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| CLW > SEC Filings for CLW > Form 10-Q on 5-Nov-2012 | All Recent SEC Filings |
5-Nov-2012
Quarterly Report
FORWARD-LOOKING STATEMENTS
Our disclosure and analysis in this report contains, in addition to historical
information, certain forward-looking statements within the meaning of the
Private Securities Litigation Reform Act of 1995, including statements regarding
our construction of additional converting and paper making capacity and the cost
and timing to complete new facilities, including our facilities in Shelby, North
Carolina, the cost and timing to upgrade existing paper making facilities,
including those in Las Vegas, Nevada, the integration of and expected benefits
from the former Cellu Tissue operations, including expected cost savings from
synergies, future growth opportunities, the stock repurchase program, future
revenues, cash flows, capital expenditures, tax rates, operating costs,
manufacturing capability, liquidity, benefit plan funding levels, total selling,
general and administrative costs, interest expenses, the tax treatment of the
alternative fuels and cellulosic biofuels tax credits and the conversion of
additional gallons of fuel from the Alternative Fuel Mixture Tax Credit to the
Cellulosic Biofuel Producer Credit. Words such as "anticipate," "expect,"
"intend," "plan," "target," "project," "believe," "schedule," "estimate," "may,"
and similar expressions are intended to identify such forward-looking
statements. These forward-looking statements are based on management's current
expectations, estimates, assumptions and projections that are subject to change.
Our actual results of operations may differ materially from those expressed or
implied by the forward-looking statements contained in this report. Important
factors that could cause or contribute to such differences include those risks
discussed in the section entitled "Risk Factors" in our 2011 Form 10-K, as well
as the following:
• difficulties with the integration process or the realization of the
benefits expected from the acquisition of Cellu Tissue;
• difficulties with completion, or significant delays in the construction or upgrade of, our new and existing tissue manufacturing and converting facilities, including the completion of our new through-air-dried, or TAD, paper machine;
• changes in the cost and availability of wood fiber used in the production of our products;
• changes in transportation costs and disruptions in transportation services;
• changes in raw material and energy costs and availability;
• the loss of business from any large customer;
• changes in customer product preferences and competitors' product offerings;
• our qualification to retain, or ability to utilize, tax credits associated with alternative fuels or cellulosic biofuels and the tax treatment associated with receipt of such credits;
• labor disruptions;
• changes in the U.S. and international economies and in general economic conditions in the regions and industries in which we operate;
• changes in expenses and required contributions associated with our pension plans;
• cyclical industry conditions;
• competitive pricing pressures for our products, including as a result of increased capacity as additional manufacturing sites for consumer tissue products are constructed by our competitors;
• changes in exchange rates between the U.S. dollar and other currencies;
• reliance on a limited number of third-party suppliers for raw materials;
• unforeseen environmental liabilities or expenditures;
• unanticipated manufacturing or operating disruptions, including equipment malfunction and damage to our manufacturing facilities caused by fire or weather-related events and IT system failures;
• an inability to fund our debt obligations;
• restrictions on our business from debt covenants and terms; and
• changes in laws, regulations or industry standards affecting our business.
Forward-looking statements contained in this report present management's views only as of the date of this report. Except as required under applicable law, we do not intend to issue updates concerning any future revisions of management's views to reflect events or circumstances occurring after the date of this report.
OVERVIEW
Background
We manufacture and sell pulp-based products. We currently manufacture quality
consumer tissue, away-from-home tissue, parent roll tissue, machine-glazed
tissue, bleached paperboard, and pulp at 15 manufacturing locations in the U.S.
and Canada. Our private label tissue products, such as facial and bath tissue,
paper towels and napkins, are used primarily at home and are principally sold to
major retailers and wholesale distributors, which include grocery, drug, mass
merchant and discount stores. Our paperboard is sold primarily in the high-end
segment of the packaging industry and is ultimately used by our customers to
make packaging for products ranging from liquids to pharmaceuticals to consumer
goods packaging, all of which demand high quality construction and print
surfaces for graphics. Our products primarily utilize pulp made from wood fiber.
In addition to wood fiber, other major cost categories include chemicals,
transportation, energy, packaging, and costs associated with our manufacturing
facilities.
Recent Developments
Consumer Products Expansion
In 2010, as part of our TAD tissue expansion project, or TAD project, we began
construction of new tissue manufacturing and converting facilities in Shelby,
North Carolina to expand our Consumer Products segment in the Eastern United
States. This site will include a TAD paper machine capable of producing ultra
grades of private label tissue products and is currently expected to have five
converting lines. The first two converting lines became operational during the
second quarter of 2011. Two additional converting lines are expected to become
operational in the fourth quarter of 2012 and the fifth line in 2013. The new
TAD paper machine is scheduled to start-up in the fourth quarter of 2012. Also
as part of our TAD project, during the third quarter of 2012, we began
improvements to our TAD tissue manufacturing capabilities in Las Vegas that we
completed in October 2012.
The TAD project will allow us to supply a full range of TAD products, including
paper towels and bath tissue, to customers across the U.S., while minimizing
transportation costs. We believe this project, along with our existing
manufacturing capabilities, will establish us as the only private label tissue
products company to offer a full line of tissue products to our customers.
We estimate the TAD project will cost approximately $275 million, excluding
capitalized interest. As of September 30, 2012, we have incurred a total of
$231.2 million in TAD project costs, of which $39.3 million and $121.9 million
were incurred in the three and nine months ended September 30, 2012,
respectively. We expect approximately $23 million will be spent during the
fourth quarter of 2012, with the remaining balance of approximately $21 million
to be spent in 2013. We have capitalized $13.2 million of interest related to
the TAD project to date, of which $4.1 million and $9.0 million were incurred in
the three and nine months ended September 30, 2012, respectively, and we
estimate total capitalized interest for the project will be approximately $18
million.
Integration of Cellu Tissue Holdings, Inc.
On December 27, 2010, we acquired Cellu Tissue Holdings, Inc., or Cellu Tissue,
which includes nine tissue manufacturing facilities located in the Southern,
Midwestern and Eastern United States and one facility in Eastern Canada. These
facilities allow us to better serve existing private label grocery customers by
creating a national manufacturing footprint and provide us with the capability
to expand into new private label channels. We recognized $8.6 million of net
cost savings from synergies relating to the acquisition in the third quarter of
2012, and $20.6 million for the first three quarters of 2012. We expect to
achieve total net cost savings from synergies of approximately $29.0 million in
2012, and by the end of 2012 to be on track to achieve $35 to $40 million
annually in net cost savings from synergies in 2013.
Components and Trends in our Business
Net sales
Net sales consist of sales of consumer tissue, paperboard products and pulp, net
of discounts, returns and allowances and any sales taxes collected. Prices for
our consumer tissue products primarily tend to be driven by the value of our
products to our customers, and are generally priced relative to the prices of
branded tissue products. Demand and pricing for our pulp and paperboard products
are largely determined by general global market conditions and the demand for
high quality paperboard.
Operating costs
Three Months Ended September 30,
(Dollars in thousands) 2012 2011
Percentage of Percentage of
Cost Cost of Sales Cost Cost of Sales
Purchased pulp $ 61,785 15.1 % $ 80,351 17.9 %
Chemicals 45,546 11.1 43,931 9.8
Transportation1 43,348 10.6 49,510 11.0
Chips, sawdust and logs 40,856 10.0 47,606 10.6
Energy 27,658 6.7 33,412 7.4
Packaging supplies 20,644 5.0 23,775 5.3
Maintenance and repairs2 20,597 5.0 23,767 5.3
$ 260,434 63.5 % $ 302,352 67.3 %
Nine Months Ended September 30,
(Dollars in thousands) 2012 2011
Percentage of Percentage of
Cost Cost of Sales Cost Cost of Sales
Purchased pulp $ 184,181 15.2 % $ 229,772 17.7 %
Chemicals 138,410 11.4 126,817 9.8
Transportation1 126,859 10.5 141,762 10.9
Chips, sawdust and logs 124,777 10.3 150,477 11.6
Energy 81,013 6.7 98,872 7.6
Maintenance and repairs2 77,706 6.4 74,974 5.8
Packaging supplies 63,981 5.3 70,688 5.5
$ 796,927 65.8 % $ 893,362 68.9 %
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1 Includes internal and external transportation costs.
2 Excluding related labor costs.
Purchased pulp. We purchase a significant amount of the pulp needed to supply our consumer products, and to a lesser extent our pulp and paperboard, manufacturing facilities from external suppliers. For the three and nine months ended September 30, 2012, total purchased pulp costs were 15.1% and 15.2%, respectively, of our cost of sales, representing decreases of 2.8 percentage points and 2.5 percentage points, respectively, compared to the same periods in 2011. Our costs for purchased pulp, which were at record highs in 2011, decreased through the first three quarters of 2012 due to lower average external pulp prices and our continued focus on using our internally produced pulp. Chemicals. We consume a substantial amount of chemicals in the production of pulp and paperboard. The chemicals we generally use include polyethylene, caustic, starch, sodium chlorate, latex and specialty paper process chemicals. A large portion of the chemicals used in our manufacturing processes, particularly in the pulp-making process, are petroleum-based and are impacted by petroleum prices. Our chemical costs increased $1.6 million, or 1.3 percentage points, for the three months ended September 30, 2012, compared to the comparable period ended September 30, 2011. Chemical costs for the nine months ended September 30, 2012, increased $11.6 million, or 1.6 percentage points, over the 2011 comparable period. Costs increased during both the three and nine month periods primarily as a result of increased production volumes and year to date increased caustic and other chemical costs.
Transportation. Fuel prices largely impact transportation costs related to
delivery of raw materials to our manufacturing facilities, internal inventory
transfers and delivery of our finished products to customers. Changing fuel
prices particularly affect our margins for consumer products because we supply
customers throughout the U.S., and we transport unconverted parent rolls from
our tissue mills to our tissue converting facilities. Our transportation costs
for the three and nine months ended September 30, 2012, compared to the prior
year periods, decreased as less fuel was used due to an overall decline in miles
shipped as a result of synergies from the Cellu Tissue acquisition, as well as
improvement in negotiated rates. In addition, as a result of the sale of our
Lewiston, Idaho sawmill in November 2011, overall transportation costs were
lower for the nine months ended September 30, 2012, compared to the same period
ending 2011.
Chips, sawdust and logs. We purchase chips, sawdust and logs used to manufacture
pulp. We source these residual wood fibers under both long-term and short-term
supply agreements, as well as in the spot market. Overall costs for chips,
sawdust and logs for the three and nine months ended September 30, 2012,
decreased compared to the same 2011 periods, both in dollars and as a percentage
of cost of sales, primarily due to the sale of our Lewiston, Idaho sawmill in
November 2011. Excluding the effects of our former sawmill, the cost of chips,
sawdust and logs decreased slightly when compared to the prior year periods
primarily due to lower pricing at our Idaho pulp and paperboard mill.
Energy. We use energy in the form of electricity, hog fuel, steam, natural gas
and, to a much lesser extent, coal to operate our mills. Energy prices have
fluctuated widely over the past decade. We have taken steps to reduce our
exposure to volatile energy prices through conservation. In addition,
cogeneration facilities that produce steam and electricity at our East Hartford,
Connecticut, Lewiston, Idaho and Menominee, Michigan manufacturing sites help to
lower our energy costs. To help mitigate our exposure to changes in natural gas
prices, from time to time we have used firm-price contracts to supply a portion
of our natural gas requirements. As of September 30, 2012, these contracts
covered approximately 18% of our expected average monthly natural gas
requirements for our manufacturing facilities for the remainder of 2012, plus
lesser amounts for 2013. Energy costs for the three and nine months ended
September 30, 2012 were lower than the prior year period due to lower natural
gas and electricity costs. Our energy costs in future periods will depend
principally on our ability to produce a substantial portion of our electricity
needs internally, on changes in market prices for natural gas and on our ability
to reduce our energy usage.
Maintenance and repairs. We regularly incur significant costs to maintain our
manufacturing equipment. We perform routine maintenance on our machines and
periodically replace a variety of parts such as motors, pumps, pipes and
electrical parts.
Major equipment maintenance and repairs in our Pulp and Paperboard segment also
require maintenance shutdowns annually at our Idaho facility and approximately
every 18 months at our Arkansas facility, which increases costs and may reduce
net sales in the quarters in which the major maintenance shutdowns occur. In the
first quarter of 2012, we had 17 combined days of scheduled machine downtime for
the two paperboard machines at our Idaho pulp and paperboard mill and incurred
approximately $15.5 million in major maintenance costs, excluding labor,
compared to major maintenance costs of $11.4 million and $3.1 million,
respectively, at the same mill in the first and third quarters of 2011. There
was no major maintenance in the second and third quarters of 2012. A portion of
our major maintenance originally planned for the fourth quarter of 2012 at our
Arkansas facility has been deferred to the first quarter of 2013. Of the $4.3
million of costs we expect to incur for this major maintenance, $2.0 million is
expected to be incurred in the fourth quarter of 2012, and the remainder is
expected to be spent in the first quarter of 2013.
In addition to ongoing maintenance and repair costs, we make capital
expenditures to increase our operating capacity and efficiency, to improve our
safety and to comply with environmental laws. Excluding $39.3 million and $121.9
million, respectively, of expenditures for our TAD project during the three and
nine months ended September 30, 2012, we spent $16.1 million and $36.7 million,
respectively, on capital expenditures during the three and nine months ended
September 30, 2012, compared to $8.6 million and $32.7 million in the same
periods in 2011. Capital expenditures for 2012 are expected to be between
approximately $205 million and $210 million, which include an estimated $145
million associated with our TAD project.
Packaging supplies. As a significant producer of private label consumer tissue
products, we package to order for retail chains, wholesalers and cooperative
buying organizations. Under these agreements, we incur expenses related to the
unique packaging of our products for direct retail sale to consumers. For the
three and nine months ended September 30, 2012, packaging costs were lower than
the same period in 2011 primarily due to procurement synergies resulting from
the Cellu Tissue acquisition.
Other. Other costs not mentioned in the above table primarily consist of wage
and benefit expenses and miscellaneous operating costs. Although period cut-offs
and inventory levels can impact other cost of sales amounts, we would expect
this amount to stay relatively steady as a percentage of costs.
Selling, general and administrative expenses
Selling, general and administrative expenses primarily consist of compensation
and associated expenses for sales and administrative personnel, as well as
commission expenses related to sales of our products. Our selling, general and
administrative expenses for the three months ended September 30, 2012, and 2011,
were $30.6 million and $26.8 million, respectively. The $3.8 million increase
was primarily a result of higher wage and benefit, incentive based compensation
and director equity-based compensation expenses.
Interest expense
Interest expense is mostly comprised of interest on our $375.0 million aggregate
principal amount 7.125% senior notes due 2018 issued in October 2010, which we
refer to as the 2010 Notes, and our $150.0 million aggregate principal amount of
10.625% senior notes due 2016 issued in June 2009, which we refer to as the 2009
Notes. Interest expense also includes amortization of deferred finance costs
associated with the 2009 Notes, 2010 Notes, and our revolving credit facility.
Interest expense will be partially offset by our continued capitalization of
interest for our TAD project, which we estimate will be $13.8 million in 2012
and approximately $18 million in total over the construction phase of the
project. Interest expense before reductions for capitalized interest in 2012 is
expected to continue decreasing slightly compared to 2011 as a result of the
2011 third quarter redemption of our industrial revenue bonds.
Income taxes
Income taxes are based on reported earnings and tax rates in the jurisdictions
in which our operations occur and offices are located, adjusted for available
credits, changes in valuation allowances and differences between reported
earnings and taxable income using current tax laws and rates. We generally
expect our effective income tax rate, excluding discrete items, to remain fairly
constant, but it could fluctuate due to changes in tax law.
We are registered with the Internal Revenue Service, or IRS, as both an
alternative fuel mixer and a producer of cellulosic biofuel. During 2009 we
received refundable tax credit payments in connection with our use of an
alternative fuel mixture to produce energy at our pulp mills. The amount of the
refundable tax credit is equal to $0.50 per gallon of alternative fuel mixture
used. The Alternative Fuel Mixture Tax Credit, or AFMTC, expired on December 31,
2009.
The Cellulosic Biofuel Producer Credit, or CBPC, enables us to claim $1.01 per
gallon in regards to black liquor produced and used as a fuel by us at our pulp
mills in 2009. During 2010, the IRS issued guidance clarifying the treatment of
the CBPC and the AFMTC in regards to the production or use of black liquor at
the same facility, in the same tax year. Under the guidance provided, both
credits may be claimed in the same year as long as the credits are not claimed
for the same gallons of fuel. Furthermore, the IRS guidance clarified the
ability to convert previously claimed gallons from the AFMTC to the CBPC.
In the first quarter of 2012 Congress identified the elimination or modification
of the CBPC in connection with black liquor as a possible revenue source. Such
proposed legislative action, if enacted, could limit or eliminate our ability to
convert AFMTC gallons to CBPC gallons and/or CBPC gallons to AFMTC gallons and,
accordingly, limit or eliminate our ability to claim carry forward credits.
Although provisions relating to CBPC and AFMTC were removed from the proposed
Highway Investment, Job Creation and Economic Growth Act of 2012, the ultimate
outcome of these provisions or future provisions could be adverse. As a result,
we made the determination to convert all gallons relating to CBPC carryforwards
back to AFMTC and as of September 30, 2012 we have no remaining CBPC
carryforwards. As a result of this determination, we recorded net discrete
expense of $6.5 million through the nine months ended September 30, 2012
comprised of $3.4 million relating to the conversion back to the AFMTC and a
resulting additional $3.1 million increase in our liabilities for uncertain tax
positions. Although under current federal tax law we have the ability to convert
gallons of AFMTC to CBPC until 2013, we do not currently intend to do so. See
Note 5 "Income Taxes" of our Condensed Consolidated Financial Statements for
further discussion.
There is relatively little guidance regarding the AFMTC and the law governing
the issue is complex. Accordingly, there remains uncertainty as to our
qualification to receive the tax credit in 2009, as well as to whether we will
be entitled to retain the amounts we received upon further review by the IRS. In
addition, while it is our position that payments received or credits taken in
relation to the AFMTC should not be subject to corporate income tax, there can
be no assurance as to whether or not the amounts we have received will be
subject to taxation.
Subsequent to September 30, 2012, the IRS has undertaken an audit of the company
for the 2009 through 2011 tax years. Other audits opened during the third
quarter of 2012 include a Canada Revenue Agency audit of our Canadian
subsidiary, which we acquired in the Cellu Tissue acquisition, for the fiscal
year ended February 2010 and calendar years 2010 and 2011.
RESULTS OF OPERATIONS
Three Months Ended September 30, 2012 Compared to Three Months Ended
September 30, 2011
The following table sets forth data included in our Condensed Consolidated
Statements of Operations as a percentage of net sales.
Three Months Ended September 30,
(Dollars in thousands) 2012 2011
Net sales $ 480,233 100.0 % $ 501,125 100.0 %
Costs and expenses:
Cost of sales (409,822 ) 85.3 (448,927 ) 89.6
Selling, general and administrative expenses (30,649 ) 6.4 (26,815 ) 5.4
Total operating costs and expenses (440,471 ) 91.7 (475,742 ) 94.9
Income from operations 39,762 8.3 25,383 5.1
Interest expense, net (7,900 ) 1.6 (12,100 ) 2.4
Other, net - - 1,290 0.3
Earnings before income taxes 31,862 6.6 14,573 2.9
Income tax provision (12,798 ) 2.7 (5,928 ) 1.2
Net earnings $ 19,064 4.0 $ 8,645 1.7
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Net sales-Third quarter 2012 net sales decreased by $20.9 million, or 4.2%,
compared to the third quarter of 2011, due to the sale of our Lewiston, Idaho
sawmill in November 2011. Excluding net sales of $22.0 million from the sawmill
in the third quarter of 2011, net sales for the third quarter of 2012 were
slightly higher as a result of record quarterly shipments of approximately
139,000 tons from our Consumer Products segment as well as higher paperboard
shipments. The increase in net sales was partially offset by lower external pulp
sales due to increased internal usage of the pulp we produce, a 2.4% decline in
paperboard net selling prices, and slightly lower overall tissue net selling
prices due to increased non-retail tissue sales, which had lower net sales
prices. These items are discussed further below under "Business Segment
Discussion."
Cost of sales-Cost of sales was 85.3% of net sales for the three months ended
September 30, 2012 and 89.6% of net sales for the same period in 2011. The
decrease was due primarily to lower costs for purchased pulp, chips, sawdust,
logs, transportation and energy, partially offset by higher chemical costs.
Selling, general and administrative expenses-Selling, general and administrative
expenses increased $3.8 million over the prior year period primarily as a result
of higher wage and benefit, incentive compensation and director equity-based
compensation expenses.
Interest expense-Interest expense decreased $4.2 million during the three months
ended September 30, 2012, compared to the same period of 2011. The decrease was
largely attributable to capitalized interest of $4.1 million associated with our
TAD project, compared to $0.8 million of capitalized interest in 2011. The
increase in capitalized interest was due to a higher level of cumulative capital
expenditures associated with the TAD project in the 2012 period.
Income tax expense-We recorded income tax expense of $12.8 million in the three
months ended September 30, 2012, compared to $5.9 million in the three months
ended September 30, 2011. The effective rate for the three months ended
September 30, 2012, was 40.2%, compared to an effective rate of 40.7% for the
same period of 2011. Income tax expense for both quarters included interest
accrued on uncertain tax positions.
Business Segment Discussion
Consumer Products
Three Months Ended
September 30,
(Dollars in thousands) 2012 2011
Net sales $ 292,959 $ 285,237
Operating income 18,453 7,075
Percent of net sales 6.3 % 2.5 %
. . .
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