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(920) 725-7000
(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: NONE
Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act. Yes o No þ
Indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or Section 15(d) of the Act. Yes o No þ
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 þ 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 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. þ
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated
filer, or a non-accelerated filer. See definition of “accelerated filer and large accelerated
filer” in Rule 12b-2 of the Exchange Act.
Large accelerated filer o Accelerated filer o Non-accelerated filer þ
Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of
the Act). Yes o No þ
State the aggregate market value of the voting and non-voting common equity held by
non-affiliates computed by reference to the price at which the common equity was last sold, or the
average bid and asked price of such common equity, as of the last business day of the registrant’s
most recently completed second fiscal quarter. The aggregate market value of the common equity of
Neenah Foundry Company held by non-affiliates as of March 31, 2006 was zero. All of the common
stock of Neenah Foundry Company is held by NFC Castings, Inc., a wholly owned subsidiary of ACP
Holding Company.
Indicate by check mark whether the registrant has filed all documents and reports required to
be filed by Section 12, 13 or 15(d) of the Securities Exchange Act of 1934 subsequent to the
distribution of securities under a plan confirmed by a court. Yes þ No o
Indicate the number of shares outstanding of each of the issuer’s classes of common stock, as
of the latest practicable date. On December 15, 2006, Neenah Foundry Company had 1,000 shares of
Common Stock, par value $100 per share, outstanding, all of which were owned by NFC Castings, Inc.,
a wholly owned subsidiary of ACP Holding Company.
Unless the context indicates otherwise, in this report, the terms “we,”“us,”“our,”“the
Company,” and “Neenah” refer to Neenah Foundry Company and its wholly owned subsidiaries, Deeter
Foundry, Inc. (“Deeter”), Mercer Forge Corporation (“Mercer”), Dalton Corporation (“Dalton”),
Advanced Cast Products, Inc. (“Advanced Cast Products”), Gregg Industries, Inc. (“Gregg”), Neenah
Transport, Inc. (“Neenah Transport”) and Cast Alloys, Inc. (“Cast Alloys”), which is inactive, and
their respective subsidiaries. Neenah, a Wisconsin corporation, is a wholly owned subsidiary of
NFC Castings, Inc. (“NFC”), a Delaware corporation, which is a wholly owned subsidiary of ACP
Holding Company (“ACP”), a Delaware corporation. Neither ACP nor NFC have any material assets or
liabilities other than their ownership of us.
Unless the context indicates otherwise, in this report, the terms “year” or “years” refer to
our fiscal year ending on September 30 of the referenced calendar year.
Forward-Looking Statements
In addition to historical information, this Annual Report on Form 10-K contains
forward-looking statements that involve risks and uncertainties that could cause our actual results
to differ materially. Factors that might cause or contribute to such differences include, but are
not limited to, those discussed in Item 1A, “Risk Factors,” or elsewhere in this report. When used
in this report, the words “expects,”“anticipates,”“intends,”“plans,”“believes,”“seeks,”“estimates” and similar expressions are generally intended to identify forward-looking statements.
These include, among other things, statements relating to the effects of general industry and
economic conditions on our operating results, our ability to retain our significant customers and
rely on our significant suppliers, our ability to compete with others in our industry, possible
litigation and labor disputes, our significant indebtedness and debt service obligations, our
future cash flow and earnings, and our ability to attract and retain qualified personnel. You
should not place undue reliance on these forward-looking statements, which reflect our opinions
only as of the date of this Annual Report. We undertake no obligation to publicly release any
revisions to the forward-looking statements after the date of this document. You should carefully
review the risk factors described in other documents we file from time to time with the Securities
and Exchange Commission, including the Quarterly Reports on Form 10-Q to be filed by us in our 2007
fiscal year, which runs from October 1, 2006 to September 30, 2007.
PART I
Item 1. BUSINESS
Overview
We are one of the largest independent foundry companies in the United States, and we believe
we are one of only two national suppliers of castings to the heavy municipal market. Our broad
range of heavy municipal iron castings includes manhole covers and frames, storm sewer frames and
grates, heavy-duty airport castings, specialized trench drain castings and ornamental tree grates.
We sell these municipal castings throughout the United States to state and local government
entities, utility companies, precast concrete manhole structure producers and contractors for both
new construction and infrastructure replacement. We are also a leading manufacturer of a wide range
of complex industrial iron castings and steel forgings, including specialized castings and forgings
for the heavy-duty truck industry, a broad range of iron castings and steel forgings for the
construction equipment and farm equipment industries, and iron castings used in heating,
ventilation and air conditioning, or HVAC, systems.
We have been able to achieve significant market shares in the major markets we serve. Each of
our 10 manufacturing facilities has unique capabilities to effectively serve our market niches.
We believe that the following factors have contributed to our success.
•
Leadership position in a relatively stable municipal market. We are one of the leading
suppliers of castings to the domestic municipal products market and, we believe, one of
only two national suppliers, with approximately 15,000 customers in all 50 states and over
6,000 part numbers shipped every year.
Approximately 40% of the individual part numbers we
shipped last year for the municipal market were in quantities of fewer than 10 pieces,
which we believe creates a significant barrier to entry. We also believe that we are the
only manufacturer that has invested in the unique patterns required to make many of these
specific products, resulting in significant barriers to entry.
•
Significant customer dependence on Neenah. The patterns for municipal products seldom
become obsolete and have been developed to various state and municipality specifications.
These patterns are 100% owned by Neenah. As a market leader, our municipal castings are
often specified as the standard in municipal contracts. Although the patterns for
industrial castings are owned by the customer and not the foundry, industrial patterns are
not readily transferable to other foundries without, in most cases, significant additional
investment. We estimate that we have historically retained throughout the product life
cycle over 95% of the patterns that we have been awarded. We believe we have the only
tooling for a significant majority of our industrial products by net sales.
•
Large and experienced sales and marketing force. Neenah has one of the largest sales
and marketing forces serving the U.S. heavy municipal end-user market. We also employ a
dedicated industrial casting sales force organized by facility. Our sales force supports
ongoing customer relationships, and works with customers’ engineers and procurement
representatives as well as our own engineers, manufacturing management and quality
assurance representatives throughout all stages of the production process to ensure that
the final product consistently meets or exceeds the specifications of our customers. This
team approach, consisting of sales, marketing, manufacturing, engineering and quality
assurance efforts, is an integral part of our marketing strategy. In addition, our 14
distribution and sales centers around the U.S. provide our municipal products customers
with readily available castings to meet their needs.
•
Focused manufacturing facilities with an emphasis on quality and implementation of lean
manufacturing concepts. We operate 10 focused manufacturing facilities in six states. We
focus our facilities on the specific markets and market segments that they are best suited
to serve, creating what we believe to be an efficient process flow which enables us to
provide superior products to each of our chosen markets. We continuously focus on
productivity gains by improving upon the individual steps of the casting process, which
enables us to produce castings in low and medium volume quantities on high volume,
cost-effective molding equipment. With a major focus on implementing lean manufacturing and
Six Sigma, we are continuously striving for improvement of operations and personnel,
emphasizing defect prevention, safety and the reduction of variation and waste in all
areas.
•
Value-added machining capabilities. Through our four machining facilities, we are able
to deliver a machined product to many of our customers, capturing a greater share of the
value chain and ensuring a closer working relationship. The casting machining process can
contribute significantly to the value of the end-product, in particular in certain custom
situations where high-value specialized machining is required. We continually evaluate
opportunities to increase our value-added machining services.
•
Experienced and well-respected senior management team. Our senior management team
provides a depth and continuity of experience in the casting industry.
Background
Our business was founded in 1872 and operated for 125 years by the founding family. In 1997,
Neenah Corporation (our parent holding company at that time) was acquired by NFC, which was a
holding company and a wholly owned subsidiary of ACP. A short time later Neenah Foundry Company
merged with and into Neenah Corporation and the surviving company changed its name to Neenah
Foundry Company.
In 1998, Neenah acquired all the capital stock of Deeter Foundry, Inc. (“Deeter”), Mercer
Forge Corporation (“Mercer”) and Dalton Corporation (“Dalton”). Advanced Cast Products, Inc.
(“Advanced Cast Products”) was owned by ACP prior to the time ACP acquired its interest in NFC. In
1999, Neenah acquired Gregg Industries, Inc. (“Gregg”).
Since 1945, Deeter has been producing gray iron castings for the heavy municipal market. The
municipal casting product line of Deeter includes manhole frames and covers, storm sewer inlet
frames, grates and curbs, trench grating and tree grates. Deeter also produces a wide variety of
special application construction castings. These products are utilized in waste treatment plants,
airports, telephone and electrical construction projects.
Founded in 1954, Mercer produces complex-shaped forged components for use in transportation,
railroad, mining and heavy industrial applications. Mercer is also a producer of microalloy
forgings.
Dalton manufactures and sells gray iron castings for refrigeration systems, air conditioners,
heavy equipment, engines, gear boxes, stationary transmissions, heavy-duty truck transmissions and
other automotive parts.
Advanced Cast Products manufactures ductile iron castings, primarily for companies in the
heavy-duty truck, construction equipment and railroad industries. Advanced Cast Products’
production capabilities also include a range of finishing operations including austempering and
machining.
Gregg manufactures gray and ductile iron castings, primarily for engine turbo-chargers and
heavy-duty truck applications.
Prior to 2003, Neenah also purchased and either sold or discontinued several other operations,
including Cast Alloys, a manufacturer of investment-cast titanium and stainless steel golf
clubheads, Hartley Controls Corporation, a manufacturer of foundry sand control equipment, Peerless
Corporation, which machined roller bearing adaptors for the railroad industry, and Belcher
Corporation, a malleable iron green sand foundry.
Beginning in 2000, several trends converged to create an extremely difficult operating
environment for the Company. First, there were dramatic cyclical declines in some of our most
important markets including trucks, railroad, construction and agriculture equipment. Second, there
was a major inventory adjustment by manufacturers in the residential segment of the HVAC equipment
industry, resulting in fewer orders for Dalton’s HVAC castings. Third, domestic foundries had been
suffering from underutilized capacity, significantly increased foreign competition, continued price
reduction pressure from customers and other competitors, and increased costs associated with
heightened safety and environmental regulations. These factors caused and to some extent continue
to cause a substantial number of foundries to cease operations or file for bankruptcy protection.
Beginning in May 2000, we took aggressive steps to offset the impact of the decline in sales and
earnings and improve cash flow in the difficult market environment, including an executive
management change, sales of non-core assets, a reduction in our labor force, a slowdown in capital
expenditures, and selected price increases. Despite these steps, the credit rating agencies began
to downgrade our outstanding debt obligations in early 2000.On July 1, 2003, Neenah together with
ACP, NFC and all of our wholly-owned domestic subsidiaries filed voluntary petitions for relief
under Chapter 11 of the United States Bankruptcy Code. By order dated September 26, 2003, the
Bankruptcy Court confirmed our Plan of Reorganization and the Plan of Reorganization became
effective on October 8, 2003. The Plan of Reorganization allowed us to emerge from bankruptcy with
an improved capital structure and, because we had arranged to continue paying our trade debt on a
timely basis during the pendency of the Chapter 11 case, at the time of emergence, we had
sufficient trade credit to continue operations in the ordinary course of business.
On July 29, 2005, Neenah and ACP announced that an investment banking firm had been engaged to
assist in exploring the potential sale or merger of Neenah or ACP or a significant portion of their
assets or
capital stock. On November 29, 2005, we announced that our board of directors, which is also
the board of directors of ACP, had unanimously voted to end the sale or merger process and turn our
focus to successfully implementing our business plan.
On May 25, 2006, we experienced a change of control when Tontine Capital Partners, L.P.
(“Tontine”) became the beneficial owner of more than a majority of the outstanding shares, on a
fully diluted basis, of our parent, ACP. As of December 15, 2006, Tontine beneficially owned, in
the aggregate, 22,929,467 shares, and 21,139,220 warrants to purchase shares, representing 54.5% of
all shares outstanding of ACP on a fully-diluted basis.
There are approximately 2,200 independent foundries in the United States with 80% of those
employing fewer than 100 employees. Only a small portion compete regularly with us, along with a
number of foreign foundries. The iron foundry industry has gone through significant consolidation
over the past 20 years, which has resulted in a significant reduction in the number of foundries
and a rise in the share of production by the remaining foundries. We have gained business as a
result of ongoing consolidation. Metal casting has historically been a cyclical industry with
performance generally correlated with overall economic conditions and also directly affected by
government (including environmental) regulation, foreign imports, and energy costs.
Most manufactured goods either contain or are made on equipment containing one or more cast
components. Metal castings are prevalent in most major market segments, including pipes and
fittings, air conditioners, automobiles, trucks, construction equipment and agricultural equipment
as well as within streets and highways. While general economic conditions have a directional effect
on the foundry industry as a whole, the strength of a particular end-market has a significant
effect on the performance of particular foundries serving those markets. The historic stability of
the heavy municipal market has helped mitigate the effects of downturns in our more cyclical
industrial end-markets, such as the heavy-duty truck market.
Business Strategy
We are focused on increasing stakeholder value through continued growth and refinement of our
business, improvement of our profit margins and continually providing our customers with the
highest levels of product quality and customer service. Key elements of our strategy are outlined
below.
•
Continued penetration of core markets. We seek to optimize our competitive position in
heavy municipal and industrial castings through separate strategies tailored to the
specific needs of each business. We expect to grow and leverage the strength and stability
of the municipal business by continuing to expand our participation in markets already
served and by augmenting our cost competitive capacity through the installation of a new
state-of-the-art mold line for larger, low volume castings, which we expect will enhance
production efficiencies, increase capacity and provide expanded molding capabilities. We
intend to further develop selected areas of the industrial business, such as construction
and agricultural products, and further our relationships with existing customers through
production of more complex industrial castings, while seeking out selected new customers.
Additionally, industry consolidation has resulted in a significant reduction in the number
of foundries and a rise in the share of production by the remaining foundries. We continue
to capitalize on on-going consolidation by taking advantage of opportunities created by the
closing of weak, inefficient foundries.
•
Deepen and expand customer relationships. We focus on creating close working
relationships with our customers by developing multiple points of contact throughout their
organizations. In addition to supporting on-going customer relationships, our sales force
also works with customers’ engineers and procurement representatives as well as with our
own engineers, manufacturing managers and quality assurance representatives throughout all
stages of the production process to ensure that the final product consistently meets or
exceeds the specifications of our customers. Since we are the sole-source supplier for the
majority of the products that we provide to our industrial customers, we
intend to expand those relationships by continuing to participate in the development and
production of more complex industrial castings, while seeking out selected new customers who
would value our capabilities and performance reputation, technical ability and high level of
quality and service.
•
Value-added focus. Our ability to provide value-added machining enhances the value of
the products we produce and is a competitive advantage as it positions us as a vital link
in each customer’s supply chain by providing customers with a single source alternative
that reduces supply chain costs and shortens lead times. Customers are increasingly
requesting that foundries supply machined components as it reduces handling as well as
their cost to process. We focus on value-added precision machined components involving
highly specialized and complex processes and, in some cases, difficult to machine
materials. We are currently working to further increase our market position by expanding
our value-adding machining capacity and our austempered ductile iron capabilities.
Continuous efficiency gains and cost reductions. We continually seek ways to reduce
our operating costs and increase our manufacturing productivity. We believe that a
combination of pricing adjustments and cost savings has mitigated the impact of cost creep
over the last two years. To further this objective, we have undertaken the following:
•
Installation of a new mold line at Neenah to replace our 40-year-old line. We
are currently beginning to invest approximately $54 million in a major upgrade through
the installation of a state-of-the-art mold line. We believe this new mold line, which is
expected to be operational in early calendar 2008, will substantially improve our cost
position on selected new and existing municipal parts, will substantially increase our
capacity and molding capabilities, and will be one of the most capable mold lines for
parts of this nature in North America.
•
Fully integrate lean manufacturing concepts. We have incorporated and expect to
continue to incorporate efficiencies in our operations through the implementation of
lean manufacturing.
•
Centralized procurement of major raw materials and certain services through our
head office in order to generate purchasing economies of scale. We work closely with
companies that are cost competitive and with which we have long-term relationships,
providing us with competitive pricing and helping to assure us supply when raw material
availability is limited.
Business Segments — Overview
We have two reportable segments, castings and forgings. The castings segment manufactures and
sells various grades of gray and ductile iron castings for the heavy municipal and industrial
markets, while the forgings segment manufactures and sells steel forged components for the
industrial market. The segments were determined based upon the production process utilized and the
type of product manufactured. Approximately 92% of our net sales for fiscal 2006 was derived from
our castings segment, with approximately 8% from our forgings segment.
Financial information about our reportable segments and geographic areas is contained in Note
9 in the Notes to Consolidated Financial Statements.
Castings Segment
We are a leading producer of iron castings for use in heavy municipal and industrial
applications. We sell directly to state and local municipalities, contractors, precasters, supply
houses, original equipment manufacturers (“OEMs”) and tier-one suppliers, as well as to other
industrial end-users.
Products, Customers and Markets
The castings segment provides a variety of products to both the heavy municipal and industrial
markets. Our broad range of heavy municipal iron castings include storm and sanitary sewer
castings, manhole covers and frames, storm sewer frames and grates, heavy-duty airport castings,
specialized trench drain castings, specialty flood control castings and ornamental tree grates.
Customers for these products include state and local government entities, utility companies,
precast concrete structure producers and contractors. Sales to the industrial market are comprised
of differential carriers and differential cases, transmissions, gear and axle housings, yokes,
planting and harvesting equipment parts, track drive and fifth wheel components, and compressor
components. Markets for these products include medium and heavy-duty truck, construction and
agricultural equipment and HVAC manufacturers.
A few large customers generate a significant amount of our net sales. See “Risk Factors — A
relatively small number of customers account for a substantial portion of our revenues. The loss of
one or more of them could adversely affect our net sales.”
Heavy Municipal
Our broad line of heavy municipal products consists of “standard” and “specialty” castings.
Standard castings principally consist of storm and sanitary sewer castings that are consistent with
pre-existing dimensional and
strength specifications established by local authorities. Standard
castings are generally higher volume items that are routinely used in new construction and
infrastructure replacement. Specialty castings are generally lower volume products, such as
heavy-duty airport castings, trench drain castings, flood control castings, special manhole and
inlet castings and ornamental tree grates. These specialty items are frequently selected and/or
specified from our municipal product catalog and tree grate catalog, which together encompass
thousands of pattern combinations. For many of these products, we believe that we are the only
manufacturer with existing patterns to produce such a particular casting.
Our municipal customers generally make purchase decisions based on a number of criteria,
including acceptability of the product per local specification, quality, availability, price and
the customer’s relationship with the foundry. We supply our municipal customers with anywhere from
one up to thousands of municipal castings in any given year.
During the over 70 years that we have manufactured municipal products, we have emphasized
servicing specific market needs and believe that we have built a strong reputation for customer
service. We believe that we are one of the leaders in U.S. heavy municipal casting production and
that we have strong name recognition. We have one of the largest sales and marketing forces of any
foundry serving the heavy municipal market. Our dedicated sales force works out of regional sales
offices and distribution yards to market municipal castings to contractors and state and local
governmental entities throughout the United States. We operate 14 regional distribution and sales
centers throughout the United States. We believe that this regional approach enhances our vast
knowledge of local specifications and our leadership position in the heavy municipal market.
Industrial
Industrial castings are generally more complex and usually are produced in higher volumes than
municipal castings. Complexity in the industrial market is determined by the intricacy of a
casting’s shape, the thinness of its walls and the amount of processing by a customer required
before a part is suitable for use. OEMs and their tier-one suppliers have been demanding more
complex parts principally to reduce their own labor costs by using fewer parts to manufacture the
same finished product or assembly and by using parts that require less subsequent processing before
being considered a finished product.
We primarily sell our industrial castings to OEMs and tier-one suppliers with whom we have
established close working relationships. These customers base their purchasing decisions on, among
other things, our technical ability, price, service, quality assurance systems, facility
capabilities and reputation. Our assistance in product engineering plays an important role in
winning bids for industrial castings. For the average industrial casting, 12 to 18 months typically
elapse between the completed design phase and full production. The product life cycle of a typical
industrial casting in the markets we serve is quite long, in many cases over 10 years. Although the
patterns for industrial castings are owned by the customer and not
the foundry, industrial patterns are not readily transferable to other foundries without, in
most cases, significant additional investment. Foundries, including our company, generally do not
design industrial castings. Nevertheless, a close working relationship between the foundry and the
customer during a product launch is critical to reduce potential production problems and minimize
the customer’s risk of incurring lost sales or damage to its reputation due to a delayed launch.
Involvement by a foundry early in the design process generally increases the likelihood that the
customer will design a casting within the manufacturing capabilities of that foundry and also
improves the likelihood that the foundry will be awarded the casting for full production.
We employ a dedicated industrial casting sales force organized by facility. Our sales forces
support ongoing customer relationships and work with customers’ engineers and procurement
representatives as well as our own engineers, manufacturing management and quality assurance
representatives throughout all stages of the production process to ensure that the final product
consistently meets or exceeds the specifications of our customers. This team approach, consisting
of sales, marketing, manufacturing, engineering and quality assurance efforts, is an integral part
of our marketing strategy.
Our foundries manufacture gray and ductile iron and cast it into intricate shapes according to
customer metallurgical and dimensional specifications. We continually invest in upgrading our
manufacturing capacity and in the improvement of process controls and believe that these
investments and our significant experience in the industry have made us one of the more efficient
manufacturers of industrial and heavy municipal casting products.
The sand casting process we employ involves using metal, wood or urethane patterns to make an
impression of a desired shape in a mold made primarily of sand. Cores, also made primarily of sand,
are used to make the internal cavities and openings in a casting. Once the casting impression is
made in the mold, the cores are set into the mold and the mold is closed. Molten metal is then
poured into the mold, which fills the mold cavity and takes on the shape of the desired casting.
Once the iron has solidified and cooled, the mold sand is separated from the casting and the sand
is recycled. The selection of the appropriate casting method, pattern, core-making equipment and
sand, and other raw materials depends on the final product and its complexity, specifications and
function as well as the intended production volumes. Because the casting process involves many
critical variables, such as choice of raw materials, design and production of tooling, iron
chemistry and metallurgy and core and molding sand properties, it is important to monitor the
process parameters closely to ensure dimensional precision and metallurgical consistency. We
continually seek out ways to expand the capabilities of existing technology to improve our
manufacturing processes.
Through incorporation of lean manufacturing concepts, we continuously focus on productivity
gains by improving upon the individual steps of the casting process such as reducing the amount of
time required to make a pattern change or to produce a different casting product. Such improvements
enable us to produce castings in low and medium volume quantities on high volume, cost-effective
molding equipment. Additionally, our extensive effort in real time process controls permits us to
produce a consistent, dimensionally accurate casting, which saves time and effort in the final
processing stages of production. This dimensional accuracy contributes significantly to our
manufacturing efficiency.
Continual testing and monitoring of the manufacturing process is important to maintain product
quality. We, therefore, have adopted sophisticated quality assurance techniques and Six Sigma for
our manufacturing operations. During and after the casting process, we perform numerous tests,
including tensile, proof-load, radiography, ultrasonic, magnetic particle and chemical analysis. We
utilize statistical process data to evaluate and control significant process variables and casting
dimensions. We document the results of this testing in metallurgical certifications that are
sometimes included with each shipment to our industrial customers. We strive to maintain systems
that provide for continual improvement of operations and personnel, emphasizing defect prevention,
safety and the reduction of variation and waste in all areas.
Raw Materials
The primary raw materials we use to manufacture ductile and gray iron castings are steel
scrap, pig iron, metallurgical coke and sand (core sand and molding sand). While there are multiple
suppliers for each of these commodities, we have generally elected to maintain single-source
arrangements with our suppliers for most of these major raw materials. Due to long standing
relationships with each of our suppliers, we believe that we will continue to be able to secure the
proper amount and type of raw materials in the quantities required and at competitive prices, even
when raw materials are in short supply. The owner of our major coke supplier recently announced
that it is considering strategic alternatives relating to this supplier. Should there be a change
in control of this supplier, the terms and conditions of our current supply arrangements with this
supplier could be impacted, possibly causing us to consider other alternatives. See “Risk Factors — Increases in the price or interruptions in the availability of raw materials and energy could
reduce our profits.”
Although the prices of the raw materials used vary, fluctuations in the cost of steel scrap
are the most significant to us. We generally have arrangements with our industrial customers that
enable us to adjust prices to reflect steel scrap cost fluctuations. In periods of rapidly rising
or falling steel scrap costs, these adjustments will lag behind the current cost of steel scrap
reflected in our casting price because they are generally based on average market prices for prior
periods. Such prior periods vary by customer, but are generally no longer than one month. We
generally recover steel scrap cost increases for municipal products through periodic price
increases. However, castings are sometimes sold to the heavy municipal market on a bid basis and
after a bid is won the price for the municipal
casting generally is not adjusted for increases in
the costs of raw materials. Rapidly fluctuating steel scrap costs may, however, have an adverse or
positive effect on our business, financial condition and results of operations.
Seasonality and Cyclicality
We experience seasonality in our municipal business where sales tend to be higher during the
construction season, which occurs during the warmer months, generally the third and fourth quarters
of our fiscal year. We attempt to maintain level production throughout the year in anticipation of
such seasonality and therefore do not experience significant production volume fluctuations. We
build inventory in anticipation of the construction season. This inventory build-up has a negative
impact on working capital and increases our liquidity needs during the second quarter. We have not
historically experienced significant seasonality in industrial casting sales.
We have historically experienced some cyclicality in the heavy municipal market as sales of
municipal products are influenced by, among other things, public spending and the state of the new
housing market. There is generally not a large backlog of business in the municipal market due to
the nature of the market. In the industrial market, we experience cyclicality in sales resulting
from fluctuations in our markets, including the medium and heavy-duty truck and the construction
and farm equipment markets, which are subject to general economic trends.
Competition
The markets for our products are highly competitive. Competition is based mainly on price, but
also on quality of product, range of capability, level of service and reliability of delivery. We
compete with numerous domestic foundries, as well as with some foreign iron foundries. We also
compete with several large domestic manufacturers whose products are made with materials other than
ductile and gray iron, such as steel or aluminum. Industry consolidation over the past 20 years has
resulted in a significant reduction in the number of foundries and a rise in the share of
production by the remaining foundries, some of which have significantly greater financial resources
than do we. Competition from foreign foundries has had an ongoing presence in the industrial and
heavy municipal market and continues to be a factor.
Forgings Segment
Our forgings segment, operated by Mercer, produces complex-shaped forged steel and micro alloy
components for use in transportation, railroad, mining and heavy industrial applications. Mercer
sells directly to OEMs and tier-one suppliers, as well as to industrial end-users. Mercer’s
subsidiary, A&M Specialties, Inc., machines forgings and castings for Mercer and various industrial
customers.
Products, Customers and Markets
Mercer produces hundreds of individually forged components and has developed specialized
expertise in forgings of micro alloy steel. Mercer currently operates mechanical press lines, from 1,300 tons to 4,000 tons. Mercer’s
primary customers include manufacturers of components and assemblies for heavy-duty trucks,
railroad equipment and construction equipment.
Mercer’s in-house sales organization sells directly to end-users and OEMs. A key element of
Mercer’s sales strategy is its ability to develop strong customer relationships through responsive
engineering capability, dependable quality and reliable delivery performance.
Demand for forged products closely follows the general business cycles of the various market
segments and the demand level for capital goods. While there is a more consistent base level of
demand for the replacement parts portion of the business, the strongest expansions in the forging
industry coincide with the periods of industrial segment economic growth.
Manufacturing Process
In forging, metal is pressed, pounded or squeezed under great pressure, with or without the
use of heat, into parts that retain the metal’s original grain flow, imparting high strength.
Forging usually entails one of four principal
processes: impression die; open die; cold; and
seamless rolled ring forging. Impression die forging, commonly referred to as “closed die” forging,
is the principal process employed by Mercer, and involves bringing two or more dies containing
“impressions” of the part shape together under extreme pressure, causing the bar stock to take the
desired shape. Because the metal flow is restricted by the die, this process can yield more complex
shapes and closer tolerances than the “open die” forging process. Impression die forging is used to
produce products such as military and off-highway track and drive train parts; automotive and truck
drive train and suspension parts; railroad engine, coupling and suspension parts; military
ordinance parts and other items where close tolerances are required.
Once a rough forging is shaped, regardless of the forging process, it must generally still be
machined. This process, known as “finishing” or “conversion,” smoothes the component’s exterior and
mating surfaces and adds any required specification, such as groves, threads and bolt holes. The
finishing process can contribute significantly to the value of the end product, in particular in
certain custom situations where high value specialized machining is required. Machining can be
performed either in-house by the forger, by a machine shop which performs this process exclusively
or by the end-user.
Mercer’s internal staff of engineers designs impression dies to meet customer specifications
incorporating computer assisted design workstations for the design. Management believes that Mercer
is an industry leader in forging techniques using micro alloy steel which produces parts which are
lighter and stronger than those forged from conventional carbon steel.
Raw Materials
The principal raw materials used in Mercer’s products are carbon and micro alloy steel. Mercer
purchases substantially all of its carbon steel from four principal sources. While Mercer has never
suffered any significant interruption of materials supply, management believes that, in the event
of any disruption from any individual source, adequate alternative sources of supply are available
within the immediate vicinity.
Seasonality and Cyclicality
Mercer experiences only minimal seasonality in its business. Mercer has experienced moderate
cyclicality in sales resulting from fluctuations in the medium and heavy-duty truck market and the
heavy industrial market, which are subject to general economic trends.
Competition
Mercer competes primarily in a highly fragmented industry which includes several dozen other
press forgers and hammer forge shops. Hammer shops cannot typically match press forgers for high
volume, single component manufacturing or close tolerance production. Competition in the forging
industry has also historically been determined both by product and geography, with a large number
of relatively small forgers across the country carving out their own product and customer niches.
In addition, most end-users manufacture some forgings internally, often maintaining a critical
minimum level of production in-house and contracting out the balance. The primary basis of
competition in the forging industry is price, but engineering, quality and dependability are also
important, particularly with respect to building and maintaining customer relationships. Some of
Mercer’s competitors have significantly greater resources than Mercer. There can be no assurance
that Mercer will be able to maintain or improve its competitive position in the markets in which it
competes.
Employees
As of September 30, 2006, we had 2,950 full time employees, of whom 2,380 were hourly
employees and 570 were salaried employees. Approximately 81% of our hourly employees are
represented by unions. Nearly all of the hourly employees at Neenah, Dalton, Advanced Cast Products
and Mercer are members of either the United Steelworkers of America or the Glass, Molders, Pottery,
Plastics and Allied Workers International Union. A collective bargaining agreement is negotiated
every two to five years. The material agreements expire as follows: Neenah, December 2006;
Dalton-Warsaw, April 2008; Dalton-Kendallville, June 2007; Advanced Cast Products-Meadville,
October 2010; and Mercer, June 2008. All employees at Deeter and Gregg are non-union. We believe
that we have a good relationship with our employees.
Our facilities are subject to federal, state and local laws and regulations relating to the
protection of the environment and worker health and safety, including those relating to discharges
to air, water and land, the generation, handling and disposal of solid and hazardous waste, the
cleanup of properties affected by hazardous substances, and the health and safety of our employees.
Such laws include the Federal Clean Air Act, the Clean Water Act, the Resource Conservation and
Recovery Act, the Comprehensive Environmental Response, Compensation, and Liability Act of 1980,
and the Occupational Health and Safety Act. Under certain environmental laws, we could be held
responsible for all of the costs relating to any contamination at our past or present facilities
and at third party waste disposal sites. We could also be held liable for any and all consequences
arising out of human exposure to such substances or other environmental damage.
We are presently operating our Gregg facility under the terms of an order of abatement with
the California South Coast Air Quality Management District (SCAQMD). See “Legal Proceedings.”
We believe we have no liabilities relating to environmental matters which would have a
material adverse effect on our operations, financial condition or competitive position. However,
the risk of environmental liability is inherent in the manufacture of castings and forgings. Any of
our businesses might in the future incur significant costs to meet current or more stringent
compliance, cleanup or other obligations pursuant to environmental requirements. Such costs may
include expenditures related to remediation of historical releases of hazardous substances or
clean-up of physical structures prior to decommissioning. We have incurred in the past, and expect
to incur in the future, capital and other expenditures related to environmental compliance. Such
expenditures are generally included in our overall capital and operating budgets and are not
separately accounted for. However, we do not anticipate that compliance with existing environmental
laws will have a material adverse effect on our capital expenditures, earnings or competitive
position.
Under the Federal Clean Air Act Amendments of 1990, the Environmental Protection Agency is
directed to establish maximum achievable control technology (MACT) standards for certain industrial
operations that are major sources of hazardous air pollutants. The iron foundry industry will be
required to implement the MACT emission limits, control technologies or work practices by April
2007. Our Neenah foundry and both Dalton foundries are subject to this requirement (due to their
size). Our Dalton facilities received one-year extensions, which requires them to be in compliance
with the new standards by April 2008. A majority of the approximately $3.0 million of capital
expenditures necessary to bring these three facilities into compliance with MACT requirements has
already been made and we expect all three facilities to achieve MACT compliance by the applicable
deadlines.
The Clean Water Act requires point dischargers to obtain storm water discharge permits. In
Wisconsin, Neenah is covered by the state’s General Permit to Discharge Storm Water Associated with
Industrial Activity. The Wisconsin Department of Natural Resources, which is authorized to
administer the storm water program, has adopted new benchmark values for various storm water
contaminants. Neenah expects to spend $1.2 million in fiscal year 2007 on storm water treatment
devices that will allow it to achieve compliance with the new benchmarks.
Intellectual Property
We have registered, or are in the process of registering, various trademarks and service marks
with the U.S. Patent and Trademark Office.
Item 1A. RISK FACTORS
Owning our securities and those of our parent, ACP, involves a high degree of risk. The risks
described below are not the only risks facing us. Additional risks and uncertainties not currently
known to us or those we currently view to be immaterial may also materially and adversely affect
our business, financial condition or results of operations. If any of the following risks
materialize, our business, financial condition or results of operations could be materially and
adversely affected. In that case, security holders may lose some or all of their investment.
A relatively small number of customers account for a substantial portion of our revenues. The loss
of one or more of them could adversely affect our net sales.
A few large customers generate a significant amount of our net sales.
•
Sales to our largest customer and entities related to such customer accounted for
approximately 10% of our total net sales for the fiscal year ended September 30, 2006.
•
Sales to our top five customers and entities related to such customers accounted for
approximately 31% of our total net sales for the fiscal year ended September 30, 2006.
The loss of one or more of these large customers, therefore, could adversely affect our net
sales. We do not generally have long-term contracts with our customers and we also do not own the
patterns used to produce industrial castings. As a result, our customers could switch to other
suppliers at any time. If our customers should move production of their products outside the United
States, they would likely attempt to find local suppliers for the components they purchase from us.
Certain of our largest industrial customers, particularly in the heavy-duty truck market, are
experiencing financial challenges. For example, on March 3, 2006, Dana Corporation (“Dana”), our
largest customer, filed a voluntary petition for relief under Chapter 11 of the United States
Bankruptcy Code. As a result, we estimate that the Company will lose approximately $0.1 million of
the $4.7 million that Dana owed us at the time of Dana’s bankruptcy filing. See “Management’s
Discussion and Analysis of Financial Condition and Results of Operations — Recent Developments.”
Although we are an important supplier to many of our customers, there can be no assurance that we
would be designated an “essential supplier” or “critical
vendor” (as we were by Dana) if any of our other major customers becomes a debtor in
bankruptcy, and the loss of any of our major customers could adversely affect our net sales.
Decreases in demand for heavy-duty trucks, HVAC equipment, construction or farm equipment or other
end markets could have a significant impact on our profitability, cash flows and ability to service
our indebtedness.
Our company has historically experienced industry cyclicality in most of our industrial
markets, including the truck and farm equipment markets. These industries and markets fluctuate in
response to factors that are beyond our control, such as general economic conditions, interest
rates, federal and state regulations, consumer spending, fuel costs and our customers’ inventory
levels and production rates. These major markets will likely continue to experience such
fluctuations. A downturn in one or more of these markets could reduce demand for, and prices of,
our products. Such a downturn in one or more of these major markets could have a significant
negative impact on sales of our products, which could lower our profitability, cash flows, and
ability to service our indebtedness. Historically, our heavy municipal business has been less
cyclical than our industrial markets. We have historically experienced some cyclicality in the
heavy municipal market as sales of municipal products are influenced by, among other things, public
spending and the state of the new housing market.
Due to new emissions standards set to take effect on January 1, 2007, heavy-duty truck
production is expected to decline significantly beginning early in calendar 2007, as many customers
have accelerated purchases to 2006, artificially increasing 2006 sales to this segment. Additional
emissions regulations are scheduled to take effect in calendar 2010, which may have a similar
effect of accelerating sales to 2009. In addition, housing starts are expected to decline further
in calendar 2007, reflecting softness in the overall housing sector.
As a result, we are now experiencing a decline in our sales into
these end-markets, and we expect our
sales to these end-markets to further deteriorate in fiscal 2007 from fiscal 2006 levels, which
will lower our profitability and cash flows.
Our market share may be adversely impacted at any time by a significant number of competitors.
The markets in which we compete are highly competitive and are expected to remain so. The
foundry industry overall has excess capacity, which exerts downward pressure on prices of our
products. We may be unable to maintain or improve our competitive position in the markets in which
we compete. Although quality of product, range of capability, level of service and reliability of
delivery are important factors in selecting foundry suppliers, we are also forced to compete on
price. We compete with numerous domestic and some foreign foundries. Although our castings are
manufactured from ductile and gray iron, we also compete in our industrial markets with several
manufacturers whose products are made with other materials, such as steel or aluminum. Industry
consolidation over the past 20 years has significantly reduced the number of foundries operating in
the United States. While such consolidation has translated into greater market share for the
remaining foundries, some of these remaining foundries have significantly greater financial
resources than we do and may be better able to sustain periods of decreased demand or increased
pricing pressure. At the same time, the prices of products imported from foreign foundries,
particularly from China, India, Mexico and South America, are generally lower than the prices we
charge to our customers. Countervailing duties and/or anti-dumping orders on imports currently
apply to China, Brazil, Mexico and Canada, and any reduction thereof could increase foreign
competition. Furthermore, despite the reduction in the number of domestic operating foundries,
total production capacity continues to exceed demand. Any of these factors could impede our ability
to remain competitive in the markets in which we operate.
International economic and political factors could affect demand for products which could impact
our financial condition and results of operations.
Our operations may be affected by actions of foreign governments and global or regional
economic developments. Global economic events, such as foreign countries’ import/export policies,
the cost of complying with environmental regulations or currency fluctuations, could also affect
the level of U.S. imports and exports, thereby affecting our sales. Foreign subsidies, foreign
trade agreements and each country’s adherence to the terms of such agreements can raise or lower
demand for castings produced by us
and other U.S. foundries. National and international boycotts and embargoes of other
countries’ or U.S. imports and/or exports together with the raising or lowering of tariff rates
could affect the level of competition between us and our foreign competitors. If the value of the
U.S. dollar strengthens against other currencies, imports to the United States may increase and put
downward pressure on the prices of our products, which may adversely affect our sales, margins and
profitability. Such actions or developments could have a material adverse effect on our business,
financial condition and results of operations.
Increases in the price or interruptions in the availability of raw materials and energy could
reduce our profits.
The costs and availability of raw materials and energy represent significant factors in the
operations of our business. As a result of domestic and international events, the prices and
availability of our key raw materials and energy fluctuate. We have single-source, just-in-time
arrangements with many of our suppliers for the major raw materials that we use. If a single-source
supplier were to become unable or unwilling to furnish us with essential materials for any reason,
that could impair our ability to manufacture some of our products. Potential causes of such
interruptions could include, among others, any casualty, labor unrest, or regulatory problems of
the supplier, or a change in ownership of a supplier leading to subsequent business decisions that
do not align with our own business interests. The owner of our major coke supplier recently
announced that it is considering strategic alternatives relating to this supplier. Should there be
a change in control of this supplier, the terms and conditions of our current supply arrangements
with this supplier could be impacted, possibly causing us to consider other alternatives. Also, the
failure of these single-source arrangements to result in the most highly competitive prices for raw
materials could increase our cost of sales and lower our profit. If our raw material or energy
costs increase, we may not be able to pass these higher costs on to our customers in full or at
all.
Of all the varying costs of raw materials, fluctuations in the cost of steel scrap impact our
business the most. The cost for steel scrap is subject to market forces that are unpredictable and
largely beyond our control, including demand by U.S. and international foundries, freight costs and
speculation. Although we have arrangements with our industrial customers that enable us to adjust
industrial casting prices to reflect steel scrap cost fluctuations, these adjustments lag behind
the current cost of steel scrap during periods of rapidly rising or falling steel scrap costs
because these adjustments are generally based on average market costs for prior periods. Thus, our
profitability could be negatively impacted if we are unable to pass along increases in the cost of
steel scrap to our customers effectively.
We may incur potential product liability and recall costs.
We are subject to the risk of exposure to product liability and product recall claims in the
event any of our products results in property damage, personal injury or death, or does not conform
to specifications. We may not be able to continue to maintain suitable and adequate insurance on
acceptable terms that will provide adequate protection against potential liabilities. In addition,
if any of our products proves to be defective, we may be required
to participate in a recall
involving such products. A successful claim brought against us in excess of available insurance
coverage, if any, or a requirement to participate in a major product recall, could have a material
adverse effect on our business, results of operations or financial condition.
Litigation against us could be costly and time consuming to defend.
We and our subsidiaries are regularly subject to legal proceedings and claims that arise in
the ordinary course of business. We are presently disputing a claim from an investment bank for
$3.34 million in fees allegedly arising from Tontine’s acquisition of control of the Company in May
2006. We are also subject to workers’ compensation claims (including those related to silicosis),
employment disputes, unfair labor practice charges, customer and supplier disputes, product
liability claims and contractual disputes related to warranties and guarantees arising out of the
conduct of our business. Litigation may result in substantial costs and may divert management’s
attention and resources, which could adversely affect our business, results of operations or
financial condition.
The departure of key personnel could adversely affect our operations.
The success of our business depends upon our senior management closely supervising all aspects
of our business. We believe our senior management has technological and manufacturing experience
that is important to the metal casting and forging business. The loss of such key personnel could
have a material adverse effect on our operations if we were unable to attract and retain qualified
replacements.
In addition, we have from time to time experienced difficulty hiring enough skilled employees
with the necessary expertise to build the products ordered by our customers in the metal casting
and forging business. An inability to hire and retain such employees could have a material adverse
effect on our operations.
The seasonal nature of our business could impact our business, financial condition and results
of operations.
Our business is seasonal. Therefore, our quarterly revenues and profits historically have been
lower during the first and second fiscal quarters of the year (October through March) and higher
during the third and fourth fiscal quarters (April through September). In addition, our working
capital requirements fluctuate throughout the year. Adverse market or operating conditions during
any seasonal part of the fiscal year could have a material adverse effect on our business,
financial condition and results of operations.
We face the risk of work stoppages or other labor disruptions that could impact our results of
operations negatively.
As of September 30, 2006, approximately 81% of our workforce consisted of hourly employees,
and of those approximately 81% are represented by unions. Nearly all of the hourly employees at
Neenah, Dalton, Advanced Cast Products and Mercer are members of either the United Steelworkers of
America or the Glass, Molders, Pottery, Plastics and Allied Workers International Union. As a
result, we could experience work stoppages or other labor disruptions. If this were to occur, we
may not be able to satisfy our customers’ orders on a timely basis. Our principal collective
bargaining agreement at our Neenah facility expires in December 2006 and no assurances can be made
that we will be able to renegotiate this agreement on terms that are acceptable to us. Our
operations could be adversely affected if we experience a work stoppage or other labor disruption.
The nature of our business exposes us to liability for violations of environmental regulations
and releases of hazardous substances.
The risk of environmental liability is inherent in the manufacturing of casting and forging
products. We are subject to numerous laws and regulations governing, among other things: discharges
to air, water and land; the generation, handling and disposal of solid and hazardous waste; the
cleanup of properties affected by hazardous substances; and the health and safety of our employees.
Changes in environmental laws and regulations, or the discovery of previously unknown contamination
or other liabilities relating to our properties and operations, could require us to sustain
significant environmental liabilities. In addition, we might incur significant capital and other
costs to comply with increasingly stringent emission control laws and enforcement policies which
could decrease our cash flow. We are also required to obtain permits from governmental authorities
for certain operations. We
cannot assure you that we have been or will be at all times in complete
compliance with such laws, regulations and permits. If we violate or fail to comply with these
laws, regulations or permits, we could be fined or otherwise sanctioned by regulators.
Under certain environmental laws, we could be held responsible for all of the costs relating
to any contamination at our past or present facilities and at third party waste disposal sites. We
could also be held liable for any and all consequences arising out of human exposure to such
substances or other environmental damage.
Environmental laws are complex, change frequently and have tended to become increasingly
stringent over time. We incur operating costs and capital expenditures on an ongoing basis to
ensure our compliance
with applicable environmental laws and regulations. We cannot assure you that our costs of
complying with current and future environmental and health and safety laws and regulations, and our
liabilities arising from past or future releases of, or exposure to, hazardous substances will not
adversely affect our business, results of operations or financial condition. See “Business —
Environmental Matters.”
Failure to raise necessary capital could restrict our ability to operate and further develop
our business.
Our capital resources may be insufficient to enable us to maintain operating profitability.
Failure to generate or raise sufficient funds may require us to delay or abandon some expansion
plans or expenditures, which could harm our business and competitive position.
We estimate that our aggregate expenditure requirements in fiscal 2007 will include projected
costs of:
•
approximately $22.0 million primarily for necessary maintenance capital expenditures
and selected strategic capital investments required to maintain optimum operating
efficiencies, not including the new mold line described elsewhere herein;
•
approximately $32.2 million for the new mold line (of the total cost of approximately
$54 million); and
•
approximately $31.7 million for debt service on our outstanding 11% Senior Secured
Notes and 13% Senior Subordinated Notes plus any additional interest expense from amounts
outstanding under the credit facility.
In addition, we will require funds for general corporate expenses, other expenses (including
pension expenses discussed in “Management’s Discussion and Analysis of Financial Condition and
Results of Operations — Contractual Obligations”), certain environmental capital expenditures and
for working capital fluctuations.
We may choose to meet any additional financial needs by borrowing additional funds under our
credit facility or from other sources. As of September 30, 2006, subject to certain limitations, we
had $54.1 million available to borrow under our credit facility. See “Management’s Discussion and
Analysis of Financial Condition and Results of Operations — Liquidity and Capital Resources.” Our
ability to issue debt securities, borrow funds from additional lenders and participate in vendor
financing programs are restricted under the terms of the credit facility and the indentures
governing our outstanding notes.
We may not achieve the expected benefits of our new mold line.
As part of our business strategy, we are beginning to invest in a $54 million capital project
to replace an existing mold line at our Neenah facility. We expect the new mold line to become
operational in early calendar 2008. We believe we will have access to sufficient funds to support
this project. However, similar to other large capital expenditure projects, we are at risk to many
factors beyond our control that may prevent or hinder our launch of the new mold line or lead to
cost overruns, including new or more expensive obligations to comply with environmental
regulations, technical or mechanical problems, construction delays, shortages of equipment,
materials or skilled labor, lack of available capital and other factors. Even if we effectively
complete this project, we may not be able to capitalize on the additional capacity the mold line
will provide, which may result in sales or profitability at lower levels than anticipated. Failure
to successfully implement this business strategy may adversely affect our business prospects and
results of operations.
Our controlling shareholder may have interests that differ from the interests of our other security holders.
Nearly half of the outstanding stock of our parent corporation, ACP Holding Company, and a
majority of such stock on a fully-diluted basis, is owned by Tontine Capital Partners, L.P.
(“Tontine”). As a result, Tontine controls ACP’s and our affairs, including the election of
directors who in turn appoint management for both us and ACP. Tontine controls any action requiring
the approval of the holders of stock of our parent corporation, including adoption of amendments to
its corporate charter and approval of a merger or sale of all or substantially all assets. It also
controls decisions affecting our capital structure, such as decisions regarding the issuance of
additional capital stock, the implementation of stock repurchase programs and the declaration of
dividends. The interests of Tontine may not in all cases be aligned with the interests of our other
equity holders and with holders of our outstanding notes. For example, the equity holders may have
an interest in pursuing acquisitions, divestitures, financings and other transactions that, in
their judgment, could enhance their equity investments, even though those transactions might
involve risks to the holders of outstanding notes. Additionally, Tontine is in the business of
investing in companies and may, from time to time, acquire and hold interests in businesses that
compete directly or indirectly with us. Tontine may also pursue acquisition opportunities that may
be complementary to our business and, as a result, those acquisition opportunities may not be
available to us.
Terrorist attacks could adversely affect our results of operations, our ability to raise capital or our future growth.
The impact that terrorist attacks, such as those carried out on September 11, 2001, and the
war in Iraq, as well as events occurring in response to or in connection with them, may have on our
industry in general, and on us in particular, is unknown at this time. Such attacks, and the
uncertainty surrounding them, may impact our operations in unpredictable ways, including
disruptions of rail lines, highways and fuel supplies and the possibility that our facilities could
be direct targets of, or indirect casualties of, an act of terror. In addition, war or risk of war
may also have an adverse effect on the economy. A decline in economic activity could adversely
affect our revenues or restrict our future growth. Instability in the financial markets as a result
of terrorism or war could also affect our ability to raise capital. Such attacks may lead to
increased volatility in fuel costs and availability and could affect the results of operations. In
addition, the insurance premiums charged for some or all of the coverages we currently maintain
could increase dramatically, or the coverages could be unavailable in the future.
Our substantial indebtedness could adversely affect our financial health.
We have a significant amount of indebtedness. At September 30, 2006, we and our subsidiaries
had approximately $265.4 million of secured indebtedness outstanding, consisting of approximately
$1.2 million of capital lease obligations, approximately $38.0 million of indebtedness under our
credit facility and approximately $226.2 million of outstanding notes. In addition, we and our
subsidiaries had approximately $54.1 million of undrawn borrowing capacity under our credit
facility.
Our substantial indebtedness could have important consequences to the holders of our and ACP’s
securities. For example, it could:
•
make it more difficult for us to satisfy our obligations with respect to our outstanding notes;
•
increase our vulnerability to general adverse economic and industry conditions;
•
require us to dedicate a substantial portion of our cash flow from operations to
payments on our indebtedness, thereby reducing the availability of our cash flow to fund
working capital, capital expenditures, research and development efforts and other general
corporate purposes;
•
increase our vulnerability to and limit our flexibility in planning for, or reacting
to, changes in our business and the industry in which we operate;
•
expose us to the risk of increased interest rates as borrowings under our credit
facility are subject to variable rates of interest;
•
place us at a competitive disadvantage compared to our competitors that have less debt; and
In addition, the indentures for our outstanding notes and our credit facility contain
financial and other restrictive covenants that limit our ability to engage in activities that may
be in our long-term best interests. Our failure to comply with those covenants could result in an
event of default which, if not cured or waived, could result in the acceleration of all of our
debts.
Despite our current substantial indebtedness levels, we and our subsidiaries may still be able to
incur substantially more debt. This could intensify the risks associated with our substantial
leverage.
We and our subsidiaries may be able to incur substantial additional indebtedness in the future
because the terms of the indentures governing our outstanding notes and our credit facility do not
fully prohibit us or our subsidiaries from doing so. If new indebtedness is added to our and our
subsidiaries’ current debt levels, the related risks that we and they now face could intensify.
To service our indebtedness, we will require a significant amount of cash. Our ability to generate
cash depends on many factors beyond our control.
Our ability to make payments on and to refinance our indebtedness and to fund planned capital
expenditures, research and development efforts and other cash needs will depend on our ability to
generate cash in the future. This, to a certain extent, is subject to general economic, financial,
competitive, legislative, regulatory and other factors that are beyond our control.
We cannot assure you that our business will generate sufficient cash flow from operations or
that future borrowings will be available to us under our credit facility or otherwise in an amount
sufficient to enable us to pay our indebtedness or to fund our other liquidity needs. We may need
to refinance all or a portion of our indebtedness on or before the maturity thereof. We cannot
assure you that we will be able to refinance any of our indebtedness on commercially reasonable
terms or at all. If we cannot service our indebtedness, we may have to take actions such as selling
assets, seeking additional equity or reducing or delaying capital expenditures, strategic
acquisitions, investments and alliances. We cannot assure you that any such actions, if necessary,
could be effected on commercially reasonable terms or at all.
The terms of our debt impose restrictions on us that may affect our ability to successfully operate
our business.
Our credit facility and the indentures governing our outstanding notes contain covenants that
limit our actions. These covenants could materially and adversely affect our ability to finance our
future operations or capital needs or to engage in other business activities that may be in our
best interests. The covenants limit our ability to, among other things:
•
incur or guarantee additional indebtedness;
•
pay dividends or make other distributions on capital stock;
•
repurchase capital stock;
•
make loans and investments;
•
enter into agreements restricting our subsidiaries’ ability to pay dividends;
Our credit facility also contains financial covenants. Our ability to comply with these
covenants and requirements may be affected by events beyond our control, such as prevailing
economic conditions and changes in regulations, and if such events occur, we cannot be sure that we
will be able to comply. A breach of these covenants could result in a default under the indentures
governing our outstanding notes and/or our credit facility. If there were an event of default under
the indentures for the notes and/or the credit facility, holders of such defaulted debt could cause
all amounts borrowed under these instruments to be due and payable immediately, they could
foreclose on the collateral securing our debts and the lenders under the credit facility could
terminate their commitments to lend. We cannot assure you that our assets or cash flow will be
sufficient to repay borrowings under the outstanding debt instruments in the event of a default
thereunder.
There is no active trading market for any of our or ACP’s securities, and there is no assurance
that any active trading market will develop for them.
There is no established public trading market for our outstanding notes or ACP’s outstanding
stock or warrants. We cannot assure you that an active market for any of those securities will
develop or, if developed, that it will continue.
Item 1B. UNRESOLVED STAFF COMMENTS
Not applicable.
Item 2. PROPERTIES
We maintain the following manufacturing, machining and office facilities. We own all of the
facilities except Mercer’s machining facility, which we lease.
Entity
Location
Purpose
Sq. Feet
Castings Segment
Neenah Foundry Company
Neenah, WI
2 manufacturing facilities and office facility
550,000
Dalton Corporation
Warsaw, IN
Manufacturing and office facilities
375,000
Kendallville, IN
Manufacturing facility
250,000
Stryker, OH
Machining facility
45,000
Advanced Cast Products, Inc.
Meadville, PA
Manufacturing, machining and office facility
229,000
Deeter Foundry, Inc.
Lincoln, NE
Manufacturing and office facility
75,000
Gregg Industries, Inc.
El Monte, CA
Manufacturing, machining and office facility
200,000
Forgings Segment
Mercer Forge Corporation
Mercer, PA
Manufacturing, machining and office facility
130,000
Wheatland, PA
Machining facility
18,000
The principal equipment at the facilities consists of foundry equipment used to make
castings, such as melting furnaces, core making machines and mold lines, including ancillary
equipment needed to support a foundry operation and presses used to make forgings. We regard our
plant and equipment as appropriately maintained and adequate for our needs. We are proceeding with
a major capital project to install a new mold line at our Neenah location. This project will result
in a building expansion that will add approximately 75,000 square feet of
manufacturing area to the plant. In addition to the facilities described above, we operate 14
distribution and sales centers. We own six of those properties and lease eight of them.
Substantially all of our tangible and intangible assets are pledged to secure our existing
credit facility and our 11% Senior Secured Notes due 2010. See Note 5 in the Notes to Consolidated
Financial Statements in this report.
Item 3. LEGAL PROCEEDINGS
We are involved in various claims and litigation in the normal course of business. In the
judgment of management, the ultimate resolution of these matters is not likely to materially affect
our consolidated financial statements, except with respect to the matters described below.
We are presently operating our Gregg facility under the terms of an order of abatement with
the California South Coast Air Quality Management District (SCAQMD). The order requires us to
comply with certain operating parameters in an effort to reduce odors. Failure to operate within
such criteria could result in the SCAQMD terminating operations at the Gregg facility. The current
order expires on March 31, 2007. We believe we are in compliance with the testing and operating
requirements mandated by the order and that our actions have resulted in a substantial reduction in
the intensity and frequency of observable downwind odors.
We are presently disputing a claim from an investment bank for $3.34 million in fees allegedly
arising from Tontine’s acquisition of control of the Company in May 2006. See “Certain
Relationships and Related Transactions.”
Item 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
There were no matters submitted to a vote of security holders during the quarter ended
September 30, 2006.
Item 5. MARKET FOR REGISTRANT’S COMMON EQUITY, RELATED STOCKHOLDER MATTERS AND ISSUER PURCHASES OF EQUITY SECURITIES.
There is no public market for our common stock. There was one holder of record of our common
stock as of December 15, 2006, NFC Castings, Inc., a wholly
owned subsidiary of ACP Holding Company.
We have not paid any cash dividends on our common stock in the last two fiscal years nor have
we repurchased any equity securities in the fourth quarter of fiscal 2006. Our credit facility and
the indentures providing for our senior secured and senior subordinated notes severely restrict our
ability to pay dividends or repurchase equity. See “Liquidity and Capital Resources” in Item 7 and
Note 5 in the Notes to Consolidated Financial Statements for a description of those limitations.
Item 6. SELECTED FINANCIAL DATA
The following table sets forth our selected historical consolidated financial data as of and
for the years ended September 30, 2006, 2005, 2004, 2003 and 2002, which have been derived from our
audited consolidated financial statements. The historical results presented below are not
necessarily indicative of financial results to be achieved in future periods.
The information contained in the following table should also be read in conjunction with
“Management’s Discussion and Analysis of Financial Condition and Results of Operations,” and our
historical consolidated financial statements and related notes included elsewhere in this document.
On August 5, 2003, ACP, NFC, and Neenah filed for bankruptcy
protection. They emerged from bankruptcy on October 8, 2003.
Although the Plan of Reorganization became effective on October 8,2003 (the “Effective Date”), due to the immateriality of the
results of operations for the period between October 1, 2003 and
the Effective Date, for financial reporting purposes we recorded
the fresh-start adjustments necessitated by the American
Institute of Certified Public Accountants Statement of Position
90-7, “Financial Reporting by Entities in Reorganization under the
Bankruptcy Code,” (“SOP 90-7”) on October 1, 2003. As a result of
the gain on extinguishment of debt and adjustments to the fair
value of assets and liabilities, we recognized a $43.9 million
reorganization gain on October 1, 2003. As a result of our
emergence from Chapter 11 bankruptcy and the application of
fresh-start reporting, our consolidated financial statements for
the periods commencing on October 1, 2003 are referred to as the
“Reorganized Company” and are not comparable with any periods
prior to October 1, 2003, which are referred to as the
“Predecessor Company”. All references to the years ended September30, 2006, 2005 and 2004 are to the Reorganized Company. All
references to the years ended September 30, 2003 and 2002 are to
the Predecessor Company.
(2)
During the year ended September 30, 2002, we discontinued the
operations of Cast Alloys. The results of Cast Alloys have been
reported separately as discontinued operations for all periods
presented.
(3)
During the year ended September 30, 2003, we sold substantially
all of the assets of Belcher Corporation. The results of Belcher
Corporation have been reported separately as discontinued
operations for all periods presented.
(4)
For purposes of computing the ratio of earnings to fixed charges,
earnings consist of income before income taxes plus fixed charges.
Fixed charges consist of interest expense, amortization of
deferred financing fees and a portion of rental expense that
management believes is representative of the interest component of
rental expense. Earnings were insufficient to cover fixed charges
for the years ended September 30, 2003 and 2002 by $31.4 million,
and $11.9 million, respectively.
Item 7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS
Due to the Company’s emergence from its Chapter 11 proceedings on October 8, 2003, the Company
has implemented the “fresh start” accounting provisions of AICPA Statement of Position 90-7,
“Financial Reporting by Entities in Reorganization under the Bankruptcy Code,” (“SOP 90-7”) to its
financial statements. Fresh start requires that, upon the Company’s emergence, the Company
establish a “fair value” basis for the carrying value of the assets and liabilities for the
reorganized Company. Although the effective date of the Plan of Reorganization was October 8, 2003,
due to the immateriality of the results of operations for the period between October 1, 2003 and
the effective date, the Company accounted for the consummation of the Plan of Reorganization as if
it had occurred on October 1, 2003 and implemented fresh start accounting as of that date.
Overview
We derive substantially all of our revenue from manufacturing and marketing a wide range of
iron castings and steel forgings for the heavy municipal market and selected segments of the
industrial market. We have two reportable segments, castings and forgings. Through our castings
segment, we are a leading producer of iron castings for use in heavy municipal and industrial
applications. For heavy municipal market applications, we sell to state and local municipalities,
contractors, precasters and supply houses. We primarily sell our industrial castings directly to
OEMs and tier-one suppliers with whom we have established close working relationships. Through our
forgings segment, operated by Mercer, we produce complex-shaped forged steel and micro alloy
components for use in transportation, railroad, mining and heavy industrial applications. Mercer
sells directly to OEMs, as well as to industrial end-users. Mercer’s subsidiary, A&M Specialties,
Inc., machines forgings and castings for Mercer and various industrial customers. Restructuring
charges and certain other expenses, such as income taxes, general corporate expenses and financing
costs, are not allocated between our two operating segments.
New Mold Line. We are proceeding with a $54 million capital project to replace a 40-year-old
mold line at our Neenah facility. Our new state-of-the-art mold line is expected to significantly
enhance operating efficiencies, increase capacity and provide expanded molding capabilities for our
heavy municipal products. Based on our current and projected level of operations, we anticipate
that our operating cash flows and our current credit facility will be sufficient to fund this and
other anticipated operational investments, including working capital and capital expenditure needs,
over the two year construction timeframe. We expect the new mold line to become operational in
early calendar 2008.
Change of Control. We experienced a change of control on May 25, 2006, when Tontine became
the beneficial owner of more than a majority of the outstanding shares, on a fully-diluted basis,
of our parent, ACP. The change of control required us to make change of control tender offers to
purchase our 11% Notes and 13% Notes, with Tontine, as the Company’s designee, purchasing notes tendered pursuant to the offers.
Major Customer Declares Bankruptcy. On March 3, 2006, Dana Corporation (“Dana”), one of our
major customers, filed a voluntary petition for relief under Chapter 11 of the United States
Bankruptcy Code. The total accounts receivable owed to us by Dana on March 3, 2006 were
approximately $4.7 million. Total payments received from Dana in the 90 days preceding the
bankruptcy filing were approximately $7.4 million. Sales to Dana accounted for approximately 6%, 6%
and 5% of our net sales for the fiscal years ended September 30, 2006, 2005, and 2004,
respectively. These amounts reflect our transactions directly with Dana and exclude Dana products
supplied to machine shops, which are not owned by Dana but whose business sourcing is controlled by
Dana. We negotiated a settlement with Dana and received partial payment of $3.9 million of the $4.7
million outstanding accounts receivable owed to us on March 3, 2006, and the majority of the
remaining receivables were sold to a third party in October 2006 for $0.7 million.
Expected Decline in Heavy-Duty Truck Production and New Housing Starts. Due to new emissions
standards set to take effect on January 1, 2007, heavy-duty truck production is expected to decline
significantly beginning early in calendar 2007, as many customers have accelerated purchases into
2006, artificially increasing 2006 sales to this segment. Additional emissions regulations are
scheduled to take effect in 2010, which may have a similar effect of accelerating sales to 2009. In
addition, new housing starts are expected to decline further in calendar 2007, reflecting softness
in the overall housing sector. As a result, we expect our sales to these end markets to decline
significantly in fiscal 2007 from fiscal 2006 levels, while sales of municipal products castings
are expected to be flat to down slightly for the same period.
Order
of Abatement at Gregg Facility. We are presently operating our Gregg facility under the
terms of an order of abatement with the California South Coast Air Quality Management District
(SCAQMD). The order requires us to comply with certain operating parameters in an effort to reduce
odors. Failure to operate within such criteria could result in the SCAQMD terminating operations at
the Gregg facility. The current order expires on March 31, 2007. We believe we are in compliance
with the testing and operating requirements mandated by the order and that our actions have resulted
in a substantial reduction in the intensity and frequency of observable downwind odors.
2003 Reorganization
On August 5, 2003, we, together with ACP and NFC filed voluntary petitions for relief under
Chapter 11 of the United States Bankruptcy Code, as amended, with the United States Bankruptcy
Court for the District of Delaware and submitted to the Bankruptcy Court for approval the
Disclosure Statement for our Amended Prepackaged Joint Chapter 11 Plan of Reorganization, which we
call the Plan of Reorganization.
By order dated September 26, 2003, the Bankruptcy Court confirmed the Plan of Reorganization
and the Plan of Reorganization became effective on October 8, 2003. October 8, 2003 is hereinafter
referred to as the “Effective Date”. The Plan of Reorganization allowed us to emerge from
bankruptcy with an improved capital structure. Because we had arranged to continue paying our trade
debt on a timely basis, we had sufficient trade credit to continue operations in the ordinary
course of business during the pendency of the Chapter 11 proceedings.
As a result of the Plan of Reorganization, significant changes resulted to our capital
structure. Although the Plan of Reorganization became effective on October 8, 2003, due to the
immateriality of the results of operations for the period between October 1, 2003 and the Effective
Date, for financial reporting purposes we recorded the fresh-start adjustments necessitated by SOP
90-7 on October 1, 2003.
As a result of our emergence from Chapter 11 bankruptcy and the application of fresh-start
reporting, our consolidated financial statements for the periods commencing on October 1, 2003 are
referred to as the “Reorganized Company” and are not comparable with any periods prior to October1, 2003, which are referred to as the “Predecessor Company” (see Note 1 in the Notes to
Consolidated Financial Statements).
All references to the periods subsequent to October 1, 2003 are to the Reorganized Company.
All references to periods prior to that date are to the Predecessor Company.
Net Sales. Net sales for the year ended September 30, 2006 were $542.5 million, which was $0.7
million or 0.1% higher than the year ended September 30, 2005. The increase was due to increased
shipments of heavy duty truck and municipal products, somewhat offset by reduced shipments of
products to the HVAC (heating, ventilation and air conditioning) market and various normal mix
changes within the remaining market segments of our business.
Cost of Sales. Cost of sales was $442.6 million for the year ended September 30, 2006, which
was $1.8 million or 0.4% higher than the year ended September 30, 2005. Cost of sales as a
percentage of net sales increased to 81.6% during the year ended September 30, 2006 from 81.4% for
the fiscal year ended September 30, 2005. The increase in cost of sales was due to a slightly less
favorable mix of products sold throughout the Company and operating inefficiencies at two of our
locations.
Gross Profit. Gross profit was $99.9 million for the year ended September 30, 2006, which was
$1.1 million or 1.1% lower than the year ended September 30, 2005. Gross profit as a percentage of
net sales decreased to 18.4% during the year ended September 30, 2006 from 18.6% for the fiscal
year ended September 30, 2005. The decrease in gross profit resulted from a slightly less favorable
mix of products sold throughout the Company and operating inefficiencies at two of our locations.
Selling, General and Administrative Expenses. Selling, general and administrative expenses for
the year ended September 30, 2006 were $34.3 million, a decrease of $0.2 million from the $34.5
million for the year ended September 30, 2005. As a percentage of net sales, selling, general and
administrative expenses decreased to 6.3% for the year ended September 30, 2006 from 6.4% for the
fiscal year ended September 30, 2005.
Amortization of Intangible Assets. Amortization of intangible assets was $7.1 million for each
of the years ended September 30, 2006 and September 30, 2005.
Other Expenses. Other expenses for the years ended September 30, 2006 and 2005 consist of
losses of $0.1 million and $1.0 million, respectively, for the disposal of long-lived assets in the
ordinary course of business.
Operating Income. Operating income was $58.3 million for the year ended September 30, 2006, an
increase of $6.4 million or 12.3% from the year ended September 30, 2005. The increase was due to
the $6.5 million litigation settlement incurred in the year ended September 30, 2005. As a
percentage of net sales, operating income increased from 9.6% for the year ended September 30, 2005
to 10.7% for the year ended September 30, 2006.
Net Interest Expense. Net interest expense was $33.3 million and $33.4 million for the years
ended September 30, 2006 and 2005, respectively.
Provision for Income Taxes. The effective tax rate for years ended September 30, 2006 and 2005
was 35% and 18%, respectively. The provision for income taxes for the year ended September 30, 2005
is lower than the amount
computed by applying our statutory rate of 35% to the income before income
taxes principally due to a change in the tax method of determining LIFO inventory and the
recognition of permanent differences due to the reorganization. The change in tax method of
determining LIFO inventory resulted in a tax benefit of $2.7 million, which increased fiscal 2005
net income by $2.7 million.
Net Sales. Net sales for the year ended September 30, 2005 were $541.8 million, which was
$90.9 million or 20.2% higher than the year ended September 30, 2004. The increase was due to
increased demand for industrial castings used in the heavy duty truck market, increased shipments
of municipal products, higher pricing (including steel scrap cost recovery) on both industrial and
construction castings, and new business at all locations.
Cost of Sales. Cost of sales was $440.8 million for the year ended September 30, 2005, which
was $65.7 million or 17.5% higher than the year ended September 30, 2004. Cost of sales as a
percentage of net sales decreased to 81.4% during the year ended September 30, 2005 from 83.2% for
the fiscal year ended September 30, 2004. The decrease in cost of sales as a percentage of net
sales was due to efficiencies achieved by operating the manufacturing plants at higher capacity.
Gross Profit. Gross profit was $101.0 million for the year ended September 30, 2005, which was
$25.2 million or 33.2% higher than the year ended September 30, 2004. Gross profit as a percentage
of net sales increased to 18.6% during the year ended September 30, 2005 from 16.8% for the fiscal
year ended September 30, 2004. The majority of the increase in gross profit resulted from sales
volume increases and the efficiencies achieved by operating the manufacturing plants at higher
capacity.
Selling, General and Administrative Expenses. Selling, general and administrative expenses for
the year ended September 30, 2005 were $34.5 million, an increase of $7.1 million from the $27.4
million for the year ended September 30, 2004. As a percentage of net sales, selling, general and
administrative expenses increased to 6.4% for the year ended September 30, 2005 from 6.1% for the
fiscal year ended September 30, 2004. The increase was due to increased expense for incentive plans
based on improved profitability, the writeoff of a large accounts receivable balance of a customer
who filed for Chapter 11 bankruptcy protection, a decrease in the rebate received from
countervailing duties assessed on imported products, and increases in fringe benefit costs,
specifically health care. Also, legal and professional costs increased in comparison to the prior
year; however, the prior year cost level was abnormally low due to the majority of the 2004 legal
and professional fees related to the bankruptcy reorganization, which were recorded in fresh start
accounting.
Settlement of Litigation. On November 22, 2004, Neenah entered into a letter of intent (“LOI”)
with respect to a proposed management buyout of all the outstanding stock of our wholly owned
subsidiary Mercer Forge Corporation (“Mercer”). The parties to the LOI, however, were unable to
agree on the terms of a definitive agreement by the extended termination date of the LOI, which had
lapsed. On January 24, 2005, JD Holdings, LLC (“JDH”), one of the counterparties to the LOI, filed
a complaint in the United States District Court for the Southern District of New York against
Neenah alleging, among other things, that Neenah breached the terms of the LOI by not consummating
the sale of the stock of Mercer to JDH.
On August 5, 2005, the parties agreed to settle this matter. The settlement provided for a
$6.5 million cash payment by the Company to JDH and the exchange of full and final releases by the
parties on behalf of themselves and their respective members, officers, directors, affiliates and
shareholders.
Amortization of Intangible Assets. Amortization of intangible assets was $7.1 million for each
of the years ended September 30, 2005 and September 30, 2004.
Other Expenses. Other expenses for the years ended September 30, 2005 and 2004 consist of
losses of $1.0 million and $0.5 million, respectively, for the disposal of long-lived assets in the
ordinary course of business.
Operating Income. Operating income was $51.9 million for the year ended September 30, 2005, an
increase of $11.1 million or 27.1% from the year ended September 30, 2004. The increase was caused
by the reasons discussed above under gross profit and was partially offset by the $6.5 million
litigation settlement and increased selling, general and administrative expenses. As a percentage
of net sales, operating income increased from 9.1% for the year ended September 30, 2004 to 9.6%
for the year ended September 30, 2005.
Net Interest Expense. Net interest expense was $33.4 million for each of the years ended
September 30, 2005 and 2004.
Provision for Income Taxes. The provision for income taxes for the year ended September 30,2005 is lower than the amount computed by applying our statutory rate of 35% to the income before
income taxes principally due to a change in the tax method of determining LIFO inventory and the
recognition of permanent differences due to the reorganization. The change in tax method of
determining LIFO inventory resulted in a tax benefit of $2.7 million, which increased fiscal 2005
net income by $2.7 million.
LIQUIDITY AND CAPITAL RESOURCES
Credit Facility. On July 28, 2005, the Company amended its bank Loan and Security Agreement
(the “Credit Facility”), which was originally entered into as of October 8, 2003 upon our emergence
from bankruptcy. The following principal changes were made to the Credit Facility: (i) the
revolving loan commitment under the Credit Facility was increased from $70 million to $92.1 million
(provided, however, that the outstanding aggregate amount of revolving loans, letters of credit and
term loans provided under the Credit Facility may not exceed the revolving loan commitment at any
time), (ii) the interest rates applicable to revolving loans and term loans were reduced, (iii) the
maturity of the Credit Facility was extended by one year, to October 8, 2009 (iv) the Company was
provided additional flexibility to pay deferrable interest on its outstanding 13% Senior
Subordinated Notes due 2013 and to make repayments, prepayments, redemptions and repurchases of the
Senior Subordinated Notes, (v) the Company was authorized to sell Mercer Forge Corporation and/or
Gregg Industries, Inc., subject to certain conditions, and (vi) the principal financial covenant in
the Credit Facility was revised in a manner that is more favorable to the Company than before.
The Company’s Credit Facility, as amended on July 28, 2005, consists of a revolving credit
facility of up to $92.1 million (with sublimits of $5 million available for letters of credit and
term loans in the aggregate original principal amount of $22.1 million). The Credit Facility
matures on October 8, 2009, and bears interest at rates based on the lenders’ Base Rate, as defined
in the Credit Facility, or an adjusted rate based on LIBOR. Availability under the Credit Facility
is based on various advance rates against the Company’s accounts receivable and inventory. Amounts
under the revolving credit facility may be borrowed, repaid and reborrowed subject to the terms of
the facility. At September 30, 2006, the Company had approximately $24.6 million outstanding under
the revolving credit facility and approximately $13.4 million outstanding under the term loan
facility. No portion of the term loan, once repaid, may be reborrowed. However, repayments of the
term loan increase availability for borrowings under the revolving credit facility.
Substantially all of the Company’s wholly owned subsidiaries are co-borrowers with the Company
under the Credit Facility and are jointly and severally liable with the Company for all obligations
under the Credit Facility, subject to customary exceptions for transactions of this type. In
addition, NFC Castings, Inc. (“NFC”), the Company’s immediate parent, and the remaining wholly
owned subsidiaries of the Company jointly and severally guarantee the Company’s obligations under
the Credit Facility, subject to customary exceptions for transactions of this type. The borrowers’
and guarantors’ obligations under the Credit Facility are secured by a first priority perfected
security interest, subject to customary restrictions, in substantially all of the tangible and
intangible assets of the Company and its subsidiaries. The senior secured notes discussed below,
and the guarantees in respect thereof, are equal in right of payment to the Credit Facility, and
the guarantees in respect thereof. The liens in respect of the senior secured notes are junior to
the liens securing the Credit Facility and guarantees thereof.
Voluntary prepayments may be made at any time on the term loan borrowings or the revolving
borrowings upon customary prior notice. Prepayments on the term loan borrowings may be made at any
time without premium or penalty unless a simultaneous reduction of the revolving loan commitment
amount is being made or if any such reduction of the revolving loan commitment amount has been made
previously. Reductions of the revolving loan
commitment are subject to certain premiums specified
in the Credit Facility. Mandatory repayments are required under certain circumstances, including a
sale of assets or the issuance of debt or equity.
The Credit Facility requires the Company to observe certain customary conditions, affirmative
covenants and negative covenants including financial covenants. The Credit Facility also contains
events of default customary for these types of facilities, including, without limitation, payment
defaults, material misrepresentations, covenant defaults, bankruptcy and a change of ownership of
the Company, NFC or ACP Holding Company, NFC’s immediate parent company. The Company is prohibited
from paying dividends and is restricted to a maximum yearly stock repurchase of $250,000.
Subsequent to the end of fiscal 2005, the Company further amended the Credit Facility to allow
the $6.5 million settlement in connection with the Mercer litigation, discussed above, to be added
back in the calculation of Adjusted EBITDA. The amendment was executed and became effective on
December 9, 2005.
11% Senior Secured Notes due 2010. The Company has outstanding Senior Secured Notes due 2010
in the principal amount of $133.1 million, with a coupon rate of 11%. These notes were issued at a
price which included a discount of $11.7 million. The obligations under the Senior Secured Notes
due 2010 are equal in right of payment to the Credit Facility and the associated guarantees. The
liens securing the senior secured notes are junior to the liens securing the Credit Facility and
guarantees thereof. Interest on the Senior Secured Notes due 2010 is payable on a semi-annual
basis. The Company’s obligations under the notes are guaranteed on a secured basis by each of its
wholly owned subsidiaries. Subject to the restrictions in the Credit Facility, the notes are
redeemable at the Company’s option in whole or in part at any time on or after September 30, 2007,
with not less than 30 days nor more than 60 days notice, at the redemption price specified in the
indenture governing the notes (105.500% of the principal amount redeemed beginning September 30,2007, 104.125% beginning September 30, 2008, and 102.750% beginning September 30, 2009 and
thereafter), plus accrued and unpaid interest up to the redemption date. Upon the occurrence of a
“change of control” as defined in the indenture governing the notes, the Company may be required to
make an offer to purchase the secured notes at 101% of the outstanding principal amount thereof,
plus accrued and unpaid interest up to the purchase date. The secured notes contain customary
covenants typical to this type of financing, such as limitations on (1) indebtedness, (2)
restricted payments (among other things, currently limiting most dividends and similar payments by
Neenah and its subsidiaries to no more than approximately $14 million), (3) liens, (4) restrictions
on distributions from restricted subsidiaries, (5) sale of assets, (6) affiliate transactions, (7)
mergers and consolidations and (8) lines of business. The secured notes also contain customary
events of default typical to this type of financing, such as (1) failure to pay principal and/or
interest when due, (2) failure to observe covenants, (3) certain events of bankruptcy, (4) the
rendering of certain judgments or (5) the loss of any guarantee.
13% Senior Subordinated Notes due 2013. The Company has outstanding Senior Subordinated Notes
due 2013 in the principal amount of $100 million, with a coupon rate of 13%. The obligations under
the senior subordinated notes are senior to the Company’s subordinated unsecured indebtedness, if
any, and are subordinate to the Credit Facility and the senior secured notes. Interest on the
senior subordinated notes is payable on a semi-annual basis. Not less than five percent of the
interest on the senior subordinated notes must be paid in cash and up to 8% interest may be
paid-in-kind. To date, all interest payments have been made in cash. The Company’s obligations
under the notes are guaranteed on an unsecured basis by each of its wholly owned subsidiaries.
Subject to the restrictions in the Credit Facility, the notes are redeemable at our option in whole
or in part at any time, with not less than 30 days nor more than 60 days notice, at the redemption
price specified in the indenture governing the notes (currently 100%), plus accrued and unpaid
interest up to the redemption date. The indenture does not allow for redemption of the 13% Senior
Subordinated Notes while the 11% Senior Secured Notes remain outstanding. Upon the occurrence of a
“change of control” as defined in the indenture governing the notes, the Company may be required to
make an offer to purchase the subordinated notes at 101% of the outstanding principal amount
thereof, plus accrued and unpaid interest up to the purchase date. The subordinated notes contain
customary covenants typical to this type of financing, such as limitations on (1) indebtedness, (2)
restricted payments (among other things, currently limiting most dividends and similar payments by
Neenah and its subsidiaries to no more than approximately $14 million), (3) liens, (4) restrictions
on distributions from restricted subsidiaries, (5) sale of assets, (6) affiliate transactions, (7)
mergers and consolidations and (8) lines of business. The subordinated notes also contain customary
events of
default typical to this type of financing, such as, (1) failure to pay principal and/or
interest when due, (2) failure to observe covenants, (3) certain events of bankruptcy, (4) the
rendering of certain judgments or (5) the loss of any guarantee.
For the fiscal years ended September 30, 2006, 2005 and 2004, capital expenditures were $17.8
million, $17.6 million, and $12.7 million, respectively. These amounts represent a level of capital
expenditures necessary to maintain equipment and facilities. Certain foundries are required to
comply with the “maximum achievable control technology” or “MACT” standards of the Environmental
Protection Agency. Our Neenah foundry and both Dalton foundries are subject to this requirement
(due to their size). A majority of the approximate $3.0 million of capital expenditures necessary
to bring these facilities into compliance with MACT requirements has already been made and we
expect all three facilities to achieve MACT compliance by the applicable deadlines, the earliest of
which is April 2007. We estimate that our aggregate expenditure requirements in fiscal 2007 will
include projected costs of:
•
approximately $22.0 million primarily for necessary maintenance capital expenditures
and selected strategic
capital investments required to maintain optimum operating efficiencies, not including the
new mold line described elsewhere herein;
•
approximately $32.2 million for the new mold line (of the total cost of approximately
$54 million); and
•
approximately $31.7 million for debt service on our outstanding 11% Senior Secured
Notes and 13% Senior Subordinated Notes plus any additional interest expense from amounts
outstanding under the credit facility.
In addition, we will require funds for general corporate expenses, other expenses (including
pension expenses discussed in “— Contractual Obligations”) and for working capital fluctuations.
The Company’s principal source of cash to fund its liquidity needs will be net cash from
operating activities and borrowings under the revolving loan commitment under the Credit Facility.
Net cash provided by operating activities for the fiscal year ended September 30, 2006 was $24.8
million, a decrease of $8.8 million from cash provided by operating activities for the fiscal year
ended September 30, 2005 of $33.6 million. The decrease in net cash provided by operating
activities during fiscal 2006 was primarily due to the decrease in accrued liabilities and an
increase in income taxes paid. Net cash provided by operating activities for the fiscal year ended
September 30, 2005 represented an increase of $30.9 million from cash provided by operating
activities for the fiscal year ended September 30, 2004 of $2.7 million. The increase in net cash
provided by operating activities during fiscal 2005 was primarily due to the increase in net
income, as well as a decrease in working capital accounts (primarily from accounts receivable).
Future Capital Needs. Despite the Company’s significant decrease in leverage as a result of
the Plan of Reorganization, the Company is still significantly leveraged and the ability to meet
its debt obligations will depend upon future operating performance which will be affected by many
factors, some of which are beyond the Company’s control. Based on the Company’s current level of
operations, it anticipates that operating cash flows and available credit facilities will be
sufficient to fund the anticipated operational investments, including working capital and capital
expenditure needs, for at least the next twelve months. As part of the Company’s ongoing review of
both its short term and long term cash requirements, the Company continues to evaluate strategic
alternatives relative to its current capital structure in order to provide for increased
flexibility and liquidity. If, however, the Company is unable to service its debt requirements as
they become due or is unable to maintain ongoing compliance with restrictive covenants, it may be
forced to adopt alternative strategies that may include reducing or delaying capital expenditures,
selling assets, restructuring or refinancing indebtedness or seeking additional equity capital.
There can be no assurances that any of these strategies could be effected on satisfactory terms, if
at all.
Adjusted EBITDA. The Company’s borrowing arrangement contains certain financial covenants
which are tied to ratios based on Adjusted EBITDA. Adjusted EBITDA is defined in the credit
facility as “EBITDA” and is generally calculated as the sum of net income (excluding non-recurring
non-cash charges and certain one-time cash charges), income taxes, interest expense, and
depreciation and amortization. Adjusted EBITDA is presented herein because it is a material
component of the covenants contained within our credit facility. Non-compliance with the covenants
could result in the requirement to immediately repay all amounts outstanding under the credit
facility which could have a material adverse effect on the Company’s results of operations,
financial position and cash flow.
Management also believes that certain investors use information
concerning Adjusted EBITDA as a measure of a company’s performance and ability to service its debt.
Adjusted EBITDA should not be considered a substitute for, or more meaningful than, income from
operations, net income, cash flows or other measures of financial performance prepared in
accordance with accounting principles generally accepted in the United States. Adjusted EBITDA, as
presented by the Company, may not be comparable to similarly titled measures reported by other
companies.
A reconciliation of Adjusted EBITDA for the fiscal years ended September 30, 2006, 2005 and
2004 is provided below (in thousands):
Fiscal Year Ended
September 30
2006
2005
2004
Net income
$
16,149
$
15,095
$
3,255
Income tax provision
8,857
3,409
3,881
Net interest expense
33,327
33,406
33,363
Depreciation and amortization
20,243
18,864
17,992
EBITDA
78,576
70,774
58,491
Loss on disposal of equipment
127
953
465
Loss from discontinued operations.
—
—
359
Non-cash inventory charge
100
242
1,796
Litigation settlement
—
6,500
—
Gregg write-off of lease deposits.
—
64
—
Adjusted EBITDA (as defined above)
$
78,803
$
78,533
$
61,111
OFF-BALANCE SHEET ARRANGEMENTS
None.
CONTRACTUAL OBLIGATIONS
The following table includes the Company’s significant contractual obligations at September30, 2006 (in millions):
Expected Payments Due by Period
Less Than
More Than
Total
1 year
1-3 Years
3-5 Years
5 Years
Long-term debt
$
239.6
$
3.2
$
10.2
$
126.2
$
100.0
Interest on long-term debt
151.3
28.5
56.2
40.6
26.0
Revolving line of credit
24.6
24.6
—
—
—
Interest and fees on revolving line of credit
1.5
.9
.3
.3
—
Capital leases
1.2
.2
.4
.4
.2
Operating leases
5.2
1.9
2.3
.8
.2
New mold line commitments
30.2
30.2
—
—
—
Total contractual obligations
$
453.6
$
89.5
$
69.4
$
168.3
$
126.4
As of September 30, 2006, other than the new mold line commitments listed above, the
Company had no material purchase obligations other than those created in the ordinary course of
business related to inventory and property, plant and equipment, which generally have terms of less
than 90 days. The Company also has long-term obligations related to its pension and post-retirement
plans which are discussed in detail in Note 8 of the Notes to Consolidated Financial Statements. As
of the most recent actuarial measurement date, the Company anticipates making $2.5 million of
contributions to pension plans in fiscal 2007. Post-retirement medical claims are paid as they are
submitted and are anticipated to be $0.5 million in fiscal 2007.
Critical accounting estimates are those that are, in management’s view, both very important to
the portrayal of our financial condition and results of operations and require management’s most
difficult, subjective or complex judgments, often as a result of the need to make estimates about
the effect of matters that are inherently uncertain.
Future events and their effects cannot be determined with absolute certainty. The
determination of estimates, therefore, requires the exercise of judgment. Actual results may differ
from those estimates, and such differences may be material to the financial statements. Our
accounting policies are more fully described in Note 2 in the Notes to Consolidated Financial
Statements.
We believe that the most significant accounting estimates inherent in the preparation of our
financial statements include estimates associated with the evaluation of the recoverability of
certain assets including goodwill, other intangible assets and property, plant and equipment as
well as those estimates used in the determination of reserves related to the allowance for doubtful
accounts, inventory obsolescence, workers compensation and pensions and other post-retirement
benefits. Various assumptions and other factors underlie the determination of these significant
estimates. In addition to assumptions regarding general economic conditions, the process of
determining significant estimates is fact-specific and accounts for such factors as historical
experience, product mix and, in some cases, actuarial techniques. We constantly reevaluate these
significant factors and make adjustments where facts and circumstances necessitate. Historically,
our actual results have not significantly deviated from those determined using the estimates
described above.
We believe the following critical accounting estimates affect our more significant judgments
and estimates used in the preparation of our consolidated financial statements:
•
Defined-Benefit Pension Plans. We account for our defined benefit pension plans in
accordance with Statement of Financial Accounting Standards No. 87, “Employers’ Accounting
for Pensions” (“SFAS 87”), which requires that amounts recognized in financial statements be
determined on an actuarial basis. The most significant element in determining our pension
expense in accordance with SFAS 87 is the expected return on plan assets. We have assumed
that the expected long-term rate of return on plan assets will be 7.50% to 8.50%, depending
on the plan. Over the long term, our pension plan assets have earned in excess of these
rates; therefore, we believe that our assumption of future returns is reasonable. The plan
assets, however, have earned a rate of return substantially less than these rates in the
last three years. Should this trend continue, our future pension expense would likely
increase. At the measurement date, we determine the discount rate to be used to discount
plan liabilities. In developing this rate, we use the Moody’s Average AA Corporate Bonds
index. At the measurement date of June 30, 2006, we determined the discount rate to be
6.25%. Changes in discount rates over the past few years have not materially affected our
pension expense. The net effect of changes in this rate, as well as other changes in
actuarial assumptions and experience, have been deferred as allowed by SFAS 87.
•
Other Postretirement Benefits. We provide retiree health benefits to qualified employees
under an unfunded plan. We use various actuarial assumptions including the discount rate and
the expected trend in health care costs and benefit obligations for our retiree health plan.
Consistent with our pension plans, we used a discount rate of 6.25%. In 2006, our assumed
healthcare cost trend rate was 10.0% decreasing gradually to 5.0% in 2016 and then remaining
at that level thereafter. Changes in these rates could materially affect our future
operating results and net worth. A one percentage point change in the healthcare cost trend
rate would have the following effect (in thousands):
1% Increase
1% Decrease
Effect on total of service cost and interest cost
$
104
$
(77
)
Effect on postretirement benefit obligation
996
(778
)
Recent Accounting Pronouncements
In November 2004, the Financial Accounting Standards Board (FASB) issued SFAS No. 151,
“Inventory Costs, an Amendment of ARB No. 43, Chapter 4.” SFAS No. 151 clarifies that abnormal
amounts of idle facility expense,
freight, handling costs, and wasted materials (spoilage) should
be recognized as current-period charges and requires the allocation of fixed production overhead to
inventory based on the normal capacity of the production facilities. SFAS No. 151 is effective for
inventory costs incurred during fiscal years beginning after June 15, 2005. Adoption of SFAS No.
151 did not have a material impact on the Company’s financial condition, results of operations or
cash flows.
In July 2006, the FASB issued FASB Interpretation No. 48, “Accounting for Uncertainty in
Income Taxes — an interpretation of FASB Statement No. 109” (FIN 48), which clarifies the
accounting for uncertainty in tax positions. This Interpretation requires that the Company
recognize in its financial statements the impact of a tax position, if that position is more likely
than not of being sustained on audit, based on the technical merits of the position. This
interpretation is effective for fiscal years beginning after December 15, 2006, with the cumulative
effect of the change in accounting principle recorded as an adjustment to opening retained
earnings. The Company is currently evaluating the impact FIN 48 will have on its financial
statements.
In September 2006, the FASB issued SFAS No. 158, “Employers’ Accounting for Defined Benefit
Pension and Other Postretirement Plans” (SFAS No. 158). SFAS No. 158 amends SFAS No. 87,
“Employers’ Accounting for Pensions,” SFAS No. 88, “Employers’ Accounting for Settlements and
Curtailments of Defined Benefit Pension Plans and for Termination Benefits,” SFAS No. 106,
“Employers’ Accounting for Postretirement Benefits Other than Pensions,” and SFAS No. 132,
“Employers’ Disclosures about Pensions and Other Postretirement Benefits.” The amendments retain
most of the existing measurement and disclosure guidance and will not change the amounts
recognized in the Company’s statement of operations. SFAS No. 158 requires companies to
recognize a net asset or liability with an offset to equity, by which the defined benefit
post-retirement obligation is over- or under-funded. SFAS No. 158 requires prospective application,
and the recognition and disclosure requirements will be effective for the Company’s fiscal year
ending September 30, 2007. The Company is currently evaluating the impact SFAS No. 158 will have on
its consolidated balance sheets.
Item 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK
We are exposed to market risk related to changes in interest rates. We do not use derivative
financial instruments for speculative or trading purposes.
Interest Rate Sensitivity. Our earnings are affected by changes in short-term interest rates
as a result of our borrowings under the credit facility. If market interest rates for our
borrowings increase or decrease by 100 basis points, the Company’s interest expense would increase
or decrease by approximately $0.4 million. This analysis does not consider the effects of changes
in the level of overall economic activity that could occur due to interest rate changes. Further,
in the event of an upward change of such magnitude, management could take actions to further
mitigate our exposure to the change. However, due to the uncertainty of the specific actions that
would be taken and their possible effects, the sensitivity analysis assumes no changes in our
financial structure.
Item 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA
The financial statements and schedules are listed in Part IV Item 15 of this Annual Report on
Form 10-K and are incorporated by reference in this Item 8.
Item 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE.
None.
Item 9A. CONTROLS AND PROCEDURES
Disclosure Controls and Procedures. The Company’s management, with the participation of the
Company’s Chief Executive Officer and Chief Financial Officer, have evaluated the effectiveness of
the Company’s disclosure controls and procedures (as defined in Rules 13a-15(e) and 15d-15(e) under
the Securities Exchange Act of 1934, as amended (the “Exchange Act”)) as of the end of the period
covered by this report. Based upon such evaluation, the Chief Executive Officer and the Chief
Financial Officer have concluded that, as of the end of such period, the
Company’s disclosure controls and procedures are effective in recording, processing, summarizing and reporting, on a
timely basis, information required to be disclosed by the Company in the reports that the Company
files or submits under the Exchange Act.
Internal Control Over Financial Reporting. There have not been any changes in the Company’s
internal control over financial reporting (as such term is defined in Rules 13a-15(f) and 15d-15(f)
under the Exchange Act) during the last fiscal quarter that have materially affected, or are
reasonably likely to materially affect, the Company’s internal control over financial reporting.
Item 9B. OTHER INFORMATION
On
December 14, 2006, the Board of Directors of Neenah increased
the size of the Board from six to seven members, effective as of
January 1, 2007, and elected Gerald E. Morris as a new
director to fill the newly created directorship, effective as of
January 1, 2007. Mr. Morris was also elected to serve as a
director, effective as of January 1, 2007, of ACP, NFC and Neenah's subsidiaries.
Item 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT
The following sets forth certain information with respect to the persons who
are members of the board of directors and executive officers of the Company. All executive officers
are appointed by the board of directors. Under our bylaws, each director holds office until the next annual meeting of shareholders and
until the director’s successor has been elected and qualified. All of our directors are also
directors of ACP.
Mr. Barrett has served as our President and Chief Executive Officer since May 2000. Mr.
Barrett joined us in 1992 serving as General Sales Manager — Industrial Castings until May 1,1997. Mr. Barrett was Vice President and General Manager from May 1, 1997 to September 30, 1998 and
President from October 1, 1998 to April 30, 2000. From 1985 to 1992, Mr. Barrett was the Vice
President — Sales for Harvard Industries Cast Products Group. Mr. Barrett has also been one of our
directors and Chairman of the Board since May 2000.
Mr. LaChey has served as our Corporate Vice President — Finance and Chief Financial Officer
since June 2000. Mr. LaChey joined us in 1971 and has served in a variety of positions of
increasing responsibility in the finance department.
Mr. Ackerman has served as the Division President of Mercer since 2000. Previously, Mr.
Ackerman served as the Vice President/CFO of Mercer Forge since 1990. Prior to joining Mercer in
1990, Mr. Ackerman worked for Sheet Metal Coating & Litho as its Controller, Dunlop
Industrial/Angus Fire Armour Corp. as its Controller and Ajax Magnethermic Corporation as its Vice
President-Finance (CFO).
Mr. Andrews has served as our Corporate Vice President — Manufacturing since August 2003 and
as Chief Operating Officer of Manufacturing Operations since November 2005. Mr. Andrews joined us
in 1988 and has served in a variety of manufacturing positions with increasing responsibility.
Prior to joining Neenah Foundry, Mr. Andrews was Division Manager for Dayton Walther Corporation’s
Camden Casting Center from 1986 to 1988 and served as Manufacturing Manager and then Plant Manager
for Waupaca Foundry’s Marinette Plant from 1973 to 1986.
Mr. DeRita has served as Division President of Dalton since 1999. He joined Newnam
Manufacturing in 1989 and became the Vice President — Sales when Dalton acquired Newnam
Manufacturing in 1992. Prior to joining our Company, Mr. DeRita was the Manager of Engineering and
Maintenance at Erie Malleable, the same position he held previously at Zurn Industries.
Mr. Headington has served as our Corporate Vice President — Technology since August 2003.
Previously, Mr. Headington was our Manager of Technical Services and Director of Product
Reliability since January 1989. Prior to joining the Company, Mr. Headington co-founded and
operated Sintered Precision Components, a powdered metal company. Prior to his involvement with
Precision Components, he was employed by Wagner Casting Company as Quality Manager.
Mr. Koller has served as our Vice President — Municipal Products Sales and Engineering since
May 1998. Mr. Koller has worked within our Municipal products area for the last 27 years serving
with increasing responsibility as Sales Representative, Specifications Manager, and General Sales
Manager.
Mr. Varkoly has served as our Corporate Vice President — Industrial Products Sales since
August 2003. Previously, Mr. Varkoly was our Vice President of Business Development since March
2000. Prior to joining our Company in 2000, he served as the Director — Finance of Betzdearborn, Inc. Previously, he was
a Manager for Performance Improvement Management Consulting with Ernst & Young LLP and the Business
Development Manager of FMC Corporation.
Mr. Ferrara has served as a director since October 2006. Mr. Ferrara has been the Vice
President, Finance and Chief Financial Officer of AK Steel Holding Corporation, a producer of
flat-rolled carbon, stainless and electrical steels and tubular products, since November 2003. Mr.
Ferrara joined AK Steel in June 2003 as Director, Strategic Planning and was named Acting Chief
Financial Officer in September 2003. Prior to joining AK Steel, Mr. Ferrara was Vice President,
Corporate Development for NS Group, Inc., a tubular products producer, and previously held
positions as Senior Vice President and Treasurer with U.S. Steel Corporation and Vice President,
Strategic Planning at USX Corporation
Mr. Gendell has served as a director since May 2006. Mr. Gendell has been employed by an
affiliate of Tontine, a Greenwich, Connecticut-based investment partnership, since January 2004. In
this capacity, he assists in the oversight and management of the Tontine portfolio. Prior to that,
Mr. Gendell held senior positions at several venture-backed startups. He was President and Chief
Operating Officer of Homserv, LLC, a privately-held data aggregator focused on real estate
transactions. Prior to that, he served as President and Chief Operating Officer of Cogent Design
Inc., a privately-held practice management software system.
Mr. Graham has served as a director since May 2006. Mr. Graham has been the Chief Financial
Officer of Shiloh Industries, Inc., a publicly traded manufacturer of automotive components, since
joining Shiloh in October 2001. Prior to that, Mr. Graham has held the position of Chief Financial
Officer with several companies, the first in 1994 when he joined Truck Components Inc., a publicly
traded company with foundry and machining operations serving the heavy truck, automotive,
construction and agricultural industries. Following his tenure at Truck Components Inc., Mr. Graham
served as the Chief Financial Officer of Dura Automotive Systems, Inc., also a publicly traded
manufacturer of automotive components from May 1996 until February 2000. After Dura Automotive
Systems, Inc., and immediately before joining Shiloh Industries, Inc., Mr. Graham joined Republic
Technologies International, a fully integrated steel producer that filed for bankruptcy in April
2001.
Mr. Lash has served as a director since May 2006. Mr. Lash has been employed by an affiliate
of Tontine, a Greenwich, Connecticut-based investment partnership, since July 2005. In this
capacity, he assists in the oversight and management of the Tontine portfolio. Prior to that, Mr.
Lash was a Senior Managing Director of Conway, Del
Genio, Gries & Co. LLC, a financial advisory
firm, from April 2002 to July 2005. From June 1998 to April 2001, Mr. Lash was a Managing Director
of JP Morgan Chase & Co., a financial services firm. Mr. Lash also serves as a director of
Integrated Electrical Services, Inc.
Mr. Marshall has served as a director since October 2003. Mr. Marshall is currently the
Chairman of Smith Marshall, a subsidiary of the NextMedia Company Limited. Previously, he was the
President and Chief Executive Officer of Aluma Enterprises, Inc., a construction technology
company, for six years. Prior to joining Aluma Enterprises, Inc., Mr. Marshall successively held
the positions of President and Chief Executive Officer at Marshall Steel Limited, Marshall Drummond
McCall Inc. and the Ontario Clean Water Agency. Mr. Marshall also serves as a director of Brand
Energy & Infrastructure Services, Inc. and Toronto Hydro Corporation.
Committees of the Board
The current members of the audit committee of the board of directors are Stephen E. K. Graham
(Chairman) and Jeffrey G. Marshall. The board of directors has determined that all members of the
audit committee are independent and financially literate in accordance with the audit committee
requirements of the New York Stock Exchange. The board has determined that Mr. Graham is an audit
committee financial expert within the meaning of SEC rules. Currently the full board handles
compensation matters since the two directors who were members of the compensation committee
resigned in connection with Tontine’s acquisition of control in May 2006. See “Certain
Relationships and Related Transactions.”
Code of Ethics
In December 2004, the Company adopted a Code of Ethics applicable to all of our officers as
well as certain other key accounting staff. A copy of the Code of Ethics can be obtained free of
charge by writing to us.
Board Composition
The board of directors of ACP, our ultimate parent company, currently consists of the same six
directors who serve as our board. ACP’s amended and restated bylaws permit the holders of a
majority of the shares of common stock of ACP then entitled to vote at an election of directors, to
remove any director or the entire board of directors at any time, with or without cause. Under
ACP’s amended and restated bylaws, vacancies on the board of directors may be filled by the
affirmative vote of a majority of the holders of ACP’s outstanding stock entitled to vote thereon,
or may be filled by the vote of a majority of the directors then in office, although less than a
quorum, or by a sole remaining director. Nearly half of the outstanding stock of ACP, and a
majority of such stock on a fully-diluted basis, is owned by Tontine. As a result, Tontine controls
ACP’s and our affairs, including the election of directors who in turn appoint management for both
us and ACP. ACP intends to expand its board to seven members by adding one additional independent
director.
Summary Compensation Table. The following table summarizes compensation awarded to, earned by
or paid to our chief executive officer and each of our other four most highly compensated executive
officers (collectively, the “named executive officers”) for services rendered to ACP, NFC, and the
Company during the 2006, 2005 and 2004 fiscal years.
Finance, Treasurer, Secretary and Chief Financial Officer
2004
(1)
242,996
74,100
—
—
—
—
26,306
Joseph Varkoly
2006
201,673
74,458
—
—
—
—
24,819
Corporate Vice President —
2005
192,419
237,302
—
—
—
—
25,107
Industrial Products Sales
2004
(1)
199,250
55,800
—
—
—
—
24,320
John H. Andrews
2006
233,507
85,477
—
—
—
—
26,367
Corporate Vice President —
2005
214,004
252,791
—
—
—
—
26,694
Manufacturing and Chief
2004
(1)
193,336
60,000
—
—
—
—
25,687
Operating Officer of
Manufacturing Operations
Joseph L. DeRita
2006
263,667
97,000
—
—
—
—
20,186
Division President — Dalton
2005
256,000
313,645
—
—
—
—
18,700
Corporation
2004
(1)
243,000
74,100
—
—
—
—
14,281
(1)
Certain prior year amounts have been reclassified.
(2)
The Company provides its executive officers with personal benefits
as part of providing a competitive compensation program. These may
include such benefits as a company automobile, and personal
liability insurance. These benefits are valued based upon the
incremental cost to the Company. The incremental cost to the
Company of such benefits did not exceed the SEC’s disclosure
threshold for any named executive officer for any of the three
years.
(3)
The aggregate unvested restricted stock holdings of ACP common
stock at the end of fiscal 2005 for the named executive officers
were as follows: Mr. Barrett — 312,500 shares, Mr. LaChey —
238,971 shares, Mr. Varkoly — 55,147 shares, Mr. Andrews —
36,765 shares, and Mr. DeRita — 101,103 shares. All of these
shares vested upon our change in control in May 2006, and
one-third of the total number of shares held by these and certain
other officers and employees were subsequently sold to Tontine.
See “Certain Relationships and Related Transactions.”
(4)
All other compensation for fiscal 2006 for Messrs. Barrett,
LaChey, Varkoly, Andrews, and DeRita, respectively, includes: (i)
matching contributions to the 401(k) plan for each named executive
officer of $5,500, $5,500, $5,500, $5,500, and $6,600; (ii)
contributions pursuant to the profit sharing plan for each named
executive officer of $15,750, $15,750, $15,750, $15,750, and $0;
(iii) an executive life insurance premium for each named executive
officer of $2,838, $2,518, $464, $2,012, and $7,407; and (iv)
health insurance reimbursement premiums for each named executive
officer of $3,105, $3,105, $3,105, $3,105, and $6,179.
Under the 2003 Management Annual Incentive Plan, members of management and certain other
specified employees will receive annual performance awards if the Company achieves certain Adjusted
EBITDA targets set by the board of directors of the Company at the beginning of each fiscal year.
The bonus paid will equal (i) 50% of the target bonus amount for each individual should the Company
reach 85% of the Adjusted EBITDA target, (ii) 100% of the target bonus on reaching 100% of the
target Adjusted EBITDA, and (iii) 200% of the target bonus on reaching 120% of the target Adjusted
EBITDA. For 2005, the $6.5 million settlement in connection with the Mercer litigation was added
back to calculate Adjusted EBITDA for purposes of the bonus calculation.
Target bonuses range up to 30.0% of base salary depending upon job responsibility. In
addition, the 2003 Management Annual Incentive Plan was amended to allow management the ability to
earn additional cash compensation based on varying levels of debt reduction achieved during the
year. Earned bonus is payable within 10 business days of the approval of the Company’s audited
financial statements by the board of directors.
In addition, a one-time aggregate incremental $450,000 emergence bonus was paid upon emergence
from Chapter 11 bankruptcy in fiscal 2004 to certain members of management upon the Effective Date.
For fiscal 2007, the executives and certain other specified employees will be entitled to
receive annual performance awards upon achieving certain milestones, including Adjusted EBITDA
targets and certain other criteria as determined by the compensation committee or the board of
directors. Target bonus as a percentage of salary for each member of management will be consistent
with historical levels. Target levels, timing of payments and other terms and conditions of the
annual incentive plan will be approved by the compensation committee or the board.
2003 Management Equity Incentive Plan
Under the 2003 Management Equity Incentive Plan, which was established on the Effective Date,
certain members of management received restricted shares which represented 5% of the common stock
of ACP on a fully-diluted basis as of the Effective Date. The 4,000,000 restricted shares issued
pursuant to the 2003 Management Equity Incentive Plan were 25% vested upon grant and the balance
vested on an annual straight-line basis over the ensuing three years subject to acceleration in the
event of a Significant Transaction, as defined in the award agreement. The remaining unvested
shares became vested as of May 25, 2006 as a result of Tontine’s acquisition of control of ACP.
See “Certain Relationships and Related Transactions.” Under the 2003 Management Equity Incentive
Plan, an additional 4,000,000 shares of common stock of ACP are reserved for future grants as
determined by the compensation committee or the board of directors. Grants of incentive or
non-qualified stock options and restricted stock awards may be made under the plan.
Employment Agreements
We have entered into employment agreements with each of the named executive officers. The
agreements establish a base salary as well as providing for a severance payment calculation in the
event of termination (pursuant to the 2003 Severance and Change of Control Plan described below),
health (subject to satisfying insurability requirements), 401(k) and other benefits that the named
employees are entitled to receive. Non-competition and non-solicitation agreements have been signed
as part of the employment agreements, which will apply during a period of three years for our chief
executive officer and two years for the chief financial officer and other members of management of
the Company, in each case, after termination.
2003 Severance and Change of Control Plan
Under the 2003 Severance and Change of Control Plan, the executives with whom we have executed
employment agreements are entitled to receive Severance Payments, as defined in the 2003 Severance
and Change of Control Plan, health benefits and outplacement services if the Company terminates his
or her employment without cause or if he or she terminates his or her employment for Good Reason
and a Change of Control Payment, health benefits and outplacement services if a participating
executive’s employment is terminated or the executive resigns from employment for Good Reason
within 180 days of a Change of Control, as such terms are defined in the 2003 Severance and Change
of Control Plan. The acquisition by Tontine in May 2006 of beneficial ownership of a
majority of ACP’s common stock was a Change of Control for this purpose. See “Certain Relationships and Related
Transactions.”
The Severance Payment is equal to (1) the severance multiple listed in each executive’s
employment agreement multiplied by (2) the base salary of such executive. The Change of Control
Payment is equal to (1) the change of control multiple listed in each executive’s employment
agreement multiplied by (2) the base salary of such executive. The severance multiples for Messrs.
Barrett, LaChey, Varkoly, Andrews, and DeRita, respectively are 2.70, 2.03, 2.03, 1.88, and 2.03.
The change of control multiples for Messrs. Barrett, LaChey, Varkoly, Andrews,
and DeRita, respectively are 3.38, 2.70, 2.03, 1.88, and 2.03. The plan also requires payments
in certain circumstances to executives sufficient to make them whole for any excise tax imposed
under Section 4999 of the Internal Revenue Code.
Director Compensation
For fiscal 2005 and the first quarter of fiscal 2006, each member of the board
of directors of ACP who was not an officer of ACP was entitled to receive annual compensation for
services as a director of ACP and its subsidiaries, including Neenah, in the amount of $40,000,
payable in cash quarterly in four equal installments, and was also entitled to receive
reimbursement for all reasonable out-of-pocket expenses, including, without limitation, travel
expenses, incurred by the director in connection with the performance of the director’s duties.
Effective July 1, 2005, members of the audit committee were entitled to receive an additional
$10,000 per quarter for serving on that committee. In addition, each member of the board of
directors who was not an officer was paid a fee of $1,000 for in person attendance at annual,
regular, special and adjourned meetings of the board of directors or committee meetings of the
board of directors. Meeting fees paid to the four outside directors for fiscal 2005 totaled
$69,000. Members of the special litigation committee of the board of directors (Mr. Marshall and a
former director) were also each granted a special one time payment of $20,000 to recognize their
work in connection in arriving at a settlement of the Mercer litigation in 2005.
Effective January 1, 2006, each member of the board of directors of ACP who is not an officer
of ACP is entitled to receive annual compensation in the amount of $100,000 for services as a
director, payable in cash quarterly in four equal installments. Members of the audit committee or
other committees of the board are entitled to receive an additional $15,000 of annual cash
compensation for serving on each such committee. Each director who is not an officer of ACP is also
entitled to receive reimbursement by ACP for all reasonable out-of-pocket expenses, including,
without limitation, travel expenses, incurred in connection with the performance of the director’s
duties. Mr. Gendell and Mr. Lash have declined to accept directors’ fees and currently receive only
reimbursement for expenses for serving on the board.
Upon emerging from bankruptcy in October 2003, ACP issued 200,000 shares of ACP common stock,
representing 0.25% of ACP’s common stock on a fully-diluted basis, to each person then serving as
an outside director.
Item 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT AND RELATED STOCKHOLDER MATTERS.
The following table sets forth information known to us with respect to the
beneficial ownership of the common stock of ACP, our ultimate parent
company, as of December 14,2006, or as otherwise indicated, by:
•
each person or entity who owns beneficially more than 5% or more of any class of
ACP’s voting securities;
All executive officers and directors as a group (13 persons)(6)
2,577,453
3.2
%
*
Less than 1%
(1)
As used in this table, a beneficial owner of a security includes any person who, directly or indirectly, through contract,
arrangement, understanding, relationship or otherwise has or shares (1) the power to vote, or direct the voting of, such security
or (2) investing power which includes the power to dispose, or to direct the disposition of, such security. In addition, a person
is deemed to be the beneficial owner of a security if that person has the right to acquire beneficial ownership of such security
within 60 days of December 14, 2006. Except as otherwise noted, the persons and entities listed on this table have sole voting
and investment power with respect to all of the shares of common stock owned by them. Calculations are based on a total of
80,800,000 shares of common stock deemed to be outstanding as of December 14, 2006, which includes warrants to purchase common
stock. The warrants are exercisable at any time until October 7, 2013 and have a nominal exercise price of $.01 per share.
(2)
Includes the following number of shares issuable upon exercise of warrants presently exercisable: 21,139,220 warrants held by
Tontine Capital Partners, L.P.; 5,544,764 warrants held by Harbinger Capital Partners Master Fund I, Ltd.
(3)
See “Certain Relationships and Related Transactions” for a description of the May 2006 transactions in which Tontine Capital
Partners, L.P. acquired most of these shares. Mr. Gendell and Mr. Lash are employed by an affiliate of Tontine Capital Partners,
L.P. Each disclaims beneficial ownership of the ACP shares and warrants beneficially owned by Tontine. The address for Tontine
Capital Partners, L.P. is 55 Railroad Avenue, 1st Floor, Greenwich, CT06830.
(4)
The address for Harbinger Capital Partners Master Fund I, Ltd. is Third Floor, Bishop’s Square, Redmond’s Hill, Dublin 2, Ireland.
(5)
Pursuant to the plan of reorganization, Mr. Marshall received 200,000 shares of common stock as of the effective date of the plan
of reorganization.
(6)
Excludes 289,217 shares beneficially owned by other managerial employees. Collectively, our management and directors own an
aggregate of 2,866,670 shares of common stock, 1,333,330 of which may be sold to Tontine as described under “Certain
Relationships and Related Transactions.”
The following table sets forth information about our 2003 Management Equity Incentive Plan as
of September 30, 2006:
Number of Securities
Remaining Available for
Weighted-Average
Future Issuance Under
Exercise Price of
Equity Compensation
Number of Securities to be Issued
Outstanding
Plans (Excluding
Upon Exercise of Outstanding
Options, Warrants
Securities Reflected in
Plan Category
Options, Warrants and Rights
and Rights
the First Column)
Equity compensation
plans approved by
security holders
(1)
—
—
4,000,000
Equity compensation
plans not approved
by security holders
—
—
—
Total
—
—
4,000,000
(1)
The 2003 Management Equity Incentive Plan was adopted in connection with the Plan of
Reorganization. The securities issuable under the plan are shares of ACP common stock.
Item 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS
ACP Holding Company is the parent company of NFC Castings, Inc., our immediate parent company,
and thus ACP indirectly owns 100% of the common stock of the Company. William M. Barrett, who
serves as the president and chief executive officer of the Company, currently serves as president
and chief executive officer of ACP. Gary W. LaChey, who serves as corporate vice president-finance,
treasurer and secretary of the Company, also serves in those capacities for ACP.
Over a period of several months, the Company’s officers were apprised by representatives of
Tontine, an existing stockholder of ACP, of Tontine’s interest in acquiring additional shares of
common stock of ACP. On May 19, 2006, ACP received a Transfer Notice (the “Transfer Notice”) along
with an executed Securities Purchase Agreement, dated as of May 19, 2006 (the “Securities Purchase
Agreement”), by and among Tontine, MacKay Shields LLC (“MacKay Shields”), Citicorp Mezzanine III,
L.P. and certain of its affiliates, collectively (“CM-III”) and certain affiliates of Trust Company
of the West (“TCW” and with MacKay Shields and CM-III, the “Major Sellers”) and Metropolitan Life
Insurance Company (“Met Life”). The Transfer Notice was required under the terms of the
Stockholders Agreement dated as of October 8, 2003 (the “Stockholders Agreement”) among ACP, the
Management Stockholders (as defined therein) and the Major Sellers, which provided ACP with a first
option to purchase the ACP securities proposed to be sold to Tontine by MacKay Shields and CM-III,
for the same consideration being offered by Tontine. ACP determined not to exercise its first
option to purchase those securities, and on May 25, 2006, pursuant to the Securities Purchase
Agreement, Tontine purchased all of the shares of common stock of ACP (the “Shares”) and warrants
to purchase Shares for an exercise price of $.01 per Share (the “Warrants” and together with the
Shares, the “ACP Securities”) held by the Major Sellers and Met Life for $1.80 per Share and $1.79
per Warrant, payable in cash.
On May 26, 2006, Tontine also purchased 1,333,330 Shares for $1.80 per Share from certain
officers and employees of Neenah and/or ACP (including Messrs. Barrett, LaChey, Varkoly, Andrews
and DeRita) who collectively owned a total of 4,000,000 Shares (the “Sellers”) pursuant to the
terms of a Stock Purchase Agreement, dated as of May 19, 2006 (the “Stock Purchase Agreement”). The
Stock Purchase Agreement also grants each Seller
a right to “put” an additional one-third of his or
her Shares, collectively 1,333,330 additional Shares, subject to specified terms and conditions, to
Tontine one year after the initial closing for $1.80 per Share.
The amount of ACP Securities purchased pursuant to the Securities Purchase Agreement and the
Stock Purchase Agreement was 18,152,355 Shares and 20,992,053 Warrants, representing 48.4% of all
Shares outstanding on a fully-diluted basis. The aggregate consideration paid for such securities
was approximately $70.25 million. ACP Securities purchased by Tontine were purchased with working
capital and on margin collateralized by other securities owned by Tontine. Tontine’s margin
transactions are with UBS Securities LLC, on that firm’s usual terms and conditions.
In connection with the purchase of the ACP Securities by Tontine pursuant to the Securities
Purchase Agreement and the Stock Purchase Agreement, the provisions of the Stockholders Agreement
terminated on May 25, 2006.
As provided by the Stockholders Agreement, the board of directors of ACP then consisted of
five directors. Under the Stockholders Agreement, MacKay Shields designated two members to the
board of directors and CM-III and TCW each designated one member to the board of directors.
Effective upon consummation of the transactions described above, all but one of those four
directors resigned from the board of directors of ACP and its subsidiaries, including Neenah, and
the board of directors unanimously elected Joseph V. Lash, David B. Gendell and Stephen E. K.
Graham to the board of directors to fill the vacancies created by those resignations. William M.
Barrett and Jeffrey G. Marshall continued to serve on the board of directors. Tontine purchased an
aggregate of 400,000 Shares of ACP common stock, at a price of $1.80 per Share, from two of the
former directors subsequent to their resignation from the board and purchased 200,000 Shares from a
charity that acquired those Shares from a third director.
As of December 14, 2006, Tontine beneficially owned, in the aggregate, 22,929,467 Shares, and
21,139,220 Warrants, representing 54.5% of all Shares outstanding on a fully-diluted basis, which
includes the 4,177,112 Shares and 147,167 Warrants that Tontine beneficially owned prior to
entering into the Securities Purchase Agreement and the Stock Purchase Agreement.
The purchase of the ACP Securities by Tontine as described above constituted a Change of
Control of Neenah, as defined in the indentures governing Neenah’s $133.1 million of outstanding
11% Notes and $100 million of outstanding 13% Notes. In accordance with those indentures, upon a
Change of Control, Neenah was required to make tender offers to purchase all outstanding 11% Notes
and all outstanding 13% Notes. Both tender offers were required to be made at a price of 101% of
the principal amount of the Notes, plus accrued and unpaid interest to the date of purchase. Neenah
entered into an agreement with Tontine whereby Tontine agreed that Tontine or an affiliate would
acquire directly any 11% Notes and any 13% Notes that were tendered in the change of control tender
offers. In accordance with that agreement, Tontine purchased all $115,000 of 11% Notes and all
$76,292,000 of 13% Notes that were tendered in the change of control tender offers. As of
December 14, 2006, Tontine continued to own, and to receive the interest payable on, those
securities.
Audit Fees. Fees for audit services totaled $475,600 and $410,900 for the years ended
September 30, 2006 and 2005, respectively, which included fees associated with the annual audit,
filings under the Securities Act of 1933, as amended, and other services performed related to
regulatory filings.
Audit-Related Fees. Fees for audit-related services totaled $15,000 and $116,500 for the years
ended September 30, 2006 and 2005, respectively, for accounting consultations.
Tax Fees. Fees for tax services totaled $311,175 and $509,300 for the years ended September30, 2006 and 2005, respectively, and consisted primarily of tax consulting services.
The Company’s Audit Committee appoints the independent registered public accounting firm and
pre-approves the services in regularly scheduled audit committee meetings. The Audit Committee has
considered whether the fees of Ernst & Young LLP for non-audit services are compatible with
maintaining Ernst & Young LLP’s independence.
PART IV
Item 15. EXHIBITS AND FINANCIAL STATEMENT SCHEDULES
Page
(a) (1)
Consolidated Financial Statements of Neenah Foundry Company
Schedules I, III, IV, and V are omitted since they are not applicable or not required under the
rules of Regulation S-X.
(3) Exhibits
See (b) below
(b) Exhibits
See the Exhibit Index following the signature page of this report, which is incorporated
herein by reference. Each management contract and compensatory plan or arrangement required to be
filed as an exhibit to this report is identified in the Exhibit Index by an asterisk following its
exhibit number.
(c) Financial Statements Excluded From Annual Report to Shareholders
Report of Independent Registered Public Accounting Firm
The Board of Directors
Neenah Foundry Company
We have audited the accompanying consolidated balance sheets of Neenah Foundry Company and
Subsidiaries (the Company) as of September 30, 2006 and 2005 (Reorganized Company), and the related
consolidated statements of operations, changes in stockholder’s equity and cash flows for the years
ended September 30, 2006 and 2005 and the period from October 1, 2003 to September 30, 2004
(Reorganized Company) and the portion of October 1, 2003 related to the Predecessor Company’s
reorganization gain. These financial statements are the responsibility of the Company’s management.
Our responsibility is to express an opinion on these financial statements based on our audits.
We conducted our audits in accordance with standards of the Public Company Accounting Oversight
Board (United States). Those standards require that we plan and perform the audit to obtain
reasonable assurance about whether the financial statements are free of material misstatement. We
were not engaged to perform an audit of the Company’s internal control over financial reporting.
Our audits included consideration of internal control over financial reporting as a basis for
designing audit procedures that are appropriate in the circumstances, but not for the purpose of
expressing an opinion on the effectiveness of the Company’s internal control over financial
reporting. Accordingly, we express no such opinion. An audit also includes examining, on a test
basis, evidence supporting the amounts and disclosures in the financial statements, assessing the
accounting principles used and significant estimates made by management, and evaluating the overall
financial statement presentation. We believe that our audits provide a reasonable basis for our
opinion.
In our opinion, the financial statements referred to above present fairly, in all material
respects, the consolidated financial position of the Reorganized Company at September 30, 2006 and
2005, and the consolidated results of operations and cash flows for the years ended September 30,2006 and 2005 and the period from October 1, 2003 to September 30, 2004 (Reorganized Company) and
the portion of October 1, 2003 related to the Predecessor Company’s reorganization gain, in
conformity with U.S. generally accepted accounting principles.
As discussed in Note 1 to the financial statements, effective October 8, 2003, the Company was
reorganized under a plan of reorganization confirmed by the United States Bankruptcy Court,
District of Delaware. The financial statements of the Reorganized Company reflect the impact of
adjustments to reflect the fair value of assets and liabilities under fresh start accounting, which
was applied effective October 1, 2003. As a result, the financial statements of the Reorganized
Company are presented on a different basis than those of the Predecessor Company and, therefore,
are not comparable in all respects.
Neenah Foundry Company (Neenah), together with its subsidiaries (collectively, the Company),
manufactures gray and ductile iron castings and forged components for sale to industrial and
municipal customers. Industrial castings are custom-engineered and are produced for customers in
several industries, including the medium and heavy-duty truck components, farm equipment, heating,
ventilation and air-conditioning industries. Municipal castings include manhole covers and frames,
storm sewer frames and grates, tree grates and specialty castings for a variety of applications and
are sold principally to state and local government entities, utilities and contractors. The
Company’s sales generally are unsecured.
Neenah is a wholly owned subsidiary of NFC Castings, Inc., which is a wholly owned subsidiary of
ACP Holding Company. Neenah has the following subsidiaries, all of which are wholly owned: Deeter
Foundry, Inc. (Deeter); Mercer Forge Corporation and subsidiaries (Mercer); Dalton Corporation and
subsidiaries (Dalton); Advanced Cast Products, Inc. and subsidiaries (Advanced Cast Products);
Gregg Industries, Inc. (Gregg); Neenah Transport, Inc. (Transport) and Cast Alloys, Inc. (Cast
Alloys), which is inactive. Deeter manufactures gray iron castings for the municipal market and
special application construction castings. Mercer manufactures forged components for use in
transportation, railroad, mining and heavy industrial applications and microalloy forgings for use
by original equipment manufacturers and industrial end users. Dalton manufactures gray iron
castings for refrigeration systems, air conditioners, heavy equipment, engines, gear boxes,
stationary transmissions, heavy-duty truck transmissions and other automotive parts. Advanced Cast
Products manufactures ductile and malleable iron castings for use in various industrial segments,
including heavy truck, construction equipment, railroad, mining and automotive. Gregg manufactures
gray and ductile iron castings for industrial and commercial use. Transport is a common and
contract carrier licensed to operate in the continental United States. The majority of Transport’s
revenues are derived from transport services provided to the Company.
On August 5, 2003, the Company filed a voluntary petition for relief under Chapter 11 of the United
States Bankruptcy Code with the United States Bankruptcy Court, District of Delaware (the
Bankruptcy Court). On September 26, 2003, the Bankruptcy Court confirmed the Company’s Plan of
Reorganization, and on October 8, 2003, the Company consummated the Plan of Reorganization and
emerged from its Chapter 11 reorganization proceedings with a significantly restructured balance
sheet. The accompanying consolidated financial statements for
Notes to Consolidated Financial Statements (continued) (In Thousands)
1. Organization and Description of Business (continued)
the portion of October 1, 2003 related to the reorganization gain have been prepared in accordance
with American Institute of Certified Public Accountant’s Statement of Position 90-7, “Financial
Reporting by Entities in Reorganization under the Bankruptcy Code” (SOP 90-7).
Although the effective date of the Plan of Reorganization was October 8, 2003, due to the
immateriality of the results of operations for the period between October 1, 2003 and the effective
date, the Company has accounted for the consummation of the Plan of Reorganization as if it had
occurred on October 1, 2003 and implemented the fresh start provisions (fresh start) of SOP 90-7 as
of that date. Fresh start required that the Company adjust the historical cost of its assets and
liabilities to their fair value. The fair value of the reorganized Company, or the reorganization
value, of approximately $290,000 was determined by an independent party based on multiples of
earnings before interest, income taxes, depreciation and amortization (EBITDA) and discounted cash
flows under the Company’s financial projections.
Reorganization gain for the Predecessor on October 1, 2003 consisted of the following:
Net gain on extinguishment of debt
$
168,208
Net loss resulting from fresh start fair value adjustments to assets and liabilities
(124,265
)
Total reorganization gain
$
43,943
2. Summary of Significant Accounting Policies
Principles of Consolidation
The consolidated financial statements include the accounts of Neenah and its subsidiaries. All
intercompany transactions have been eliminated in consolidation.
Use of Estimates
The preparation of financial statements in conformity with U.S. generally accepted accounting principles requires management to make
estimates and assumptions
that affect the amounts reported in the financial statements and accompanying notes. Actual results could differ from those estimates.
Notes to Consolidated Financial Statements (continued)
2. Summary of Significant Accounting Policies (continued)
Accounts Receivable
The Company evaluates the collectibility of its accounts receivable based on a number of factors.
For known collectibility concerns, an allowance for doubtful accounts is recorded based on the
customer’s ability and likelihood to pay based on management’s review of the facts. For all other
accounts, the Company recognizes an allowance based on the length of time the receivable is past
due based on historical experience. Adjustments to these estimates may be required if the
financial condition of the Company’s customers were to change. The Company does not require
collateral or other security on accounts receivable.
Inventories
Inventories at September 30, 2006 and 2005 are stated at the lower of cost or market. The cost of
inventories for Neenah and Dalton is determined on the last-in, first-out (LIFO) method for
substantially all inventories except supplies, for which cost is determined on the first-in,
first-out (FIFO) method. The cost of inventories for Deeter, Mercer, Advanced Cast Products and
Gregg is determined on the FIFO method. LIFO inventories comprise 38% and 42% of total inventories
at September 30, 2006 and 2005, respectively. If the FIFO method of inventory valuation had been
used by all companies, inventories would have been approximately $6,600 and $6,901 higher than
reported at September 30, 2006 and 2005, respectively. Additionally, cost of sales in the
accompanying consolidated statements of operations would have been approximately $721 and $1,039
higher for the years ended September 30, 2006 and 2005, respectively, had the Company not
experienced a decrement in certain inventory quantities that are valued on the LIFO method.
Property, Plant and Equipment
Property, plant and equipment acquired prior to September 30, 2003 are stated at fair value, as
required by fresh start accounting. Additions to property, plant and equipment subsequent to
October 1, 2003 are stated at cost. Depreciation for financial reporting purposes is provided over
the estimated useful lives (3 to 40 years) of the respective assets using the straight-line method.
Deferred Financing Costs
Costs incurred to obtain long-term financing are amortized using the effective interest method over
the term of the related debt.
Notes to Consolidated Financial Statements (continued)
2. Summary of Significant Accounting Policies (continued)
Identifiable Intangible Assets
Identifiable intangible assets, primarily customer lists and tradenames, are amortized on a
straight-line basis over the estimated useful lives of 10 to 40 years.
Goodwill
Goodwill is tested for impairment annually during the fourth fiscal quarter or more frequently if
an event indicates that the goodwill might be impaired in accordance with Statement of Financial
Accounting Standards (SFAS) No. 142, “Goodwill and Other Intangible Assets.” Based on such tests,
there was no impairment of goodwill recorded in fiscal 2006, 2005 or 2004.
Impairment of Long-Lived Assets
Property, plant and equipment and identifiable intangible assets are reviewed for impairment
whenever events or changes in circumstances indicate that the carrying amount may not be
recoverable. If the sum of the expected undiscounted cash flows is less than the carrying value of
the related asset or group of assets, a loss is recognized for the difference between the fair
value and carrying value of the asset or group of assets. Such analyses necessarily involve
significant judgment.
Revenue Recognition
Revenues are recognized when all of the following criteria are met: persuasive evidence of an
arrangement exists; delivery has occurred and ownership has transferred to customer; the price to
the customer is fixed and determinable; and collectibility is reasonably assured. The Company meets
these criteria for revenue recognition upon shipment of product, which corresponds with transfer of
title.
Shipping and Handling Costs
Shipping and handling costs billed to customers are recognized within net sales. Shipping and
handling costs are included in cost of sales.
Notes to Consolidated Financial Statements (continued)
2. Summary of Significant Accounting Policies (continued)
Advertising Costs
Advertising costs are expensed as incurred. Advertising costs for continuing operations were $564,
$470 and $525 for the years ended September 30, 2006, 2005 and 2004, respectively.
Income Taxes
Deferred income taxes are provided for temporary differences between the financial reporting and
income tax basis of the Company’s assets and liabilities and are measured using currently enacted
tax rates and laws.
Financial Instruments
The carrying value of the Company’s financial instruments, including cash, accounts receivable and
accounts payable approximate fair value. The fair value of the Company’s long-term debt is
approximately $281,634 at September 30, 2006 and compares to a carrying value of $264,195. The fair
value of the Senior Subordinated and Senior Secured Notes with a face value of $233,130 is based on
quoted market prices.
Comprehensive Income
Comprehensive income represents net income plus any gains or losses that, under U.S. generally
accepted accounting principles, are excluded from net income and recognized directly as a component
of stockholder’s equity.
Reclassifications
Certain reclassifications have been made to the prior year financial statements to conform to the
current year presentation.
Notes to Consolidated Financial Statements (continued)
2. Summary of Significant Accounting Policies (continued)
New Accounting Pronouncements
In November 2004, the Financial Accounting Standards Board (FASB) issued SFAS No. 151, “Inventory
Costs, an Amendment of ARB No. 43, Chapter 4.” SFAS No. 151 clarifies that abnormal amounts of idle
facility expense, freight, handling costs, and wasted materials (spoilage) should be recognized as
current-period charges and requires the allocation of fixed production overhead to inventory based
on the normal capacity of the production facilities. SFAS No. 151 is effective for inventory costs
incurred during fiscal years beginning after June 15, 2005. Adoption of SFAS No. 151 did not have a
material impact on the Company’s financial condition, results of operations or cash flows.
In July 2006, the FASB issued FASB Interpretation No. 48, “Accounting for Uncertainty in Income
Taxes — an interpretation of FASB Statement No. 109” (FIN 48), which clarifies the accounting for
uncertainty in tax positions. This interpretation requires that the Company recognize in its
financial statements the impact of a tax position, if that position is more likely than not of
being sustained on audit, based on the technical merits of the position. This interpretation is
effective for fiscal years beginning after December 15, 2006, with the cumulative effect of the
change in accounting principle recorded as an adjustment to opening retained earnings. The Company
is currently evaluating the impact FIN 48 will have on its financial statements.
In September 2006, the FASB issued SFAS No. 158, “Employers’ Accounting for Defined Benefit Pension
and Other Postretirement Plans.” SFAS No. 158 amends SFAS No. 87, “Employers’ Accounting for
Pensions,” SFAS No. 88, “Employers’ Accounting for Settlements and Curtailments of Defined Benefit
Pension Plans and for Termination Benefits,” SFAS No. 106, “Employers’ Accounting for
Postretirement Benefits Other than Pensions,” and SFAS No. 132, “Employers’ Disclosures about
Pensions and Other Postretirement Benefits.” The amendments retain most of the existing measurement
and disclosure guidance and will not change the amounts recognized in the Company’s statement of
operations. SFAS No. 158 requires companies to recognize a net asset or liability with an offset to
equity, by which the defined benefit post-retirement obligation is over- or under-funded. SFAS No.
158 requires prospective application, and the recognition and disclosure requirements will be
effective for the Company’s fiscal year ending September 30, 2007. The Company is currently
evaluating the impact SFAS No. 158 will have on its consolidated balance sheets.
Notes to Consolidated Financial Statements (continued)
3. Inventories
Inventories consist of the following as of September 30:
2006
2005
Raw materials
$
7,857
$
6,905
Work in process and finished goods
38,437
37,088
Supplies
15,553
15,130
$
61,847
$
59,123
4. Intangible Assets
Identifiable intangible assets consist of the following as of September 30:
2006
2005
Gross
Gross
Carrying
Accumulated
Carrying
Accumulated
Amount
Amortization
Amount
Amortization
Amortizable intangible assets:
Customer lists
$
67,000
$
20,100
$
67,000
$
13,401
Tradenames
16,282
1,234
16,282
823
Other
155
31
155
21
$
83,437
$
21,365
$
83,437
$
14,245
The Company does not have any intangible assets deemed to have indefinite lives. The Company
expects to recognize amortization expense of $7,120 in each of the five fiscal years subsequent to
September 30, 2006.
Notes to Consolidated Financial Statements (continued)
5. Long-Term Debt
Long-term debt consists of the following as of September 30:
2006
2005
13% Senior Subordinated Notes
$
100,000
$
100,000
11% Senior Secured Notes, less unamortized discount of $6,337 and $7,921
126,191
124,607
Term Loan Facilities
13,409
16,564
Revolving Credit Facility
24,595
30,502
Other
—
81
264,195
271,754
Less current portion
27,750
33,668
$
236,445
$
238,086
The Company’s Credit Facility provides for a revolving credit line of up to $92,085 (with a
$5,000 sublimit available for letters of credit and a term loan in the aggregate original principal
amount of $22,085 which requires annual principal payments of $3,155 through fiscal 2008, with the
remainder due in fiscal 2009). The Credit Facility matures on October 8, 2009. The Credit Facility
is secured by substantially all of the Company’s tangible and intangible assets. The interest rate
on the Credit Facility is based on LIBOR (5.625% at September 30, 2006) or prime plus an applicable
margin, based upon the Company meeting certain financial statistics. The weighted-average interest
rate on the revolving credit line outstanding borrowings at September 30, 2006 is 7.65%. Substantially
all of Neenah’s wholly owned subsidiaries are co-borrowers with
Neenah under the Credit Facility and are jointly and severally liable with Neenah for all
obligations under the Credit Facility, subject to customary exceptions for transactions of this
type. In addition, NFC Castings, Inc. (Neenah’s immediate parent), and the remaining wholly owned
subsidiaries of Neenah jointly and severally guarantee Neenah’s obligations under the Credit
Facility, subject to customary exceptions for transactions of this type.
Notes to Consolidated Financial Statements (continued)
5. Long-Term Debt (continued)
The borrowers’ and guarantors’ obligations under the Credit Facility are secured by a first
priority perfected security interest, subject to customary restrictions, in substantially all of
the tangible and intangible assets of the Company and its subsidiaries. The Senior Secured Notes,
and the guarantees in respect thereof, are equal in right of payment to the Credit Facility, and
the guarantees in respect thereof. The liens in respect of the Senior Secured Notes are junior to
the liens securing the Credit Facility and guarantees thereof. Borrowings under the Revolving
Credit Facility have been classified as current liabilities in the accompanying consolidated
balance sheets in accordance with the consensus of Emerging Issues Task Force No. 95-22, “Balance
Sheet Classification of Borrowings Outstanding under Revolving Credit Agreements that include both
a Subjective Acceleration Clause and a Lock-Box Arrangement.”
The Senior Secured Notes mature on September 30, 2010 and bear interest at 11%. Interest is payable
semiannually on January 1 and July 1. The Senior Secured Notes are secured by substantially all of
the Company’s tangible and intangible assets; however, they are second in priority to the
borrowings under the Credit Facility. The Company’s obligations under the Senior Secured Notes are
guaranteed on a secured basis by each of its wholly owned subsidiaries. The Senior Subordinated
Notes are unsecured, mature on September 30, 2013 and bear interest at 13%. Interest of 5% is
payable in cash and 8% may be paid-in-kind semiannually on January 1 and July 1. Through July 1,2006, the Company has paid the interest in cash. The Senior Secured and the Senior Subordinated
Notes are fully, unconditionally, jointly and severally guaranteed by all subsidiaries.
The Credit Facility, Senior Secured and the Senior Subordinated Notes contain various financial and
nonfinancial covenants, including those which restrict the Company from incurring additional
indebtedness and prohibit dividend payments, stock redemptions and certain other transactions. At
September 30, 2006, the Company is in compliance with all covenants.
Scheduled annual principal payments on long-term debt for fiscal years subsequent to September 30,2006 are:
Notes to Consolidated Financial Statements (continued)
6. Commitments and Contingencies
The Company leases certain plants, warehouse space, machinery and equipment, office equipment and
vehicles under operating leases. Rent expense for continuing operations under these operating
leases for the years ended September 30, 2006, 2005 and 2004 totaled $2,923, $2,920 and $2,999,
respectively.
During the year ended September 30, 2006, the Company financed purchases of property, plant and
equipment totaling $1,271 by entering into capital lease obligations. Property, plant and
equipment under leases accounted for as capital leases as of September 30, 2006 are as follows:
Machinery and equipment
$
1,344
Less accumulated depreciation
214
$
1,130
Minimum rental payments due under operating and capital leases for fiscal years subsequent to
September 30, 2006, are as follows:
Notes to Consolidated Financial Statements (continued)
6. Commitments and Contingencies (continued)
The Company is partially self-insured for workers’ compensation claims. An accrued liability is
recorded for claims incurred but not yet paid or reported and is based on current and historical
claim information. The accrued liability may ultimately be settled for an amount different than the
recorded amount. Adjustments of the accrued liability are recorded in the period in which they
become known.
Approximately 65% of the Company’s work force is covered by collective bargaining agreements. The
collective bargaining agreements for Neenah and the Kendallville location of Dalton, which
represent 35% of the Company’s work force, are scheduled to expire during fiscal 2007.
In the normal course of business, the Company is named in legal proceedings. There are currently no
material legal proceedings pending with respect to the Company. On August 5, 2005the Company settled a legal matter related to the proposed sale of one of its subsidiaries by
paying a cash settlement of $6,500.
The Company is proceeding with a $54,000 capital project to replace a mold line at its Neenah
facility. The new mold line is expected to significantly enhance operating efficiencies, increase
capacity and provide expanded molding capabilities for municipal products. The Company anticipates
that operating cash flows and its Credit Facility will be sufficient to fund this and other
anticipated operational investments, including working capital and capital expenditure needs, over
the two year construction timeframe. The Company expects the new mold line to become operational in
early calendar 2008. The Company has committed to $30,155 of expenditures related to the new mold
line.
The Company is presently disputing a claim from an investment bank for $3,340 in fees allegedly
arising from the acquisition of control of ACP Holding Company by Tontine Capital Partners, LP in
May 2006. Although it is not possible to predict with certainty the outcome of this unresolved
matter, the Company believes that based on current information, it has reserved for this matter in
accordance with U.S. generally accepted accounting principles.
Notes to Consolidated Financial Statements (continued)
7. Income Taxes
The provision for income taxes consists of the following:
Years Ended September 30
2006
2005
2004
Current:
Federal
$
7,553
$
7,032
$
(700
)
State
1,314
1,568
721
8,867
8,600
21
Deferred
(10
)
(5,191
)
3,620
$
8,857
$
3,409
$
3,641
The provision for income taxes is included in the consolidated statements of operations as
follows:
Years Ended September 30
2006
2005
2004
Continuing operations
$
8,857
$
3,409
$
3,881
Discontinued operations
—
—
(240
)
$
8,857
$
3,409
$
3,641
The provision for income taxes differs from the amount computed by applying the federal
statutory rate of 35% to income before income taxes as follows:
Years Ended September 30
2006
2005
2004
Provision at statutory rate
$
8,752
$
6,476
$
2,414
State income taxes, net of federal taxes
851
815
469
Permanent differences due to reorganization
—
(885
)
763
Change in tax method of determining LIFO inventory
Notes to Consolidated Financial Statements (continued)
7. Income Taxes (continued)
Deferred income tax assets and liabilities consist of the following as of September 30:
2006
2005
Deferred income tax liabilities:
Inventories
$
(1,195
)
$
(905
)
Property, plant and equipment
(11,667
)
(10,939
)
Identifiable intangible assets
(24,069
)
(27,677
)
Other
(336
)
(382
)
(37,267
)
(39,903
)
Deferred income tax assets:
Employee benefit plans
8,926
14,972
Accrued vacation
2,237
2,191
Other accrued liabilities
997
1,414
State net operating loss carryforwards
155
264
Other
873
871
Total deferred tax assets
13,188
19,712
Valuation allowance for deferred income tax assets
(155
)
(264
)
13,033
19,448
Net deferred income tax liability
$
(24,234
)
$
(20,455
)
Included in the consolidated balance sheets as:
Current deferred income tax asset
$
2,697
$
3,304
Noncurrent deferred income tax liability
(26,931
)
(23,759
)
$
(24,234
)
$
(20,455
)
As of September 30, 2006, the Company has state net operating loss carryforwards of $1,405
which expire through fiscal 2016. A full valuation allowance has been established for all state net
operating loss carryforwards due to the uncertainty regarding the realization of the deferred tax
benefit through future earnings.
Notes to Consolidated Financial Statements (continued)
8. Employee Benefit Plans
Defined-Benefit Pension Plans and Postretirement Benefits
The Company sponsors five defined-benefit pension plans covering the majority of its hourly
employees. Retirement benefits under the pension plans are based on years of service and
defined-benefit rates. The Company has elected a measurement date of June 30 for all of its
pension plans. The Company funds the pension plans based on actuarially determined cost methods
allowable under Internal Revenue Service regulations. During the year ended September 30, 2006,
the Company amended one of its defined-benefit pension plans to freeze its defined benefit rate and
credited years of service as of December 31, 2005. No curtailment gain or loss was required in
conjunction with freezing this defined-benefit plan.
The Company also sponsors unfunded defined-benefit postretirement health care plans covering
substantially all salaried and hourly employees at Neenah and their dependents. For salaried
employees at Neenah, benefits are provided from the date of retirement for the duration of the
employee’s life, while benefits for hourly employees at Neenah are provided from retirement to age
65. Retirees’ contributions to the plans are based on years of service and age at retirement. The
Company funds benefits as incurred. The Company has elected a measurement date of June 30 for these
plans.
FASB Financial Staff Position No. FAS 106-2, “Accounting and Disclosure Requirements Related to the
Medicare Prescription Drug, Improvement and Modernization Act of 2003” (the Act), addresses the
impact of the Act enacted in December 2003. The Act provides a prescription drug subsidy benefit
for Medicare eligible employees starting in 2006. During fiscal 2005, it was determined that the
benefit levels of the Company’s defined-benefit postretirement health care plan covering salaried
employees met the criteria set forth by the Act to qualify for the subsidy. Effective with the
June 30, 2005 measurement date, the effects of the subsidy were used in measuring the plan’s
benefit obligation and net periodic postretirement benefit cost. The effect of the subsidy was to
reduce the net periodic postretirement benefit cost by approximately $337 and $56 for the years
ended September 30, 2006 and 2005, respectively, and reduce the accumulated postretirement benefit
obligation by approximately $2,044 and $415 as of the June 30, 2006 and 2005, respectively,
measurement date. The amount of subsidy payments expected to be received is approximately $58 in
fiscal 2007.
Notes to Consolidated Financial Statements (continued)
8. Employee Benefit Plans (continued)
Obligations and Funded Status
The following table summarizes the funded status of the pension plans and postretirement benefit
plans and the amounts recognized in the consolidated balance sheets at September 30, 2006 and 2005:
Pension
Postretirement
Benefits
Benefits
2006
2005
2006
2005
Change in benefit obligation:
Benefit obligation, October 1
$
78,162
$
62,190
$
7,351
$
8,914
Service cost
2,328
2,008
153
161
Interest cost
4,083
3,870
282
363
Unrecognized prior service cost
422
—
—
—
Actuarial (gains) losses
(10,324
)
12,548
(1,748
)
(1,655
)
Benefits paid
(2,757
)
(2,454
)
(407
)
(432
)
Benefit obligation, September 30
$
71,914
$
78,162
$
5,631
$
7,351
Change in plan assets:
Fair value of plan assets, October 1
$
54,648
$
49,020
$
—
$
—
Actual return on plan assets
3,963
3,892
—
—
Company contributions
8,519
4,190
407
432
Benefits paid
(2,757
)
(2,454
)
(407
)
(432
)
Fair value of plan assets, September 30
$
64,373
$
54,648
$
—
$
—
Funded status of the plans:
Benefit obligation in excess of plan assets
$
(7,541
)
$
(23,514
)
$
(5,631
)
$
(7,351
)
Unrecognized prior service cost
392
—
(396
)
(429
)
4th quarter contributions
—
1,200
101
109
Unrecognized net (gains) losses
908
10,789
(4,215
)
(2,733
)
$
(6,241
)
$
(11,525
)
$
(10,141
)
$
(10,404
)
Amounts recognized in the consolidated balance sheets at
September 30:
Accrued pension or postretirement benefit liability
$
(8,036
)
$
(22,401
)
$
(10,141
)
$
(10,404
)
Intangible asset (included in other assets)
392
—
—
—
Deferred income tax asset
561
4,350
—
—
Accumulated other comprehensive loss
842
6,526
—
—
$
(6,241
)
$
(11,525
)
$
(10,141
)
$
(10,404
)
The accumulated benefit obligation for the Company’s defined benefit pension plans was $71,930
and $78,248 at September 30, 2006 and 2005, respectively. At September 30, 2006, pension plans
with benefit obligations in excess of plan assets had an aggregate projected benefit obligation of
$67,884 and aggregate fair value of plan assets of $60,236.
Notes to Consolidated Financial Statements (continued)
8. Employee Benefit Plans (continued)
Benefit Costs
Components of net periodic benefit cost for the years ended September 30 are as follows:
Pension Benefits
Postretirement Benefits
2006
2005
2004
2006
2005
2004
Service cost
$
2,328
$
2,008
$
1,964
$
153
$
161
$
286
Interest cost
4,083
3,870
3,663
282
363
523
Expected return on plan
assets
(4,732
)
(4,157
)
(3,630
)
—
—
—
Amortization of prior
service cost
30
—
—
(33
)
(32
)
(32
)
Recognized net actuarial
(gain) loss
185
2
20
(265
)
(244
)
(33
)
Net periodic benefit cost
$
1,894
$
1,723
$
2,017
$
137
$
248
$
744
Assumptions
Weighted-average assumptions used to determine benefit obligations as of September 30 are as
follows:
Pension Benefits
Postretirement Benefits
2006
2005
2006
2005
Discount rate
6.25
%
5.25
%
6.25
%
5.25
%
The increase in the discount rate used to determine benefit obligations as of September 30,2006 from 5.25% to 6.25% caused a decrease of $10,396 in the projected benefit obligation of the
Company’s pension plans.
Notes to Consolidated Financial Statements (continued)
8. Employee Benefit Plans (continued)
Weighted-average assumptions used to determine net periodic benefit cost for the years ended
September 30 are as follows:
Pension Benefits
Postretirement Benefits
2006
2005
2004
2006
2005
2004
Discount rate
5.25
%
6.25
%
6.25
%
5.25
%
6.25
%
6.25
%
Expected long-term
rate of return on
7.50
% to
7.50
% to
7.50
% to
plan assets
8.50
%
8.50
%
8.50
%
—
—
—
For measurement purposes, the healthcare cost trend rate was assumed to be 10% decreasing
gradually to 5.0% in 2016 and then remaining at that level thereafter. The healthcare cost trend
rate assumption has a significant effect on the amounts reported. A one percentage point change in
the healthcare cost trend rate would have the following effect:
1% Increase
1% Decrease
Effect on total of service cost and interest cost
$
104
$
(77
)
Effect on postretirement benefit obligation
996
(778
)
Pension Plan Assets
The following table summarizes the weighted-average asset allocations of the pension plans at
September 30:
Notes to Consolidated Financial Statements (continued)
8. Employee Benefit Plans (continued)
The Company employs a total return investment approach whereby a mix of equities and fixed income
investments are used to maximize the long-term return of plan assets for a prudent level of risk.
The intent of this strategy is to minimize plan expenses by maximizing investment returns within
that prudent level of risk. The investment portfolio contains a diversified blend of equity and
fixed income investments. Furthermore, equity investments are diversified across U.S. and non-U.S.
stocks as well as growth, value, and small and large capitalizations. The Company’s targeted asset
allocation ranges as a percentage of total market value are as follows: equity securities 45% to
55% and debt securities 30% to 35%. None of the plans’ equity securities are invested in common
stock of the plan sponsor’s parent company, ACP Holding Company. Additionally, cash balances are
maintained at levels adequate to meet near term plan expenses and benefit payments. Investment risk
is measured and monitored on an ongoing basis through quarterly investment portfolio reviews.
The Company’s overall expected long-term rates of return on assets range from 7.50% to 8.50%. The
expected long-term rates of return are based on the portfolio of each defined benefit pension plan
as a whole and not on the sum of the returns of individual asset categories. The rates of return
are based on historical returns adjusted to reflect the current view of the long-term investment
market.
Benefit Payments and Contributions
The following benefit payments, which reflect expected future service, as appropriate, and are net
of expected Medicare subsidy receipts, are expected to be paid for fiscal years subsequent to
September 30, 2006:
2007
$
2,986
2008
3,048
2009
3,300
2010
3,473
2011
3,707
2012 — 2016
24,254
$
40,768
The Company expects to contribute $2,530 to its pension plans during fiscal 2007.
Notes to Consolidated Financial Statements (continued)
8. Employee Benefit Plans (continued)
Defined-Contribution Retirement Plans
The Company sponsors various defined-contribution retirement plans (the Plans) covering
substantially all salaried and certain hourly employees. The Plans allow participants to make
401(k) contributions in amounts ranging from 1% to 15% of their compensation. The Company matches
between 35% and 50% of the participants’ contributions up to a maximum of 6% of the employee’s
compensation, as defined. The Company may make additional voluntary contributions to the Plans as
determined annually by the Board of Directors. Total Company contributions amounted to $2,034,
$1,861 and $1,195 for the years ended September 30, 2006, 2005 and 2004, respectively.
Other Employee Benefits
The Company provides unfunded supplemental retirement benefits to certain active and retired
employees at Dalton. At September 30, 2006, the present value of the current and long-term portion
of these supplemental retirement obligations totaled $246 and $2,117, respectively. At September30, 2005, the present value of the current and long-term portion of these supplemental retirement
obligations totaled $232 and $2,347, respectively.
Certain of Dalton’s hourly employees are covered by a multi-employer, defined-benefit pension plan
pursuant to a collective bargaining agreement. The Company’s expense for the years ended September30, 2006, 2005 and 2004, was $356, $337 and $361, respectively.
Substantially all of Mercer’s union employees are covered by a multiemployer, defined-benefit
pension plan pursuant to a collective bargaining agreement. The Company’s expense for the years
ended September 30, 2006, 2005 and 2004, was $221, $290 and $141, respectively.
9. Segment Information
The Company has two reportable segments, Castings and Forgings. The Castings segment manufactures
and sells gray and ductile iron castings for the industrial and municipal markets, while the
Forgings segment manufactures forged components for the industrial market. The Other segment
includes machining operations and freight hauling.
Notes to Consolidated Financial Statements (continued)
9. Segment Information (continued)
The Company evaluates performance and allocates resources based on the operating income before
depreciation and amortization charges of each segment. The accounting policies of the reportable
segments are the same as those described in the summary of significant accounting policies.
Intersegment sales and transfers are recorded at cost plus a share of operating profit. The
following segment information is presented for continuing operations:
The following tables present condensed consolidating financial information as of and for the years
ended September 30, 2006 and 2005 and for the period from October 1, 2003 to September 30, 2004
for: (a) Neenah, and (b) on a combined basis, the guarantors of the Senior Secured Notes and the
Senior Subordinated Notes, which include all of the wholly owned subsidiaries of Neenah (Subsidiary
Guarantors). Separate financial statements of the Subsidiary Guarantors are not presented because
the guarantors are jointly, severally and unconditionally liable under the guarantees, and the
Company believes separate financial statements and other disclosures regarding the Subsidiary
Guarantors are not material to investors.
Report of Independent Registered Public Accounting Firm
The Board of Directors
Neenah Foundry Company
We have audited the consolidated financial statements of Neenah Foundry Company as of September 30,2006 and 2005 (Reorganized Company) and for the years ended September 30, 2006 and 2005 and the
period from October 1, 2003 to September 30, 2004 (Reorganized Company) and the portion of October1, 2003 related to the Predecessor Company’s reorganization gain and have issued our report thereon
dated November 3, 2006 (included elsewhere in this Annual Report on Form 10-K). Our audits also
included the financial statement schedule listed in the index at Item 15(a). This schedule is the
responsibility of the Company’s management. Our responsibility is to express an opinion based on
our audits.
In our opinion, the financial statement schedule referred to above, when considered in relation to
the basic financial statements taken as a whole, presents fairly in all material respects the
information set forth therein.
Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, the
registrant has duly caused this report to be signed on its behalf by the undersigned, thereunto
duly authorized.
Corporate Vice President - Finance and Chief Financial Officer
Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed
below on December 15, 2006, by the following persons on behalf of the registrant and in the
capacities indicated.
SUPPLEMENTAL INFORMATION TO BE FURNISHED WITH REPORTS FILED PURSUANT TO SECTION 15(d) OF THE
ACT BY REGISTRANTS WHICH HAVE NOT REGISTERED SECURITIES PURSUANT TO SECTION 12 OF THE ACT
The Company is not required to nor does it intend to furnish an annual report or a proxy
statement to its security holders.
Disclosure Statement for Pre-Petition of Votes
with respect to the Prepackaged Joint Plan of
Reorganization of ACP Holding Company, NFC
Castings, Inc., and Neenah Foundry Company
Exhibit T3E-1 to application for
qualification of indenture on Form T-3
filed 7/1/03 (File No. 022-28687)
2.2
Prepackaged Joint Plan of Reorganization of ACP
Holding Company, NFC Castings, Inc. Neenah Foundry
Company and Certain of its Subsidiaries under
Chapter 11 of the United States Bankruptcy Code
Exhibit T3E-2 to application for
qualification of indenture on Form T-3
filed 7/1/03 (File No. 022-28687)
3.1
Amended and Restated Certificate [Articles] of
Incorporation of Neenah Foundry Company
Exhibit 3.2 to Amendment No. 1 to the
Registrant’s Form S-4 Registration
Statement (File No. 333-111008) filed on
January 28, 2004 (the “1/28/04 S-4
Amendment”)
Warrant Agreement, dated October 8, by and between
ACP Holding Company and the Bank of New York as
warrant agent
Exhibit 10.4 hereto
4.2
Stockholders Agreement, dated October 8, 2003, by
and among ACP Holding Company, the Standby
Purchasers, the Executives and Directors (as such
terms are defined therein), which terminated on
May 25, 2006
Exhibit 10.5 to the Form S-4 (as defined
at Exhibit 10.3 below)
Indenture by and among Neenah Foundry Company, the
guarantors named therein, and the Bank of New
York, as Trustee, dated October 8, 2003, for the
13% Senior Subordinated Notes due 2013
Exhibit 10.7 hereto
4.3(a)
Supplemental Indenture, dated as of May 23, 2006,
to the Indenture dated October 8, 2003, for the
13% Senior Subordinated Notes due 2013, among
Neenah Foundry Company, the guarantors named
therein, and the Bank of New York, as Trustee
Exhibit 10.7(a) hereto
4.4
Form of Note for the 13% Senior Subordinated Notes
due 2013
Exhibit 10.8 hereto
4.5
Indenture by and among Neenah Foundry Company, the
guarantors named therein and The Bank of New York,
as Trustee, dated October 8, 2003, for the 11%
Senior Secured Notes due 2010
Exhibit 10.21 hereto
4.5(a)
Supplemental Indenture, dated as of May 23, 2006,
to the Indenture dated October 8, 2003, for the
11% Senior Secured Notes due 2010, among Neenah
Foundry Company, the guarantors named therein, and
the Bank of New York, as Trustee
Exhibit 10.21(a) hereto
4.6
Form of Note for the 11% Senior Secured Notes due
2010
Exhibit 10.22 hereto
10.1
Loan and Security Agreement, dated October 8,2003, by and among Neenah Foundry Company, its
subsidiaries party thereto, the various lenders
party thereto and Fleet Capital Corporation, as
agent
Amendment No. 1, dated as of July 28, 2005, to
Loan and Security Agreement, dated as of October8, 2003, by and among Neenah Foundry Company, its
subsidiaries party thereto, the various lenders
party thereto and Fleet Capital Corporation, as
agent
Amendment No. 2, dated as of December 9, 2005, to
Loan and Security Agreement, dated as of October8, 2003, by and among Neenah Foundry Company, its
subsidiaries party thereto, the various lenders
party thereto and Fleet Capital Corporation, as
agent
Exhibit 10.2(a) to 2005 Form 10-K
10.2(b)
Amendment No. 3, dated as of May 19, 2006, to Loan
and Security Agreement, dated as of October 8,2003, by and among Neenah Foundry Company, its
subsidiaries party thereto, the various lenders
party thereto and Fleet Capital Corporation, as
agent
Amendment No. 4, dated as of July 31, 2006, to
Loan and Security Agreement, dated as of October8, 2003, by and among Neenah Foundry Company, its
subsidiaries party thereto, the various lenders
party thereto and Fleet Capital Corporation, as
agent
Amendment No. 5, dated as of August 31, 2006, to
Loan and Security Agreement, dated as of October8, 2003, by and among Neenah Foundry Company, its
subsidiaries party thereto, the various lenders
party thereto and Fleet Capital Corporation, as
agent
X
10.3
Subscription Agreement, dated as of October 7,2003, by and among ACP Holding Company, Neenah
Foundry Company, the subsidiary Guarantors named
therein and the Investors as defined therein
Indenture by and among Neenah Foundry Company, the
guarantors named therein, and the Bank of New
York, as Trustee, dated October 8, 2003, for the
13% Senior Subordinated Notes due 2013
Senior Subordinated Notes due 2013, among
Neenah Foundry Company, the guarantors named
therein, and the Bank of New York, as Trustee
10.8
Form of Note for the 13% Senior Subordinated Notes
due 2013
Exhibit 10.6 to the Form S-4
10.9
Registration Rights Agreement, dated October 8,2003, by and among ACP Holding Company and the
parties named therein for the 13% Senior
Subordinated Noted due 2013
Exhibit 10.8 to the Form S-4
10.10*
Form of Amendment to the Employment Agreements and
Restricted Grants listed in Exhibits 10.10(a)
through 10.18
Exhibit 10.10 to 2005 Form 10-K
10.10(a)*
Employment Agreement and Restricted Stock Grant by
and among Neenah Foundry Company, ACP Holding
Company and John Andrews
Exhibit 10.9 to the 1/28/04 S-4 Amendment
10.11*
Employment Agreement and Restricted Stock Grant by
and among Neenah Foundry Company, ACP Holding
Company and William M. Barrett
Exhibit 10.10 to the 1/28/04 S-4 Amendment
10.12*
Employment Agreement and Restricted Stock Grant by
and among Dalton Corporation, ACP Holding Company
and Joseph L. DeRita
Exhibit 10.11 to the 1/28/04 S-4 Amendment
10.13*
Employment Agreement and Restricted Stock Grant by
and among Neenah Foundry Company, ACP Holding
Company and Frank C. Headington
Indenture by and among Neenah Foundry Company, the
guarantors named therein and The Bank of New York,
as Trustee, dated October 8, 2003, for the 11%
Senior Secured Notes due 2010
Exhibit 4.1 to the Form S-4
10.21(a)
Supplemental Indenture, dated as of May 23, 2006,
to the Indenture dated October 8, 2003, for the
11% Senior Secured Notes due 2010, among Neenah
Foundry Company, the guarantors named therein, and
the Bank of New York, as Trustee
Form of Note for the 11% Senior Secured Notes due
2010
Exhibit 4.1 to the Form S-4
10.23
Lien Subordination Agreement, dated October 8,2003, by and among Fleet Capital Corporation,
Neenah Foundry Company, the subsidiaries named
therein, NFC Castings, Inc. and The Bank of New
York as Trustee on behalf of the Noteholders under
the Indenture governing the 11% Senior Secured
Notes due 2010
Exhibit 4.3 to the Form S-4
10.24
Registration Rights Agreement, dated October 8,2003, by and among Neenah Foundry Company, the
Guarantors named therein and The Bank of New York
as Trustee for the 11% Senior Secured Notes due
2010
Exhibit 4.4 to the Form S-4
10.25
Subordinated Security Agreement, dated October 8,2003, by Neenah Foundry Company and the guarantors
named therein in favor of The
Bank of New York as
Trustee for the Noteholders under the Indenture
governing the 11% Senior Secured Noted due 2010
10.26
Subordinated Pledge Agreement, dated October 8,2003, by Dalton Corporation in favor of The Bank
of New York as Trustee for the Noteholders under
the Indenture governing the 11% Senior Secured
Notes due 2010.
Exhibit 4.6 to the Form S-4
10.27
Subordinated Pledge Agreement, dated October 8,2003, by Mercer Forge Corporation in favor of The
Bank of New York as Trustee for the Noteholders
under the Indenture governing the 11% Senior
Secured Notes due 2010
Exhibit 4.7 to the Form S-4
10.28
Subordinated Copyright, Patent, Trademark and
License Mortgage, dated October 8, 2003, by Neenah
Foundry Company in favor of The Bank of New York
as Trustee for the Noteholders under the Indenture
governing the 11% Senior Secured Notes due 2010
Exhibit 4.8 to the Form S-4
10.29
Subordinated Copyright, Patent, Trademark and
License Mortgage, dated October 8, 2003, by
Advanced Cast Products, Inc. in favor of The Bank
of New York as Trustee for the Noteholders under
the Indenture governing the 11% Senior Secured
Notes due 2010
Exhibit 4.9 to the Form S-4
10.30
Subordinated Copyright, Patent, Trademark and
License
Mortgage, dated October 8, 2003, by
Peerless Corporation in favor of The Bank of New
York as Trustee for the Noteholders under the
Indenture governing the 11% Senior Secured Notes
due 2010
10.31
Subordinated Pledge Agreement, dated October 8,2003, by Neenah Foundry Company in favor of The
Bank of New York as Trustee for the Noteholders
under the Indenture governing the 11% Senior
Securities due 2010
Exhibit 4.11 to the Form S-4
10.32
Subordinated Pledge Agreement, dated October 8,2003, by Advanced Cast Products, Inc. in favor of
The Bank of New York as Trustee for the
Noteholders under the Indenture governing the 11%
Senior Securities due 2010
Certification of Chief Executive Officer pursuant
to Rule 13a-14(a) or Rule 15d-14(a), as adopted
pursuant to Section 302 of the Sarbanes-Oxley Act
of 2002
X
31.2
Certification of Chief Financial Officer pursuant
to Rule 13a-14(a)
or Rule 15d-14(a), as adopted
pursuant to Section 302 of the Sarbanes-Oxley Act
of 2002
32
Chief Executive and Chief Financial Officers’
certification pursuant to 18 U.S.C. Section 1350,
as adopted pursuant to Section 906 of the
Sarbanes-Oxley Act of 2002
X
99.1
Securities Purchase Agreement, dated as of May 19,2006