competitive position. Recovered fiber costs were lower on average in 2001
compared to 2000. Our average same-mill cost for recovered fiber per ton of
recycled paperboard produced was approximately $65 during 2001, a 38% decrease
from $104 per ton in 2000. Although no specific information is available about
competitors' actual recovered fiber costs, we believe that our delivered
recovered fiber costs are among the lowest in the recycled paperboard industry.
Relative to other competitors, we believe that our lower recovered fiber costs
are attributable in part to lower shipping costs resulting from the location of
our paperboard mills and paperstock facilities near major metropolitan areas
that generate substantial supplies of paperstock. Many of the paperboard mills
operated by our principal competitors are located away from major metropolitan
areas, and we believe, based on our knowledge of freight rates, that these
competitors incur higher freight costs associated with their fiber recovery
efforts, adding to their total cost of delivered recovered fiber.
Our relatively low recovered fiber costs are also attributable to our
emphasis on certain recovery methods that enable us to avoid baling operations.
We believe that our competitors rely primarily on off-site, company-owned and
operated paperstock baling operations that collect and bale paperstock for
shipment and processing at the mill site. We also operate such facilities, and
our experience is that the baling operation results in $25-$30 per ton higher
recovered fiber costs. We equip most of our paperboard mills to accept unbaled
paperstock for processing directly into its pulpers. In 2001 and 2000, unbaled
paperstock represented approximately 6% and 8%, respectively, of our total
recovered fiber purchases. We also use other fiber recovery methods -- our small
baler program and our recovery of paperstock from customers -- that result in
lower recovered fiber costs.
Environmental Matters. Our operations are subject to various
international, federal, state and local environmental laws and regulations.
These laws and regulations are administered by international, federal, state and
local agencies. Among other things, these laws and regulations regulate the
discharge of materials into the water, air and land, and govern the use and
disposal of hazardous substances. We believe that our operations are in
substantial compliance with all applicable environmental laws and regulations,
except for violations that we believe would not have a material adverse effect
on our business or financial position.
Our recycled paperboard mills use substantial amounts of water in the
papermaking process. Our mills discharge process wastewater into local sewer
systems or directly into nearby waters pursuant to wastewater discharge permits.
We use only small amounts of hazardous substances, and we believe the
concentration of these substances in our wastewater discharge generally is below
permitted maximums. From time to time, the imposition of stricter limits on the
solids, sulfides, BOD (biological oxygen demand) or metals content of a mill's
wastewater requires us to alter the content of our wastewater. We can effect
reductions by additional screening of the wastewater, by otherwise changing the
flow of process wastewater from the mill or from pretreatment ponds into the
sewer system, and by adding chemicals to the wastewater. We also are subject to
regulatory requirements related to the disposal of solid wastes and air
emissions from our facilities. We are not currently aware of any required
expenditures relating to wastewater discharge, solid waste disposal or air
emissions that we expect to have a material adverse effect on our business or
financial condition, but we are unable to assure you that we will not incur
material expenditures in these areas in the future.
In addition, under certain environmental laws, we can be held strictly
liable if hazardous substances are found on real property we have owned,
operated or used as a disposal site. In recent years, we have adopted a
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policy of assessing real property for environmental risks prior to purchase. We
are aware of issues regarding hazardous substances at certain facilities, but in
each case we believe that any possible liabilities will not have a material
adverse effect on our business or financial position.
Employees. As of December 31, 2001, the 99 facilities we operate had
approximately 5,715 employees, of whom 4,450 are hourly and 1,265 are salaried.
Approximately 2,282 of our hourly employees are represented by labor unions. All
principal union contracts expire during the period 2002-2005. We consider our
relations with our employees to be excellent.
Executive Officers. The names and ages, positions and period of service of
each of our company's executive officers are set forth below. The term of office
for each executive officer expires upon the earlier of the appointment and
qualification of a successor or such officer's death, resignation, retirement,
removal or disqualification.
PERIOD OF SERVICE AS EXECUTIVE OFFICER AND
PRE-EXECUTIVE OFFICER EXPERIENCE (IF AN
NAME AND AGE POSITION EXECUTIVE OFFICER FOR LESS THAN 5 YEARS)
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Thomas V. Brown(61).................. President and Chief Executive President since 1/1991; CEO since 10/1991;
Officer; Director Director since 4/1991
Michael J. Keough(50)................ Senior Vice President and Chief Since 3/2002; 2000-2002, President and
Operating Officer Chief Operating Officer and 1993-2000,
Vice President and General Manager,
Container Operations, of Gaylord
Container Corporation, a manufacturer
and distributor of corrugated
containers.
H. Lee Thrash, III(51)............... Vice President, Planning and Vice President and CFO since 1986;
Development; Chief Financial Director since 1987
Officer; Director
William A. Nix, III(50).............. Vice President, Treasurer and Since 4/2001; 1995-2000, Vice President,
Controller Treasurer, AGCO Corporation, a worldwide
manufacturer and distributor
of agricultural equipment.
Jimmy A. Russell(54)................. Vice President, Industrial and Vice President since 4/1993; CEO of Star
Consumer Products Group Paper Tube, Inc., the predecessor of the
Industrial and Consumer Products Group,
since 1/1993
James L. Walden(56).................. Vice President, Custom Packaging Since 2/1993
Group
Barry A. Smedstad(55)................ Vice President, Human Resources Since 1/1999; 1997-1998, Vice President,
and Public Relations Human Resources, Box USA, a manufacturer
of corrugated shipping containers;
1996-1997, Director of Human Resources,
Northeast Region, Baxter Healthcare
Corporation, a diversified healthcare
products and technology manufacturer;
1985-1996, Director, Labor & Employee
Relations, Federal Paper Board Company,
Inc., a paper manufacturer.
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PERIOD OF SERVICE AS EXECUTIVE OFFICER AND
PRE-EXECUTIVE OFFICER EXPERIENCE (IF AN
NAME AND AGE POSITION EXECUTIVE OFFICER FOR LESS THAN 5 YEARS)
- ------------ -------- ------------------------------------------
John R. Foster(56)................... Vice President, Sales and Since 9/96; 1995-96, Chief Operating
Marketing Officer, Pace International LP, a
chemical company; 1991-94, President and
General Manager, Eagle-Gypsum, Products,
a gypsum wallboard manufacturer.
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RISK FACTORS
Investors should consider the following risk factors, in addition to the
other information presented in this Report and the other reports and
registration statements we file from time to time with the Securities and
Exchange Commission, in evaluating us, our business and an investment in our
securities. Any of the following risks, as well as other risks and
uncertainties, could harm our business and financial results and cause the value
of our securities to decline, which in turn could cause investors to lose all or
part of their investment in our company. The risks below are not the only ones
facing our company. Additional risks not currently known to us or that we
currently deem immaterial also may impair our business.
OUR BUSINESS AND FINANCIAL PERFORMANCE MAY BE HARMED BY FUTURE INCREASES IN RAW
MATERIAL COSTS.
Our primary raw material is recycled paper, which is known in our industry
as "recovered fiber." The cost of recovered fiber has, at times, fluctuated
greatly because of factors such as shortages or surpluses created by market or
industry conditions. Although we have historically raised the selling prices of
our products in response to raw material price increases, sometimes raw material
prices have increased so quickly or to such levels that we have been unable to
pass the price increases through to our customers on a timely basis, which has
adversely affected our operating margins. We cannot assure you that we will be
able to pass such price changes through to our customers on a timely basis and
maintain our margins in the face of raw material cost fluctuations in the
future.
OUR OPERATING MARGINS MAY BE ADVERSELY AFFECTED BY RISING ENERGY COSTS.
Excluding labor, energy is our most significant manufacturing cost. We use
energy to generate steam used in the paper making process and to operate our
paperboard machines and all of our other converting machinery. Our energy costs
increased steadily throughout 2000 and in the first quarter 2001 before showing
some improvement by the end of 2001. In 2000, the average energy cost in our
mill system was approximately $52 per ton. In 2001, energy costs increased by
9.6% to $57 per ton. This was due primarily to increases in natural gas and fuel
oil costs. Until recently, our business had not been significantly affected by
energy costs, and we historically have not passed energy costs through to our
customers. We have not been able to pass through to our customers all of the
energy cost increases we incurred in 2000 and 2001. We continue to evaluate our
energy costs and consider ways to factor energy costs into our pricing. However,
we cannot assure you that our operating margins and results of operations will
not continue to be adversely affected by rising energy costs.
OUR BUSINESS AND FINANCIAL PERFORMANCE MAY BE ADVERSELY AFFECTED BY DOWNTURNS IN
INDUSTRIAL PRODUCTION, HOUSING AND CONSTRUCTION AND THE CONSUMPTION OF
NONDURABLE AND DURABLE GOODS.
Demand for our products in our four principal end use markets is primarily
driven by the following factors:
- Tube, core and composite container -- industrial production, construction
spending and consumer nondurable consumption
- Folding cartons -- consumer nondurable consumption and industrial
production
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- Gypsum wallboard facing paper -- single and multifamily construction,
repair and remodeling construction and commercial construction
- Other specialty products -- consumer nondurable consumption and consumer
durable consumption.
Downturns in any of these sectors will result in decreased demand for our
products. In particular, our business has been adversely affected in recent
periods by the general slow down in industrial demand and softness in the
housing markets. These conditions are beyond our ability to control, but have
had, and will continue to have, a significant impact on our sales and results of
operations.
In addition, the September 11, 2001 terrorist attacks and the uncertainties
surrounding those events have contributed to the general slowdown in U.S.
economic activity. If those events, other terrorist activities, the U.S.
military response and the resulting uncertainties continue to adversely affect
the United States economy in general, the sectors above may be negatively
impacted, which would cause our business to be adversely affected.
WE ARE ADVERSELY AFFECTED BY THE CYCLES, CONDITIONS AND PROBLEMS INHERENT IN OUR
INDUSTRY.
Our operating results tend to reflect the general cyclical nature of the
business in which we operate. In addition, our industry has suffered from excess
capacity. Our industry also is capital intensive, which leads to high fixed
costs and generally results in continued production as long as prices are
sufficient to cover marginal costs. These conditions have contributed to
substantial price competition and volatility within our industry. In the event
of a recession, demand and prices are likely to drop substantially. Our
profitability historically has been more sensitive to price changes than to
changes in volume. Future decreases in prices for our products would adversely
affect our operating results. These factors, coupled with our substantially
leveraged financial position, may adversely affect our ability to respond to
competition and to other market conditions or to otherwise take advantage of
business opportunities.
THE LINGERING EFFECTS OF OUR TENTATIVELY SETTLED DISPUTE WITH GEORGIA-PACIFIC
MAY CONTINUE TO MATERIALLY AND ADVERSELY AFFECT OUR OPERATING RESULTS AND
FINANCIAL CONDITION.
As reported in our previous SEC reports on Form 10-K and 10-Q, we have been
in litigation with Georgia-Pacific Corporation over Georgia-Pacific's refusal to
continue purchasing its requirements of gypsum facing paper for certain plants
pursuant to the terms of a long-term supply contract. As a result of the
dispute, by the end of the third quarter of 2000, Georgia-Pacific's purchases
fell by more than 80% from an average of 7,000 tons per month during the first
half of 2000, and fell to approximately 300 tons per month in the fourth quarter
of 2000. As a result of this loss in volume, we have closed our Camden, New
Jersey paperboard mill. In May 2001, we announced that we reached a tentative
settlement pursuant to which we entered into a new supply agreement with G-P
Gypsum, a subsidiary of Georgia-Pacific, subject to completion of a transition
period. Ongoing discussions with G-P Gypsum led the parties to extend the
outside expiration date of the transition period initially to December 31, 2001,
and the parties have since agreed to further extend the outside expiration date
of the transition period to April 1, 2002. See "Management's Discussion and
Analysis of Financial Condition and Results of Operations -- Georgia-Pacific
Litigation." We can give no assurance that the conditions to the new agreement
will be satisfied (or that G-P Gypsum will determine or agree that the
conditions have been satisfied), or that the new agreement will be implemented
in accordance with its terms and the pending litigation will be dismissed.
Accordingly, we believe that our operating results and financial condition will
continue to be materially and adversely affected by the loss of contract volume
from Georgia-Pacific unless and until a new supply agreement is implemented with
significant volume requirements, and until the new supply agreement has been
effective long enough to generate a substantial volume of required purchases
from Georgia-Pacific.
OUR BUSINESS MAY SUFFER FROM RISKS ASSOCIATED WITH GROWTH AND ACQUISITIONS.
Historically, we have grown our business, revenues and production capacity
to a significant degree through acquisitions. In the current difficult operating
climate facing our industry and our financial position, the pace of our
acquisition activity, and accordingly, our revenue growth, has slowed
significantly as we have
8
focused on conserving cash and maximizing the productivity of our existing
facilities. However, we expect to continue evaluating and pursuing acquisition
opportunities on a selective basis, subject to available funding and credit
flexibility. Growth through acquisitions involves risks, many of which may
continue to affect us based on acquisitions we have completed in the past. For
example, we have suffered significant unexpected losses at our Sprague mill in
Versailles, Connecticut, which we acquired from International Paper Company in
1999, resulting from unfavorable fixed price contracts, low capacity
utilization, high energy costs and higher fiber costs that we were unable to
pass through to our customers. Sprague incurred operating losses of $17.2
million and $7.2 million in 2000 and 2001, respectively, including the reversal
of reserves related to unfavorable supply contracts. See "Management's
Discussion and Analysis of Financial Condition and Results of Operations." We
cannot assure you that our acquired businesses will achieve the same levels of
revenue, profit or productivity as our existing locations or otherwise perform
as we expect.
Acquisitions also involve specific risks. Some of these risks include:
- assumption of unanticipated liabilities and contingencies;
- diversion of management's attention; and
- possible reduction of our reported earnings because of:
- increased goodwill write-offs;
- increased interest costs;
- issuances of additional securities or debt; and
- difficulties in integrating acquired businesses.
As we grow, we can give no assurance that we will be able to:
- use the increased production capacity of any new or improved facilities;
- identify suitable acquisition candidates;
- complete additional acquisitions; or
- integrate acquired businesses into our operations.
IF WE CANNOT RAISE THE NECESSARY CAPITAL FOR, OR USE OUR STOCK TO FINANCE,
ACQUISITIONS, EXPANSION PLANS OR OTHER SIGNIFICANT CORPORATE OPPORTUNITIES, OUR
GROWTH MAY BE IMPAIRED.
Without additional capital, we may have to curtail any acquisition and
expansion plans or forego other significant corporate opportunities that may be
vital to our long-term success. Although we expect to use borrowed funds to
pursue these opportunities, we must continue to comply with financial and other
covenants in order to do so. If our revenues and cash flow do not meet
expectations, then we may lose our ability to borrow money or to do so on terms
that we consider favorable. Conditions in the capital markets also will affect
our ability to borrow, as well as the terms of those borrowings. Existing
weaknesses in the U.S. capital markets have been, and may continue to be,
aggravated by the September 11, 2001 terrorist attacks and their aftermath. In
addition, our financial performance and the conditions of the capital markets
will also affect the value of our common stock, which could make it a less
attractive form of consideration in making acquisitions. All of these factors
could also make it difficult or impossible for us to expand in the future.
OUR SUBSTANTIAL INDEBTEDNESS COULD ADVERSELY AFFECT OUR CASH FLOW AND OUR
ABILITY TO FULFILL OUR OBLIGATIONS UNDER OUR INDEBTEDNESS.
We have a substantial amount of outstanding indebtedness. See "Selected
Financial Data," "Management's Discussion and Analysis of Financial Condition
and Results of Operations" and "Financial Statements and Supplemental Data"
included in Part II of this Report. In addition, as described in "Management's
Discussion and Analysis of Financial Condition and Results of Operations," we
have guaranteed indebtedness of our joint ventures for which we could also be
liable. Our substantial level of indebtedness increases the
9
possibility that we may be unable to generate cash sufficient to pay when due
the principal of, interest on or other amounts due in respect of our
indebtedness. We may also obtain additional long-term debt, increasing the risks
discussed below. Our substantial leverage could have significant consequences to
holders of our debt and equity securities. For example, it could:
- make it more difficult for us to satisfy our obligations with respect to
our indebtedness;
- increase our vulnerability to general adverse economic and industry
conditions;
- limit our ability to obtain additional financing;
- require us to dedicate a substantial portion of our cash flow from
operations to payments on our indebtedness, reducing the amount of our
cash flow available for other purposes, including capital expenditures
and other general corporate purposes;
- require us to sell debt or equity securities or to sell some of our core
assets, possibly on unfavorable terms, to meet payment obligations;
- restrict us from making strategic acquisitions, introducing new
technologies or exploiting business opportunities;
- limit our flexibility in planning for, or reacting to, changes in our
business and our industry;
- place us at a possible competitive disadvantage compared to our
competitors that have less debt; and
- adversely affect the value of our common stock.
OUR INTEREST EXPENSE COULD BE ADVERSELY AFFECTED BY RISKS ASSOCIATED WITH OUR
INTEREST RATE SWAP AGREEMENTS.
Interest rate swap agreements carry a certain inherent element of interest
rate risk. During 2001, we entered into several interest rate swap agreements in
order to take advantage of the current market conditions. These agreements
converted a significant portion of our fixed rate 9 7/8% senior subordinated
notes and our fixed rate 7 3/8% senior notes into variable rate obligations. The
variable rates are based on the three-month LIBOR plus a fixed margin. These
swap agreements lowered our interest expense in 2001, and we expect these
agreements to continue to positively impact our interest expense. If, however,
LIBOR increases significantly, our interest expense could be adversely affected.
See "Management's Discussion and Analysis of Financial Condition and Results of
Operations" for additional information on our swap agreements.
WE ARE SUBJECT TO MANY ENVIRONMENTAL LAWS AND REGULATIONS THAT REQUIRE
SIGNIFICANT EXPENDITURES FOR COMPLIANCE AND REMEDIATION EFFORTS, AND CHANGES IN
THE LAW COULD INCREASE THOSE EXPENSES AND ADVERSELY AFFECT OUR OPERATIONS.
Compliance with the environmental requirements of international, federal,
state and local governments significantly affects our business. Among other
things, these requirements regulate the discharge of materials into the water,
air and land and govern the use and disposal of hazardous substances. Under
environmental laws, we can be held strictly liable if hazardous substances are
found on real property we have ever owned, operated or used as a disposal site.
In recent years, we have adopted a policy of assessing real property for
environmental risks prior to purchase. We are aware of issues regarding
hazardous substances at some facilities, and we have put into place a remedial
plan at each site where we believe such a plan is necessary. We regularly make
capital and operating expenditures to stay in compliance with environmental
laws. Despite these compliance efforts, risk of environmental liability is part
of the nature of our business. We cannot assure you that environmental
liabilities, including compliance and remediation costs, will not have a
material adverse effect on us in the future. In addition, future events may lead
to additional compliance or other costs that could have a material adverse
effect on our business. Such future events could include changes in, or new
interpretations of, existing laws, regulations or enforcement policies or
further investigation of the potential health hazards of certain products or
business activities.
10
ITEM 2. PROPERTIES
Facilities. The following table sets forth certain information concerning our
facilities. Unless otherwise indicated, we own such facilities.
NUMBER OF
TYPE OF FACILITY FACILITIES LOCATIONS
- ---------------- ---------- ---------
PAPERBOARD
Paperboard Mills (1) 14 Versailles, CT; Austell, GA (Mill #1); Austell, GA
(Mill #2); Austell, GA (Sweetwater); Tama, IA;
Buffalo, NY; Charlotte, NC; Roanoke Rapids, NC;
Cincinnati, OH; Rittman, OH; Reading, PA;
Greenville, SC; Chattanooga, TN; Richmond, VA
Specialty Converting Plants 5 Austell, GA; Charlotte, NC; Fayetteville, NC;
Mooresville, NC; Taylors, SC
Recovered Fiber Collection and Processing 8 Columbus, GA; Dalton, GA; Doraville, GA;
Plants (2) Charlotte,NC; Cleveland, OH; Rittman, OH;
Hardeeville, SC; Texarkana, TX (leased)
TUBE, CORE AND COMPOSITE CONTAINER
Tube and Core Plants 28 Linden, AL; McGehee, AR (leased); Phoenix, AZ
(leased); Cantonment, FL; Palatka, FL; Austell, GA;
Cedar Springs, GA; Dalton, GA; West Monroe, LA;
Mexico City, Mexico (leased); Saginaw, MI; Corinth,
MS; Kernersville, NC; Minerva, OH; Perrysburg, OH;
Lancaster, PA (leased); Rock Hill, SC; Taylors, SC;
Amarillo, TX (leased); Arlington, TX; Silsbee, TX;
Texarkana, TX; Leyland, Lancaster, United Kingdom;
Salt Lake City, UT (leased); Danville, VA;
Franklin, VA; West Point, VA; Weyers Cave, VA
Composite Container Plants 3 Orrville, OH; Saint Paris, OH; Stevens Point, WI
Specialty Converting Plants 4 Austell, GA; Mexico City, Mexico (65% interest);
Lancaster, PA; Arlington, TX
Plastics Plants 3 New Smyrna Beach, FL (leased); Georgetown, KY; Union,
SC (80% interest)
Special Services and Other Facilities 2 Kernersville, NC (leased); Saint Paris, OH
CARTON AND CUSTOM PACKAGING
Carton Plants 16 Birmingham, AL (leased); Denver, CO; Versailles, CT;
Thorndike, MA; Hunt Valley, MD; Archdale, NC;
Burlington, NC; Charlotte, NC; Randleman, NC;
Ashland, OH; Mentor, OH; Grand Rapids, MI; St.
Louis, MO; York, PA; Kingston Springs, TN; Chicago,
IL (leased)
Contract Packaging and Contract 8 Thorndike, MA; Clifton, NJ; Pine Brook, NJ (leased);
Manufacturing Plants Robersonville, NC; Bucyrus, OH; Strasburg, OH
(three facilities)
Special Services 2 Versailles, CT; Cleveland, OH
11
NUMBER OF
TYPE OF FACILITY FACILITIES LOCATIONS
- ---------------- ---------- ---------
JOINT VENTURES
Gypsum Wallboard 2 Cumberland, TN (50% interest); McQueeney, TX (50%
interest)
Tube and Core Plants 2 Scarborough, ON (Canada) (49% interest); Tacoma, WA
(50% interest)
Tube and Core Specialty 1 Tacoma, WA (50% interest)
Converting Facility
Paperboard Mill 1 Newport, IN (50% interest)
- ---------------
(1) All of our paperboard mills produce uncoated recycled paperboard with the
exceptions of our Rittman, OH, Tama, IA and Versailles, CT paperboard mills,
which produce clay-coated boxboard.
(2) Paperstock collection and/or processing also occurs at each of our mill
sites and all of our carton plants and tube and core plants.
ITEM 3. LEGAL PROCEEDINGS
On May 9, 2001, we and Georgia-Pacific Corporation jointly announced a
tentative settlement regarding the litigation over the terms of the long-term
supply contract the parties entered in April 1996. The pending litigation
relating to that contract has been previously reported in our annual report on
Form 10-K for the year ended December 31, 2000 and in our previous quarterly
reports on Form 10-Q. Under the terms of the tentative settlement, we and G-P
Gypsum Corporation, a wholly-owned subsidiary of Georgia-Pacific, entered into a
new ten-year agreement under which we would supply a minimum of 50,000 tons of
gypsum facing paper per year to G-P Gypsum. Implementation of the new agreement,
and settlement of the pending litigation over the 1996 agreement, is subject to
satisfactory completion of a transition period. The transition period initially
was to expire no later than August 6, 2001. As described below, however, the
parties have twice agreed to extend the outside termination date of the
transition period, most recently to April 1, 2002. During the transition period,
we are supplying G-P Gypsum with such facing paper as it requests to enable it
to evaluate the paper's compliance with its specifications for quality and
end-use suitability. Once G-P Gypsum is satisfied with the paper, it is to
notify us that the transition period has ended, and at that time the term of the
new agreement, including the annual minimum quantity requirement described
above, is to commence. If and when the new agreement commences, the parties will
dismiss all pending litigation relating to the 1996 agreement. Under the terms
of the tentative settlement, either party may terminate its obligations under
the new agreement during the transition period without cause and without
liability to the other party.
During the second quarter of 2001, ongoing discussions with G-P Gypsum led
to a mutual agreement to extend the outside expiration date of the transition
period initially to December 31, 2001. The extension was the result of
Georgia-Pacific's recent curtailment of a significant portion of its gypsum
wallboard manufacturing capacity because of adverse market conditions. This
curtailment, along with Georgia-Pacific's stated reservations about committing
to the minimum tonnage requirement under the new agreement in light of current
market conditions, led the parties to agree to the extension of the transition
period. Continued recent discussions, however, have led the parties to agree to
further extend the outside expiration date of the transition period to April 1,
2002.
Although we believe that we are able to satisfy G-P Gypsum's product
requirements, we can give no assurance that the new agreement will be
implemented in accordance with its terms or that the pending litigation will be
dismissed. Specifically, we cannot predict whether Georgia-Pacific's recent
curtailment of gypsum wallboard manufacturing capacity will further affect
whether, when or how a new agreement is implemented, including whether such
curtailment will result in modifications to the ultimate volume requirements
under any new contract that may be implemented. Accordingly, we believe that our
operating results and financial condition will continue to be materially and
adversely affected by the loss of contract volume from Georgia-Pacific unless
and until a new supply agreement is implemented with significant volume
12
requirements, and until a new supply agreement has been effective long enough to
generate a substantial volume of required purchases from Georgia-Pacific.
We are involved in certain other litigation arising in the ordinary course
of business. In the opinion of management, the ultimate resolution of these
matters (other than the litigation described above with Georgia-Pacific) will
not have a material adverse effect on our financial condition or results of
operations.
ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
There were no matters submitted to the Company's security holders during
the fourth fiscal quarter ended December 31, 2001.
13
PART II
ITEM 5. MARKET FOR REGISTRANT'S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS
Since October 1, 1992, our common shares, $.10 par value (the "Common
Shares") have traded on the National Association of Securities Dealers, Inc.
NASDAQ National Market System ("NASDAQ") under the symbol CSAR. As of March 14,
2002, there were approximately 624 shareholders of record and, as of that date,
we estimate that there were approximately 2,500 beneficial owners holding stock
in nominee or "street" name. The table below sets forth quarterly high and low
stock prices and dividends declared during the years 2001 and 2000.
2000 HIGH LOW DIVIDEND
- ---- ------ ------ --------
First Quarter........ $23.50 $12.25 $0.18
Second Quarter....... 19.38 12.75 0.18
Third Quarter........ 17.25 10.31 0.18
Fourth Quarter....... 12.13 7.63 0.18
2001 HIGH LOW DIVIDEND
- ---- ------ ------ --------
First Quarter........ $13.38 $ 6.78 $0.09
Second Quarter....... 11.08 6.35 0.03
Third Quarter........ 10.70 7.51 0.03
Fourth Quarter....... 9.50 6.06 0.03
We paid dividends of $0.18 per share during each quarter of 2000. In
February 2001, we announced that the first quarter dividend was reduced by
one-half to $0.09 per issued and outstanding common share. In June 2001, we
reduced our second, third and fourth quarter dividend from $0.09 to $0.03 per
issued and outstanding common share. As described below under "Subsequent
Events", we have temporarily suspended future payments of quarterly dividends,
beginning in the first quarter of 2002. The decision to reduce the quarterly
dividend was made to preserve our financial flexibility in light of difficult
industry conditions. Although our former debt agreements contained no specific
limitations on the payment of dividends, our new debt agreements, as described
in Item 7 ("Liquidity and Capital Resources"), contain certain limitations on
the payment of future dividends.
On March 29, 2001, we sold $29.0 million aggregate principal amount of
7 1/4% senior notes due 2010 and $285.0 million aggregate principal amount of
9 7/8% senior subordinated notes due 2011 to Credit Suisse First Boston
Corporation, Banc of America Securities LLC, Deutsche Banc Alex. Brown Inc. and
SunTrust Equitable Securities Corporation, as purchasers. Aggregate discounts
and commissions to the purchasers were approximately $7.1 million. These notes
were sold to the purchasers in a transaction not involving a public offering in
reliance on the exemption from registration provided by Section 4(2) of the
Securities Act and Regulation D thereunder.
14
ITEM 6. SELECTED FINANCIAL DATA
YEAR ENDED DECEMBER 31,(A)
------------------------------------------------------
2001 2000 1999 1998 1997
-------- ---------- -------- -------- --------
(IN THOUSANDS, EXCEPT PER SHARE DATA AND RATIOS)
SUMMARY OF OPERATIONS
Sales......................................... $913,686 $1,014,615 $936,928 $774,312 $696,093
Cost of sales................................. 680,172 759,521 683,772 536,890 483,164
-------- ---------- -------- -------- --------
Gross profit.................................. 233,514 255,094 253,156 237,422 212,929
Freight....................................... 52,806 51,184 46,839 37,454 27,955
Selling, general and administrative
expenses.................................... 146,934 145,268 125,784 105,052 88,978
Restructuring and other nonrecurring costs.... 7,083 16,777 -- -- --
-------- ---------- -------- -------- --------
Operating income.............................. 26,691 41,865 80,533 94,916 95,996
Other (expense) income:
Interest expense.............................. (41,153) (34,063) (25,456) (16,072) (14,111)
Interest income............................... 986 412 603 334 312
Equity in (loss) income of unconsolidated
affiliates.................................. (2,610) 6,533 9,224 4,308 1,665
Other, net.................................... (1,904) (918) (459) (433) (674)
-------- ---------- -------- -------- --------
(44,681) (28,036) (16,088) (11,863) (12,808)
-------- ---------- -------- -------- --------
(Loss) income before minority interest, income
taxes and extraordinary items............... (17,990) 13,829 64,445 83,053 83,188
Minority interest............................. 180 (169) (356) (730) (1,721)
Tax (benefit) provision....................... (5,903) 5,485 23,142 30,483 30,468
-------- ---------- -------- -------- --------
(Loss) income from continuing operations
before extraordinary items.................. $(11,907) $ 8,175 $ 40,947 $ 51,840 $ 50,999
-------- ---------- -------- -------- --------
Net (loss) income............................. $(14,602) $ 8,175 $ 40,947 $ 51,840 $ 50,999
-------- ---------- -------- -------- --------
Diluted weighted average shares outstanding... 27,845 26,301 25,199 25,423 25,216
PER SHARE DATA
(Loss) income from continuing operations
before extraordinary items.................. (0.42) 0.31 1.62 2.04 2.02
Net (loss) income............................. (0.52) 0.31 1.62 2.04 2.02
Cash dividends declared....................... 0.18 0.72 0.72 0.66 0.58
Market price on December 31................... $ 6.93 $ 9.38 $ 24.00 $ 28.56 $ 34.25
Shares outstanding December 31................ 27,854 26,205 25,488 24,681 25,331
Price/Earnings ratio.......................... N/A 30.16 14.77 14.00 16.93
TOTAL MARKET VALUE OF COMMON STOCK............ $193,028 $ 245,672 $611,712 $704,889 $867,587
BALANCE SHEET DATA
Cash and cash equivalents..................... $ 64,244 $ 8,900 $ 18,771 $ 2,610 $ 1,391
Property, plant and equipment, net............ 450,376 483,309 479,856 324,470 291,036
Depreciation and amortization................. 63,323 60,858 52,741 38,705 33,661
Capital expenditures.......................... 28,059 58,306 35,696 40,716 36,275
Total assets.................................. 960,981 934,097 879,880 620,156 551,414
Current maturities of long-term debt.......... 48 1,259 16,615 26,103 9
Revolving credit loans........................ -- 194,000 140,000 147,000 129,000
Long-term debt, less current maturities....... 508,691 272,813 269,739 82,881 83,129
Shareholders' equity.......................... 279,579 279,808 279,184 234,221 214,756
Total capital................................. $788,318 $ 747,880 $705,538 $490,205 $426,894
OTHER KEY FINANCIAL MEASURES
Total debt-to-total capital................... 64.5% 62.6% 60.4% 52.2% 49.7%
Net debt-to-net capital....................... 61.4% 62.1% 59.3% 52.0% 49.5%
Effective tax rate............................ -33.1% 40.2% 36.1% 36.7% 37.4%
Return on shareholders' equity(B)............. N/A 6.7% 16.0% 23.1% 26.4%
Return on average capital(B).................. N/A 5.4% 9.6% 13.5% 15.3%
Dividend payout ratio......................... N/A 231.6% 44.3% 32.4% 28.7%
- ---------------
(A) Restated to reflect the change in inventory costing method of accounting
from LIFO to FIFO at one of the Company's subsidiaries. See Note 1 in the
accompanying financial statements for additional information.
(B) Excludes restructuring and other nonrecurring costs.
15
ITEM 7. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS
OF OPERATIONS
GENERAL
We are a major manufacturer of recycled paperboard and converted paperboard
products. We operate in three business segments. The paperboard segment
manufactures 100% recycled uncoated and clay-coated paperboard and collects
recycled paper and brokers recycled paper and other paper rolls. The tube, core
and composite container segment produces spiral and convolute-wound tubes, cores
and cans. The carton and custom packaging segment produces printed and unprinted
folding and set-up cartons and provides contract manufacturing and packaging
services.
Our business is vertically integrated to a large extent. This means that
our converting operations consume a large portion of our own paperboard
production, approximately 38% in 2001. The remaining 62% of our paperboard
production is sold to external customers in any of the four recycled paperboard
end-use markets: tube, core and composite containers; folding cartons; gypsum
wallboard facing paper and other specialty products. We are the only major
manufacturer to serve all four end-use markets. As part of our strategy to
maintain optimum levels of production capacity, we regularly purchase paperboard
from other manufacturers in an effort to minimize the potential impact of demand
declines on our own mill system. Additionally, each of our mills can produce
recycled paperboard for more than one end-use market. This allows us to shift
production between mills in response to customer or market demands.
Recovered fiber, which is derived from recycled paper stock, is our most
significant raw material. Historically, the cost of recovered fiber has
fluctuated significantly due to market and industry conditions. For example, our
average recovered fiber cost per ton of paperboard produced increased from $43
per ton in 1993 to $144 per ton in 1995, an increase of 235%, before dropping to
$66 per ton in 1996. Same-mill recovered fiber cost per ton averaged $65 and
$104 during 2001 and 2000, respectively.
We raise our selling prices in response to increases in raw material costs.
However, we often are unable to pass the full amount of these costs through to
our customers on a timely basis, and as a result often cannot maintain our
operating margins in the face of dramatic cost increases. We experience margin
shrinkage during all periods of price increases due to customary time lags in
implementing our price increases. We cannot assure you that we will be able to
recover any future increases in the cost of recovered fiber by raising the
prices of our products. Even if we are able to recover future cost increases,
our operating margins and results of operations may still be materially and
adversely affected by time delays in the implementation of price increases.
Excluding labor, energy is our most significant manufacturing cost. Energy
is used to generate steam used in the paper making process and to operate our
paperboard machines and all of our other converting machinery. Our energy costs
increased steadily throughout 2000 and the first quarter of 2001 before showing
some improvement by the end of 2001. In 2000, the average energy cost in our
mill system was approximately $52 per ton. In 2001, energy costs increased 9.6%
to approximately $57 per ton. The increase was due primarily to increases in
natural gas and fuel oil costs. Until recently, our business had not been
significantly affected by energy costs, and we historically have not passed
increases in energy costs through to our customers. Consequently, we were not
able to pass through to our customers all of the energy cost increases we
incurred in 2000 and 2001. As a result, our operating margins were adversely
affected. We continue to evaluate our energy costs and consider ways to factor
energy costs into our pricing. However, we cannot assure you that our operating
margins and results of operations will not continue to be adversely affected by
rising energy costs.
Historically, we have grown our business, revenues and production capacity
to a significant degree through acquisitions. Based on the difficult operating
climate for our industry and our financial position, the pace of our acquisition
activity, and accordingly, our revenue growth, has slowed as we have focused on
conserving cash and maximizing the productivity of our existing facilities. We
made no acquisitions in 2001.
We are a holding company that currently operates our business through 19
subsidiaries. We also own a 50% interest in two joint ventures with
Temple-Inland, Inc. We have an additional joint venture with an
16
unrelated entity of which our investment and share of earnings of this venture
is immaterial. We account for these interests in our joint ventures under the
equity method of accounting.
CRITICAL ACCOUNTING POLICIES
Our accompanying consolidated financial statements have been prepared in
conformity with accounting principles generally accepted in the United States of
America, which require management to make estimates that affect the amounts of
revenues, expenses, assets and liabilities reported. The following are critical
accounting matters which are both very important to the portrayal of our
financial condition and results and which require some of management's most
difficult, subjective and complex judgments. The accounting for these matters
involves the making of estimates based on current facts, circumstances and
assumptions which, in management's judgment, could change in a manner that would
materially affect management's future estimates with respect to such matters
and, accordingly, could cause future reported financial condition and results to
differ materially from financial results reported based on management's current
estimates.
Revenue Recognition. We recognize revenue in accordance with SEC Staff
Accounting Bulletin No. 101, "Revenue Recognition in Financial Statements,"
("SAB 101"). SAB 101 requires that four basic criteria must be met before
revenue can be recognized: (1) persuasive evidence of an arrangement exists; (2)
delivery has occurred; (3) the selling price is fixed and determinable; and (4)
collectibility is reasonably assured. Determination of criteria (4) is based on
management's judgments regarding the collectibility of our accounts receivable.
Accounts Receivable. We perform ongoing credit evaluations of our
customers and adjust credit limits based upon payment history and the customer's
current credit worthiness, as determined by our review of their current credit
information. We continuously monitor collections from our customers and maintain
a provision for estimated credit losses based upon our historical experience and
any specific customer collection issues that we have identified. While such
credit losses have historically been within our expectations and the provisions
established, we cannot guarantee that we will continue to experience the same
credit loss rates that we have in the past.
Inventory. Inventories are carried at the lower of cost or market. Cost
includes materials, labor and overhead. Market, with respect to all inventories,
is replacement cost or net realizable value. Management frequently reviews
inventory to determine the necessity of reserves for excess, obsolete or
unsaleable inventory. These reviews require management to assess customer and
market demand. These estimates may prove to be inaccurate, in which case we may
have over or under stated the reserve required for excess, obsolete or
unsaleable inventory.
Impairment of Goodwill. We periodically evaluate acquired businesses for
potential impairment indicators. Our judgments regarding the existence of
impairment indicators are based on legal factors, market conditions and
operational performance of our acquired businesses. Future events could cause us
to conclude that impairment indicators exist and that goodwill associated with
our acquired businesses is impaired. Evaluating the impairment of goodwill also
requires us to estimate future operating results and cash flows which also
require judgment by management. Any resulting impairment loss could have a
material adverse impact on our financial condition and results of operations.
Self-Insurance. We are self-insured for the majority of our workers'
compensation costs and group health insurance costs, subject to specific
retention levels. Consulting actuaries and administrators assist us in
determining our liability for self-insured claims. While we believe that our
assumptions are appropriate, significant differences in our actual experience or
significant changes in our assumptions may materially affect our workers'
compensation costs and group health insurance costs.
Accounting for Income Taxes. As part of the process of preparing our
consolidated financial statements we are required to estimate our income taxes
in each of the jurisdictions in which we operate. This process involves us
estimating our actual current tax exposure together with assessing temporary
differences resulting from differing treatment of items for tax and accounting
purposes. These differences result in deferred tax assets and liabilities, which
are included within our consolidated balance sheet. We must then assess the
17
likelihood that our deferred tax assets will be recovered from future taxable
income and to the extent we believe that recovery is not likely, we must
establish a valuation allowance. To the extent we establish a valuation
allowance or increase this allowance in a period, we must include an expense
within the tax provision in the statement of operations.
Significant management judgment is required in determining our provision
for income taxes, our deferred tax assets and liabilities and any valuation
allowance recorded against our deferred tax assets. We record valuation
allowances due to uncertainties related to our ability to utilize some of our
deferred tax assets, primarily consisting of certain state net operating losses
carried forward and state tax credits, before they expire. The valuation
allowance is based on our estimates of taxable income by jurisdiction in which
we operate and the period over which our deferred tax assets will be
recoverable. In the event that actual results differ from these estimates or we
adjust these estimates in future periods we may need to establish an additional
valuation allowance which could materially impact our financial position and
results of operations.
Pension and Other Postretirement Benefits. The determination of our
obligation and expense for pension and other postretirement benefits is
dependent on our selection of certain assumptions used by actuaries in
calculating such amounts. Those assumptions are described in Note 8 to the
consolidated financial statements and include, among others, the discount rate,
expected long-term rate of return on plan assets and rates of increase in
compensation and healthcare costs. In accordance with generally accepted
accounting principles, actual results that differ from our assumptions are
accumulated and amortized over future periods and therefore, generally affect
our recognized expense, recorded obligation and funding requirements in future
periods. While we believe that our assumptions are appropriate, significant
differences in our actual experience or significant changes in our assumptions
may materially affect our pension and other postretirement benefit obligations
and our future expense.
RESULTS OF OPERATIONS 2001 -- 2000
The following table shows volume, gross paper margins and related data for
the periods indicated. The volume information shown below includes shipments of
unconverted paperboard and converted paperboard products. Tonnage volumes from
our business segments, excluding tonnage produced or converted by our
unconsolidated joint ventures, are combined and presented along end-use market
lines. Additional financial information is reported by segment in Note 11 of the
consolidated financial statements.
YEARS ENDED
DECEMBER 31,
------------------- %
2000 2001 CHANGE CHANGE
-------- -------- ------- ------
Production source of paperboard tons sold (in thousands):
From paperboard mill production........................ 999.1 892.4 (106.7) -10.7%
Outside purchases...................................... 122.4 123.1 0.7 0.6%
-------- -------- ------- ------
Total paperboard tonnage....................... 1,121.5 1,015.5 (106.0) -9.5%
======== ======== ======= ======
Tons sold by market (in thousands):
Tube, core and composite container volume
Paperboard (internal)............................... 202.9 187.6 (15.3) -7.5%
Outside purchases................................... 25.9 25.9 -- 0.0%
-------- -------- ------- ------
Tube, core and composite container converted
products............................................ 228.8 213.5 (15.3) -6.7%
Unconverted paperboard................................. 37.6 32.7 (4.9) -13.0%
-------- -------- ------- ------
Tube, core and composite container volume...... 266.4 246.2 (20.2) -7.6%
18
YEARS ENDED
DECEMBER 31,
------------------- %
2000 2001 CHANGE CHANGE
-------- -------- ------- ------
Folding carton volume
Paperboard (internal)............................... 67.9 85.2 17.3 25.5%
Outside purchases................................... 86.8 92.2 5.4 6.2%
-------- -------- ------- ------
Folding carton converted products...................... 154.7 177.4 22.7 14.7%
Unconverted paperboard................................. 270.2 232.4 (37.8) -14.0%
-------- -------- ------- ------
Folding carton volume.......................... 424.9 409.8 (15.1) -3.6%
Gypsum wallboard facing paper volume
Unconverted paperboard.............................. 196.1 151.5 (44.6) -22.7%
Outside purchases (for resale)...................... 0.5 -- (0.5) -100.0%
-------- -------- ------- ------
Gypsum wallboard facing paper volume........... 196.6 151.5 (45.1) -22.9%
Other specialty products volume
Paperboard (internal)............................... 108.7 68.0 (40.7) -37.4%
Outside purchases................................... 9.2 5.0 (4.2) -45.7%
-------- -------- ------- ------
Other specialty converted products..................... 117.9 73.0 (44.9) -38.1%
Unconverted paperboard................................. 115.7 135.0 19.3 16.7%
-------- -------- ------- ------
Other specialty products volume................ 233.6 208.0 (25.6) -11.0%
-------- -------- ------- ------
Total paperboard tonnage....................... 1,121.5 1,015.5 (106.0) -9.5%
======== ======== ======= ======
Gross paper margins ($/ton):
Paperboard mill:
Average same-mill net selling price................. $ 445 $ 413 $ (32) -7.2%
Average same-mill recovered fiber cost.............. 104 65 (39) -37.5%
-------- -------- ------- ------
Paperboard mill gross paper margin............. $ 341 $ 348 $ 7 2.1%
======== ======== ======= ======
Tube and core:
Average net selling price........................... $ 786 $ 783 $ (3) -0.4%
Average paperboard cost............................. 441 447 6 1.4%
-------- -------- ------- ------
Tube and core gross paper margin............... $ 345 $ 336 $ (9) -2.6%
======== ======== ======= ======
Sales. Our consolidated sales for the year ended December 31, 2001 decreased
9.9% to $913.7 million from $1,014.6 million in 2000. Acquisitions completed
during 2000 accounted for $33.7 million of sales during 2001. These acquisitions
included MilPak, Inc., Arrow Paper Products Company and Crane Carton Company,
LLC. These acquisitions were accounted for using the purchase method of
accounting, and their results of operations were included only from and after
the date of the acquisition. Excluding acquisitions completed during 2000, sales
decreased 13.3% during 2001. This decrease was due to lower selling prices and
volume from the paperboard and the tube, core and composite container segments,
partially attributable to the dispute with Georgia-Pacific (see "Georgia-Pacific
Litigation" below), along with lower selling prices from the carton and custom
packaging segment due to competitive pressures. The decline in volume from the
tube, core and composite container segment was primarily attributable to the
downturn in the textile industry.
Total paperboard tonnage for 2001 decreased 9.5% to 1,015.5 thousand tons
from 1,121.5 thousand tons in 2000. Excluding acquisitions completed during
2000, total paperboard tonnage declined 11.3% to 994.3 thousand tons. This
decrease was primarily due to lower shipments of unconverted paperboard to
external customers combined with lower internal conversion by our converting
operations in the other specialty products and the tube, core and composite
container markets. The decrease in shipments of unconverted paperboard was due
primarily to a decline in industry demand and partially attributable to the
dispute with Georgia-Pacific. Excluding 2000 acquisitions, outside purchases
decreased 16.5% to 101.9 thousand tons. Tons sold from paperboard mill
production decreased 10.7% for 2001 to 892.4 thousand tons, compared with 999.1
thousand tons for 2000. Total tonnage converted decreased 7.5% for 2001 to 463.9
thousand tons compared to 501.4 thousand tons in 2000, and decreased 12.2% from
2000, excluding acquisitions. Excluding
19
acquisitions completed during 2000, volumes in the folding carton and tube, core
and composite container end-use markets decreased 8.3% and 7.8%, respectively.
Gross Margin. Gross margin for 2001 increased to 25.6% of sales from 25.1% in
2000. Excluding the $7.1 million reduction in reserves related to expiring
unfavorable supply contracts at the Sprague paperboard mill, gross margin was
24.8% for 2001. This margin decrease was due primarily to lower margins in the
carton and custom packaging and tube, core and composite container segments,
partially offset by improved margins in the paperboard segment. Margins
decreased in the carton and custom packaging segment due to lower selling prices
resulting from competitive pressures. Margins in the tube, core and composite
container segment decreased as a result of lower selling prices, higher
paperboard costs and a decline in the textile industry. The improved margins in
the paperboard segment were the result of cost-cutting efforts to reduce
expenses combined with the substantial decline in fiber costs, which were
partially offset by the decline in selling prices and the increase in energy
costs.
Restructuring and Other Nonrecurring Costs. In January 2001, we initiated a
plan to close our paperboard mill located in Chicago, Illinois and recorded a
pretax charge to operations of approximately $4.4 million. The mill was
profitable through 1998, but declining sales resulted in losses of approximately
$2.6 million and $1.5 million in 1999 and 2000, respectively. We expect the
proceeds from the sale of the real estate to more than offset the pretax charge.
The $4.4 million charge included a $2.2 million noncash asset impairment write
down of fixed assets to estimated net realizable value, a $1.2 million accrual
for severance and termination benefits for 16 salaried and 59 hourly employees
terminated in connection with this plan and a $989 thousand accrual for other
exit costs. During 2001, we paid $1.2 million in severance and termination
benefits and $597 thousand in other exit costs. The remaining other exit costs
will be paid by December 31, 2002. As of December 31, 2001, one employee
remained to assist in the closing of the mill. We are marketing the property and
will complete the exit plan upon the sale of the property, which we anticipate
will occur prior to December 31, 2002.
In March 2001, we initiated a plan to consolidate the operations of our
Salt Lake City, Utah carton plant into our Denver, Colorado carton plant and
recorded a pretax charge to operations of approximately $2.6 million. The $2.6
million charge included a $1.8 million noncash asset impairment write down of
fixed assets to estimated net realizable value, a $464 thousand accrual for
severance and termination benefits for 5 salaried and 31 hourly employees
terminated in connection with this plan and a $422 thousand accrual for other
exit costs. All exit costs were paid as of December 31, 2001. As of December 31,
2001, no employees remained at the plant.
In February 2000, we initiated a plan to close our paperboard mill located
in Baltimore, Maryland and recorded a pretax charge to operations of
approximately $6.9 million. We adopted the plan to close the mill in conjunction
with our ongoing efforts to increase manufacturing efficiency and reduce costs
in our mill system. The $6.9 million charge included a $5.7 million noncash
asset impairment charge to write-down machinery and equipment to estimated net
realizable value. The charge also included a $604 thousand accrual for severance
and termination benefits for 21 salaried and 83 hourly employees terminated in
connection with this plan and a $613 thousand accrual for other exit costs. All
exit costs were paid by December 31, 2000. As of December 31, 2001, one employee
remained to assist in marketing the land and building. We will complete the exit
plan upon the sale of the property, which we anticipate will occur prior to
December 31, 2002. The mill closure did not have a material impact on our
operations.
In September 2000, we initiated a plan to close our paperboard mill located
in Camden, New Jersey and recorded a pretax charge to operations of
approximately $8.6 million. The mill experienced a slowdown in gypsum facing
paper shipments during the third quarter of 2000, and the shutdown was
precipitated by the refusal of Georgia-Pacific, formerly our largest gypsum
facing paper customer, to continue purchasing facing paper under a long-term
supply agreement. The $8.6 million charge included a $7.0 million noncash asset
impairment write-down of fixed assets to estimated net realizable value, a $558
thousand accrual for severance and termination benefits for 19 salaried and 46
hourly employees terminated in connection with this plan, and a $968 thousand
accrual for other exit costs. During 2001 and 2000, we paid $178 thousand and
$380 thousand, respectively, in severance and termination benefits and $548
thousand and $346 thousand,
20
respectively, in other exit costs. The remaining other exit costs will be paid
by June 30, 2002. As of December 31, 2001, no employees remained at the mill. We
are marketing the property and will complete the exit plan upon the sale of the
property, which we anticipate will occur prior to December 31, 2002. This mill
contributed sales and operating income of $12.4 million and $1.2 million,
respectively, for the nine months ended September 30, 2000 and $20.5 million and
$2.1 million, respectively, for the year ended December 31, 1999.
In December 2000, we recognized a nonrecurring cost of $1.3 million related
to the settlement of a dispute over abandoned property.
Operating Income. Operating income for 2001 was $26.7 million, a decrease of
$15.2 million, or 36.2% from 2000. Operating income excluding the Sprague
reserve reduction, restructuring charges and 2000 acquisitions was $25.1 million
for 2001, a decrease of $33.6 million, or 57.2%, from operating income of $58.6
million in 2000, excluding restructuring charges and other nonrecurring costs.
This decline was due primarily to lower volume in the tube, core and composite
container and paperboard segments, partially attributable to the dispute with
Georgia-Pacific, and lower margins in the carton and custom packaging and tube,
core and composite container segments. Selling, general and administrative
expenses increased by $1.7 million, or 1.1%, in 2001 compared to 2000, but
decreased $2.5 million, or 1.7%, excluding acquisitions. This decrease was
primarily due to mill closures in the paperboard segment.
Other Income (Expense). Interest expense increased 20.8% to $41.2 million for
2001 from $34.1 million in 2000. This increase was due to higher outstanding
debt balances at higher interest rates, partially offset by savings from
interest rate swap agreements which effectively converted portions of our fixed
rate notes into variable rate obligations. See "Liquidity and Capital Resources"
for additional information regarding our debt, interest expense and interest
rate swap agreements.
Equity in loss from unconsolidated affiliates was $2.6 million in 2001,
down $9.1 million from equity in income of $6.5 million in 2000. This decrease
was primarily due to lower operating results for Standard Gypsum, L.P., our
gypsum wallboard joint venture with Temple-Inland. The lower results were due
primarily to significantly lower selling prices in 2001 compared to 2000 due to
excess capacity in that market.
Net Income (Loss). As discussed above, our results for 2001 included
restructuring charges recorded in conjunction with the closing of our Chicago,
Illinois paperboard mill and the consolidation of operations of our Salt Lake
City, Utah carton plant into our Denver, Colorado carton plant. These charges
were $7.1 million in the aggregate ($4.4 million, net of tax benefit, or $0.16
per common share on a diluted basis). Also included in the results for 2001 was
an extraordinary loss of $4.3 million related to the early extinguishment of
debt ($2.7 million, net of tax benefit, or $0.10 per common share on a diluted
basis). Partially offsetting these charges was the $7.1 million reduction in
reserves related to expiring unfavorable supply contracts at the Sprague
paperboard mill ($4.5 million, net of tax provision, or $0.16 per common share
on a diluted basis). Excluding the extraordinary loss, restructuring charges and
the Sprague reserve reduction, net loss in 2001 was $11.9 million, or $0.43 net
loss per common share on a diluted basis, compared to net income before
restructuring charges and other nonrecurring costs of $18.7 million, or $0.71
net income per common share on a diluted basis, in 2000. Including the
extraordinary loss, restructuring charges, other nonrecurring costs and the
Sprague reserve reduction, net loss was $14.6 million in 2001, or $0.52 net loss
per common share on a diluted basis, compared with net income of $8.2 million,
or $0.31 net income per common share on a diluted basis, in 2000.
Events of September 11, 2001. The horrific terrorist attacks against the United
States and their aftermath did not, during 2001, and are not currently expected
to, have a direct material effect on our operations. However, to the extent that
those events, other terrorist activities, the U.S. military response and the
resulting uncertainties have adversely affected, or will continue to adversely
affect, the United States economy in general, sectors on which we depend in
particular, and the U.S. capital markets, our results of operations, financial
condition and stock price have been, and could continue to be, adversely
affected.
21
RESULTS OF OPERATIONS 2000 -- 1999
The following tables show volume, gross paper margins and related data for
the periods indicated. The volume information shown below includes shipments of
unconverted paperboard and converted paperboard products. Tonnage volumes from
our business segments, excluding tonnage produced or converted by our
unconsolidated joint ventures, are combined and presented along end-use market
lines. Additional financial information is reported by segment in Note 11 of the
consolidated financial statements.
YEARS ENDED
DECEMBER 31,
------------------- %
1999 2000 CHANGE CHANGE
-------- -------- ------ ------
Production source of paperboard tons sold (in thousands):
From paperboard mill production.......................... 1,064.9 999.1 (65.8) -6.2%
Outside purchases........................................ 90.6 122.4 31.8 35.1%
-------- -------- ------ -----
Total paperboard tonnage......................... 1,155.5 1,121.5 (34.0) -2.9%
======== ======== ====== =====
Tons sold by market (in thousands):
Tube, core and composite container volume
Paperboard (internal)................................. 203.2 202.9 (0.3) -0.1%
Outside purchases..................................... 18.9 25.9 7.0 37.0%
-------- -------- ------ -----
Tube, core and composite container converted products.... 222.1 228.8 6.7 3.0%
Unconverted paperboard................................... 41.6 37.6 (4.0) -9.6%
-------- -------- ------ -----
Tube, core and composite container volume........ 263.7 266.4 2.7 1.0%
Folding carton volume
Paperboard (internal)................................. 65.2 67.9 2.7 4.1%
Outside purchases..................................... 58.3 86.8 28.5 48.9%
-------- -------- ------ -----
Folding carton converted products........................ 123.5 154.7 31.2 25.3%
Unconverted paperboard................................... 286.4 270.2 (16.2) -5.7%
-------- -------- ------ -----
Folding carton volume............................ 409.9 424.9 15.0 3.7%
Gypsum wallboard facing paper volume
Unconverted paperboard................................ 265.8 196.1 (69.7) -26.2%
Outside purchases (for resale)........................ 4.5 0.5 (4.0) -88.9%
-------- -------- ------ -----
Gypsum wallboard facing paper volume............. 270.3 196.6 (73.7) -27.3%
Other specialty products volume
Paperboard (internal)................................. 91.6 108.7 17.1 18.7%
Outside purchases..................................... 8.9 9.2 0.3 3.4%
-------- -------- ------ -----
Other specialty converted products....................... 100.5 117.9 17.4 17.3%
Unconverted paperboard................................... 111.1 115.7 4.6 4.1%
-------- -------- ------ -----
Other specialty products volume.................. 211.6 233.6 22.0 10.4%
-------- -------- ------ -----
Total paperboard tonnage......................... 1,155.5 1,121.5 (34.0) -2.9%
======== ======== ====== =====
Gross paper margins ($/ton):
Paperboard mill:
Average same-mill net selling price................... $ 413 $ 441 $ 28 6.8%
Average same-mill recovered fiber cost................ 84 101 17 20.2%
-------- -------- ------ -----
Paperboard mill gross paper margin............... $ 329 $ 340 $ 11 3.3%
======== ======== ====== =====
Tube and core:
Average net selling price............................. $ 730 $ 786 $ 56 7.7%
Average paperboard cost............................... 390 441 51 13.1%
-------- -------- ------ -----
Tube and core gross paper margin................. $ 340 $ 345 $ 5 1.5%
======== ======== ====== =====
Sales. Our consolidated sales for the year ended December 31, 2000 increased
8.3% to $1,014.6 million from $936.9 million in 1999. Acquisitions completed
during 1999 and 2000 accounted for $104.9 million of sales during 2000. These
acquisitions included MilPak, Inc., Arrow Paper Products Company and Crane
Carton Company, LLC, all of which were completed in 2000. The acquisitions of
Carolina Component Concepts,
22
Inc., International Paper Company's Sprague boxboard mill, Halifax Paperboard
Co., Inc., Tenneco Packaging, Inc.'s folding carton division and Carolina
Converting, Inc. were completed in 1999. These acquisitions were accounted for
using the purchase method of accounting, and their results of operations were
included only from and after the date of the acquisition. Excluding acquisitions
completed during 1999 and 2000, sales decreased 2.9% during 2000. This decrease
was due to lower volume and sales from the paperboard segment, partially
attributable to the dispute with Georgia-Pacific, and lower sales from the
carton and custom packaging segment, partially offset by higher sales from the
tube, core and composite container segment.
Total paperboard tonnage for 2000 decreased 2.9% to 1,121.5 thousand tons
from 1,155.5 thousand tons in 1999. Excluding acquisitions completed during 1999
and 2000, total paperboard tonnage declined 8.6% to 1,056.0 thousand tons. This
decrease was primarily due to lower shipments of unconverted paperboard to
external customers in the gypsum wallboard facing paper and folding carton
markets. This decrease in shipments to gypsum wallboard facing paper customers
was partially attributable to the dispute with Georgia-Pacific. Excluding
acquisitions, outside purchases increased 10.3% to 99.9 thousand tons. Tons sold
from paperboard mill production decreased 6.2% for 2000 to 999.1 thousand tons,
compared with 1,064.9 thousand tons for 1999, and decreased 10.4% excluding
acquisitions. Total tonnage converted increased 12.5% for 2000 to 501.4 thousand
tons compared to 445.8 thousand tons in 1999, and increased 1.2% over 1999,
excluding acquisitions. Excluding acquisitions completed during 1999 and 2000,
volumes in the folding carton and other specialty end-use markets decreased 9.3%
and increased 4.9%, respectively.
Gross Margin. Gross margin for 2000 decreased to 25.1% of sales from 27.0% in
1999. This margin decrease was due primarily to lower volume and higher energy
costs in the paperboard segment, combined with lower margins in the carton and
custom packaging and tube, core and composite container segments. Margins
decreased in the carton and custom packaging segment due to lower selling prices
resulting from competitive pressures. Margins in the tube, core and composite
container segment decreased as a result of higher raw material costs and soft
volume in the plastic core and composite container businesses.
Restructuring and Other Nonrecurring Costs. In February 2000, we initiated a
plan to close our paperboard mill located in Baltimore, Maryland and recorded a
pretax charge to operations of approximately $6.9 million. We adopted the plan
to close the mill in conjunction with our ongoing efforts to increase
manufacturing efficiency and reduce costs in our mill system. The $6.9 million
charge included a $5.7 million noncash asset impairment charge to write-down
machinery and equipment to net realizable value. The charge also included a $604
thousand accrual for severance and termination benefits for 21 salaried and 83
hourly employees terminated in connection with this plan and a $613 thousand
accrual for other exit costs. All exit costs were paid by December 31, 2000. As
of December 31, 2000, one employee remained to assist in marketing the land and
building. We will complete the exit plan upon the sale of the property, which we
anticipate will occur prior to December 31, 2002. The mill closure did not have
a material impact on our operations.
In September 2000, we initiated a plan to close our paperboard mill located
in Camden, New Jersey and recorded a pretax charge to operations of
approximately $8.6 million. The mill closing was the result of a slowdown in
gypsum facing paper shipments during the third quarter of 2000 and a contract
dispute with Georgia-Pacific. The $8.6 million charge included a $7.0 million
noncash asset impairment write-down of fixed assets to net realizable value, a
$558 thousand accrual for severance and termination benefits for 19 salaried and
46 hourly employees terminated in connection with this plan, and a $968 thousand
accrual for other exit costs. During 2000, we paid $380 thousand in severance
and termination benefits and $346 thousand in other exit costs. As of December
31, 2000, two employees remained to collect receivables, process payables and
assist in marketing the land and building. We are marketing the land and
building and will complete the exit plan upon the sale of the property, which we
anticipate will occur prior to December 31, 2002. This mill contributed sales of
$12.4 million and operating income of $1.2 million for the nine months ended
September 30, 2000. It contributed sales of $20.5 million and operating income
of $2.1 million for the year ended December 31, 1999.
In December 2000, we recognized a nonrecurring cost of $1.3 million related
to the settlement of a dispute over abandoned property.
23
Operating Income. Operating income for 2000 was $41.9 million, a decrease of
$38.7 million, or 48.0%, from 1999. Operating income for comparable facilities,
excluding restructuring and other nonrecurring costs, declined $23.1 million, or
28.6%. This decline was due primarily to lower volume and higher energy costs in
the paperboard segment, combined with lower margins in the carton and custom
packaging and tube, core and composite container segments. Selling, general and
administrative expenses increased by $19.5 million, or 15.5%, in 2000 compared
to 1999. Acquisitions accounted for approximately $12.5 million of the increase
and information technology costs accounted for approximately $3.2 million of the
increase.
Other Income (Expense). Interest expense increased 33.8% to $34.1 million for
2000 from $25.5 million in 1999 due to higher average borrowings under our
senior credit facility and the effect of a full year of interest expense
attributable to our $200.0 million public debt securities offering in June 1999.
Equity in income from unconsolidated affiliates was $6.5 million, down $2.7
million, or 29.2%, from 1999 primarily due to lower operating results for
Standard Gypsum, L.P., our gypsum wallboard joint venture with Temple-Inland,
Inc. and start-up costs at Premier Boxboard Limited LLC, our containerboard mill
joint venture with Temple-Inland.
Net Income. As discussed above, our results for 2000 included restructuring and
nonrecurring charges recorded in conjunction with the closings of our Baltimore,
Maryland and Camden, New Jersey paperboard mills and a nonrecurring charge
related to the settlement of a dispute over abandoned property, which were $16.8
million in the aggregate ($10.5 million, net of tax benefit, or $0.40 per common
share on a diluted basis). Excluding these charges, net income was $18.7
million, or $0.71 per common shares on a diluted basis. Including the
restructuring and other nonrecurring costs, net income decreased 80.0% to $8.2
million from $40.9 million in 1999. Diluted net income per common share,
including the restructuring and other nonrecurring costs, decreased 81.0% to
$0.31 for 2000 from $1.62 in 1999.
LIQUIDITY AND CAPITAL RESOURCES
Liquidity Sources and Risks. Our primary sources of liquidity are cash from
operations and borrowings under the various debt facilities described below.
Downturns in operations can significantly affect our ability to generate cash.
For example, in the difficult operating climate we experienced in 2001, we
generated $25.5 million less cash from operations than we did in 2000. Factors
that can affect our operating results are discussed further in this Report under
"Risk Factors" in Part I, Item 1. However, despite the lower operating cash flow
in 2001, we managed to improve our 2001 year-end cash position by $55.3 million
over 2000 due primarily to conservative cash management. We also believe that
our existing cash and liquidity position will be further strengthened through
the sale of the real estate at our Baltimore, Maryland, Camden, New Jersey and
Chicago, Illinois paperboard mills, which we anticipate will occur in 2002.
Additionally, we expect to receive a federal tax refund of approximately $16.0
million in the first half of 2002. If, however, we were to face unexpected
liquidity needs, we could require additional funds from external sources such as
our senior credit facility.
The availability of liquidity from borrowings is primarily affected by our
continued compliance with the terms of the debt agreements governing these
facilities, including the payment of interest and compliance with various
covenants and financial maintenance tests. In addition, as described below under
"-- Joint Venture Financings," to the extent we are unable to comply with
financial maintenance tests under our senior credit facility, we will fail to
comply with identical financial maintenance covenant tests under our guarantees
of the credit facilities of our joint ventures, which could potentially
materially and adversely affect us through a series of cross-defaults under both
our joint ventures' and our own obligations if we were unable to obtain
appropriate waivers or amendments with respect to the underlying violations and
any related cross-defaults.
At December 31, 2000 and December 31, 2001, we were not in compliance with
the leverage ratio and interest coverage ratio, respectively, under both our
senior credit facility and our joint venture guarantees, but in each case were
able to obtain appropriate amendments and waivers with respect to each instance
of non-compliance (and with respect to any technical cross-default). Absent
further material deterioration of the U.S. economy as a whole or the specific
sectors on which our business depends (see Part I, Item 1, "Risk Factors -- Our
business and financial performance may be adversely affected by downturns in
industrial
24
production, housing and construction and the consumption of durable and
nondurable goods"), we believe it is unlikely that we will breach our covenants
under our debt agreements or joint venture guarantees during 2002. We also
believe that in the event of such a breach due to a further deterioration in
economic or industry conditions, our lenders would provide us with the necessary
waivers and amendments. However, we cannot assure you that we will achieve our
expected future operating results or continued compliance with our debt
covenants, or that, in such event, necessary waivers and amendments would be
available at all or on acceptable terms. If our debt or that of our joint
ventures were placed in default, or if we were called upon to satisfy our joint
venture guarantees, our liquidity and financial condition would be materially
and adversely affected.
Borrowings. At December 31, 2001 and 2000, total debt (consisting of current
maturities of debt, senior credit facility, and other long-term debt, as
reported on our consolidated balance sheets) was as follows (in thousands):
2001 2000
-------- --------
Senior credit facility...................................... $ -- $194,000
9 7/8% senior subordinated notes............................ 277,326 --
7 1/4% senior notes......................................... 25,449 --
7 3/8% senior notes......................................... 197,716 198,791
7.74% senior notes.......................................... -- 66,200
Other notes payable......................................... 8,248 9,081
-------- --------
Total debt.................................................. $508,739 $468,072
======== ========
On March 29, 2001, we completed a series of financing transactions pursuant
to which we (i) issued $29.0 million in aggregate principal amount of 7 1/4%
senior notes due May 1, 2010 and $285.0 million in aggregate principal amount of
9 7/8% senior subordinated notes due April 1, 2011, (ii) used the proceeds from
these notes to repay in full our former senior credit facility and 7.74% senior
notes, and (iii) obtained a new $75.0 million senior credit facility. The 7 1/4%
senior notes and 9 7/8% senior subordinated notes were issued at a discount to
yield effective interest rates of 9.4% and 10.5%, respectively. Aggregate
proceeds from the sale of these notes, net of issuance costs, was approximately
$291.2 million. In connection with the repayment of the 7.74% senior notes, we
incurred a prepayment penalty of approximately $3.6 million. We recorded an
extraordinary loss of $2.7 million which includes the prepayment penalty and
unamortized issuance costs of $705 thousand, net of tax benefit of $1.6 million.
The difference between issue price and principal amount at maturity of our
7 1/4% senior notes and 9 7/8% senior subordinated notes will be accreted each
year as interest expense in our financial statements. These notes are unsecured,
but are guaranteed, on a joint and several basis, by all of our domestic
subsidiaries, other than one that is not wholly-owned.
Our credit facility provides for a revolving line of credit in the
aggregate principal amount of $75.0 million for a term of three years, including
subfacilities of $10.0 million for swingline loans and $15.0 million for letters
of credit, usage of which reduces availability under the facility. No borrowings
were outstanding under the facility as of December 31, 2001, versus $194.0
million outstanding on our former senior credit facility on December 31, 2000;
however, an aggregate of $9.8 million in letter of credit obligations were
outstanding on December 31, 2001. We intend to use the facility for working
capital, capital expenditures and other general corporate purposes. Although the
facility is unsecured, our obligations under the facility are unconditionally
guaranteed, on a joint and several basis, by all of our existing and
subsequently acquired wholly-owned domestic subsidiaries.
Borrowings under the facility bear interest at a rate equal to, at our
option, either (1) the base rate (which is equal to the greater of the prime
rate most recently announced by Bank of America, N.A., the administrative agent
under the facility, or the federal funds rate plus one-half of 1%) or (2) the
adjusted Eurodollar Interbank Offered Rate, in each case plus an applicable
margin determined by reference to our leverage ratio (which is defined under the
facility as the ratio of our total debt to our total capitalization). Based on
our leverage ratio at December 31, 2001, the current margins are 2.0% for
Eurodollar rate loans and 0.75% for base rate loans. Additionally, the undrawn
portion of the facility is subject to a facility fee at an annual rate that is
currently set at 0.5% based on our leverage ratio at December 31, 2001.
25
The facility contains covenants that restrict, among other things, our
ability and our subsidiaries' ability to create liens, merge or consolidate,
dispose of assets, incur indebtedness and guarantees, pay dividends, repurchase
or redeem capital stock and indebtedness, make certain investments or
acquisitions, enter into certain transactions with affiliates, make capital
expenditures or change the nature of our business. The facility also contains
several financial maintenance covenants, including covenants establishing a
maximum leverage ratio (as described above), minimum tangible net worth and a
minimum interest coverage ratio.
The facility contains events of default including, but not limited to,
nonpayment of principal or interest, violation of covenants, incorrectness of
representations and warranties, cross-default to other indebtedness, bankruptcy
and other insolvency events, material judgments, certain ERISA events, actual or
asserted invalidity of loan documentation and certain changes of control of our
company.
During the third and fourth quarters of 2001 and the first quarter of 2002,
we completed three amendments to our senior credit facility agreement. The first
amendment, dated September 10, 2001, allows us to acquire up to $30.0 million of
our senior subordinated notes so long as no default or event of default exists
on the date of the transaction or will result from the transaction.
The second amendment, dated November 30, 2001, provides for the issuance of
letters of credit under the senior credit facility having an original expiration
date more than one year from the date of issuance, if required under related
industrial revenue bond documents and agreed to by the issuing lender.
See "Subsequent Events" below, which details the third amendment to the
senior credit facility. This amendment was completed on January 22, 2002 with an
effective date of September 30, 2001. We obtained this amendment in order to
avoid the occurrence of an event of default under our senior credit facility
agreement resulting from a violation of the interest coverage ratio covenant
contained in this agreement.
In 1998, we registered with the SEC a total of $300.0 million in public
debt sec