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13A-14(B) and 18 U.S.C. Section 1350
(Exact name of Registrant as specified in its charter)
Delaware
43-0761773
(State or other jurisdiction
(I.R.S. Employer
of incorporation or organization)
Identification No.)
120 S. Central Avenue, Suite 1700 Clayton, Missouri63105
(314) 721-4242 (Address, including zip code, and telephone number, including
area code, of registrant’s principal executive offices)
Securities registered pursuant to Section 12(b) of the Act:
Common Stock, $.75 par value
New York Stock Exchange
Title of Each Class
Name of Exchange of Which Registered
Securities registered pursuant to Section 12(g) of the Act: None
Indicate by checkmark 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, and (2)
has been subject to such filing requirements for the past 90 days. YES þ NO o
Indicate by checkmark 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 checkmark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of
the Exchange Act).
YES þ NO o
Indicate by checkmark whether the registrant is a shell company (as defined in Rule 12b-2 of the
Exchange Act).
YES o NO þ
The aggregate market value of the voting stock held by non-affiliates of the Registrant was
approximately $620,813,936 on April 30, 2005. There were 32,045,270 total shares of common stock
outstanding as of December 31, 2005.
Statements in this Form 10-K that are not purely historical, including statements which
express the Company’s belief, anticipation or expectation about future events, are forward-looking
statements. These statements may be found in (i) the description of the Company’s business in Item
1, (ii) the description of legal proceedings in Item 3 and (iii) Management’s Discussion and
Analysis of Financial Condition and Results of Operations in Item 7. These sections include
statements about new products and market benefits, expected operating trends, future capital
expenditures, expenditures for environmental compliance, and anticipated cash flow and borrowings.
“Forward-looking statements” within the meaning of the Private Securities Litigation Reform
Act of 1995 relate to future events and expectations, include statements containing such words as
“anticipates,”“believes,”“estimates,”“expects,”“would,”“should,”“will,”“will likely result,”“forecast,”“outlook,”“projects,” and similar expressions. Forward-looking statements are based
on management’s current expectations and include known and unknown risks, uncertainties and other
factors, many of which management is unable to predict or control, that may cause actual results,
performance or achievements to differ materially from those expressed or implied in the
forward-looking statements. In addition to the risk factors discussed in Item 1, Business (under
the headings Operating Segments, Raw Materials, Seasonality, Government Regulation and
Environmental Matters, and International Operations), other important factors which have impacted
and could impact the Company’s operations and results include:
(a)
adverse changes in economic or industry conditions generally, including global supply
and demand conditions and prices for products of the types produced by Spartech;
(b)
material adverse changes in the markets we serve, including the transportation,
packaging, building and construction, recreation and leisure, and other markets, some of
which tend to be cyclical;
(c)
our inability to achieve the level of cost savings, productivity improvements,
synergies, growth or other benefits anticipated from acquired businesses and their
integration;
(d)
volatility of prices and availability of supply of energy and of the raw materials that
are critical to the manufacture of our products, particularly plastic resins derived from
oil and natural gas, including future effects of natural disasters;
(e)
our inability to manage or pass through an adequate level of increases to customers in
the costs of materials, freight, utilities, or other conversion costs;
(f)
our inability to predict accurately the costs to be incurred or savings to be achieved
in connection with announced production plant restructurings;
(g)
adverse findings in significant legal or environmental proceedings or our inability to
comply with applicable environmental laws and regulations;
(h)
adverse developments with work stoppages or labor disruptions, particularly in the
automotive industry;
(i)
our inability to achieve operational efficiency goals or cost reduction initiatives;
(j)
our inability to develop and launch new products successfully;
(k)
restrictions imposed on us by instruments governing our indebtedness, and the possible
inability to comply with requirements of those instruments; and
(l)
weaknesses in internal controls.
We assume no duty to update our forward-looking statements.
Spartech Corporation (the “Company”), together with its subsidiaries, is an intermediary
processor of engineered thermoplastics. The Company converts base polymers or resins purchased
from commodity suppliers into extruded plastic sheet and rollstock, specialty film laminates,
acrylic products, specialty plastic alloys, color concentrates and blended resin compounds, and
injection molded and profile extruded products. Our products are sold to thousands of original
equipment manufacturers and other customers in a wide range of end markets. We operate 42
production facilities in North America and one in Europe, and are organized into three reportable
segments based on the products we manufacture:
Custom Sheet and Rollstock
The Custom Sheet and Rollstock segment sells its products to various manufacturers that
use plastic components in their products. Our custom sheet and rollstock is utilized in
several end markets including food/medical packaging, signs/advertising, spas, bathtubs and
shower surrounds, burial vault liners, automotive and recreational vehicle components, home
appliances and electronics, aircraft, boats and security windows. The Company is North
America’s largest extruder of custom rigid plastic sheet and rollstock, operating 23 facilities
in the United States, Canada, Mexico and France under the names Spartech Plastics and Spartech
Polycast.
Color and Specialty Compounds
The Color and Specialty Compounds segment sells custom-designed plastic alloys, compounds,
color concentrates and calendered film for utilization by a large group of manufacturing
customers servicing the food/medical packaging, automotive equipment, consumer electronics and
appliances, roofing, wall coverings, and other end markets. We produce and distribute these
products from 14 facilities in the United States, Canada, Mexico and France under the names
Spartech Polycom, Spartech PEP, Spartech Contract Manufacturing Division (“CMD”), and Spartech
Calendered and Converted Products Division.
Engineered Products
The Engineered Products segment manufactures a number of proprietary items including
thermoplastic tires and wheels for the medical, lawn and garden, refuse container, and toy
markets and window frames and fencing for the building and construction market, as well as
other custom profile extruded and acrylic products for a variety of industries. We manufacture
these molded and profile products from six facilities in the United States, Canada and Mexico
under the names Spartech Industries, Spartech Profiles, Spartech Townsend, and Spartech Marine.
Spartech was incorporated in the state of Delaware in 1968, succeeding a business which had
commenced operations in 1960. Our principal executive office is located at 120 South Central
Avenue, Suite 1700, Clayton, Missouri63105-1705. Our telephone number is (314) 721-4242. Our Web
site address is www.spartech.com.
Industry Overview
The intermediary processor segment of the plastics industry is fragmented, with over 2,000
plastics processing companies, many of which compete with us in one or more of the following areas
in which we operate:
•
Sheet Extrusion
Plastic sheet is produced by
forcing melted plastic through
a wide, flat die between
polished or textured metal
rollers and onto a flat
cooling bed for cutting to the
desired width and length.
•
Rollstock Extrusion
This production process is
similar to sheet extrusion,
except that the plastic is
wound onto rolls rather than
cut into flat pieces of a
specific length.
•
Cell Cast Acrylics
Acrylic sheet is produced by
pouring a reactive mixture of
liquid monomers, additives and
catalysts between two polished
glass sheets held together at
a desired thickness, and
allowing the mixture to
polymerize with time, heat,
and pressure in an oven or
water bath until solid.
Basic plastic resins are
melted and mixed with
additives, fillers, or other
plastics in order to impart
specific properties such as
gloss, strength or moldability
to the resulting mixture,
which is typically sold and
shipped in pellet form.
•
Color Concentrates
Basic plastic resins are
melted and mixed with pigments
in order to produce colored
pellets, which plastics
compounders or fabricators
blend with natural color
plastics to make products of
desired colors.
•
Calendering
Plastic film is produced by
drawing molten polymer between
two counter-rotating rollers
under pressure.
•
Profile Extrusion
Products having a desired
two-dimensional cross-section,
such as plastic fence rails or
window frames, are produced by
forcing melted plastic through
a die of the desired shape,
cooling it in air or in a
water bath, and cutting it to
the desired length.
•
Injection Molding
Three-dimensional products
such as wheels are formed by
forcing melted plastic into a
mold cavity under pressure so
that when cooled the plastic
reflects the shape of the
cavity.
•
Cast Acrylic Rods
and Tubes
Rods are produced from
reactive mixtures similar to
those used for cell cast
acrylics by curing the mixture
in a vertical, tubular mold
and then grinding and
polishing the rod to the
desired length and diameter.
Tubes are produced by curing a
similar mixture against the
inside of a drum shaped mold
of the desired length and
diameter while it revolves on
a horizontal axis.
Each of these processing methods has unique competitive and economic characteristics and
involves different production capabilities, operating costs and equipment and requires a different
level of capital expenditure and operating expertise. There are various other processes used
within the plastics processing industry in which we do not compete, such as continuous cast
acrylics, blown film extrusion, pipe and tube extrusion, thermoforming, blow molding and rotational
molding.
A large percentage of the plastics processors in the United States are small to mid-size
regional operations that generate less than $50 million in annual sales, and the industry is
continuing to undergo consolidation. Current trends contributing to this consolidation include:
•
Greater focus on management transition issues by plastics entrepreneurs;
•
The potential to achieve economies of scale, leverage, and fixed cost synergies;
•
Processors seeking to focus on fewer core competencies and outsourcing non-core operations;
•
Increased capital and technical capabilities necessary to increase production
efficiencies and expand capacity; and
•
Customers seeking to work with fewer suppliers.
Our Competitive Strengths
Our competitive strengths include:
Market Position
According to the Plastics News Market Data Book dated September 12, 2005, we are the
largest volume producer of extruded sheet and rollstock in North America, and we are one of the
leading producers of color and specialty compounds in North America.
New Product Development
Our diversity of product capabilities and experienced operating personnel have provided a
consistent means for identifying and developing new product applications. Our new product
development efforts are coordinated at centralized locations within our two largest operating
segments.
Benefits From Acquisitions
We have completed four significant acquisitions of businesses over the past five years.
Our successful integration of these acquisitions into our business has enabled us to achieve
synergies and operating leverage through:
Greater geographic presence to service customers and respond to certain
concentrated markets;
-
Broader product capabilities offered to our customers;
-
Centralized purchasing of raw materials and other cost synergies;
-
Improved resource utilization through manufacturing optimization; and
-
Greater absorption of fixed costs over an increased revenue base.
Commitment to Customer Service
We seek to differentiate ourselves from our competitors by emphasizing our wide range of
product offerings, consistent product quality, outstanding customer service, and innovative
technical solutions for our customers.
Diversified Customer Base
We sell our products to thousands of customers in a broad range of end markets, with no
single customer accounting for more than 5% of our fiscal 2005 sales. Our top 25 customers
represented approximately 28% of our fiscal 2005 sales. Based on our classification of end
markets, packaging is our largest single market, accounting for approximately 23% of our fiscal
2005 sales. The packaging market historically has experienced faster growth and less
cyclicality than the other major markets served by plastics processors.
Geographic Presence
Our plants are strategically located in 37 cities throughout North America and in one city
in France. The proximity of our plants to our customers saves shipping costs, reduces delivery
times and increases our presence in a variety of markets.
Due to the size and breadth of our operations, we believe we are well positioned to increase
our business through new product developments, the continuing substitution of thermoplastics for
wood, metal and fiberglass applications, and selective acquisitions. Significant acquisitions of
businesses completed over the last five years are summarized below:
As a result of our acquisitions, we have been able to enhance our market position,
aggressively develop new and diverse products, achieve synergies and operating leverage, expand our
geographic presence into 43 plants in 37 cities, and diversify our customer base, all of which help
us to better serve our customers by having the ability to offer them broader product capabilities
while being more cost-competitive.
Operating Segments
We operate our 43 production facilities in North America and Europe in three operating
segments: Custom Sheet and Rollstock, Color and Specialty Compounds, and Engineered Products. In
fiscal 2005, the Spartech PEP reporting unit was moved from the Custom Sheet and Rollstock segment
to the Color and Specialty Compounds segment because we realigned management of the operations to
better leverage our cost structure and coordinate our marketing and selling efforts. Segment
operating results have been restated as if this change occurred at the beginning of the periods
presented.
Custom Sheet and Rollstock
Net sales and operating earnings (consisting of earnings before interest, taxes and
general corporate expenses) of the Custom Sheet and Rollstock segment for fiscal years 2005,
2004 and 2003 were as follows:
Products
— Operating under the names Spartech Plastics and Spartech Polycast,
this segment processes a variety of materials into single/multilayer sheets or rollstock
and cell cast acrylic on a custom basis for end product manufacturers. The segment’s
products are utilized in several end markets including packaging, transportation, building
and construction, recreation, sign/advertising and aerospace.
New
Product Development — This segment is actively involved in the development
of new product applications. These products include engineered sheets and rollstock using
multiple layers of materials, often of different plastics and often using proprietary
mixtures of plastic compounds. This segment offers end-product manufacturers a variety of
solutions to design high-performance (such as lightweight, weatherable, formable/shapeable,
high gloss/non-painted and durable) and environmentally friendly products at reduced costs.
Our new product development efforts are coordinated at our 30,000 square foot Product
Development Center located in Warsaw, Indiana.
Manufacturing
and Production — This segment operates 22 manufacturing
facilities in North America and one in Europe. The principal raw materials used in
manufacturing sheet and rollstock are plastic resins in pellet form. We extrude a wide
variety of plastic resins, including ABS (acrylonitrile butadiene styrene), polycarbonate,
polypropylene, acrylic, PET (polyethylene terephthalate), polystyrene, polyethylene, PVC
(polyvinyl chloride) and PETG (polyethylene terephthalate glycol).
Spartech Plastics produces extruded plastic sheet and rollstock of up to seven layers
using a multi-extrusion process. This process combines materials in distinct layers as
they are extruded through a die into sheet form, providing improved and sometimes unique
properties compared to single-layer extrusions. More than half of our plastic sheet is
produced using this multi-extrusion process. The remainder is produced in a single layer
using conventional extrusion processes. In some cases, we coat plastic sheets or laminate
sheets together to achieve performance characteristics desired by our customers for
particular applications.
Spartech Polycast manufactures acrylic products through cell cast manufacturing, in
more than 60 colors and in gauges ranging from 0.030 to 6.00 inches. Acrylic sheet
manufactured by the cell cast process, which is more labor intensive than continuous cast,
extrusion or calender processes, generally yields a product that is considered to have a
higher quality than acrylic sheet produced by other processes.
Marketing,
Sales and Distribution — The custom sheet and rollstock extrusion
business has generally been a regional business supplying manufacturers within an estimated
500 mile radius of each production facility. This is due to shipping costs for rigid
plastic material and the need for prompt response to customer requirements and
specifications. The cell cast acrylic, outdoor sign, and spa markets, however, are more
national in scope.
We sell sheet and rollstock products principally through our own sales force, but we
also use a limited number of independent sales representatives. During 2005, we sold
products of the Custom Sheet and Rollstock segment to a wide range of customers, including
Sub-Zero Freezer Company, The ConAgra Brands, Inc., Jacuzzi Incorporated, Igloo
Corporation, Textron, Inc. and Newell-Rubbermaid.
Competition
— The Custom Sheet and Rollstock processing segment is highly
competitive. Because the Company manufactures a wide variety of products, we compete in
different areas with many other companies. We compete generally on the basis of price,
product performance, and customer service. Important competitive factors include the
ability to manufacture consistently to required quality levels, meet demanding delivery
times, exercise skill in raw material purchasing, achieve production efficiencies to make
our products cost effective for our customers, and provide
new product solutions to customer applications. Some of our primary competitors in the
Custom Sheet and Rollstock segment are CYRO Industries, Kama Corporation, Primex Plastics
Corporation, and Klockner-Pentaplast of America, Inc. We believe we compete effectively
with these companies in each of these key areas.
Color and Specialty Compounds
Net sales and operating earnings (consisting of earnings before interest, taxes and
general corporate expenses) of the Color and Specialty Compounds segment for fiscal years 2005,
2004 and 2003 were as follows:
Fiscal Year
2005
2004
2003
(in millions)
Net Sales
$
430.9
$
323.4
$
273.8
Operating Earnings
13.9
27.1
22.3
Products
— The Color and Specialty Compounds segment manufactures color
concentrates, proprietary or custom-designed plastic compounds, specialty film laminates or
acetates and calendered film for a large group of manufacturing customers that produce
consumer appliance components, lawn and garden equipment, food and medical packaging,
vehicle components, and numerous other products.
Customers of the Color and Specialty Compounds segment range from major integrated
manufacturers to sole-proprietor subcontractors that use injection molding, extrusion, blow
molding and blown and cast film processes.
New
Product Development — This segment has well-equipped laboratory
facilities, particularly the Spartech Polycom Technical Center in Donora, Pennsylvania.
These laboratories operate testing and simulated end-use process equipment as well as small
scale versions of our production equipment to ensure accurate scale-up from development to
production. We create new specialty compounds by adding fillers and other additives to the
base resins, in order to offer end-product manufacturers a variety of solutions for the
design of high-performance and environmentally friendly products on a cost-efficient basis.
In addition to compounding technology, the segment has developed enhanced capabilities to
produce color concentrates and additives.
Manufacturing
and Production — This segment operates 13 manufacturing
facilities in North America and one in Europe. The principal raw materials used in
manufacturing specialty plastic compounds and color concentrates are plastic resins in
powder and pellet form, primarily polypropylene, polyethylene, polystyrene, ABS, TPO’s, and
PVC. We also use colorants, mineral and glass reinforcements and other additives to impart
specific performance and appearance characteristics to the compounds. The raw materials are
mixed in a blending process and then normally fed into an extruder and formed into pellets.
Spartech PEP manufactures weatherable film laminates and cellulose specialty extruded
products. Spartech PEP manufactures its weatherable film laminates through an extruded
film process which produces films as thin as .0015 inches and as wide as ten feet, and
cellulose specialty products through a flat die casting process which produces films as
thin as .0075 inches and as wide as 60 inches. Certain cellulose products are then pressed
and polished using large hydraulic presses which produce transparent sheeting of high
optical quality.
Spartech CMD manufactures soundproofing materials and non-carpet flooring using an
extrusion production process which produces rolls or stacks of finished product. Spartech
CMD also manufactures plastic compounds using an extrusion process that forms compounds
into pellets.
Spartech Calendered and Converted Products Division manufactures colored, thin gauge
vinyl films using film calendering, rotogravure printing and lamination processes.
Marketing,
Sales and Distribution — The Company generates most of the Color
and Specialty Compounds segment’s sales in the United States and Canada but also sells to
customers in Europe and Mexico. The Company sells the segment’s products principally
through its own sales force, but also uses independent sales representatives. During 2005,
the Company sold products of the Color and Specialty Compounds segment to customers
including the Solo Cup Company, Lear Corporation, Igloo Corporation and Pactiv Corporation.
Competition
— The Color and Specialty Compounds segment operates in highly
competitive markets. We compete with some companies which are much larger and have more
extensive production facilities, larger sales and marketing staffs and substantially
greater financial resources than we do. We compete generally on the basis of price,
product performance and customer service. Important competitive factors in each of our
businesses include the ability to manufacture consistently to required quality levels, meet
demanding delivery times, provide technical support, and achieve production efficiencies to
process the products profitably. Some of our primary competitors in the Color and Specialty
Compounds segment are Ampacet Corporation, AMETEK Westchester Plastics, A. Schulman, Inc.,
Ferro Corp., PolyOne Corporation, RheTech, Inc., and Washington Penn Plastic Co., Inc. We
believe we compete effectively with these companies in each of these key areas.
Engineered Products
In the second quarter of 2005, we renamed this segment Engineered Products from its former
name of Molded and Profile Products. Net sales and operating earnings (consisting of earnings
before interest, taxes, and general corporate expenses) of the Engineered Products segment for
fiscal 2005, 2004 and 2003 were as follows:
Fiscal Year
2005
2004
2003
(in millions)
Net Sales
$
81.7
$
68.6
$
64.6
Operating Earnings
(4.5
)
6.3
5.4
Products. This segment manufactures injection molded and profile extruded products
for a large group of intermediate and end-user customers. The segment operates under four
business names:
•
Spartech Industries produces plastic tire and wheel assemblies for the
medical, lawn and garden, refuse container and toy markets, and high-performance
molded urethane tires for the medical, material handling, lawn and garden, and
recreational product applications. We also produce various injection molded and
profile extruded products that complement the wheels and tire offerings.
•
Spartech Profiles manufactures products for various industries,
including window frames and fencing for the building and construction markets.
•
Spartech Marine specializes in the fabrication of acrylic and other
custom products used in high-end marine applications.
•
Spartech Townsend manufactures acrylic rods and tubes used primarily in
display, household and medical applications.
New
Product Development — This segment brings unique, recognized capabilities to
our customers such as patented tread-cap wheel technologies and special fabrication of
profile products. In addition, this segment’s creativity, engineering and design principles
enable us to effectively respond to customer needs in the niche markets in which we
compete.
Manufacturing
and Production — This segment operates six manufacturing facilities
in North America. The principal raw materials used in our manufacturing of molded, profile
and other engineered products are PVC, acrylics, polyethylene and polypropylene. Our
products in this segment are generally manufactured either through injection molding or
profile extrusion processes.
Marketing,
Sales and Distribution — Spartech Industries, Spartech Profiles,
Spartech Marine and Spartech Townsend market their products throughout North America. We
sell the segment’s
products principally through our own sales force, but also use independent sales
representatives and wholesale distributors. During 2005, we sold products of the
Engineered Products segment to many customers, including MTD Products, Electrolux, Honda
and Invacare.
Competition
— The Engineered Products segment is highly competitive and highly
fragmented. Since we manufacture a wide variety of products, we compete in different areas
with many other companies, some of which are much larger and have more extensive production
facilities, larger sales and marketing staffs and substantially greater financial resources
than we do. We generally compete on the basis of price, product performance and customer
service. Important competitive factors in each of our businesses include the ability to
manufacture consistently to required quality levels, meet demanding delivery times, and
provide new product offerings. Some of our primary competitors in the Engineered Products
segment are Bunzl Extrusion, Inc., Flex Technologies, Inc., Royal Group Technologies
Limited, and Trintex Corporation. We believe we compete effectively with these companies in
each of these key areas.
Raw Materials
The plastic resins we use in our production processes are derivatives of crude oil or natural
gas and are available from a number of domestic and foreign suppliers. Historically, our raw
materials have been only somewhat affected by supply, demand, and price trends of the petroleum
industry; however, more recently the unusually high price of crude oil and natural gas has had a
greater impact on increasing the price of plastic resins, our most significant raw material. We
currently expect this pricing relationship to continue in the foreseeable future. Past trends in
resin pricing, periods of anticipated or actual shortages of a particular resin, and changes in
supplier capacities can also have an impact on the cost of our raw materials during a particular
period. Price spikes in crude oil and natural gas along with the political unrest in oil-producing
countries have resulted in unusually high pricing pressures during fiscal 2004 and 2005 which
resulted in dramatic increases in the prices of our raw materials. In prior years, we were able to
minimize the impact of such price increases in raw material costs by controlling our inventory
levels, increasing production efficiencies, passing through price changes to customers and
negotiating competitive prices with our suppliers. These pricing changes were more difficult for us
to manage and we increased selling prices to customers significantly in fiscal 2004 and 2005 to
help maintain our material margin per pound sold. While we will continue to implement the actions
noted above to help minimize the impact of price changes on our margins, the direction, degree of
volatility and our ability to manage future pricing changes is uncertain.
Seasonality
Our sales are somewhat seasonal in nature. Fewer orders are placed and less manufacturing
activity occurs during the November through January period. This seasonal variation tends to track
the manufacturing activities of our various customers in each region.
Backlog
We estimate that the total dollar volume of our backlog of firm orders as of October 29, 2005
and October 30, 2004 was approximately $128.2 million and $120.0 million, respectively, which
represents approximately five weeks of production for 2005 and six weeks of production for 2004.
Employees
Our total number of employees is approximately 3,500. There are approximately 2,700 production
personnel at our 43 facilities, approximately 30% of whom are union employees covered by several
collective bargaining agreements. We consider our employee relations to be good. Management and
administrative personnel total approximately 800 employees, none of whom is unionized.
Government Regulation and Environmental Matters
We operate under various laws and regulations governing employee safety and the quantities of
specified substances that may be emitted into the air, discharged into waterways, or otherwise
disposed of on and off our properties. In September 2003, the New Jersey Department of
Environmental Protection issued a directive and the United States Environmental Protection Agency
(“USEPA”) initiated an
investigation related to over 70 companies, including a Spartech subsidiary, regarding the
Lower Passaic River. Our subsidiary subsequently agreed to participate in a group of over 40
companies in funding $10 million of an estimated $20 million environmental study by the USEPA to
determine the extent and source of contamination at this site, and as of the end of fiscal 2005 it
had paid its total commitment of $0.3 million towards this study. As of the end of fiscal 2005, we
had $0.1 million accrued related to this issue representing approximately one year of legal fees.
Subsequent to fiscal 2005 year end, the group’s technical consultant advised the group of its
belief that completion of the environmental study would significantly exceed the USEPA’s original
cost estimate. We have not recorded an accrual related to future funding of the environmental
study cost overrun or other costs that may result from resolution of this issue due to several
uncertainties involved with the outcome of this issue including (i) whether or not the subsidiary
will agree to continue voluntarily participating with the other members of the group in further
funding of the environmental study, any future studies, or any remediation activities, (ii) the
number of other parties that may be identified as participants in the future and the uncertainty of
the level of participation by each of the parties ultimately named, (iii) our belief that the
subsidiary’s contribution in polluting the Lower Passaic River is negligible compared to many other
companies either already named or likely to be named as potentially responsible parties, (iv) the
fact that many of the other companies named in the directive and investigation are significantly
larger than our subsidiary in terms of market capitalization, and (v) the timing or amount of the
eventual determinations of the damage to the river, the remedial steps required, the responsible
parties, and any resulting remediation costs or assessments for which the subsidiary may be liable.
We believe that it is possible that our ultimate liability resulting from this issue could
materially differ from our October 29, 2005 accrual balance. In the event of one or more adverse
determinations related to this issue, the impact on our results of operations could be material to
any specific period. However, we believe that future expenditures for compliance with these laws
and regulations, as they relate to the Lower Passaic River issue and other potential issues, will
not have a material effect on our capital expenditures, financial position, or competitive
position.
International Operations
Information regarding our operations in various geographic segments is located in Note 17 to
the Consolidated Financial Statements included in Item 8 of this Form 10-K. Our Canadian, French
and Mexican operations may be affected periodically by foreign political and economic developments,
laws and regulations, and currency fluctuations.
Internet Access
Spartech’s Forms 10-K, 10-Q, 8-K and all amendments to those reports are available without
charge through the Company’s Web site on the Internet as soon as reasonably practicable after they
are electronically filed with or furnished to the Securities and Exchange Commission. They may be
accessed directly as follows: www.spartech.com, Investor Relations, SEC Filings.
The Company operates in plants and offices aggregating approximately 4.0 million square feet
of space. Approximately 1.7 million square feet of plant and office space is leased, with the
remaining 2.3 million square feet owned by the Company. A summary of the Company’s principal
operating facilities follows:
These plant locations represent joint production facilities for the Custom Sheet and
Rollstock and Color and Specialty Compounds segments.
In addition, the Company leases office facilities for its corporate headquarters in St. Louis,
Missouri and administrative offices in Washington, Pennsylvania, the aggregate square footage of
which is approximately 40,000.
The plants located at the premises listed above are equipped with 133 sheet extrusion lines
(80 of which run multi-layered materials), 29 casting machines, 28 profile extrusion lines (12 of
which run multi-layered materials), 61 compounding lines that are used for general compounding and
color compounding, 31 injection molding machines, 3 calendering lines, cutting and grinding
machinery, resin storage facilities, warehouse equipment, and quality laboratories at all
locations. The Company believes that its present facilities along with anticipated capital
expenditures (estimated to be approximately $28 million in fiscal 2006) are adequate for the level
of business anticipated in fiscal 2006.
In
addition to the Lower Passaic River matter described in Item 1 under the
heading Government Regulation and Environmental Matters, the Company is subject to various other claims, lawsuits and administrative proceedings
arising in the ordinary course of business with respect to
environmental, commercial, product liability,
employment and other matters, several of which claim substantial amounts of damages. While it is
not possible to estimate with certainty the ultimate legal and financial liability with respect to
these claims, lawsuits and administrative proceedings, the Company believes that the outcome of
these matters will not have a material adverse effect on the Company’s capital expenditures,
financial position or competitive position.
Item 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
No matters were submitted to a vote of the Company’s security holders during the fourth
quarter of fiscal 2005.
Item 5.
MARKET FOR THE REGISTRANT’S COMMON EQUITY, RELATED STOCKHOLDER MATTERS AND ISSUER
PURCHASES OF EQUITY SECURITIES
Spartech Corporation’s common stock is listed for trading on the New York Stock Exchange (NYSE)
under the symbol “SEH”. There were approximately 6,000 shareholders of record at December 31,2005. The following table sets forth the high and low prices of the common stock and cash
dividends per common share for each quarter of fiscal 2005 and 2004:
Common Stock Data (per share)
1stQtr.
2ndQtr.
3rdQtr.
4th Qtr.
2005
High
$
28.31
$
23.54
$
21.16
$
21.73
Low
23.03
17.83
16.00
17.50
Dividends declared
$
.12
$
.12
$
.12
$
.12
2004
High
$
26.00
$
25.41
$
26.30
$
25.95
Low
21.58
22.55
21.36
21.85
Dividends declared
$
.11
$
.11
$
.11
$
.11
The Company’s Board of Directors reviews the dividend policy each December based on the Company’s
business plan and cash flow projections for the next fiscal year.
Repurchases of equity securities during the fourth quarter of fiscal 2005 are listed in the
following table:
Total Number of
Maximum
Shares Purchased
Number of
as Part of
Shares That May
Publicly
Yet Be Purchased
Total Number
Announced Plans
Under the Plans
Of Shares
Average Price
or
or
Period
Purchased
Paid per Share
Programs
Programs
August 2005
—
$
n/a
—
656,700
September 2005
—
n/a
—
656,700
October 2005
102,300
18.16
102,300
554,400
Total
102,300
$
18.16
102,300
554,400
In October 2004, the Company’s Board of Directors authorized the repurchase of up to 1 million
shares under the October 2004 program. The maximum number of shares that may yet be purchased
under this program is 554,400.
The selected financial and other data below for the last six fiscal years presents
consolidated financial information of Spartech Corporation and subsidiaries and have been derived
from our audited consolidated financial statements.
Our operating history includes significant acquisitions; this data should be read with the
selected historical consolidated financial data set forth below in conjunction with “Management’s
Discussion and Analysis of Financial Condition and Results of Operations” and our consolidated
financial statements and the notes thereto included in Item 8 of this Form 10-K.
Fiscal Year Ended
2005
2004
2003
2002
2001
2000
(in thousands, except per share data)
Statement of Operations Data:
Net Sales:
In Dollars
$
1,396,860
$
1,121,725
$
956,160
$
898,308
$
937,059
$
987,532
In Pounds
1,472,000
1,383,000
1,207,000
1,179,000
1,170,000
1,286,000
Gross Profit
152,584
154,762
134,013
135,163
152,049
171,669
Depreciation & Amortization
40,387
35,056
31,566
28,120
34,921
31,905
Operating Earnings (a)
48,068
92,801
78,286
80,879
82,374
109,761
Interest Expense
25,195
25,436
24,965
26,816
34,821
29,131
Net Earnings
12,191
42,063
34,103
34,270
29,903
49,907
Per Share Information:
Earnings per Share-Diluted
$
.38
$
1.32
$
1.15
$
1.21
$
1.11
$
1.72
Dividends Declared per Share
.48
.44
.40
.38
.38
.34
Book Value per Share
12.91
12.98
10.98
9.93
8.11
7.86
Balance Sheet Data:
Working Capital (b)
$
171,459
$
198,253
$
127,496
$
110,082
$
123,804
$
125,125
Working Capital as a
percentage of Net Sales
12.3
%
17.7
%
13.3
%
12.3
%
13.2
%
12.7
%
Total Debt
$
379,955
$
474,091
$
383,819
$
392,971
$
443,353
$
507,484
Total Assets
1,074,395
1,141,932
923,938
872,577
821,962
896,120
Shareholders’ Equity
413,046
417,732
322,358
290,698
216,546
211,022
Ratios/Other Data:
Cash Flow from Operations
$
105,018
$
31,647
$
69,485
$
85,688
$
69,022
$
58,497
Capital Expenditures
39,265
35,003
22,009
28,217
16,237
29,192
Operating Earnings
per pound sold (actual)
3.3
¢
6.7
¢
6.5
¢
6.9
¢
7.0
¢
8.5
¢
Total Debt to
Total Debt and Equity
47.9
%
53.2
%
54.4
%
57.5
%
67.2
%
70.6
%
Number of Employees (actual)
3,500
3,750
3,325
3,475
3,300
4,075
Common Shares:
Outstanding at Year-End
31,988
32,180
29,352
29,285
26,700
26,864
Weighted Average-Diluted
32,311
33,468
29,567
28,379
28,696
31,874
Notes to table:
(a)
Fiscal 2005 operating earnings were reduced by pre-tax charges of $28.9 million related to
restructuring and exit costs ($10.1 million), a retirement settlement with our former CEO
($3.6 million), fixed asset charges ($10.7 million) and goodwill impairment ($4.5 million).
Fiscal 2001 operating earnings were reduced by pre-tax charges of $9.1 million related to
restructuring and exit costs ($3.5 million) and the impairment of long-lived assets ($5.6
million).
(b)
Calculated as total current assets excluding cash and cash equivalents less total current
liabilities excluding current maturities of long-term debt.
Item 7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITIONAND RESULTS OF OPERATIONS
The following discussion and analysis of our financial condition and results of operations
contains “Forward-looking Statements”. You should read the following discussion of our financial
condition and results of operations with “Selected Financial Data” and our consolidated financial
statements and related notes included elsewhere in this Form 10-K. We have based our
forward-looking statements about our markets and demand for our products and future results on
assumptions that we consider reasonable. Actual results may differ materially from those suggested
by our forward-looking statements for various reasons including those discussed in “Cautionary
Statements Concerning Forward-Looking Statements” on page 1 of this Form 10-K.
Business Overview
Spartech is an intermediate processor of thermoplastics which converts base polymers or resins
purchased from commodity suppliers into extruded plastic sheet and rollstock, specialty film
laminates, acrylic products, specialty plastic alloys, color concentrates and blended resin
compounds, and injection molded and profile extruded products for customers in a wide range of
markets. We operate 43 production facilities (42 throughout North America and one in Europe) that
are organized into three reportable business segments as follows:
% of Fiscal
2005 Sales
Custom Sheet and Rollstock
63%
Color and Specialty Compounds
31%
Engineered Products *
6 %
*
The segment formerly referred to as the Molded and Profile Products Segment was
renamed the Engineered Products Segment effective in the second quarter of fiscal 2005.
The discussions of results that follow incorporate acquisitions of businesses including our
fiscal 2004 acquisition of three divisions of VPI (October 2004) and our fiscal 2003 acquisitions
of the sheet extrusion business of TriEnda, a division of Wilbert Inc. (September 2003), and
Polymer Extruded Products (“PEP”), Inc. (March 2003). We consider purchases of certain assets and
liabilities that do not qualify as a business for accounting purposes (referred to as outsourcing
acquisitions) as underlying volume growth because such purchases are comparable to other internal
investments such as capital expenditures. The impact of outsourcing acquisitions on the results of
operations is disclosed when material, similar to our disclosures of the impact of major capital
investments.
We assess net sales changes using three major drivers: underlying volume, the impact of
business acquisitions and price/mix. Underlying volume is calculated as the change in pounds sold
exclusive of the impact on pounds sold from business acquisitions or divestitures.
Executive Summary
Net sales increased 25% to $1,396.9 million in fiscal 2005 over fiscal 2004 due mostly to
selling price increases and the October 2004 VPI acquisition. The selling price increases reflect
significant increases in the cost of plastic resins throughout the year that we use to manufacture
our products, the cost of which we eventually pass along to our customers as selling price
increases. Despite the significant net sales increases, operating earnings decreased 48% to $48.1
million in fiscal 2005 compared to $92.8 million in fiscal 2004, due in part to $28.9 million of
special items including restructuring and exit costs of $10.1 million, charges of $3.6 million
related to the retirement of the Company’s former CEO, a $10.7 million fixed asset charge, and $4.5
million of goodwill impairment.
Excluding the special items, operating earnings decreased $16.1 million in fiscal 2005 from
fiscal 2004 due in large part to increases in conversion costs, mostly in the labor-related,
utilities and freight areas, coupled with a decrease in underlying sales volume. Operating
earnings in fiscal 2005 were also adversely impacted by significant increases in resin prices and
our inability to pass along price increases to customers as quickly as material costs increased,
particularly in the earlier portion of the year. These factors caused a
$42.7 million increase in conversion costs which more than offset the $40.5 million increase
in material margin resulting in a $2.2 million decrease in gross margin. The $2.2 million decrease
in gross margin along with an increase in selling, general, and administrative expenses of $11.8
million and an increase in amortization of intangibles of $2.1 million led to the $16.1 million
decrease in operating earnings excluding the special items. Although operating earnings decreased
in fiscal 2005 compared to fiscal 2004, we paid down approximately $95 million of debt in fiscal
2005. A large portion of this pay-down was funded from net cash provided by operating activities of
over $105 million, which is the largest generation of cash from operations for any fiscal year in
the history of the Company. Our significant focus on net working capital management contributed
considerably to the strong operating cash flow. In addition, we substantially completed our
restructuring efforts by finalizing the shutdown and sale of most of the operations announced in
our restructuring plan initiated in the second quarter of fiscal 2005, the purpose of which is to
reduce the Company’s manufacturing footprint to a more cost-effective level by reducing the number
of the Company’s facilities. We expect these efforts to mitigate increases in conversion costs in
the future.
Results of Operations
Comparison of Fiscal Years 2005 and 2004
Consolidated Summary
Net sales were $1,396.9 million and $1,121.7 million for the fiscal years ended 2005 and 2004,
respectively, representing a 25% sales increase in fiscal 2005. The causes of this percentage
increase were as follows:
Underlying volume
(1
)%
VPI Acquisition
9
Price/Mix
17
25
%
The 1% decrease in underlying volume reflects a decrease in pounds sold of lower-priced pallet
material to a customer in the Custom Sheet and Rollstock segment and the loss of toll-compounding
business with a customer of the Color and Specialty Compounds segment. Excluding the negative
volume impact of sales to these two major customers, volume sold increased approximately 3% in
fiscal 2005 compared to fiscal 2004. The 3% increase was mostly driven by sales to the lawn and
garden market. Most of the price/mix impact reflects higher selling prices to customers from the
pass through of raw material price increases.
The following table presents the Company’s sales, cost of sales, and resulting gross margin in
dollars and on a per pound sold basis for fiscal 2005 and 2004. Cost of sales presented in the
Consolidated Statements of Operations includes material and conversion costs, the components of
which are presented in the following table. We have not presented cost of sales components as a
percentage of net sales because a comparison of this measure is distorted by changes in resin costs
that are passed through to customers as higher selling prices. These significant changes materially
affect the percentages but do not present accurate performance measures of the business.
The significant increases in net sales and material costs per pound in fiscal 2005 compared to
fiscal 2004 were mostly driven by increases in raw material costs and the impact of passing on
these increases to customers as higher selling prices. Raw material prices for the Company’s major
resins increased approximately 20% to 30%, depending upon the type of resin, during fiscal 2005
compared to fiscal 2004. Material margin per pound sold increased .7 cent in fiscal 2005 compared
to fiscal 2004. This increase was primarily due to the mix impact of the decrease in sales of the
toll-compound and lower-priced pallet material, both of which have lower material margins per
pound, and the favorable mix impact of the VPI acquisition. The favorable impacts of these items on
material margin per pound sold more than offset the negative impact of other mix changes
experienced in fiscal 2005 compared to fiscal 2004 as well as the negative impact of the rapid rise
in resin prices.
Conversion costs per pound sold increased 1.5 cents in fiscal 2005 compared to fiscal 2004.
This increase reflects the mix impact of the lower volume in sales to the two major customers
previously discussed, the impact of the VPI acquisition and other mix changes. In addition, this
increase reflects increases in labor-related costs, utilities and freight coupled with the decrease
in underlying sales volume, particularly in the first quarter of fiscal 2005. We expect the
restructuring efforts announced in early fiscal 2005 to reduce conversion costs by approximately $8
million annually which should help mitigate the impact of increases in these conversion cost
components. In addition, we initiated the consolidation of two Color and Specialty Compounds
production facilities into one plant in the fourth quarter of fiscal 2005. We expect this
consolidation project to result in $0.7 million of restructuring and exit costs in the first half
of fiscal 2006 and approximately $3 million of annual pre-tax savings beginning in the second half
of fiscal 2006. Refer to Note 3 to our Consolidated Financial Statements for additional detail
regarding these restructuring efforts. We will continue to identify other restructuring
opportunities to assist in managing our cost structure.
Selling and administrative expenses of $70.7 million in fiscal 2005 increased $11.8 million,
or 20% from the $58.9 million incurred during fiscal 2004. Approximately half of this increase is
due to the VPI acquisition. The remaining half of the increase was due to higher costs associated
with increased information technology costs, Sarbanes-Oxley compliance efforts and enhancements to
accounting and finance resources, partially offset by savings from the termination of the Company’s
airplane lease (see subsequent discussion of special items).
Amortization of intangibles was $4.9 million in fiscal 2005 compared to $2.8 million in fiscal
2004. This $2.1 million increase primarily reflects amortization of intangibles acquired as part
of the VPI acquisition.
Special Items
In the second quarter of fiscal 2005, we initiated several strategic changes to enhance
short-term operating performance and longer-term operating efficiencies. The plan involves the
consolidation, sale or closing of seven plant facilities and other cost reduction efforts including
the termination of the Company’s airplane lease which in total resulted in a $10.1 million net
charge for the year, of which $7.2 million
represented non-cash charges. Refer to Note 3 to our Consolidated Financial Statements for
detail of these charges.
In the third quarter of fiscal 2005, we entered into a Retirement Agreement with the former
chief executive officer of the Company. This resulted in a $3.6 million charge, of which $0.8
million represented a non-cash charge. Refer to Note 4 to our Consolidated Financial Statements
for detail of these charges.
As part of our Sarbanes-Oxley compliance efforts, we completed a physical count of the
Company’s property, plant and equipment in the second quarter of fiscal 2005. We reconciled the
counts to amounts recorded in our books and records and identified $8.8 million of property that no
longer physically existed and therefore was written off. We also identified another $1.9 million of
impairment losses pertaining to property that exists, which we elected to liquidate. Refer to Note
5 to our Consolidated Financial Statements for detail of these non-cash charges.
In the fourth quarter of fiscal 2005, we recorded a $4.5 million non-cash goodwill impairment
charge triggered by the underperformance of one operation and the loss of a major customer at
another operation. Refer to Note 8 to our Consolidated Financial Statements for detail of these
charges.
The following table presents the impact of special items on segment results of operations for
fiscal 2005:
Custom
Color and
Sheet and
Specialty
Engineered
(in millions)
Rollstock
Compounds
Products
Corporate
Total
Total Restructuring and Exit Costs
$
—
$
7.4
$
1.9
$
0.8
$
10.1
Total Former CEO Retirement
—
—
—
3.6
3.6
Total Fixed Asset Charge
6.7
1.6
1.8
0.6
10.7
Total Goodwill Impairment
—
2.0
2.5
—
4.5
Total Special Items
$
6.7
$
11.0
$
6.2
$
5.0
$
28.9
Operating earnings for fiscal 2005 were $48.1 million compared to $92.8 in fiscal 2004
representing a $44.7 million decrease. The decrease in operating earnings was adversely impacted
by the special items which resulted in $28.9 million of total expense in fiscal 2005. Excluding
special items, operating earnings decreased $16.1 million in fiscal 2005 compared to fiscal 2004
due to the $2.2 million decrease in gross margin, the $11.8 million increase in selling, general,
and administrative expenses, and the $2.1 million increase in amortization of intangibles, all due
to the various reasons previously discussed.
Interest expense, net was $25.2 million in fiscal 2005 compared to $25.4 million in fiscal
2004. This decrease was due to a decrease in the average interest rate from the expiration of our
interest rate swap on November 10, 2004, the benefit realized from our significant debt pay-down in
the second half of fiscal 2005, and an increase in interest income, partially offset by the
additional borrowings from the VPI acquisition.
Our effective tax rate was 46.7% and 37.6% for fiscal years ended 2005 and 2004, respectively.
The increase in tax rate is attributable to an increase to tax expense in fiscal 2005 to establish
a $1.1 million valuation allowance to offset a deferred tax asset associated with net operating
losses generated by our Donchery, France operation and non-deductibility of $3.2 million of the
goodwill impairment charge. We expect our effective tax rate going forward to approximate 37%.
We reported net earnings of $12.2 million and $42.1 million for fiscal years ended 2005 and
2004, respectively. These amounts changed due to the various reasons discussed above.
Net sales were $884.3 million and $729.8 million for fiscal 2005 and 2004, respectively,
representing a 21% sales increase in fiscal 2005. This increase was caused by:
Underlying volume
(1
)%
VPI Acquisition
6
Price/Mix
16
21
%
The 1% decrease in underlying sales volume in fiscal 2005 reflects a decrease in sales of
lower-priced pallet material to this segment’s largest customer due to the expiration of an
intermittent supply contract between this customer and a third party. Excluding this impact,
underlying volume of pounds sold increased approximately 2% in fiscal 2005 due primarily to
increases in volume sold to the packaging and appliance markets. The majority of the price/mix
impact reflects higher selling prices to customers from the pass-through of raw material price
increases.
This segment’s operating earnings for fiscal 2005 were $58.5 million, representing a $14.2
million decrease from the $72.7 million earned in fiscal 2004. The decrease in operating earnings
was adversely impacted by $6.7 million of special items. Operating earnings excluding special items
for fiscal 2005 were $7.8 million less than fiscal 2004 mostly because of increases in conversion
costs, specifically labor-related, utilities and freight costs. Operating earnings were also
adversely impacted by losses from operations sold in the current year of $0.7 million and $0.3
million of inventory write-downs related to exiting a facility.
Color and Specialty Compounds Segment
Net sales were $430.9 million and $323.4 million for fiscal 2005 and 2004, respectively,
representing a 33% sales increase in fiscal 2005. This increase was caused by:
Underlying volume
(4
)%
VPI Acquisition
19
Price/Mix
18
33
%
The decrease in underlying volume of pounds sold of 4% in fiscal 2005 compared to fiscal 2004
reflects a decrease in sales of tolling and resale pounds to one customer. Excluding this impact,
internal volume of pounds sold increased 2% in fiscal 2005 over fiscal 2004 due mostly to an
increase in sales volume to the lawn and garden market. Sales volume trends for this segment’s two
major product categories, tolling and resale products and proprietary products (engineered
compounds and color concentrates), as well as pounds sold related to businesses acquired, are
presented below:
%
2005
2004
Change
Pounds Sold (in millions)
Tolling and Resale Products
167.5
226.1
(26
)%
Proprietary Products
435.8
401.3
9
Acquired Pounds (proprietary products)
81.2
7.2
n/a
Total Pounds Sold
684.5
634.6
8
%
Tolling products represent customer-provided material that the Company compounds and charges a
conversion fee to the customer. The end markets for the tolling and resale products are generally
managed and developed by our customers. The 26% decrease in pounds sold of tolling and resale
product was mostly due to the decrease in sales to the single customer previously discussed.
Proprietary products include engineered compounds and color concentrates and are made using
formulas and manufacturing processes which are proprietary to the Company. The 9% increase in
pounds sold of proprietary product was driven by the concerted effort of our marketing team to
replace the decrease in tolling pounds with engineered compounds, color concentrates, and new
product development sales. The majority of the price/mix impact reflects higher selling prices to
customers from the pass-through of raw material price increases.
This segment’s operating earnings for fiscal 2005 were $13.9 million compared to $27.1 million
in fiscal 2004 representing a $13.2 million decrease. This decrease was primarily caused by $11.0
million of
expenses from special items. Operating earnings excluding special items for fiscal 2005 were
$2.2 million less than fiscal 2004 primarily because of the decrease in underlying volume and
increase in conversion costs, particularly due to higher freight costs. In addition, our Donchery,
France operation incurred a $2.9 million operating loss in fiscal 2005 compared to a $0.3 million
operating loss in the prior year, representing a $2.6 million decrease to the comparison. The
losses arose from the disruption associated with the significant expansion of the operation for the
new sheet business. We anticipate that this operation will return to profitability in fiscal 2006.
Engineered Products Segment
Net sales were $81.7 million and $68.6 million for fiscal 2005 and 2004, respectively,
representing a 19% sales increase in fiscal 2005. This increase was caused by:
Underlying volume
24
%
Price/Mix
(5
)
19
%
The underlying volume increase for the period was primarily driven by an increase in sales of
wheels to the lawn and garden market to new customers. The negative impact of price/mix reflects
higher selling prices, the impact of which was more than offset by the change in product mix from
selling more wheels with a lower per pound selling price.
This segment’s operating loss for fiscal 2005 was $4.5 million compared to operating earnings
of $6.3 million in fiscal 2004. This $10.8 million decrease in operating earnings was adversely
impacted by $6.2 million of expenses from special items. Operating earnings excluding special
items for fiscal 2005 were $4.6 million less than fiscal 2004 reflecting higher than expected
start-up costs associated with the ramp-up of new production capacity and start-up delays for our
wheels business. The fiscal 2005 operating loss also includes $2.0 million of losses generated
from a sold operation. We expect this segment to return to profitability in fiscal 2006.
Comparison of Fiscal Years 2004 and 2003
Consolidated Summary
Net sales were $1,121.7 million for the year ended October 30, 2004, representing a 17%
increase from the prior year. Internal volume of pounds sold comprised 9% of the net sales growth,
acquisitions accounted for 4%, and price/mix accounted for the remaining 4% of the increase. The
strong internal volume growth in 2004 was due primarily to demand increases in every major market
we serve. Demand was particularly strong in the packaging, transportation, and recreation and
leisure markets.
Cost of sales in 2004 increased to $967.0 million, or 86.2% of net sales, from $822.1 million
in 2003, or 86.0% of net sales. The slight increase in cost of sales as a percentage of net sales
reflected the net effect of sharp increases in resin prices throughout 2004 partially offset by
better leverage on conversion costs from increased sales volume and lean manufacturing initiatives.
Material margins per pound sold for 2004 dropped just under .7 cent per pound from 2003 to 2004
due to resin price increases that could not be passed on quickly enough in terms of higher sales
prices. The 2004 decrease in material margin per pound was more than offset by reductions in
conversion costs resulting from better capacity utilization rates and our lean manufacturing
initiative leading to a .2 cent increase in operating earnings per pound sold.
Amortization of intangibles increased to $2.8 million in 2004 compared to $2.2 million in
2003. This increase reflected the full year impact of the PEP acquisition, one month of the VPI
acquisition, and the 2004 outsourcing acquisition of the European Specialty Polystyrene Compounds
business of BASF in April 2004. Selling, general, and administrative expenses were $58.9 million
in 2004 compared to $53.5 million in 2003. This increase was mostly caused by the variable portion
of expenses resulting from growth in sales and the impact of acquisitions which accounted for
approximately 3% of the increase. As a percentage of net sales, selling, general, and
administrative expenses declined to 5.3% in 2004 from 5.6% in 2003 primarily reflecting leverage
from strong sales growth.
Operating earnings were $92.8 million in 2004, or 8.3% of net sales, compared to $78.3 million
in 2003, or 8.2% of net sales. More importantly, our key measure of operating earnings per pound
increased
from 6.5 cents in 2003 to 6.7 cents in 2004. Each of the operating segments generated
increases in operating earnings due primarily to increases in sales volume and cost leverage.
Interest expense was $25.4 million in 2004 compared to $25.0 million in 2003. The slight
increase in interest expense reflects an increase in our average interest rate and additional
borrowings in the fourth quarter of 2004 to finance the VPI acquisition, partially offset by lower
borrowing levels in the earlier portion of 2004. An interest rate swap encompassing $125.0 million
of bank debt expired on November 10, 2004. On this date, our effective interest rate on this bank
debt reverted back to a variable 30-day Eurodollar rate plus applicable margin (which was 2.59% at
October 30, 2004) from the fixed swap effective rate including the applicable margin totaling
6.80%.
Our effective tax rate was 37.6% in 2004 compared to 36.0% in 2003. The 2004 increase
primarily reflects the lack of favorable adjustments included in 2003 related to a final settlement
with the Internal Revenue Service on certain income tax refunds.
Net earnings increased to $42.1 million in 2004, or 23%, from $34.1 million in 2003 reflecting
the impact of strong sales volume growth from strong demand and acquisitions. Diluted earnings per
share increased to $1.32, or 15%, from $1.15 in 2003 reflecting the increase in net earnings,
partially offset by an increase in shares outstanding from our February 2004 stock offering.
Custom Sheet and Rollstock Segment
Net sales of the Custom Sheet and Rollstock segment increased 18% to $729.8 million in 2004
from $617.7 million in 2003. The percentage increase was comprised of internal volume of pounds
sold (10%), the TriEnda and VPI acquisitions (4%), and price/mix (4%). The internal volume of
pounds sold in this segment was mostly driven by strong demand primarily in the packaging, building
and construction, and transportation markets. Approximately 4% of the increase in pounds sold in
2004 compared to the prior year was due to the full year impact of our new facility in Mexico which
began shipping to customers in the spring of 2003. This segment experienced the largest
improvement in conversion costs per pound of 2.5 cents from 2003 to 2004, but this improvement was
offset by 3.3 cents of lower material margin per pound due to higher resin prices and mix.
Color and Specialty Compounds Segment
Net sales of the Color and Specialty Compounds segment increased 18% to $323.4 million in 2004
from $273.8 million in 2003. The percentage increase was comprised of internal volume of pounds
sold (8%), the impact of the VPI and PEP acquisitions (4%), and price/mix (6%). Internal volume
growth was primarily attributable to strong demand in the transportation and building and
construction markets. Operating earnings per pound improved .5 cent in 2004 compared to 2003 due
to more favorable mix of sales of engineered filled compounds and better leverage on selling costs
which more than offset pressure on material margin from resin price increases.
Engineered Products Segment
The Engineered Products segment net sales increased to $68.6 million, or 6%, from $64.6
million in 2003. The percentage increase was due mostly to price/mix as sales in pounds were flat
in 2004 compared to 2003. This segment saw 2.2 cents of an increase in operating earnings per
pound in 2004 over 2003 due mostly to a favorable shift in mix of product sold from custom profiles
to wheels sold primarily to the lawn and garden market.
Other Matters
We operate under various laws and regulations governing employee safety and the quantities of
specified substances that may be emitted into the air, discharged into waterways, or otherwise
disposed of on and off our properties. In September 2003, the New Jersey Department of
Environmental Protection issued a directive and the United States Environmental Protection Agency
(“USEPA”) initiated an investigation related to over 70 companies, including a Spartech subsidiary,
regarding the Lower Passaic River. Our subsidiary subsequently agreed to participate in a group of
over 40 companies in funding $10 million of an estimated $20 million environmental study by the
USEPA to determine the extent and source of contamination at this site, and as of the end of fiscal
2005, it had paid its total commitment of $0.3 million towards this study. As of the end of fiscal
2005, we had $0.1 million accrued related to this issue representing approximately one year of
legal fees. Subsequent to fiscal 2005 year end, the group’s technical
consultant advised the group of its belief that completion of the environmental study
would significantly exceed the USEPA’s original cost estimate. We have not recorded an accrual
related to future funding of the environmental study cost overrun or other costs that may result
from resolution of this issue due to several uncertainties involved with the outcome of this issue
including (i) whether or not the subsidiary will agree to continue voluntarily participating with
the other members of the group in further funding of the environmental study, any future studies,
or any remediation activities, (ii) the number of other parties that may be identified as
participants in the future and the uncertainty of the level of participation by each of the parties
ultimately named, (iii) our belief that the subsidiary’s contribution in polluting the Lower
Passaic River is negligible compared to many other companies either already named or likely to be
named as potentially responsible parties, (iv) the fact that many of the other companies named in
the directive and investigation are significantly larger than our subsidiary in terms of market
capitalization, and (v) the timing or amount of the eventual determinations of the damage to the
river, the remedial steps required, the responsible parties, and any resulting remediation costs or
assessments for which the subsidiary may be liable. We believe that it is possible that our
ultimate liability resulting from this issue could materially differ from our October 29, 2005
accrual balance. In the event of one or more adverse determinations related to this issue, the
impact on our results of operations could be material to any specific period. However, it is our
opinion that future expenditures for compliance with these laws and regulations, as they relate to
the Lower Passaic River issue and other potential issues, will not have a material effect on our
capital expenditures, financial position, or competitive position.
The plastic resins we use in our production processes are derived from crude oil or natural
gas, which are available from a number of domestic and foreign suppliers. Historically, our raw
materials have been only somewhat affected by supply, demand, and price trends of the petroleum
industry; however, more recently the unusually high price of crude oil and natural gas has had a
greater impact on increasing the price of plastic resins, our most significant raw material. We
currently expect this pricing relationship to continue in the foreseeable future. Past trends in
resin pricing, periods of anticipated or actual shortages of a particular resin, and changes in
supplier capacities can also have an impact on the cost of our raw materials during a particular
period. Price spikes in crude oil and natural gas along with the political unrest in oil-producing
countries have resulted in unusually high pricing pressures during fiscal 2004 and 2005 which
resulted in dramatic increases in the prices of our raw materials. In prior years, we were able to
minimize the impact of such price increases in raw material costs by controlling our inventory
levels, increasing production efficiencies, passing through price changes to customers and
negotiating competitive prices with our suppliers. These pricing changes were more difficult for us
to manage and we increased selling prices to customers significantly in fiscal 2004 and 2005 to
help maintain our material margin per pound sold. While we will continue to implement the actions
noted above to help minimize the impact of price changes on our margins, the direction, degree of
volatility and our ability to manage future pricing changes is uncertain.
Liquidity and Capital Resources
Cash Flow
Our primary sources of liquidity have been cash flows from operating activities, borrowings
from third parties and equity offerings. Our principal uses of cash have been to support our
operating activities, invest in capital improvements, pay down outstanding indebtedness, finance
strategic business and outsourcing acquisitions and pay dividends on our common stock. The
following summarizes the major categories of our changes in cash and cash equivalents for fiscal
2005, 2004 and 2003:
2005
2004
2003
Cash Flows (in millions)
Net cash provided by operating activities
$
105.0
$
31.6
$
69.5
Net cash used in investing activities
(31.4
)
(131.1
)
(49.3
)
Net cash (used for)/ provided by financing activities
(110.3
)
137.5
(21.6
)
Effect of exchange rate changes
—
0.2
0.2
(Decrease) / increase in cash and equivalents
$
(36.7
)
$
38.2
$
(1.2
)
Net cash provided by operating activities increased to $105.0 million in fiscal 2005 from
$31.6 million in fiscal 2004. Cash generated from net earnings after adding back depreciation and
amortization expense and non-cash special items approximated $76 million in fiscal 2005 and $77
million in fiscal 2004. Cash provided by working capital account changes improved to $26.8 million
in fiscal 2005 from $55.0 million
used for operating activities in fiscal 2004 and drove the
overall increase in net cash provided by operating activities. This working capital improvement
reflects our focused effort to reduce net working capital to improve cash flow. The efforts
resulted in an improvement to days sales outstanding of our year end accounts receivable balance
(calculated from the trailing two months of sales) from 53 days at the end of fiscal 2004 to 51
days at the end of fiscal 2005. In addition, our year-end inventory turns (calculated from the
trailing two months of cost of sales) improved from 7.9 times at the end of fiscal 2004 to 10.7
times at the end of fiscal 2005.
The Company’s primary investing activities are capital expenditures and business/outsourcing
acquisitions in the plastics industry. Net cash used in investing activities was $31.4 million in
fiscal 2005 compared to $131.1 million in fiscal 2004. The major cause of the change was the $88.0
million invested for the VPI acquisition in fiscal 2004 compared to $1.2 million for the final
purchase price settlement for VPI in fiscal 2005. Capital expenditures are primarily incurred to
maintain and improve productivity, as well as to modernize and expand facilities. Capital
expenditures for fiscal 2005 were $39.3 million compared to $35.0 million for fiscal 2004. The $4.3
million increase in capital expenditures was due to capacity expansions for new sheet and
compounding business at our Donchery, France facility, new wheels business in our Engineered
Products segment, and investments in new production lines for new product capabilities. In
addition, the increase reflects information technology capital investments related to
Sarbanes-Oxley compliance efforts and our company-wide Oracle 11i implementation project. We
expect capital expenditures to approximate $28 million in fiscal 2006. The net cash used in
investing activities in fiscal 2005 was partially offset by $9.1 million provided by cash received
from dispositions of operations and fixed assets.
Net cash used for financing activities totaled $110.3 million for fiscal 2005 compared to cash
provided of $137.5 in fiscal 2004. The use in the current year reflects the pay-down of $94.9
million of debt using cash flow provided by operations along with the $36.7 million decrease in
cash balance in this period. The net cash provided by financing activities in fiscal 2004 included
$150 million provided by issuance of private placement notes and $60.9 million provided by a stock
offering. A portion of these proceeds were used to pay down the bank credit facility. Other
financing activities during fiscal 2005 include $11.5 million used to pay dividends and $8.0
million used to purchase treasury stock.
Overall, cash decreased $36.7 million in fiscal 2005 due to the factors noted above. This
decrease compares to a $38.2 million increase in cash in fiscal 2004 which included the effects of
the common stock offering and issuance of private placement notes.
Financing Arrangements
At October 29, 2005, our total borrowings under our bank credit facilities were $48.3 million
at a weighted average interest rate of 5.7% and we had $168.8 million of total availability under
our credit facilities.
On February 16, 2005, our French subsidiary entered into a 20 million Euro term loan that
matures on February 16, 2010. Interest on the term loan is payable monthly at a floating rate
chosen by the Company equal to either the one-month, three-month, or six-month EURIBO rate plus a
1% borrowing margin which was 3.13% at October 29, 2005. We used the proceeds of this loan to
reimburse amounts that had been funded by the U.S. parent and more effectively match Euro
denominated debt with the Euro denominated assets of our Donchery, France facility.
Our current credit facilities contain certain affirmative and negative covenants, including
restrictions on the incurrence of additional indebtedness, limitations on both the sale of assets
and merger transactions, and requirements to maintain certain financial and debt service ratios and
net worth ratios. While we were in compliance with such covenants through the end of fiscal years
2005, 2004 and 2003, and currently expect to be in compliance through fiscal 2006, our failure to
comply with the covenants or other requirements of our financing arrangements could result in an
event of default and, among other things, acceleration of the payment of our indebtedness, which could adversely impact our
business, financial condition, and results of operations.
On July 29, 2005, the Company was granted a waiver under its revolving credit facility to
ensure compliance with a Fixed Charge Coverage Ratio. This ratio is calculated using financial
information from
our four most recent trailing fiscal quarters and was required to exceed 1.40:1
for that quarter. The waiver only applied to the third quarter ended July 30, 2005 and
automatically terminated if the Fixed Charge Coverage Ratio was less than 1.25:1. The Fixed Charge
Coverage Ratio is required to be 1.50:1 effective on October 29, 2005 and thereafter. The primary
reason for the third quarter waiver was the negative impact on the numerator of the ratio of the
$0.8 million one-time cash expenses to terminate the lease of the company airplane and the $2.7
million cash retirement payment to our former CEO, both of which were incurred in the third quarter
of fiscal 2005. In addition, the denominator of the ratio included $33 million of required
principal payments paid during the fourth quarter of 2004 which decreased to $18 million in the
fourth quarter of 2005. This benefited our fourth quarter of fiscal 2005 Fixed Charge Coverage
Ratio calculation which was 1.74:1.
We anticipate that cash flows from operations, together with the financing and borrowings
under our bank credit facility, will provide the resources for (i) satisfying our working capital
needs, regular quarterly dividends, and planned capital expenditures and (ii) managing the capital
structure on a short and long-term basis.
Contractual Obligations
The following table summarizes our contractual obligations as of October 29, 2005 and the
estimated payments due by period:
(in millions)
Less Than
Years
Years
Greater than
Contractual Obligations
Total
1 Year
2 and 3
4 and 5
5 Years
Long-term Debt
$
550.7
$
32.7
$
49.2
$
89.5
$
379.3
Capital Lease Obligations
1.1
0.3
0.4
0.2
0.2
Operating Lease
Obligations
24.4
7.2
8.8
4.2
4.2
Purchase Obligations
126.2
124.5
1.7
—
—
Other Long-Term
Liabilities
8.7
0.6
1.3
1.1
5.7
Total
$
711.1
$
165.3
$
61.4
$
95.0
$
389.4
Amounts included in long-term debt include principal and interest payments. Interest on
debt with variable rates was calculated using the current rate of 4.48% at October 29, 2005.
Purchase obligations primarily consist of inventory purchases made in the normal course of business
to meet operational requirements. Other long-term liabilities consist primarily of a guarantee to
enter into a capital lease in return for government investment subsidies. The obligations table
does not include long term contingent liabilities and liabilities related to deferred taxes because
it is not certain when these liabilities will become due.
Significant Accounting Policies, Estimates and Judgments
We prepare our consolidated financial statements in conformity with accounting principles
generally accepted in the United States. As such, we are required to make estimates and judgments
that affect the reported amounts of assets, liabilities, shareholders’ equity, revenues and
expenses, and disclosures of contingent assets and liabilities at the date of the financial
statements. Significant accounting policies, estimates and judgments which we believe are the most
critical to aid in fully understanding and evaluating our reported financial results include the
following:
Revenue
Recognition — We recognize revenue as product is shipped and title passes to the
customer. We manufacture our products either to standard specifications or to custom specifications
agreed upon with the customer in advance, and we inspect our products prior to shipment to ensure
that these specifications are met. We continuously monitor and track product returns, which have
historically been within our expectations and the provisions established. Despite our efforts to improve our
quality and service to customers, we cannot guarantee that we will continue to experience the same
or better return rates than we have in the past. Any significant increase in returns could have a
material negative impact on our operating results.
Accounts
Receivable — We perform ongoing credit evaluations of our customers and adjust credit
limits based upon payment history and the customer’s creditworthiness, as determined by our review
of their current credit information. We continuously monitor collections and payments from our
customers and
maintain a provision for estimated credit losses based upon any specific customer
collection issues identified. While such credit losses have historically been within our
expectations and the provisions established, actual credit loss rates may differ from our
estimates.
Inventories
— We value inventories at the lower of (i) cost to purchase or manufacture the
inventory or (ii) the current estimated market value of the inventory. We also buy scrap and
recyclable material (including regrind material) to be used in future production. We record these
inventories initially at purchase price, and based on the inventory aging and other considerations
for realizable value, we write down the carrying value to market value, where appropriate. We
regularly review inventory on-hand and record provisions for obsolete inventory. A significant
increase in the demand for our raw materials could result in a short-term increase in the cost of
inventory purchases, while a significant decrease in demand could result in an increase in the
amount of excess inventory quantities on hand. In addition, most of our business is custom
products, where the loss of a specific customer could increase the amount of excess or obsolete
inventory on hand. Although we make every effort to ensure the accuracy of our forecasts of future
product demand, any significant unanticipated changes in demand could have a significant impact on
the value of our inventory and operating results.
Acquisition
Accounting — We have made several acquisitions in recent years. All of these
acquisitions have been accounted for in accordance with the purchase method, and accordingly, the
results of operation were included in our Consolidated Statement of Operations from the respective
date of acquisition. The purchase price has been allocated to the identifiable assets and
liabilities, and any excess of the cost over the fair value of the net identifiable assets acquired
is recorded as goodwill. The initial allocation of purchase price is based on preliminary
information, which is subject to adjustments upon obtaining complete valuation information. While
the delayed finalization of a purchase price has historically not had a material impact on the
consolidated results of operations, we cannot guarantee the same results in future acquisitions.
Valuation
of Long-Lived Assets — We review the carrying value of our long-lived assets, which
primarily include property plant and equipment, goodwill, and other intangible assets, annually or
whenever events and changes in business circumstances indicate the carrying value of the assets may
not be recoverable. If we determine that the carrying value of a long-lived asset may not be
recoverable, a permanent impairment charge is recorded for the amount by which the carrying value
of the long-lived asset exceeds its fair value. We measure fair value based on a projected
discounted cash flow method using a discount rate determined to be commensurate with the risk
inherent in the business and achievability of the projected results. The estimates in projected
cash flows and discount rates are subject to change due to the economic environment, including such
factors as interest rates, expected market returns, and the volatility of markets served. We
believe that the estimates are reasonable; however, changes in estimates or deterioration of
results could materially affect the fair value assessments.
Contingencies
— We are involved in litigation in the ordinary course of business, including
environmental matters. Our policy is to record expense for contingencies when it is both probable
that a liability has been incurred and the amount can be reasonably estimated. Estimating probable
losses requires assessment of multiple outcomes that often depends on management’s judgments
regarding, but not limited to, potential actions by third parties such as regulators. The final
resolution of these contingencies could result in expenses different from current accruals and
therefore have a material impact on our consolidated financial results in a future reporting
period.
For additional information regarding our significant accounting policies, see Note 1 to our
2005 Consolidated Financial Statements contained in this Form 10-K.
Recently Issued Accounting Standards
In December 2004, the Financial Accounting Standards Board (“FASB”) issued a revised version
of Statement of Financial Accounting Standards (“SFAS”) 123, “Share Based Payment,” SFAS 123(R)
which replaces the original SFAS 123, “Accounting for Stock-Based Compensation” and supersedes
Accounting Principals Board (“APB”) Opinion 25, “Accounting for Stock Issued to Employees.” SFAS
123(R) requires public companies to recognize the costs associated with the award of equity
instruments to employees in the results of operations over the service period related to the award.
The cost is based on the fair value of the equity instrument at the date of grant. The provisions
of SFAS 123(R) will be effective for
us in the first quarter of 2006. The impact of the adoption
of this standard on our historical net income and earnings per share is disclosed in Note 1 to our
Consolidated Financial Statements. We expect the impact of recognizing stock option expense
associated with the adoption of SFAS 123(R) to decrease diluted earnings per share by $0.05 in
fiscal 2006.
Item 7A. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK
We are exposed to changes in interest rates primarily as a result of our borrowing activities.
Our earnings and cash flows are subject to fluctuations in interest rates on our floating rate
debt facilities. At October 29, 2005, we had $48.4 million of debt subject to variable short-term
interest rates and $331.6 million of fixed rate debt outstanding. Based upon the October 29, 2005
balance of the floating rate debt, a hypothetical 10% increase in interest rates would cause an
immaterial change in future net earnings, fair value and cash flows. We are not currently engaged
in any interest rate derivative instruments to manage our exposure to interest rate fluctuations.
The fair market value of our fixed rate debt is subject to changes in interest rates; the
October 29, 2005 fair values of such instruments are disclosed in the notes to our consolidated
financial statements. We do not anticipate material changes to the fair value of our debt in the
next 12 months.
At October 30, 2004 we had no debt subject to variable short-term interest rates. We had
$474.1 million of fixed rate financings outstanding as of October 30, 2004, including $125.0
million of floating rate debt fixed through November 2004 by an interest rate swap. Based upon the
October 30, 2004 balance of the floating rate debt fixed by an interest rate swap which expired in
November 2004, a hypothetical 10% increase in interest rates would cause an immaterial change in
future net earnings, fair value and cash flows.
See Item 7, “Management’s Discussion and Analysis of Financial Condition and Results of
Operations” for additional disclosures about market risk.
Item 8. FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA
Management’s Responsibility for Financial Statements
The Company’s financial statements are prepared and presented in accordance with accounting
principles generally accepted in the United States. The management of Spartech is responsible for
the preparation and presentation of the financial statements and other financial information
included in this annual report, including the reasonableness of estimates and judgments inherent in
the preparation of the financial statements.
The Company’s board of directors is responsible for ensuring the independence and
qualifications of audit committee members under applicable New York Stock Exchange and Securities
and Exchange Commission standards. The audit committee consists of four independent nonmanagement
directors and oversees the Company’s financial reporting and internal controls system and meets
with management, the independent auditors and the internal auditors periodically to review auditing
and financial reporting matters. The audit committee is solely responsible for the selection and
retention of the Company’s independent auditors. The audit committee held eight meetings during
fiscal 2005 and its report for fiscal 2005 can be found in the Company’s proxy statement.
In addition to the audits of the Company’s internal control over financial reporting and
management’s assessment of internal control over financial reporting, Ernst & Young LLP is also
responsible for auditing the Company’s financial statements in accordance with the standards of the
Public Company Accounting Oversight Board, and expressing an opinion as to whether the financial
statements fairly present, in all material respects, the Company’s balance sheets, statements of
operations, statements of shareholders’ equity and statements of cash flows.
Management’s Report on Internal Control over Financial Reporting
It is also management’s responsibility to establish and maintain adequate internal control
over financial reporting, as such term is defined by the U.S. Securities and Exchange Commission.
Under the supervision and with the participation of management, including the chief executive
officer and chief financial officer, the Company conducted an assessment of the effectiveness of
its internal control over financial reporting based on the framework set forth in Internal
Control-Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway
Commission (“COSO”). The Company’s internal control over financial reporting is a process designed
to provide reasonable assurance regarding the reliability of the Company’s financial reporting and
the preparation of financial statements for external purposes in accordance with generally accepted
accounting principles. Based on the Company’s evaluation under the COSO framework, Spartech
management concluded that the Company’s internal control over financial reporting was effective as
of October 29, 2005.
The Company’s independent registered public accounting firm, Ernst & Young LLP, has issued an audit report
on management’s assessment of internal control over financial reporting.
Report of Ernst & Young LLP, Independent Registered Public Accounting Firm
The Shareholders and the Board of Directors
Spartech Corporation and Subsidiaries
We have audited the accompanying consolidated balance sheets of Spartech Corporation and
Subsidiaries (the Company) as of October 29, 2005 and October 30, 2004, and the related
consolidated statements of operations, changes in shareholders’ equity, and cash flows of the
Company for each of the three years in the period ended October 29, 2005. Our audits also included the
financial statement schedules listed in the Index at Item 15(a). These financial statements and
schedules are the responsibility of the Company’s management. Our responsibility is to express an
opinion on these financial statements and schedules based on our audits.
We conducted our audits in accordance with the 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. An
audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the
financial statements. An audit also includes assessing the accounting principles used and the
significant estimates made by management, as well as 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 Spartech Corporation and Subsidiaries at October29, 2005 and October 30, 2004, and the consolidated results of their operations and their cash
flows for each of the three years in the period ended October 29, 2005, in conformity with U.S.
generally accepted accounting principles. Also, in our opinion, the related financial statement
schedules, when considered in relation to the basic financial statements taken as a whole, present
fairly in all material respects the information set forth therein.
We also have audited, in accordance with the standards of the Public Company Accounting Oversight
Board (United States), the effectiveness of Spartech Corporation and Subsidiaries’ internal control
over financial reporting as of October 29, 2005, based on criteria established in Internal
Control-Integrated Framework issued by the Committee of Sponsoring
Organizations of the Treadway
Commission and our report dated January 10, 2006 expressed an unqualified opinion thereon.
Report of Ernst & Young LLP, Independent Registered Public Accounting Firm
The Shareholders and the Board of Directors
Spartech Corporation and Subsidiaries
We have audited management’s assessment, included in the accompanying Management’s Report on
Internal Control Over Financial Reporting, that Spartech Corporation and Subsidiaries (the Company)
maintained effective internal control over financial reporting as of October 29, 2005, based on
criteria established in Internal Control—Integrated Framework issued by the Committee of Sponsoring
Organizations of the Treadway Commission (the COSO criteria). The Company’s management is
responsible for maintaining effective internal control over financial reporting and for their
assessment of the effectiveness of internal control over financial reporting. Our responsibility is
to express an opinion on management’s assessment and an opinion on the effectiveness of the
Company’s internal control over financial reporting based on our audit.
We conducted our audit in accordance with the 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 effective internal control over financial reporting was
maintained in all material respects. Our audit included obtaining an understanding of internal
control over financial reporting, evaluating management’s assessment, testing and evaluating the
design and operating effectiveness of internal control, and performing such other procedures as we
considered necessary in the circumstances. We believe that our audit provides a reasonable basis
for our opinion.
A company’s internal control over financial reporting is a process designed to provide reasonable
assurance regarding the reliability of financial reporting and the preparation of financial
statements for external purposes in accordance with generally accepted accounting principles. A
company’s internal control over financial reporting includes those policies and procedures that (1)
pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the
transactions and dispositions of the assets of the company; (2) provide reasonable assurance that
transactions are recorded as necessary to permit preparation of financial statements in accordance
with generally accepted accounting principles, and that receipts and expenditures of the company
are being made only in accordance with authorizations of management and directors of the company;
and (3) provide reasonable assurance regarding prevention or timely detection of unauthorized
acquisition, use, or disposition of the company’s assets that could have a material effect on the
financial statements.
Because of its inherent limitations, internal control over financial reporting may not prevent or
detect misstatements. Also, projections of any evaluation of effectiveness to future periods are
subject to the risk that controls may become inadequate because of changes in conditions, or that
the degree of compliance with the policies or procedures may deteriorate.
In our opinion, management’s assessment that the Company maintained effective internal control over
financial reporting as of October 29, 2005, is fairly stated, in all material respects, based on
the COSO criteria. Also, in our opinion, the Company maintained, in all material respects,
effective internal control over financial reporting as of October 29, 2005, based on the COSO
criteria.
We also have audited, in accordance with the standards of the Public Company Accounting Oversight
Board (United States), the consolidated balance sheets of the Company as of October 29, 2005 and
October 30, 2004 and the related consolidated statements of operations, changes in shareholders’
equity and cash flows of the Company for each of the three years in the period ended October 29, 2005, and
our report dated January 10, 2006 expressed an unqualified opinion thereon.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS (Dollars in thousands, except per share amounts)
1) Significant Accounting Policies
Basis of Presentation — The preparation of financial statements in conformity with generally
accepted accounting principles requires management to make estimates and assumptions that affect
reported amounts and related disclosures. Actual results could differ from those estimates.
Certain prior year amounts have been reclassified to conform to the current year presentation. The
Company’s fiscal year ends on the Saturday closest to October 31.
Principles of Consolidation — The accompanying consolidated financial statements include the
accounts of Spartech Corporation and its controlled affiliates. All intercompany transactions and
balances have been eliminated. Investments in entities of 20% to 50% of the outstanding capital
stock of such entities are accounted for by the equity method.
Foreign Currency Translation — Assets and liabilities of the Company’s non-U.S. operations are
translated from their functional currency to U.S. dollars using exchange rates in effect at the
balance sheet date. Results of operations are translated using average rates during the period.
Adjustments resulting from the translation process are included in accumulated other comprehensive
income. Transactional gains and losses arising from receivable and payable balances in the normal
course of business that are denominated in a currency other than the functional currency of the
operation are recorded in income when they occur. The Company may periodically enter into foreign
currency contracts to manage exposures to market risks from prospective changes in exchange rates.
No such contracts were outstanding as of October 29, 2005 or October 30, 2004.
Cash Equivalents — Cash equivalents consist of highly liquid investments with original
maturities of three months or less.
Allowance for Doubtful Accounts — The Company performs ongoing credit evaluations of customers
that include reviewing creditworthiness from third-party reporting agencies, monitoring payment
histories, and adjusting credit limits as necessary. The Company continually monitors collections
and payments from customers and maintains a provision for estimated credit losses based on
specifically identified customer collection issues.
Inventories — Inventories are valued at the lower of cost or market. Inventory values are
primarily based on either actual or standard costs which approximate average cost. Standard costs
are revised at least once annually, the effect of which is allocated between inventories and cost
of sales. Finished goods include the costs of material, labor, and overhead.
Property, Plant, and Equipment — Property, plant, and equipment are carried at cost less
accumulated depreciation. Depreciation expense is recorded on a straight-line basis over the
estimated useful lives of the related assets as shown below and totaled $35,448, $32,216, and
$29,379 in fiscal years 2005, 2004, and 2003, respectively.
Major additions and improvements are capitalized. Maintenance and repairs are expensed as
incurred. Long-lived assets are reviewed for impairment whenever events or changes in business
circumstances indicate that the carrying value of the assets may not be recoverable. Impairment
losses are recognized based on fair value if expected future cash flows of the related assets are
less than their carrying values.
NOTES
TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED (Dollars in thousands, except per share amounts)
Goodwill
and Intangible Assets — Assets and liabilities acquired in business combinations are
accounted for using the purchase method and recorded at their respective fair values. Goodwill is
assigned to the reporting unit which benefits from the acquired business. The Company conducts a
formal impairment test of goodwill and intangibles not subject to amortization on an annual basis
on the last day of the Company’s fiscal year and between the annual testing date if an event occurs
or circumstances change that would more likely than not reduce the fair value of a reporting unit
below its carrying amount. Under the impairment test, if a reporting unit’s carrying amount
exceeds its estimated fair value, a goodwill impairment charge is recognized to the extent that the
reporting unit’s carrying amount of goodwill exceeds the implied fair value of goodwill. Fair
values of reporting units are estimated using discounted cash flows.
The Company reviews the carrying amounts of intangibles subject to amortization and other
long-lived assets for potential impairment if an event occurs or circumstances change that
indicates the carrying amount may not be recoverable. In evaluating the recoverability of a
long-lived asset, such assets are grouped at the lowest level for which identifiable cash flows are
largely independent of the cash flows of other assets, and management compares the carrying value
of each asset group with the corresponding estimated undiscounted future operating cash flows. In
the event an asset group is not recoverable by future undiscounted operating cash flows, impairment
exists. In the event of impairment, an impairment charge would be measured as the amount by which
the carrying value of the long-lived asset group exceeds its fair value.
Financial
Instruments — The Company selectively uses derivative financial instruments to
manage its interest costs as well as its balance of floating rate and fixed rate financings. No
credit loss is anticipated from such instruments because the counterparties to these agreements are
major financial institutions with high credit ratings. The Company does not enter into derivatives
for trading purposes. The net amount paid or received under an interest rate swap agreement is
recorded as interest expense.
Derivative instruments (including certain derivative instruments embedded in other contracts)
are recorded in the balance sheet as either an asset or liability measured at fair value, and
changes in the derivative’s fair value are recognized currently in earnings unless specific hedge
accounting criteria are met. Special accounting for qualifying derivatives designated as fair
value hedges allows a derivative’s gains and losses to be offset in the income statement by the
related change in the fair value of the hedged item. Special accounting for qualifying derivatives
designated as cash flow hedges allows the effective portion of a derivative’s gains and losses to
be reported as a component of accumulated other comprehensive income or loss and reclassified into
earnings in the period during which the hedged transaction affects earnings.
The Company uses the following methods and assumptions in estimating the fair value of
financial instruments:
•
Cash, accounts receivable, accounts payable, and accrued liabilities — the carrying
value of these instruments approximates fair value due to their short-term nature;
•
Derivative financial instruments — based upon quoted market prices or market prices for
instruments with similar terms and maturities; and
•
Long-term debt (including bank credit facilities and convertible subordinated
debentures) — based on quoted, current market prices for the same or similar issues. As
of October 29, 2005, the fair value of the convertible subordinated debentures was
approximately $156,082 compared to the carrying amount of $154,639 and the fair value of
other long-term debt was $213,678 compared to the carrying amount of $214,141.
Stock-Based
Compensation — In 2003, the Company adopted SFAS 148, “Accounting for Stock-Based
Compensation — Transition and Disclosure,” which amended SFAS 123, “Accounting for Stock-Based
Compensation” to provide transition methods for a voluntary change to measuring compensation cost
in connection with employee share option plans using a fair value based method. The Company
continues to use the intrinsic value based method and does not recognize compensation expense in
the results of operations for the issuance of options with an exercise price equal to or greater
than the market price at the time of grant. As a result, the adoption of SFAS 148 had no impact on the
Company’s results of operations
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
or financial position. Had the fair value recognition provisions of SFAS 123 been adopted by the
Company, the effect on net income and earnings per common share for fiscal 2005, 2004, and 2003
would have been as follows:
2005
2004
2003
Net Earnings as Reported
$
12,191
$
42,063
$
34,103
Add: Stock-based compensation included in net
earnings as reported, net of tax
649
112
—
Deduct: Total stock-based compensation, net of tax
(2,535
)
(1,873
)
(2,089
)
Pro Forma Net Earnings
$
10,305
$
40,302
$
32,014
Earnings Per Share
As Reported:
Basic
$
.38
$
1.34
$
1.17
Diluted
.38
1.32
1.15
Pro Forma:
Basic
$
.32
$
1.28
$
1.09
*
Diluted
.32
1.26
1.08
*
*
Pro forma amounts were previously reported as $1.11 basic and $1.10 diluted earnings per
share. These amounts were restated for corrections of errors.
Using the Black-Scholes option-pricing model, the estimated weighted-average fair value of
options granted during fiscal 2005, 2004, and 2003 is as follows:
2005
2004
2003
Weighted Average Fair Value
$
7.65
$
6.94
$
5.58
Assumptions:
Expected Dividend Yield.
2
%
2
%
2
%
Expected Volatility
35
%
35
%
35
%
Risk-Free Interest Rates
3.59-3.79
%
2.95-3.70
%
2.52-3.50
%
Expected Lives
5.5 years
5.5 years
5.0 years
The effects of applying SFAS 123 in the pro forma disclosure are not necessarily indicative of
the effects that may be realized in future years. In December 2004, SFAS 123(R) a revised version
of SFAS 123, was issued which requires the recognition of compensation expense based on the fair
value as of the grant date in the results of operations for the issuance of employee stock options.
The provisions of SFAS 123(R) will be effective for the Company in the first quarter of fiscal
2006. The approximate impact of SFAS 123(R) on the Company’s historical net earnings and earnings
per share is presented in the previous table.
The Company granted 8,353 and 7,663 restricted stock units to non-employee directors during
fiscal 2005 and 2004, respectively, as follows:
2005
2004
Fair value per share granted
$
26.02
$
23.70
Compensation expense recognized
$
217
$
180
As discussed in Note 4, during fiscal 2005, the Company entered into a retirement agreement
with its former chief executive officer (“CEO”). Among other items, the agreement included an
amendment to the terms of the former CEO’s vested stock options to treat his resignation as a
retirement before having reached the minimum retirement age of 60 specified in his option
agreements, resulting in a new
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
measurement of the options for accounting purposes and a non-cash expense of $831. In addition,
the agreement required the cancellation of all of the former CEO’s unvested stock options.
Revenue
Recognition — The Company manufactures products for specific customer orders and for
standard stock inventory. Revenues are recognized and billings are rendered as the product is
shipped to the customer in accordance with U.S. generally accepted accounting principles as well as
the Securities and Exchange Commission’s Staff Accounting Bulletin 104. Shipping and handling
costs associated with the shipment of goods are recorded as costs of sales in the consolidated
statement of operations.
Income
Taxes — Deferred tax assets and liabilities are recognized for the future tax
consequences attributable to temporary differences between the financial statement carrying amounts
of assets and liabilities and their respective tax bases. Deferred tax assets are also recognized
for credit carryforwards and then assessed (including the anticipation of future income) to
determine the likelihood of realization. Deferred tax assets and liabilities are measured using
the rates expected to apply to taxable income in the years in which the temporary differences are
expected to reverse and the credits are expected to be used. The effect of a change in tax rates
on deferred tax assets and liabilities is recognized in income in the period that includes the
enactment date.
2) Acquisitions
On October 1, 2004, the Company completed the acquisition of substantially all of the assets
of three divisions of VPI, based in Sheboygan, Wisconsin. The operations purchased included (1)
The Sheet Products Division, a custom extruded sheet manufacturer serving the graphic arts, medical
packaging, and specialty retail markets; (2) The Contract Manufacturing Division, a provider of
non-carpet flooring and sound barrier products to the transportation industry; and (3) The Film and
Converting Division calenders, prints, and laminates products for distribution to various markets
including the medical, recreation, and leisure markets. The Sheet Products Division was added to
the Company’s Custom Sheet and Rollstock segment, and the Contract Manufacturing and Film and
Converting Divisions were added to the Color and Specialty Compounds segment. Sales within the
three divisions acquired totaled approximately $110,000 for the 12 months prior to acquisition.
The cash price for this acquisition of approximately $87,758 was allocated to the assets acquired
and liabilities assumed of $97,694 and $9,936, respectively. The assets acquired include $39,142 of
property, plant, and equipment, $17,780 of identified intangibles, $23,009 of working capital
assets and $17,763 of goodwill, all of which is deductible for tax purposes. The identified
intangibles and respective weighted average amortization periods are $15,310 of customer contracts
and relationships (ten years), $1,430 of technology (ten years) and $1,040 of non-compete
agreements (three years).
On September 30, 2003, the Company completed the purchase of certain assets and entered into a
supply agreement with Wilbert Inc.’s TriEnda Division located in Portage, Wisconsin. The acquired
business was a “captive” (internal consumption) manufacturer of extruded sheet, primarily for the
TriEnda line of reusable shipping and material handling containers. The total cash purchase price
for these assets was $5,420 and was allocated to assets and liabilities of $5,517 and $97,
respectively. Assets acquired included $752 of goodwill, all of which is deductible for tax
purposes. This business is reported in the Company’s Custom Sheet and Rollstock segment.
On March 31, 2003, the Company completed its acquisition of Polymer Extruded Products, Inc.
(“PEP”), a manufacturer of weatherable film laminates and cellulose specialty extruded products.
PEP had annual sales of approximately $21,000 for calendar year 2002, with nearly $4,000 of those
sales to Spartech’s Custom Sheet and Rollstock segment. The cash paid for this acquisition of
$23,761 was allocated to the assets acquired and liabilities assumed of $32,724 and $8,963,
respectively (acquired assets included $14,484 of goodwill, $1,887 of which is deductible for tax
purposes, non-compete agreements and customer relationships totaling $1,900 with amortization
periods of five years, and a trademark of $8,900 which was determined to have an indefinite life).
PEP is reported in the Company’s Color and Specialty Compounds segment.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
3) Restructuring
In the second quarter of fiscal 2005, the Company initiated several operational changes to
enhance short-term operating performance and longer-term operating efficiencies. The plan involved
the closing or sale of certain plant facilities and was segregated into three categories: (i) the
elimination of non-core operations, (ii) the consolidation of capacity for similar operations, and
(iii) the transfer of synergistic or new business to other existing operations.
The effect of the plan was to reduce the number of operating facilities by seven. In
addition, the Company had three properties held for sale at the end of fiscal 2004. Of these ten
facilities, only the two Conneaut, Ohio facilities remain held for sale at the end of fiscal 2005.
One facility is included in the Custom Sheet and Rollstock segment, while the other is included in
the Color and Specialty Compounds segment.
In addition to the reduction in operating facilities, the Company made a decision in the third
quarter of fiscal 2005 to sell a calender film line that had recently been added to the Color and
Specialty Compounds segment. The decision was made possible as a result of the late 2004 VPI
acquisition and analysis of the capabilities and capacity within the newly acquired facilities.
Also, in the third quarter of 2005, the Company terminated the lease on its airplane which resulted
in termination fees and selling expenses of $750.
During the fourth quarter of fiscal 2005, the Company initiated a plan to consolidate two
additional Color and Specialty Compounds production facilities into one plant in Donora,
Pennsylvania. There are currently two facilities in Donora that will be combined into one, with
the other converting to a warehouse operation to service the customers and production from both
plants. The implementation of this plan has also resulted in the planned closure of the Arlington,
Texas compounding operation, which was communicated to employees subsequent to year-end.
The assets held for sale by segment are $296 and $471 for Custom Sheet and Rollstock and Color
and Specialty Compounds, respectively, as of the end of fiscal 2005. The following table
summarizes the restructuring and exit costs presented in the Consolidated Statement of Operations
for fiscal 2005 from these actions:
2005
Fixed asset impairment, net
$
6,624
Goodwill write-offs
1,419
Facility restructuring
1,295
Airplane lease buy-out
750
$
10,088
Of the $10,088 total restructuring and exit costs in fiscal 2005, $2,890 represents cash
expended for facility restructuring, the airplane lease buy-out and severance associated with sold
assets. The $7,198 remaining difference represents losses on the sales of these assets and
consists of $11,183 of proceeds, of which $9,116 was received as of the end of fiscal 2005 and
$2,067 is expected to be received in the first quarter of fiscal 2006, net of $18,381 of sold net
assets.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
The fixed asset impairment, net represents charges incurred to adjust the related assets to
fair market value, less costs to sell and net of any gain or loss on the ultimate sale of the
assets. The following table summarizes the net fixed asset impairment charges recognized for fiscal
2005 by reporting segment:
2005
Custom Sheet and Rollstock
$
(1,077
)
Color and Specialty Compounds
6,655
Engineered Products
1,046
$
6,624
The goodwill write-offs represent charges incurred to dispose of goodwill related to two
businesses which were sold. The following table summarizes the goodwill impairment charges
recognized for fiscal 2005 by reporting segment:
2005
Custom Sheet and Rollstock
$
896
Color and Specialty Compounds
––
Engineered Products
523
$
1,419
Facility restructuring charges represent exit costs including severance, equipment moves,
relocation, and other related costs. The majority of these restructuring charges incurred during
fiscal 2005 were settled in cash by the end of the period. The Company will incur an additional
estimated $120 of cash restructuring related to the activities initiated in the second quarter of
fiscal 2005 and $675 related to the activities initiated in the fourth quarter of fiscal 2005 and
the plant closure communicated to employees subsequent to year-end. The following table summarizes
the facility restructuring charges incurred for fiscal 2005 by reporting segment:
2005
Custom Sheet and Rollstock
$
187
Color and Specialty Compounds
733
Engineered Products
375
$
1,295
The $750 airplane lease buy-out charge was recorded as a corporate expense. The Company
continues to evaluate other operations for opportunities which provide efficiencies or fixed cost
reductions. These evaluations may lead to further plant restructuring decisions, related exit
costs, and property, plant and equipment write-downs. Any such charges would be recorded when those
decisions are made and the plan is initiated.
4) Former CEO Retirement
The Company entered into a Retirement Agreement and Release (“Retirement Agreement”),
effective on May 6, 2005, with its former Chairman, President, and Chief Executive Officer, Bradley
B. Buechler. This Retirement Agreement replaced Mr. Buechler’s Amended and Restated Employment
Agreement dated November 2, 2002.
The Retirement Agreement includes various terms and conditions pertaining to Mr. Buechler’s
retirement. The payments and benefits paid to Mr. Buechler under this Retirement Agreement included
the following major provisions:
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
-
A cash settlement paid June 3, 2005, based upon a multiple of Mr. Buechler’s former
annual salary plus his previous deferred compensation arrangement, totaling $2,711.
-
A bonus to be paid based on the Company’s fiscal 2005 results pro-rated for Mr.
Buechler’s employment through the effective date of the Retirement Agreement.
-
An amendment to the terms of Mr. Buechler’s vested stock options to permit him to
retire before having reached the minimum retirement age of 60 specified in his option
agreements, resulting in a new measurement of the options for accounting purposes and a
non-cash expense of $831.
The provisions of the Retirement Agreement resulted in a $3,645 charge to operating earnings
in fiscal 2005.
5) Fixed Asset Charge
As part of the Company’s Sarbanes-Oxley compliance process, management initiated a complete
physical count of the Company’s property, plant and equipment in the first quarter of fiscal 2005.
The counts were reconciled to balances recorded in the Company’s books and records, and $8,794 of
equipment that no longer existed was identified and written off.
Management believes that the cause of the $8,794 in non-existent equipment was mostly related
to transactions for plant shutdowns and transfers of equipment between plants. Due to the number of
transactions, passage of time since many of them occurred, and the weaknesses in documentation and
controls over these activities, management could not specifically identify or allocate these asset
write-offs to distinct fiscal years with any certainty. In the third quarter of fiscal 2005,
management took corrective actions to institute new policies and procedures for the tracking of
equipment disposals and transfers of equipment between plants, including periodic physical
inventories of property, plant and equipment at each location.
During the count process, management also identified equipment that exists and that management
has elected to liquidate. The decision to liquidate these assets resulted in a $1,870 fixed asset
impairment charge. This impairment charge, combined with the non-existing asset write-off charge is
presented as a total non-cash fixed asset charge of $10,664 in the Consolidated Statement of
Operations in fiscal 2005. The following presents the fixed asset charge by reporting segment for
fiscal 2005 and 2004:
The acquisition of goodwill is attributable to the purchase of VPI during fiscal 2004.
Reclassifications in fiscal 2004 represent acquisition opening balance adjustments between goodwill
and deferred taxes. Reclassifications in fiscal 2005 represent acquisition opening balance
adjustments between goodwill and other intangible assets and deferred taxes, and transfer of the
Spartech PEP reporting unit from the Custom Sheet and Rollstock reporting segment to the Color and
Specialty Compound reporting segment.
The goodwill impairments in fiscal 2005 resulted from the underperformance of one profiles
operation in the Engineered Products reporting segment and the loss of a major customer at an
operation in the Color and Specialty Compounds segment both of which resulted in future operating
projections that did not support the existing fair value of goodwill. Subsequent to the
impairment, there was $24,851 remaining goodwill assigned to the reporting unit in the Engineered
Products segment and no goodwill remaining for the particular reporting unit in the Color and
Specialty Compounds segment. The fair value of the goodwill and resulting impairment were
estimated using discounted cash flows. In addition, during fiscal 2005, the Company sold two
operations that constituted businesses and disposed of the relative goodwill attributable to those
businesses.
Amortization expense for intangible assets totaled $4,939, $2,840 and $2,187 in 2005, 2004 and
2003, respectively.
Amortization expense for amortizable intangible assets over the next five fiscal years is
estimated to be:
Intangible
Fiscal Year Ended
Amortization
2006
$
4,480
2007
4,086
2008
3,008
2009
2,593
2010
2,345
$
16,512
The Company has an $8,900 trademark included in other intangible assets which has an
indefinite life and, therefore is not subject to amortization.
9) Convertible Subordinated Debentures
On March 5, 1999, the Company issued $51,546 of 6.5% convertible subordinated debentures to
Spartech Capital Trust, a Delaware trust controlled by the Company. The Company used the proceeds
to repay borrowings under its bank credit facilities. The debentures are the sole asset of the
trust. The trust purchased the debentures with the proceeds of a $50,000 private placement of 6.5%
convertible preferred securities of the trust, having an aggregate liquidation preference of
$50,000 and guaranteed by the Company. The debentures:
•
Are convertible along with the trust’s preferred securities, at the option of the
preferred security holders, into shares of the Company’s common stock at a conversion
price equivalent to $30.55 per share of common stock, for a total of 1,636,661 shares;
•
Are redeemable along with the trust’s preferred securities, at the Company’s
option, at a price equal to 102.6% of the principal amount plus accrued interest
through March 1, 2006. This amount declines annually to a price equal to the principal
amount plus accrued and unpaid interest after March 1, 2009; and
•
Mature and are payable, along with the trust’s preferred securities, on March 31,2014, if they have not been previously redeemed or converted.
On February 18, 2000, the Company issued $103,093 of 7.0% convertible subordinated debentures
to Spartech Capital Trust II, a Delaware trust controlled by the Company. The Company used the
proceeds to repay borrowings under its bank credit facility. The debentures are the sole asset of
the trust. The trust purchased the debentures with the proceeds of a $100,000 private placement of
7.0% convertible preferred securities of the trust having an aggregate liquidation preference of
$100,000 and guaranteed by Spartech. The debentures:
NOTES
TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
•
Are convertible along with the trust’s preferred securities, at the option of the
preferred security holders, into shares of the Company’s common stock at a conversion
price equivalent to $34.00 per share of common stock, for a total of 2,941,176 shares;
•
Are redeemable along with the trust’s preferred securities, at the Company’s
option, at a price equal to 103.5% of the principal amount plus accrued interest
through March 1, 2006. This amount declines annually to a price equal to the principal
amount plus accrued and unpaid interest after March 1, 2010; and
•
Mature and are payable, along with the trust’s preferred securities, on March 31,2015, if they have not been previously redeemed or converted.
On September 15, 2004, the Company completed a $150,000 private placement of 5.54% Senior
Unsecured Notes over a twelve-year term. The 2004 Notes require equal annual principal payments of
$30,000 that commence on September 15, 2012. Interest on the 2004 Notes is payable semiannually on
March 15 and September 15 of each year. On August 22, 1997, the Company completed a private
placement of 7.0% Senior Unsecured Notes consisting of $45,000 designated as Series A and $15,000
designated as Series B. The Series A 1997 Notes require equal annual principal payments of
approximately $6,429 that commenced on August 22, 2001 and the required $15,000 principal payment
due on the Series B 1997 Notes was paid on August 22, 2004. Interest on the 1997 Notes is payable
semiannually on February 22 and August 22 of each year. On September 27, 1996, the Company
completed a $30,000 private placement of 7.62% Guaranteed Unsecured Notes over a ten-year term. The
1996 Notes require equal annual principal payments of approximately $4,286 that commenced on
September 27, 2000. Interest on the 1996 Notes is payable semiannually on March 27 and September 27
of each year. On August 15, 1995, the Company completed a $50,000 private placement of 7.21% Senior
Unsecured Notes over a ten-year term. The 1995 Notes required equal annual principal payments of
approximately $7,143 with the final payment made on August 15, 2005. Interest on the 1995 Notes was
payable semiannually on February 15 and August 15 of each year.
On March 3, 2004, the Company amended its unsecured bank credit facility to an aggregate
availability of $200,000 for a new five-year term. On April 27, 2004, the Company’s Canadian
subsidiary entered into an additional $10,000 (Canadian) revolving credit facility in Canada that
expires on March 3, 2009. The total capacity under these bank credit facilities was $208,495 at
October 29, 2005. Borrowings under these facilities are classified as long-term, because no
paydowns of the aggregate facilities are required within the next fiscal year and we have the
ability to keep the balances outstanding over the next 12 months. Interest on the bank credit
facilities is payable at a rate chosen by the Company of either prime or Eurodollar rate plus a
0.5% to 1.125% borrowing margin, and the agreement requires a fee of 0.10% to 0.275% for any unused
portion of the facilities. At October 29, 2005, the Company had fixed LIBOR loans outstanding under
the bank credit facilities of $11,600 at 4.815% in the U.S. for a one-month period (LIBOR loans
totaled $125,000 at 2.59% in the U.S. on October 30, 2004). The remaining bank credit facility
borrowings of $12,600 at October 29, 2005 were at the prime rate of 6.75%. The Company had a
$125,000 interest rate
NOTES
TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
swap agreement that expired November 10, 2004 under which it paid interest at 6.06% and received
interest at LIBOR plus the borrowing margin. The swap was designated as a cash flow hedge of the
LIBOR borrowings under the bank credit facilities.
On February 16, 2005, the Company entered into a 20 million Euro term loan that matures on
February 16, 2010. Interest on the term loan is payable monthly at a floating rate chosen by the
Company equal to either the one-month, three-month, or six-month EURIBO rate plus a 1% borrowing
margin. At October 29, 2005, the 20 million Euro term loan was outstanding at a rate of 3.13%.
On July 29, 2005, Spartech Corporation was granted a waiver under its revolving credit
facility to ensure compliance with a Fixed Charge Coverage Ratio. This ratio is calculated using
financial information from the four most recent trailing fiscal quarters and is required to exceed
1.40:1. The waiver only applied to the third quarter ended July 30, 2005 and automatically
terminated if the Fixed Charge Coverage Ratio was less than 1.25:1. The Fixed Charge Coverage Ratio
is required to be 1.50:1 effective on October 29, 2005 and thereafter. The primary reason for the
third quarter waiver was the negative impact on the numerator of the ratio of the $750 one-time
cash expenses to terminate the lease of the Company airplane and the $2,711 cash retirement payment
to the former CEO, both of which were incurred in the third quarter of fiscal 2005. In addition,
the denominator of the ratio included $32,857 of required principal payments paid during the fourth
quarter of 2004 which decreased to $17,857 in the fourth quarter of 2005. This benefited the fourth
quarter of fiscal 2005 Fixed Charge Coverage Ratio calculation which was 1.74:1.
The Company’s other debt consists of industrial revenue bonds utilized to finance capital
expenditures. These financings mature between 2007 and 2015 and have interest rates ranging from
2.0% to 3.75%. Scheduled maturities of long-term debt for the next five fiscal years and
thereafter are:
Fiscal Year Ended
Maturities
2006
$
11,175
2007
6,616
2008
155
2009
24,366
2010
24,285
Thereafter
158,719
$
225,316
The long-term debt contains certain covenants which, among other matters, require the Company
to restrict the incurrence of additional indebtedness, satisfy certain ratios and net worth levels,
and limit both the sale of assets and merger transactions.
NOTES
TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
11)
Shareholders’ Equity and Equity Compensation
The authorized capital stock of the Company consists of 55 million shares of $.75 par value
common stock and 4 million shares of $1 par value preferred stock. On March 10, 2004 shareholders
approved an increase to the authorized number of shares of common stock from 45 million shares to
55 million shares. The additional authorized shares will be used to provide flexibility (i) for the
issuance of stock options and other stock-based compensation and incentive awards and (ii) raising
additional capital, acquisitions, stock dividends, or other corporate purposes.
On February 3, 2004, the Company completed a common stock offering for 2.7 million newly
issued shares. The stock was sold to the public at $24.00 per share. The net proceeds received by
the Company for the sales of the shares totaled $60,922 with $40,922 used to pay down debt and the
remaining funds used to fund capital expenditures and strategic expansions. After the offering, the
Company’s common issued shares increased by 8.8% to 33 million.
At October 29, 2005, 1.1 million shares of common stock were held in treasury shares,
primarily for issuance under the Company’s stock-based compensation plans. During 2005, 0.4
million treasury shares were acquired and 0.3 million shares were issued.
The Company has a Shareholder Rights Plan in which rights trade with, and are inseparable
from, each share of common stock. Prior to exercise, a Right does not give its holder any
dividend, voting, or liquidation rights. Under certain circumstances, a Right may be exercised to
purchase one one-thousandth of a share of Series Z Preferred Stock for $70 per share. The Rights
become exercisable, subject to certain exceptions, if a new person or group acquires beneficial
ownership of 15% or more, to purchase shares of the Company’s common stock with a market value of
$140.00, for $70.00 per Right. The Rights will expire on April 2, 2011 and may be redeemed by the
Company for $.01 per Right at any time before a new person or group becomes a beneficial owner of
15% or more of the Company’s outstanding common stock.
The Company has an Equity Compensation Plan for executive officers, key employees, and
directors which permits the granting of stock options, restricted stock units and restricted stock.
Awards may be granted under the plan for up to 3 million shares of common stock. For stock
options, the minimum exercise price is the fair market value per share at the date of grant.
Options have typically been granted with lives ranging from 5-10 years with vesting over the
minimum period of four years. Restricted stock units, which have been awarded only to directors of
the Company, provide the grantee the right to receive one share of common stock at the end of the
restricted period, and to receive dividend equivalents during the restricted period in the form of
additional restricted stock units. Subject to the limitations set forth above and in the Plan, the
number of awards granted pursuant to these plans and the terms of the awards are at the discretion
of the Compensation Committee of the Board of Directors. There have been no restricted stock
grants through the end of fiscal 2005.
A summary of the combined activity for the Company’s stock options for fiscal years 2005,
2004, and 2003 follows (shares in thousands):
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
Information with respect to options outstanding at October 29, 2005 follows (shares in
thousands):
Weighted
Weighted
Average
Remaining
Average
Outstanding
Exercise
Contractual
Exercisable
Exercise
Range of Exercise Prices
Shares
Price
Life
Shares
Price
$10.88 - 17.01
491
$
14.10
5.1 years
391
$
13.35
$18.00 - 21.00
324
18.20
6.3 years
193
18.27
$21.10 - 21.90
535
21.47
6.6 years
292
21.27
$21.94 - 28.94
827
26.45
6.7 years
437
26.98
2,177
1,313
At the end of fiscal 2005, there were 16,016 restricted stock units outstanding, all to
non-employee directors. Each unit is distributable as one share of common stock one year after the
service of the non-employee directors ends and accrues dividends declared on common stock as
additional restricted stock units also to be distributed one year after the service period ends.
The Company issued 8,071 and 7,596 restricted stock units to non-employee directors and accrued 282
and 67 additional units as dividends in fiscal 2005 and 2004, respectively.
12) Income Taxes
Earnings from continuing operations before income taxes consist of the following:
2005
2004
2003
United States
$
21,968
$
61,369
$
49,559
Non-U.S. operations
905
5,996
3,762
$
22,873
$
67,365
$
53,321
The provision for income taxes for fiscal years 2005, 2004, and 2003 is comprised of the
following:
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
The income tax provision on earnings of the Company differs from the amounts computed by
applying the U.S. Federal tax rate of 35% as follows:
2005
2004
2003
Federal income taxes at statutory rate
$
8,006
$
23,578
$
18,662
Impairment of goodwill
1,454
—
—
Foreign valuation allowance
1,133
—
—
State income taxes, net of applicable
Federal income tax benefits
338
1,787
1,609
Research and development tax credit
(524
)
(624
)
(649
)
Other
275
561
(404
)
$
10,682
$
25,302
$
19,218
The increase in tax expense from the impairment of goodwill represents the portion of goodwill
impairments of current businesses plus goodwill written off for disposed business that were not
deductible for tax purposes. State tax expense for fiscal year 2005 was reduced by $412 to reflect
the implementation of state tax planning strategies that reduced the long-term effective tax rate.
At October 29, 2005 and October 30, 2004, the net current deferred tax asset was $5,314 and
$4,429, respectively and the net noncurrent deferred tax liability was $91,605 and $94,825,
respectively.
As of October 29, 2005 no deferred taxes have been provided on the $23,054 in accumulated
earnings of the Company’s foreign subsidiaries that are not subject to United States income tax.
The Company’s intention is to reinvest these earnings indefinitely or to repatriate the earnings
only when it is tax-effective to do so. It is not practicable to determine the amount of income
tax liability that would result if such earnings were remitted to the United States. In October
2004, the American Jobs Creation Act of 2004 was signed into law. The new law creates an incentive
for U.S. multinationals to repatriate accumulated income earned abroad by providing an 85% dividend
received deduction for certain dividends from controlled foreign corporations. The Company
reviewed the implications of the new law on repatriation of earnings and determined that no
repatriation would be made in fiscal year 2005.
As of October 29, 2005, the Company had available approximately $7,626 in net operating loss
carryforwards which related to the France and Mexico operations. The Company assessed the
likelihood as
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
to whether or not these net operating loss carryforwards would be utilized prior to
their expiration based on the amount of positive evidence available. The Company concluded that it
is more likely than not that the $3,420 net operating loss carryforward in Mexico will be utilized
prior to its expiration in 2013 and 2014 based on the amount of taxable temporary differences that
will reverse over the next four years and expected future taxable income. The Company evaluated
its France net operating loss carryforward of $4,206 and determined that a valuation allowance of
$1,133 was required in the current year against $3,361 of net operating losses that cannot be
carried back or utilized through tax planning strategies. This asset would be realized upon
consistent future earnings that are sustained over a period of time. Despite the fact that the
France net operating loss carryforward has an unlimited life and that management believes it will
ultimately be realized, the positive evidence required to overcome recent operating losses was not
sufficient to support recognition as of the end of fiscal year 2005.
13) Earnings Per Share
Basic earnings per share excludes any dilution and is computed by dividing net income
available to common stockholders by the weighted average number of common shares outstanding for
the period. Diluted earnings per share reflects the potential dilution that could occur if
securities or other contracts to issue common stock were exercised or converted into common stock
or resulted in the issuance of common stock that then shared in the earnings of the entity.
The reconciliation of the net earnings and weighted average number of common shares used in
the computations of basic and diluted earnings per share for fiscal years 2005, 2004, and 2003 was
as follows
(shares in thousands):
2005
2004
2003
Earnings
Shares
Earnings
Shares
Earnings
Shares
Basic Earnings Per Share
Computation
$
12,191
32,074
$
42,063
31,426
$
34,103
29,268
Effect of stock options
—
237
—
406
—
299
Effect of convertible
subordinated debentures
—
—
2,010
1,636
—
—
Diluted Earnings Per Share
Computation
$
12,191
32,311
$
44,073
33,468
$
34,103
29,567
The effect of stock options represents the shares resulting from the assumed exercise of
outstanding stock options calculated using the treasury stock method. The effect of convertible
subordinated debentures represents the shares resulting from the assumed conversion using the “if
converted” method and the add-back of the interest expense, after tax, for the assumed conversion
at the beginning of each year. In 2004, a portion of these debentures were antidilutive, and the
diluted earnings per share calculation excluded 2,941,176 potentially dilutive shares and the
benefit of an interest expense add-back of $4,368, net of tax. In 2005 and 2003, the calculation
of diluted earnings per share excluded 4,577,838 potentially dilutive
subordinated debentures shares and the benefit of an
interest expense add-back of approximately $5,500, net of tax in 2005, and $6,500, net of tax, in
2003.
14) Employee Benefits
The Company sponsors or contributes to various defined contribution retirement benefit and
savings plans covering substantially all employees. The total cost of such plans for fiscal years
2005, 2004, and 2003 was $2,726, $2,237, and $2,530, respectively.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
15) Cash Flow and Other Information
Supplemental information on cash flows for fiscal years 2005, 2004, and 2003 was as follows:
2005
2004
2003
Cash paid during the year for:
Interest
$
26,328
$
25,524
$
26,690
Income taxes
8,182
20,647
8,896
Schedule of business and outsourcing acquisitions:
Fair value of assets acquired
$
—
$
107,712
$
37,937
Liabilities assumed
—
(10,146
)
(10,348
)
Purchase
price adjustments/(holdback payments)
1,224
(1,473
)
—
Total cash paid
$
1,224
$
96,093
$
27,589
16) Commitments and Contingencies
The Company conducts certain of its operations in facilities under operating leases. Rental
expense for fiscal years 2005, 2004, and 2003, was $12,207, $10,530, and $10,657, respectively.
Future minimum lease payments under non-cancelable operating leases, by fiscal year, are as
follows:
Operating
Fiscal Year ended
Leases
2006
$
7,177
2007
4,909
2008
3,882
2009
2,871
2010
1,364
Thereafter
4,186
$
24,389
In September 2003, the New Jersey Department of Environmental Protection issued a directive
and the United States Environmental Protection Agency (“USEPA”) initiated an investigation related
to over 70 companies, including a Spartech subsidiary, regarding the Lower Passaic River. The
subsidiary subsequently agreed to participate in a group of over 40 companies in funding $10,000 of
an estimated $20,000 environmental study by the USEPA to determine the extent and source of
contamination at this site and as of the end of fiscal 2005, it had paid its total commitment of
$250 towards this study. As of the end of fiscal 2005, the Company had $130 accrued related to
this issue representing approximately one year of legal fees. Subsequent to fiscal 2005 year end,
the group’s technical consultant advised the group of its belief that completion of the
environmental study would significantly exceed the USEPA’s original cost estimate. The Company has
not recorded an accrual related to future funding of the environmental study cost over-run or other
costs that may result from resolution of this issue due to several uncertainties involved with the
outcome of this issue including (i) whether or not the subsidiary will agree to continue
voluntarily participating with the other members of the group in further funding of the
environmental study, any future studies, or any remediation activities, (ii) the number of other
parties that may be identified as participants in the future and the uncertainty of the level of
participation by each of the parties ultimately named, (iii) management’s belief that the
subsidiary’s contribution in polluting the Lower Passaic River is negligible compared to many other
companies either already named or likely to be named as potentially responsible parties, (iv) the
fact that many of the other companies named in the directive and investigation are significantly
larger than the subsidiary in terms of market capitalization, and (v) the timing or amount of the
eventual determinations of the damage to the river, the remedial steps required, the responsible parties, and any resulting remediation costs or assessments for
which the subsidiary may be liable. Management believes that it is possible that the ultimate
liability resulting from this issue could materially differ from the October 29, 2005 accrual
balance. In the event of one or more adverse determinations related to this issue, the impact on
the Company’s results of operations could be material to any specific period. However, it is
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
management’s opinion that future expenditures for compliance with these laws and regulations, as
they relate to the Lower Passaic River issue and other potential issues, will not have a material
effect on the Company’s capital expenditures, financial position, or competitive position.
The Company is also subject to various other claims, lawsuits, and administrative proceedings
arising in the ordinary course of business with respect to commercial, product liability,
employment, and other matters, several of which claim substantial amounts of damages. While it is
not possible to estimate with certainty the ultimate legal and financial liability with respect to
these claims, lawsuits, and administrative proceedings, the Company believes that the outcome of
these other matters will not have a material adverse effect on the Company’s financial position or
results of operations.
The Company has guaranteed approximately 5.7 million Euros associated with the local
government’s financing of the Company’s Donchery, France facility expansion. The Company will
enter into a lease for the expanded facility upon finalization of the expansion cost and financing
amount, and the guarantee will decrease over the fifteen-year term of the lease. This guarantee
was recorded as an other long-term asset and other long-term liability in fiscal 2005. The
recorded amounts will be reclassified to property, plant, and equipment and other long-term debt
upon finalization of the capital lease.
17) Segment Information
The Company’s 43 facilities are organized into three reportable segments based on the nature
of the products manufactured. The Company utilizes operating earnings to evaluate business segment
performance and determine the allocation of resources. Segment accounting policies are the same as
policies described in Note 1. A description of the Company’s reportable segments follows:
Custom
Sheet and Rollstock — This segment has 23 manufacturing facilities and is the largest
extruder of plastic sheet, custom rollstock, laminates, and cell cast acrylic sheet in North
America. Its finished products are formed by its customers for use in a wide variety of markets.
Color
and Specialty Compounds — This segment operates 14 plants throughout North America and
Europe. It manufactures custom-designed plastic alloys, compounds, color concentrates, and
calendered film for utilization in numerous applications.
Engineered
Products — This segment has six North American facilities which manufacture a
number of proprietary items. These include injection molded products, complete thermoplastic wheels
and tires, and profile extruded products. The Company’s former Molded & Profile Products segment
was renamed the Engineered Products segment effective in the second quarter of fiscal 2005.
Corporate includes corporate office expenses and portions of information technology and
professional fees that are not allocated to the three segments. Assets included in Corporate
consist primarily of deferred taxes, cash and cash equivalents.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
2005
2004
2003
Assets:
Custom Sheet and Rollstock
$
575,178
$
634,123
$
555,821
Color and Specialty Compounds
399,311
361,708
265,947
Engineered Products
83,781
89,153
84,514
Corporate
16,125
56,948
17,656
$
1,074,395
$
1,141,932
$
923,938
Depreciation and Amortization:
Custom Sheet and Rollstock
$
20,430
$
18,074
$
17,293
Color and Specialty Compounds
14,304
12,414
10,914
Engineered Products
3,471
3,279
3,021
Corporate
2,182
1,289
338
$
40,387
$
35,056
$
31,566
Capital Expenditures:
Custom Sheet and Rollstock
$
15,858
$
20,573
$
10,218
Color and Specialty Compounds
12,353
8,059
6,825
Engineered Products
5,483
3,658
2,565
Corporate
5,571
2,713
2,401
$
39,265
$
35,003
$
22,009
In fiscal 2005, the Spartech PEP reporting unit was moved from the Custom Sheet and Rollstock
segment to the Color and Specialty Compounds segment because management of the operations was
realigned to better leverage the Company’s cost structure and improve coordination of marketing and
selling efforts. All fiscal years have been restated as if this change occurred at the beginning
of the periods presented.
In addition to external sales to customers, intersegment sales were $52,696, $49,769 and
$36,948 for the fiscal years ended 2005, 2004, and 2003, respectively. Most intersegment sales
were generated from the Color and Specialty Compounds segment.
The Company operates in five reportable geographic areas — the United States, Canada, Mexico,
Europe, and Asia and Other. Geographic financial information for fiscal years 2005, 2004, and 2003
was as follows:
Net Sales By Destination
Property, Plant and Equipment, Net
2005
2004
2003
2005
2004
2003
United States
$
1,145,643
$
935,321
$
815,009
$
261,582
$
282,947
$
239,825
Canada
116,197
99,996
79,023
19,780
26,437
26,500
Mexico
70,605
43,167
31,400
13,749
14,465
14,192
Europe
50,026
29,452
19,382
12,275
6,896
3,407
Asia and Other
14,389
13,789
11,346
—
—
—
$
1,396,860
$
1,121,725
$
956,160
$
307,386
$
330,745
$
283,924
18) Comprehensive Income
Comprehensive Income is an entity’s change in equity during the period related to
transactions, events, and circumstances from non-owner sources. In
fiscal 2005, a cumulative currency translation gain was recognized
during the sale of a foreign business and translation adjustments of
$2,371 were recognized from ongoing operations resulting in a
cumulative translation adjustment balance of $477 at October 29, 2005.
In fiscal 2004, accumulated other comprehensive income consisted of foreign currency translation adjustments of $15 and
cash flow hedge adjustments, net of tax of $121.
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS — CONTINUED
(Dollars in thousands, except per share amounts)
19) Quarterly Financial Information
Certain unaudited quarterly financial information for the fiscal years ended October 29, 2005
and October 30, 2004 was as follows:
Quarter Ended
Fiscal
Jan.
Apr.
Jul.
Oct.
Year
2005
Net Sales
$
304,512
$
377,658
$
348,672
$
366,018
$
1,396,860
Gross Profit
28,416
44,612
39,833
39,723
152,584
Operating Earnings (a)
10,283
6,252
13,156
18,377
48,068
Net Earnings (a)
2,818
(80
)
4,289
5,164
12,191
Net Earnings Per Share – Basic
.09
—
.13
.16
.38
– Diluted
.09
—
.13
.16
.38
Dividends declared per common share
.12
.12
.12
.12
.48
2004
Net Sales
$
241,463
$
287,591
$
288,035
$
304,636
$
1,121,725
Gross Profit (b)
33,423
43,712
40,957
36,670
154,762
Operating Earnings
18,799
28,050
24,934
21,018
92,801
Net Earnings
7,706
13,519
11,712
9,126
42,063
Net Earnings Per Share – Basic
.26
.42
.36
.28
1.34
– Diluted
.26
.41
.36
.28
1.32
Dividends declared per common share
.11
.11
.11
.11
.44
Notes to table:
(a)
Operating earnings and net earnings were impacted by restructuring and exit costs, the former
CEO retirement, fixed asset charge, goodwill impairment and the establishment of a tax
valuation allowance for each of the fiscal 2005 quarters as follows:
Quarter Ended
Fiscal
Jan.
Apr.
Jul.
Oct.
2005
Reduction to operating earnings:
Restructuring and exit costs
$
—
$
7,619
$
4,639
$
(2,170
)
$
10,088
Former CEO retirement
—
—
3,645
—
3,645
Fixed asset charge
—
10,386
206
72
10,664
Goodwill impairment
—
—
—
4,468
4,468
$
—
$
18,005
$
8,490
$
2,370
$
28,865
Reduction to net earnings:
Restructuring and exit costs
$
—
$
5,085
$
2,862
$
(1,313
)
$
6,634
Former CEO retirement
—
—
2,250
—
2,250
Fixed asset charge
—
6,428
152
44
6,624
Goodwill impairment
—
—
—
3,976
3,976
Tax valuation allowance
—
—
—
1,133
1,133
$
—
$
11,513
$
5,264
$
3,840
$
20,617
(b)
In the fourth quarter of fiscal 2004, gross profit was impacted by approximately $1.8 million
of pre-tax, out-of-period charges to correct account balances identified from the
implementation of information technology systems.
Item 9. CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE
None.
Item 9A. CONTROLS AND PROCEDURES
Spartech maintains a system of disclosure controls and procedures which are designed to ensure
that information required to be disclosed by the Company in the reports filed under the Securities
Exchange Act of 1934 is recorded, processed, summarized and reported within the time periods
specified under the SEC’s rules and forms. Based on an evaluation performed, the Company’s
certifying officers have concluded that the disclosure controls and procedures were effective as of
October 29, 2005, to provide reasonable assurance of the achievement of these objectives.
Notwithstanding the foregoing, there can be no assurance that the Company’s disclosure
controls and procedures will detect or uncover all failures of persons within the Company and its
consolidated subsidiaries to report material information otherwise required to be set forth in the
Company’s reports.
There was no change in the Company’s internal control over financial reporting during the
quarter ended October 29, 2005, that has materially affected, or is reasonably likely to materially
affect, the Company’s internal control over financial reporting, other than the remediation of the
control weakness related to property, plant and equipment noted below.
As part of our Sarbanes-Oxley process, we initiated a complete physical count of our property,
plant and equipment in the first quarter of fiscal 2005. We reconciled the counts to balances
recorded in our books and records and identified $8,794 of equipment that no longer existed, which
was subsequently written-off. We believed the $8,794 in non-existing equipment related primarily to
transactions for plant shut-downs and transfers of equipment between plants.
In the third quarter of fiscal 2005, we implemented new policies and procedures to track
equipment disposals and transfers of equipment between plants. These policies include periodic
physical counts of our equipment at each location. Management performed testing during the fourth
quarter of fiscal 2005 to ensure compliance with the new policies and procedures and that the
controls were operating as intended. The results of this analysis confirmed the material weakness
previously reported in the second quarter of fiscal 2005 had been adequately remediated by October29, 2005.
Management’s report on internal control over financial reporting, and the related report
of the Company’s independent registered public accounting firm, Ernst & Young LLP, are included in Item 8 of
this Form 10-K.
Item 10. DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT
The information concerning Directors of the Company contained in the section entitled
“Proposal 1: Election of Directors” of the Definitive Proxy Statement for the 2006 Annual Meeting
of Shareholders, to be filed with the Commission on or about January 27, 2006, is incorporated
herein by reference in response to this item.
The information concerning Equity Compensation Plans is contained in the section entitled
“Equity Plan Compensation Information” of the Definitive Proxy Statement for the 2006 Annual
Meeting of Shareholders, to be filed with the Commission on or about January 27, 2006, and is
incorporated herein by reference in response to this item.
The information regarding the audit committee and audit committee financial expert is
contained in the section entitled “Board of Directors and Committees” of the Definitive Proxy
Statement for the 2006 Annual Meeting of Shareholders, to be filed with the Commission on or about
January 27, 2006, and is incorporated herein by reference in response to this item.
The Board of Directors has established specific Corporate Governance Guidelines, a Code of
Ethics for the CEO and Senior Financial Officers, and a Code of Business Conduct and Ethics for all
directors, officers and employees. These documents are provided on the Company’s Web site at
www.spartech.com within the Investor Relations/Corporate Governance section of the site. At this
same Web site location, the Company provides an Ethics Hotline phone number that allows employees,
shareholders, and other interested parties to communicate with the Company’s management or Audit
Committee (on an anonymous basis, if so desired) through an independent third-party hotline. In
addition, this same Web site location provides instructions for shareholders or other interested
parties to contact the Company’s Board of Directors.
The rules of the New York Stock Exchange (NYSE) require Mr. Abd, our Chief Executive Officer,
to certify to the NYSE annually that he is not aware of any violation by the Company of the NYSE’s
corporate governance listing standards. In addition, pursuant to Section 302 of the Sarbanes-Oxley
Act of 2002, Mr. Abd and Mr. Martin, our Chief Financial Officer, must each execute a certificate
as to the quality of our public disclosure as part of our quarterly reports to the Securities and
Exchange Commission (“SEC”). Their latest Section 302 certifications are filed with the SEC as
exhibits to this Form 10-K.
The following table provides certain information about the Company’s executive officers, their
positions with the Company, and their prior business experience and employment for at least the
past five years:
Name
Age
Current Office, and Prior Positions and Employment
Chief Executive Officer and President (since May
2005), Executive Vice President, Color and
Specialty Compounds (September 2000 to May 2005)
and Engineered Products (May 2004 to May 2005);
Vice President of Compounding for the Company’s
Spartech Polycom Division from March 1998 to
September 2000. Mr. Abd held various positions
with Polycom Huntsman, Inc. for eleven years
prior to its acquisition by the Company in March
1998. Mr. Abd is also a member of the board of
directors of the Company.
Executive Vice President (since September 2000)
Corporate Development (since May 2004) and Chief
Financial Officer (since May 1996); Corporate
Controller from September 1995 to May 1996; Vice
President, Finance from May 1996 to September
2000. Mr. Martin, a CPA and CMA, was with KPMG
Peat Marwick LLP for eleven years before joining
the Company in 1995. Mr. Martin is also a member
of the board of directors of the Company.
Current Office, and Prior Positions and Employment
Steven J. Ploeger
44
Executive Vice President Custom Sheet and
Rollstock and Engineered Products (since May
2004); Vice President Spartech Plastics from 2000
to 2004; General Manager Spartech Plastics –
North Region from 1996 to 2000. Mr. Ploeger also
held various sales management positions with the
Company from 1985 to 1996.
Jeffrey D. Fisher
57
Senior Vice President and General Counsel (since
July 1999); and Secretary (since September 2000).
Mr. Fisher, an attorney, was with the law firm
of Armstrong Teasdale LLP for 24 years, the last
17 years as a partner, before joining the Company
in July 1999.
Darrel W. Betz
42
Senior Vice President of Global Human Resources
(since April 2005). Mr. Betz was with Emerson
Electric for 16 years in various human resource
positions prior to joining the Company in April
2005.
Michael G. Marcely
38
Vice President (since December 2004) and
Corporate Controller (since July 2004), Director
of Internal Audit (January 2003 to July 2004).
Mr. Marcely, a CPA, was with Ernst & Young LLP
for four years, Emerson Electric for four years
and KPMG LLP for six years before joining the
Company in 2003.
Phillip M. Karig
49
Vice President-Purchasing and Supply Chain
Management (since September 2001), Director of
Purchasing from February 2000 to September 2001.
Mr. Karig was with Uniroyal Technology
Corporation for 12 years in various purchasing,
logistics, and materials management positions
before joining the Company in February 2000.
Item 11. EXECUTIVE COMPENSATION
The information contained in the sections entitled “Executive Compensation” and “Compensation
of Directors” of the Definitive Proxy Statement for the 2006 Annual Meeting of Shareholders, to be
filed with the Commission on or about January 27, 2006, is incorporated herein by reference in
response to this item.
Item 12. SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT
The information contained in the section entitled “Security Ownership” of the Definitive Proxy
Statement for the 2006 Annual Meeting of Shareholders, to be filed with the Commission on or about
January 27, 2006, is incorporated herein by reference in response to this item.
Item 13. CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS
The information contained in the sections entitled “Proposal 1: Election of Directors,”“Executive Compensation” and “Certain Business Relationships and Transactions” of the Definitive
Proxy Statement for the 2006 Annual Meeting of Shareholders, to be filed with the Commission on or
about January 27, 2006, is incorporated herein by reference in response to this item.
Item 14. PRINCIPAL ACCOUNTING FEES AND SERVICES
The information contained in the section entitled “Fees Paid to Auditors” of the Definitive
Proxy Statement for the 2006 Annual Meeting of Shareholders, to be filed with the Commission on or
about January 27, 2006, is incorporated herein by reference in response to this item.
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.
Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been
signed below by the following persons on behalf of the Registrant and in the capacities and on the
dates indicated.
SPARTECH CORPORATION AND SUBSIDIARIES
SCHEDULE II — VALUATION AND QUALIFYING ACCOUNTS
FOR FISCAL YEARS ENDED 2005, 2004, AND 2003.
(Dollars in thousands)
Fiscal year 2003 and 2004 additions and write-offs include activity relating to the acquisition of
certain of the businesses and assets of Polymer Extruded Products in April 2003 and the three
divisions of VPI in October 2004.
F-1
Dates Referenced Herein and Documents Incorporated by Reference