SECURITIES AND EXCHANGE COMMISSION
Washington, D.C. 20549
FORM 10-K
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Annual Report Pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934 |
For the Fiscal Year Ended December 31, 2002 |
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Transition Report Pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934 |
For the Transition Period From to |
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Commission file number 0-11951
JSCE, Inc.
(Exact name of registrant as specified in its charter)
| Delaware (State of incorporation or organization) |
37-1337160 (I.R.S. Employer Identification No.) |
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150 North Michigan Avenue Chicago, Illinois (Address of principal executive offices) |
60601 (Zip Code) |
Registrant's Telephone Number: (312) 346-6600
Securities registered pursuant to Section 12(b) of the Act: None
Securities registered pursuant to Section 12(g) of the Act: None
Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days. Yes ý No o
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 the 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. o
Indicate by check mark if the registrant is an accelerated filer (as defined in Rule 12b-2 of the Act). Yes o No ý
As of February 28, 2003, none of the registrant's voting stock was held by non-affiliates.
The number of shares outstanding of the registrant's common stock as of February 28, 2003: 1,000
DOCUMENTS INCORPORATED BY REFERENCE: None
The registrant meets the conditions set forth in General Instruction (I)(1)(a) and (b) of Form 10-K and is therefore filing this form with the reduced disclosure format permitted thereby.
JSCE, INC.
ANNUAL REPORT ON FORM 10-K
December 31, 2002
TABLE OF CONTENTS
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Page No. |
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| PART I | ||||
| Item 1. | Business | 2 | ||
| Item 2. | Properties | 7 | ||
| Item 3. | Legal Proceedings | 7 | ||
PART II |
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| Item 5. | Market for Registrant's Common Equity and Related Stockholder Matters | 9 | ||
| Item 6. | Selected Financial Data | 10 | ||
| Item 7. | Management's Discussion and Analysis of Financial Condition and Results of Operations | 11 | ||
| Item 7a. | Quantitative and Qualitative Disclosures About Market Risk | 22 | ||
| Item 8. | Financial Statements and Supplementary Data | 24 | ||
| Item 9. | Changes in and Disagreements With Accountants on Accounting and Financial Disclosure | 53 | ||
PART IV |
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| Item 14. | Controls and Procedures | 53 | ||
| Item 15. | Exhibits, Financial Statement Schedules and Reports on Form 8-K | 53 | ||
FORWARD-LOOKING STATEMENTS
Except for the historical information contained in this Annual Report on Form 10-K, certain matters discussed herein, including (without limitation) under Part I, Item 1, "BusinessEnvironmental Compliance," under Part I, Item 3, "Legal Proceedings" and under Part II, Item 7, "Management's Discussion and Analysis of Financial Condition and Results of Operations," contain forward-looking statements within the meaning of Section 21E of the Securities Exchange Act of 1934, as amended. Although we believe that, in making any such statements, our expectations are based on reasonable assumptions, any such statements may be influenced by factors that could cause actual outcomes and results to be materially different from those projected. When used in this document, the words "anticipates," "believes," "expects," "intends," and similar expressions, as they relate to JSCE, Inc. or its management, are intended to identify such forward-looking statements. These forward-looking statements are subject to numerous risks and uncertainties. There are important factors that could cause actual results to differ materially from those in forward-looking statements, certain of which are beyond our control. These factors, risks and uncertainties include the following:
Our actual results, performance or achievement could differ materially from those expressed in, or implied by, these forward-looking statements. Accordingly, we can give no assurances that any of the events anticipated by the forward-looking statements will transpire or occur, or if any of them do so, what impact they will have on our results of operations or financial condition. We expressly decline any obligation to publicly revise any forward-looking statements that have been made to reflect the occurrence of events after the date hereof.
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Unless the context otherwise requires, "we," "us," "our" or "JSCE" refers to the business of JSCE, Inc. and its subsidiaries.
GENERAL
JSCE, Inc., a Delaware corporation, is an integrated producer of containerboard, corrugated containers and other packaging products. We conduct our business operations through our wholly-owned subsidiary Jefferson Smurfit Corporation (U.S.), a Delaware corporation (Jefferson Smurfit (U.S.) or JSC(U.S.)). Jefferson Smurfit (U.S.) has extensive operations located primarily in the United States. For the year ended December 31, 2002, our net sales were $3,456 million and net income was $111 million.
JSCE, Inc. is a wholly-owned subsidiary of Smurfit-Stone Container Corporation, a Delaware corporation. Smurfit-Stone is a holding company with no business operations of its own. Smurfit-Stone conducts its business operations through two wholly-owned subsidiaries: JSCE and Stone Container Corporation, a Delaware corporation.
On September 30, 2002, Jefferson Smurfit (U.S.) acquired a corrugating medium mill located in Stevenson, Alabama that has an annual capacity of 830,000 tons, seven corrugated container plants, one hardwood sawmill and approximately 82,000 acres of timberland from MeadWestvaco Corporation (the Stevenson Mill Acquisition). Jefferson Smurfit (U.S.) subsequently closed three of the corrugated container plants acquired as part of the Stevenson Mill Acquisition. Amounts included in the discussions herein include the Stevenson Mill Acquisition after September 30, 2002.
PRODUCTS
We report our results of operations in three industry segments, all of which are reportable: 1) Containerboard and Corrugated Containers, 2) Consumer Packaging and 3) Reclamation. On January 1, 2002, we combined the former Specialty Packaging segment with the Consumer Packaging segment. The Specialty Packaging segment was previously not a reportable segment. The information for 2001 and 2000 has been restated in order to conform to the 2002 presentation. The industrial packaging operations, which were previously part of the Consumer Packaging segment, were sold in 2002 and have been classified as discontinued and are excluded from the segment results for all periods presented. For financial information relating to our segments, see the information set forth in Note 18 of the Notes to Consolidated Financial Statements.
CONTAINERBOARD AND CORRUGATED CONTAINERS SEGMENT
The Containerboard and Corrugated Containers segment includes five paper mills, 50 container plants and two wood products plants located in the United States, one container plant located in Mexico and one container plant located in Puerto Rico. In addition, we own approximately 82,000 acres of timberland located in the United States. The primary products of our Containerboard and Corrugated Containers segment include:
We produce a full range of high quality corrugated containers designed to protect, ship, store and display products made to our customers' merchandising and distribution specifications. Corrugated containers are sold to a broad range of manufacturers of consumer goods. Corrugated containers are used to ship
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such diverse products as home appliances, electric motors, small machinery, grocery products, produce, computers, books, furniture and many other products. We provide customers with innovative packaging solutions to advertise and sell their products. In addition, we manufacture and sell a variety of retail ready, point of purchase displays and a full line of specialty products, including pizza boxes, corrugated clamshells for the food industry, Cordeck® recyclable pallets and custom die-cut boxes to display packaged merchandise on the sales floor. Our container plants serve local customers and large national accounts.
Our containerboard mills produce a full line of containerboard, which is used primarily in the production of corrugated packaging. In 2002, we produced 781,000 tons of unbleached kraft linerboard, 295,000 tons of white top linerboard and 428,000 tons of medium. Our containerboard mills and corrugated container operations are highly integrated, with the majority of our containerboard used internally by our corrugated container operations or by Stone Container's corrugated container operations. In 2002, our container plants consumed 1,699,000 tons of containerboard, representing an integration level of approximately 77%.
Our paper mills also produce solid bleached sulfate (SBS), specializing in high-quality grades of SBS, which are designed to meet the demanding print requirements of folding carton and carded packaging customers in the food, pharmaceutical, cosmetics and other niche markets. A portion of our SBS is consumed internally by our folding carton plants.
Production for our paper mills and sales volume for our corrugated container facilities for the last three years were:
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2002 |
2001 |
2000 |
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| Tons produced (in thousands) | |||||||
| Containerboard | 1,504 | 1,334 | 1,433 | ||||
| Solid bleached sulfate | 179 | 187 | 190 | ||||
| Corrugated containers sold (in billion sq. ft.) | 28.6 | 27.1 | 28.7 | ||||
CONSUMER PACKAGING SEGMENT
The Consumer Packaging segment includes four paper mills, 17 folding carton plants and 14 other converting plants. Our Consumer Packaging operations are located in the United States. The primary products of our Consumer Packaging segment include:
Folding cartons are used primarily to protect customers' products, while providing point of purchase advertising. We produce a full range of carton styles appropriate to nearly all carton end uses. The folding carton plants offer extensive converting capabilities, including sheet and web lithographic, rotogravure and flexographic printing and laminating. In addition, we provide Lithoflute packaging for a number of applications. The folding carton plants also provide a full line of structural and graphic design services tailored to specific technical requirements, as well as photography for packaging, sales promotion concepts and point of purchase displays. Converting capabilities include gluing, tray forming, windowing, waxing and laminating, plus other specialties. Our customer base is made up primarily of producers of packaged foods, beverages, fast food, detergents, paper, pharmaceuticals and cosmetics. Our customers range from local accounts to large national accounts.
Our coated recycled boxboard mills produce a broad range of recycled grades, including clay-coated newsback, kraftback and whiteback, as well as waxable and laminated grades. Our coated boxboard
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mills and folding carton operations are highly integrated, with the majority of our coated boxboard used internally by our folding carton operations. In 2002, our folding carton plants consumed 366,000 tons of recycled boxboard, representing an integration level of approximately 63%.
Production for our coated recycled boxboard mills and sales volume for the folding carton facilities for the last three years were:
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2002 |
2001 |
2000 |
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| Tons in thousands | |||||||
| Coated recycled boxboard produced | 582 | 569 | 590 | ||||
| Folding cartons sold | 504 | 523 | 561 | ||||
We also produce printed paper, foil and DI-NA-CAL® heat transfer labels, which are used in a wide range of industrial and consumer product applications. DI-NA-CAL® is a proprietary labeling system that applies high-speed heat transfer labels to plastic containers. We also produce specialized laminations of film, foil and paper. We have a full-service organization experienced in the production of color separations and lithographic film for the commercial printing, advertising and packaging industries.
RECLAMATION SEGMENT
Our reclamation operations procure fiber resources for Smurfit-Stone's paper mills as well as for other producers. We operate 23 reclamation facilities in the United States that collect, sort, grade and bale recovered paper. We also collect aluminum and glass for resale to manufacturers of these products. In addition, we operate a nationwide brokerage system whereby we purchase and resell recovered paper to Smurfit-Stone's recycled paper mills and other producers on a regional and national contract basis. Brokerage contracts provide bulk purchasing, often resulting in lower prices and cleaner recovered paper. Many of our reclamation facilities are located close to Smurfit-Stone's recycled paper mills, ensuring availability of supply with minimal shipping costs. Domestic tons of fiber reclaimed and brokered for 2002, 2001 and 2000 were 6,582,000, 6,714,000 and 6,768,000, respectively.
RAW MATERIALS
Wood fiber and reclaimed fiber are the principal raw materials used in the manufacture of our paper products. We satisfy the majority of our need for wood fiber through purchases on the open market or under supply agreements. We satisfy essentially all of our need for reclaimed fiber through our reclamation operations and nationwide brokerage system.
Wood fiber and reclaimed fiber are purchased in highly competitive, price-sensitive markets, which have historically exhibited price and demand cyclicality. Conservation regulations have caused, and will likely continue to cause, a decrease in the supply of wood fiber and higher wood fiber costs in some of the regions in which we procure wood fiber. Fluctuations in supply and demand for reclaimed fiber have occasionally caused tight supplies of reclaimed fiber. At those times, we have experienced an increase in the cost of such fiber.
MARKETING
Our marketing strategy is to sell a broad range of paper-based packaging products to marketers of industrial and consumer products. In managing the marketing activities of our paperboard mills, we seek to meet the quality and service needs of the customers of our converting plants at the most efficient cost, while balancing those needs against the demands of our open market customers. Our converting plants focus on supplying both specialized packaging with high value graphics that enhance a product's market appeal and high-volume commodity products. Our board sales group is responsible for marketing and selling paper and paperboard products to third parties worldwide.
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We seek to serve a broad customer base for each of our industry segments. As a result, we serve thousands of accounts from our plants. Each plant has its own sales force and many have product design engineers and other service professionals who are in close contact with customers to respond to their specific needs. We complement our local plants' marketing and service capabilities with regional and national design and service capabilities, as well as national sales offices for customers who purchase through a centralized purchasing office. National account business may be allocated to more than one plant due to production capacity, logistics and equipment requirements.
Our business is not dependent upon a single customer or upon a small number of major customers. We do not believe the loss of any one customer would have a material adverse effect on our business.
COMPETITION
The markets in which we sell our principal products are highly competitive and comprised of many participants. Although no single company is dominant, we do face significant competitors in each of our businesses. Our competitors include large vertically integrated companies as well as numerous smaller companies. The industries in which we compete have historically been sensitive to price fluctuations brought about by shifts in industry capacity and other cyclical industry conditions. While we compete primarily on the basis of price in many of our product lines, other competitive factors include design, quality and service, with varying emphasis depending on product line.
BACKLOG
Demand for our major product lines is relatively constant throughout the year and seasonal fluctuations in marketing, production, shipments and inventories are not significant. Backlogs are not a significant factor in the industry. We do not have a significant backlog of orders as most orders are placed for delivery within 30 days.
RESEARCH AND DEVELOPMENT
Our research and development center, located in Carol Stream, Illinois, uses advanced technology to assist all levels of the manufacturing and sales processes, from raw material supply through finished packaging performance. Research programs have provided improvements in coatings and barriers, stiffeners, inks and printing. Our technical staff conducts basic, applied and diagnostic research, develops processes and products and provides a wide range of other technical services.
We actively pursue applications for patents on new inventions and designs and attempt to protect our patents against infringement. Nevertheless, we believe our success and growth are more dependent on the quality of our products and our relationships with customers than on the extent of our patent protection. We hold or are licensed to use certain patents, licenses, trademarks and trade names on products, but do not consider the successful continuation of any material aspect of our business to be dependent upon such intellectual property.
EMPLOYEES
We had approximately 13,900 employees at December 31, 2002, of which approximately 13,700 were employees of U.S. operations. Approximately 8,700 (63%) of our U.S. employees are represented by collective bargaining units. The expiration dates of union contracts for our major paper mill facilities are as follows:
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We believe our employee relations are generally good. We are currently in the process of bargaining with unions representing production employees at a number of our operations. There were no significant or material work stoppages during 2002. While the terms of our collective bargaining agreements may vary, we believe the material terms of the agreements are customary for the industry, the type of facility, the classification of the employees and the geographic location covered thereby.
ENVIRONMENTAL COMPLIANCE
Our operations are subject to extensive environmental regulation by federal, state and local authorities. In the past, we have made significant capital expenditures to comply with water, air, solid and hazardous waste and other environmental laws and regulations. We expect to make significant expenditures in the future for environmental compliance. Because various environmental standards are subject to change, it is difficult to predict with certainty the amount of capital expenditures that will ultimately be required to comply with future standards.
In particular, the United States Environmental Protection Agency (EPA) has finalized significant portions of its comprehensive rule governing air emissions (Maximum Achievable Control Technology-MACT) and water discharges (Effluent Limitation Guidelines) from the pulp, paper and paperboard industry, known as the "Cluster Rule". Phase I of MACT I and the Effluent Limitation Guidelines of the Cluster Rule required us to convert our bleached linerboard mill at Brewton, Alabama to an elemental chlorine free bleaching process, to install systems at several of our mills for the collection and destruction of low volume, high concentration gases and to implement best management practices, such as spill controls. These projects have been completed at a cost of approximately $76 million. Phase II of MACT I of the Cluster Rule will require the implementation of systems to collect high volume, low concentration gases at various mills and has a compliance date of 2006. MACT II of the Cluster Rule will require control of particulate from recovery boilers, smelt tanks and lime kilns and has a compliance date of 2004. We have spent approximately $12 million (of which approximately $10 million was spent in 2002) for capital projects related to MACT II of the Cluster Rule. We continue to study possible means of compliance with phase II of MACT I and MACT II of the Cluster Rule. Based on currently available information, we estimate that the aggregate compliance cost of phase II of MACT I and MACT II of the Cluster Rule is likely to be in the range of $15 million to $20 million and that such cost will be incurred over the next four years.
In recent years, the EPA has undertaken significant air quality initiatives associated with nitrogen oxide emissions, regional haze and national ambient air quality standards. Several of our mills are located in states affected by these EPA initiatives. The EPA is also currently proposing to limit particulate emissions from industrial boilers in a new Boiler MACT regulation. Several of our mills will be subject to the Boiler MACT regulation when it is finalized. When regulatory requirements for new and changing standards are finalized, we will add any resulting future cost projections to our expenditure forecast.
In addition to Cluster Rule compliance, we anticipate additional capital expenditures related to environmental compliance. Excluding the spending on Cluster Rule projects described above, for the past three years, we have spent an average of approximately $2 million annually on capital expenditures for environmental purposes. Since our principal competitors are subject to comparable environmental standards, including the Cluster Rule, it is our opinion, based on current information, that compliance with environmental standards should not adversely affect our competitive position. However, we could incur significant expenditures due to changes in law or the discovery of new information, which could have a material adverse effect on our operating results.
AVAILABLE INFORMATION
Smurfit-Stone's Internet address is www.smurfit-stone.com. Smurfit-Stone's Internet address is included in this annual report on Form 10-K as an inactive textual reference only. The information contained on Smurfit-Stone's website is not incorporated by reference into this annual report on Form 10-K and should not be considered part of this report. We file annual, quarterly and current reports and other information
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with the Securities and Exchange Commission (SEC). We make available free of charge most of our SEC filings through Smurfit-Stone's Internet website as soon as reasonably practicable after we electronically file such information with, or furnish it to, the SEC. You may access these SEC filings via the hyperlink provided on Smurfit-Stone's Internet website to a third-party SEC filings website.
Our manufacturing facilities are located primarily in the United States. We believe that our facilities are adequately insured, properly maintained and equipped with machinery suitable for their use. Our manufacturing facilities as of December 31, 2002 are summarized below.
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Number of Facilities |
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State Locations(a) |
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Total |
Owned |
Leased |
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| United States | |||||||||
| Containerboard and Corrugated Containers Segment: | |||||||||
| Paper mills | 5 | 5 | 4 | ||||||
| Corrugated container plants | 50 | 39 | 11 | 23 | |||||
| Wood products plants | 2 | 2 | 2 | ||||||
| Consumer Packaging Segment: | |||||||||
| Coated recycled boxboard mills | 4 | 4 | 4 | ||||||
| Consumer packaging plants | 31 | 21 | 10 | 13 | |||||
| Reclamation Segment | 23 | 16 | 7 | 14 | |||||
| Subtotal | 115 | 87 | 28 | 27 | |||||
Other North America |
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| Containerboard and Corrugated Containers Segment: | |||||||||
| Corrugated container plants | 2 | 2 | N/A | ||||||
| Total | 117 | 89 | 28 | N/A | |||||
Our paper mills represent approximately 61% of our investment in property, plant and equipment. In addition to manufacturing facilities, we own approximately 82,000 acres of timberland in the states of Alabama and Tennessee. The approximate annual tons of productive capacity of our paper mills at December 31, 2002 were:
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Annual Capacity |
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(in thousands) |
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| Containerboard | 2,339 | ||
| Solid bleached sulfate | 190 | ||
| Coated recycled boxboard | 609 | ||
| Total | 3,138 | ||
Substantially all of our operating facilities have been pledged as collateral under Jefferson Smurfit (U.S.)'s credit agreement. See Part II, Item 7, Management's Discussion and Analysis of Financial Condition and Results of OperationsLiquidity and Capital ResourcesFinancing Activities.
LITIGATION
In 1998, seven putative class action complaints were filed in the United States District Court for the Northern District of Illinois and in the United States District Court for the Eastern District of Pennsylvania.
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These complaints alleged that Stone Container reached agreements in restraint of trade that affected the manufacture, sale and pricing of corrugated products in violation of antitrust laws. The complaints have been amended to name several other defendants, including Jefferson Smurfit (U.S.) and Smurfit-Stone. The suits seek an unspecified amount of damages arising out of the sale of corrugated products for the period from October 1, 1993 through March 31, 1995. Under the provisions of the applicable statutes, any award of actual damages could be trebled. The complaints have been transferred to and consolidated in the United States District Court for the Eastern District of Pennsylvania, which has certified two plaintiff classes. The defendants' appeal of the class certification rulings in the Third Circuit Court of Appeals has been denied. We continue to vigorously defend these cases.
We are a defendant in a number of lawsuits and claims arising out of the conduct of our business, including those related to environmental matters. While the ultimate results of such suits or other proceedings against us cannot be predicted with certainty, we believe the resolution of these matters will not have a material adverse effect on our consolidated financial condition or results of operations.
ENVIRONMENTAL MATTERS
Federal, state and local environmental requirements are a significant factor in our business. We employ processes in the manufacture of paperboard and other products, which result in various discharges, emissions and wastes. These processes are subject to numerous federal, state and local environmental laws and regulations, including reporting and disclosure obligations. We operate and expect to continue to operate under permits and similar authorizations from various governmental authorities that regulate such discharges, emissions and wastes.
We also face potential liability as a result of releases, or threatened releases, of hazardous substances into the environment from various sites owned and operated by third parties at which company-generated wastes have allegedly been deposited. Generators of hazardous substances sent to off-site disposal locations at which environmental problems exist, as well as the owners of those sites and certain other classes of persons (generally referred to as "potentially responsible parties" or "PRPs"), are, in most instances, subject to joint and several liability for response costs for the investigation and remediation of such sites under the Comprehensive Environmental Response, Compensation and Liability Act of 1980 (CERCLA) and analogous state laws, regardless of fault or the lawfulness of the original disposal. We have received notice that we are or may be a PRP at a number of federal and/or state sites where response action may be required and as a result may have joint and several liability for cleanup costs at such sites. However, liability for CERCLA sites is typically shared with other PRPs and costs are commonly allocated according to relative amounts of waste deposited. Our relative percentage of waste deposited at these sites ranges from 1% to 6%. In addition to participating in the remediation of sites owned by third parties, we have entered into consent orders for the investigation and/or remediation of certain of our owned properties.
Based on current information, we believe the probable costs of the potential environmental enforcement matters discussed above, response costs under CERCLA and similar state laws, and the remediation of owned property will not have a material adverse effect on our financial condition or results of operations. As of December 31, 2002, we had approximately $13 million reserved for environmental liabilities. We believe our liability for these matters was adequately reserved at December 31, 2002.
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ITEM 5. MARKET FOR REGISTRANT'S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS
MARKET INFORMATION
We are a wholly-owned subsidiary of Smurfit-Stone. Therefore, all of our outstanding common stock is owned by Smurfit-Stone. As a result, there is no established public market for our common stock.
DIVIDENDS ON COMMON STOCK
We paid dividends to Smurfit-Stone in the aggregate amount of approximately $8 million in 2002 to fund the dividend obligations of Smurfit-Stone to the holders of the 7% Series A Cumulative Exchangeable Redeemable Convertible Preferred Stock of Smurfit-Stone. Our ability to pay dividends in the future is restricted by certain provisions contained in Jefferson Smurfit (U.S.)'s credit agreement and the indentures relating to Jefferson Smurfit (U.S.)'s outstanding indebtedness, which we guarantee. See Item 7, Management's Discussion and Analysis of Financial Condition and Results of OperationsLiquidity and Capital Resources.
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ITEM 6. SELECTED FINANCIAL DATA
| (In millions, except statistical data) |
2002(a) |
2001 |
2000 |
1999(b) |
1998 |
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| Summary of Operations | ||||||||||||||||
| Net sales | $ | 3,456 | $ | 3,344 | $ | 3,739 | $ | 3,293 | $ | 3,036 | ||||||
| Income (loss) from operations (c) | 177 | 236 | 333 | 619 | (97 | ) | ||||||||||
| Income (loss) from continuing operations before extraordinary item and cumulative effect of accounting change | 96 | 106 | 138 | 267 | (183 | ) | ||||||||||
| Discontinued operations, net of income tax provision (d) | 27 | 4 | 14 | 15 | 39 | |||||||||||
| Net income (loss) | 111 | 108 | 151 | 272 | (160 | ) | ||||||||||
Other Financial Data |
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| Net income (loss), adjusted to exclude goodwill amortization (e) | $ | 111 | $ | 115 | $ | 158 | $ | 279 | $ | (153 | ) | |||||
| Net cash provided by operating activities | 238 | 183 | 247 | 103 | 117 | |||||||||||
| Net cash provided by (used for) investing activities | (353 | ) | (75 | ) | (129 | ) | 829 | (595 | ) | |||||||
| Net cash provided by (used for) financing activities | 109 | (118 | ) | (108 | ) | (939 | ) | 484 | ||||||||
| Depreciation, depletion and amortization (e) | 123 | 124 | 120 | 134 | 134 | |||||||||||
| Capital investments and acquisitions | 442 | 86 | 116 | 69 | 265 | |||||||||||
| Working capital, net | 65 | (12 | ) | 104 | 41 | 145 | ||||||||||
| Property, plant, equipment and timberland, net | 1,477 | 1,223 | 1,262 | 1,309 | 1,760 | |||||||||||
| Total assets | 2,918 | 2,544 | 2,667 | 2,736 | 3,174 | |||||||||||
| Long-term debt | 1,601 | 1,427 | 1,529 | 1,636 | 2,570 | |||||||||||
| Stockholder's equity (deficit) | (95 | ) | (44 | ) | (84 | ) | (235 | ) | (538 | ) | ||||||
Statistical Data (tons in thousands) |
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| Containerboard production (tons) | 1,504 | 1,334 | 1,433 | 1,592 | 1,978 | |||||||||||
| Solid bleached sulfate production (tons) | 179 | 187 | 190 | 189 | 185 | |||||||||||
| Coated boxboard production (tons) | 582 | 569 | 590 | 581 | 582 | |||||||||||
| Corrugated containers sold (billion sq. ft.) | 28.6 | 27.1 | 28.7 | 29.1 | 29.9 | |||||||||||
| Folding cartons sold (tons) | 504 | 523 | 561 | 549 | 507 | |||||||||||
| Fiber reclaimed and brokered (tons) | 6,582 | 6,714 | 6,768 | 6,560 | 5,155 | |||||||||||
| Number of employees | 13,900 | 13,800 | 14,100 | 14,400 | 15,000 | |||||||||||
Notes to Selected Financial Data
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amortized, but instead be tested for impairment at least annually. Depreciation, depletion and amortization includes goodwill amortization of $7 million in 2001, 2000, 1999 and 1998.
ITEM 7. MANAGEMENT'S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND
RESULTS OF OPERATIONS
GENERAL
Containerboard market conditions and demand for containerboard and corrugated containers, our primary products, have historically been subject to cyclical changes in the economy and changes in industry capacity, both of which can significantly impact selling prices and our profitability.
Containerboard market conditions were generally strong in the first half of 2000. Linerboard prices increased to $480 per ton during the first quarter and held through the end of the year. Domestic economic growth began to slow in the second half of 2000, however, and market conditions began to deteriorate. In addition, the sustained strength of the U.S. dollar made products manufactured in the U.S. less competitive in global markets. Industry shipments of corrugated containers for 2000 declined 1% compared to 1999 and declined an additional 6% in 2001, the worst performance since 1975. The slowdown in the U.S. economy, in addition to weak export markets, exerted downward pressure on containerboard demand. In order to maintain a balance between supply and demand, certain companies in the containerboard industry took extensive market related downtime in 2000 and 2001. The sluggish corrugated demand in 2001 and the excess supply of containerboard resulted in an 11% decline in linerboard pricing to $425 per ton as of December 31, 2001. Linerboard prices decreased an additional $5 per ton in the first quarter of 2002. Corrugated container prices also declined during this period. Certain companies in the containerboard industry continued to take market related downtime in 2002. Markets gradually improved in 2002 and a linerboard price increase was implemented effective July 1, 2002. Corresponding price increases were implemented for corrugated containers in the third and fourth quarters of 2002. As of December 31, 2002, linerboard prices were approximately $440 per ton, but have decreased $10 per ton in the first quarter of 2003. Industry shipments of corrugated containers in 2002 were flat compared to 2001. We do not expect a recovery in demand for corrugated containers until the U.S. economy strengthens.
Market conditions in the folding carton and recycled boxboard mill industry were strong going into 2000 and sales price increases were implemented in the second quarter of 2000. Shipments of folding cartons in 2000 increased 3% compared to 1999. Recycled boxboard mill operating rates were lower, however, and production in 2000 decreased 1% compared to 1999. Markets for the most part weakened in 2001, as industry shipments of folding cartons declined 1% and recycled boxboard production declined by 5% compared to 2000. Prices for folding cartons in 2001, however, increased by 1% compared to 2000. In 2002, folding carton shipments declined for the second consecutive year, as the industry contended with maturing markets and slowing sector growth rates. The carton industry also faces a shrinking supply chain, as customers continue to work down inventories to reduce supply. Shipments of folding cartons and recycled boxboard production both declined by 1% in 2002 and prices for folding cartons decreased by 2% compared to 2001. In March 2003, we announced a price increase of $40 per ton for recycled boxboard effective April 1.
Wood fiber and reclaimed fiber are the principal raw materials used in the manufacture of our products. Fluctuations in supply and demand have occasionally caused tight supplies of fiber and, at those times, we have experienced a temporary increase in the cost of such fiber. Demand for reclaimed fiber, which was generally strong in 1999 and early 2000, has weakened in recent years as certain domestic companies in the containerboard industry have taken extensive market related downtime. Prices declined in 2000 and continued to be depressed throughout 2001 as more paper mills took downtime to manage their inventories. The average price of old corrugated containers, commonly known as OCC, the principal grade used in recycled containerboard mills, was lower in 2001 compared to 2000 by approximately 40%. Higher demand and tight supplies in the second and third quarters of 2002 caused OCC prices to temporarily escalate. Although prices subsequently dropped, the high prices in the second
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and third quarters caused the average price of OCC to be higher than 2001 by 55%. Wood fiber prices, in areas where we procure wood, increased 1% in 2001 compared to 2000, but declined in 2002 by 6% compared to 2001. Recent wet weather in the southeast U.S. has resulted in lower availability and higher prices for wood fiber in the first quarter of 2003.
ACQUISITION
On September 30, 2002, Jefferson Smurfit (U.S.) purchased a corrugating medium mill with an annual capacity of 830,000 tons, seven corrugated container plants, one hardwood sawmill and approximately 82,000 acres of timberland from MeadWestvaco Corporation (the Stevenson Mill Acquisition). The Stevenson Mill Acquisition was accounted for as a purchase business combination. Accordingly, the related results of operations have been included in our consolidated statement of operations after September 30, 2002. The cost to acquire these operations was preliminarily allocated to the assets acquired and liabilities assumed using fair values. No goodwill was recorded related to the Stevenson Mill Acquisition. In connection with the Stevenson Mill Acquisition, Jefferson Smurfit (U.S.) announced the closure of three of the acquired corrugated container plants and recorded exit liabilities of $7 million in our preliminary purchase allocation for the termination of certain employees and liabilities for lease commitments and facility closure costs. We expect to finalize our preliminary purchase price allocation upon completion of the property, plant and equipment and timberland valuations.
Smurfit-Stone has targeted synergy savings of $40 million from the Stevenson Mill Acquisition by the end of 2003. We expect to achieve these synergies through a combination of administrative cost reductions, system optimization and purchasing savings.
RESULTS OF OPERATIONS
Segment Data
| |
2002 |
2001 |
2000 |
|||||||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| (In millions) |
Net Sales |
Profit/ (Loss) |
Net Sales |
Profit/ (Loss) |
Net Sales |
Profit/ (Loss) |
||||||||||||||
| Containerboard and corrugated containers | $ | 1,955 | $ | 128 | $ | 1,905 | $ | 156 | $ | 2,033 | $ | 220 | ||||||||
| Consumer packaging | 1,021 | 76 | 1,047 | 94 | 1,085 | 100 | ||||||||||||||
| Reclamation | 469 | 19 | 375 | 6 | 605 | 26 | ||||||||||||||
| Other operations | 11 | 1 | 17 | 16 | (1 | ) | ||||||||||||||
| Total operations | $ | 3,456 | 224 | $ | 3,344 | 256 | $ | 3,739 | 345 | |||||||||||
Restructuring charges |
(4 |
) |
(4 |
) |
||||||||||||||||
| Gain on sale of assets | 1 | 1 | 4 | |||||||||||||||||
| Goodwill amortization | (7 | ) | (7 | ) | ||||||||||||||||
| Interest income from Smurfit-Stone | 73 | 65 | 53 | |||||||||||||||||
| Interest expense | (94 | ) | (125 | ) | (156 | ) | ||||||||||||||
| Corporate expenses and other | (41 | ) | (7 | ) | (7 | ) | ||||||||||||||
| Income from continuing operations before income taxes and extraordinary item | $ | 159 | $ | 179 | $ | 232 | ||||||||||||||
Corporate expenses and other includes corporate expenses, intracompany profit elimination and LIFO expense, corporate charges to segments for working capital interest and other expenses not allocated to segments. The effects of lower intracompany profit elimination and LIFO expense favorably impacted corporate expenses and other in 2000 and 2001.
Amortization of goodwill ceased on January 1, 2002, when we adopted SFAS No. 142, "Goodwill and Other Intangible Assets."
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2002 COMPARED TO 2001
Consolidated net sales of $3,456 million in 2002 were 3% higher compared to last year due primarily to additional sales attributable to the Stevenson Mill Acquisition and higher shipments of containerboard and corrugated containers. Sales prices for containerboard and corrugated containers were lower compared to 2001. The increase (decrease) in net sales for each of our segments is summarized in the chart below:
| (In millions) |
Containerboard & Corrugated Containers |
Consumer Packaging |
Reclamation |
Other Operations |
Total |
||||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Sales prices and product mix | $ | (88 | ) | $ | (12 | ) | $ | 103 | $ | $ | 3 | ||||||
| Sales volume | 49 | (14 | ) | (7 | ) | 28 | |||||||||||
| Acquisition | 91 | 91 | |||||||||||||||
| Closed or sold facilities | (2 | ) | (2 | ) | (6 | ) | (10 | ) | |||||||||
| Total | $ | 50 | $ | (26 | ) | $ | 94 | $ | (6 | ) | $ | 112 | |||||
Cost of goods sold increased due primarily to the Stevenson Mill Acquisition, higher sales volumes for containerboard and corrugated containers and higher reclaimed fiber cost ($124 million). Cost of goods sold was favorably impacted by lower energy cost ($16 million) and the elimination of goodwill amortization ($7 million). Cost of goods sold as a percent of net sales in 2002 was 86% compared to 85% in 2001 due primarily to the effects of our lower average sales prices.
Selling and administrative expenses increased 6% due primarily to the impact of costs associated with the Stevenson Mill Acquisition. Selling and administrative expenses as a percent of net sales was 8% in 2002, comparable to 2001.
During 2002, we recorded restructuring charges of $4 million related to the shutdown and sale of our Cladwood® operations.
Interest expense declined $31 million due to the favorable impacts of overall average interest rates ($25 million) and from lower average borrowings ($6 million). The overall average effective interest rate in 2002 was lower than 2001 by approximately 180 basis points. Interest income for 2002 increased $8 million due to accrued interest on our intercompany notes receivable from Smurfit-Stone.
Income from continuing operations before income taxes and extraordinary item in 2002 was $159 million, a decrease of $20 million compared to 2001. The decline in segment earnings was due primarily to lower average sales prices for containerboard and corrugated containers. The decline in interest expense partially offset the decline in segment earnings.
The effective income tax rate for 2002 was 40%, compared to 41% in 2001. Provision for income taxes in 2002 differed from the federal statutory tax rate due to several factors, the most significant of which was state income taxes. For information concerning income taxes, seeLiquidity and Capital Resources and Note 10 of the Notes to Consolidated Financial Statements.
Containerboard and Corrugated Containers Segment
Net sales increased by 3% due primarily to the Stevenson Mill Acquisition and higher shipments of containerboard and corrugated containers. Shipments of corrugated containers increased 6%. The average sales price of corrugated containers decreased 5%, linerboard sales prices were lower by 4% and SBS average sales prices decreased 5%.
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Production of containerboard increased 13% due primarily to the Stevenson Mill Acquisition. We continued to take market related downtime (approximately 201,000 tons) in 2002 in order to maintain a lower level of inventory. SBS production was lower by 4%.
Profits decreased by $28 million due primarily to the lower average sales prices. Profits were favorably impacted by the Stevenson Mill Acquisition and lower energy cost compared to 2001. Cost of goods sold as a percent of net sales increased to 88% in 2002 compared to 86% in 2001 due primarily to the lower average sales prices.
Consumer Packaging Segment
Net sales decreased by 2% due primarily to lower sales volumes and lower average sales prices. Folding carton shipments decreased 4%. Production of coated boxboard in 2002 was 2% higher compared to 2001.
The averag