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Business Segments | 12 Months Ended
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Jan. 02, 2016
Segment Reporting [Abstract] |
BUSINESS SEGMENTS | BUSINESS SEGMENTS Effective December 29, 2013, the Company's business operations were reorganized into three industry segments: Feed Ingredients, Food Ingredients and Fuel Ingredients, in order to better align its business with the underlying markets and customers that the Company serves. All historical periods have been recast for the changes to the segment reporting structure. The Company sells its products domestically and internationally. The measure of segment profit (loss) includes all revenues, operating expenses (excluding certain amortization of intangibles), and selling, general and administrative expenses incurred at all operating locations and excludes general corporate expenses. Included in corporate activities are general corporate expenses and the amortization of intangibles. Assets of corporate activities include cash, unallocated prepaid expenses, deferred tax assets, prepaid pension, and miscellaneous other assets. Feed Ingredients Feed Ingredients consists principally of (i) the Company's U.S. ingredients business, including the Company's used cooking oil, trap grease and food residuals collection businesses, the Rothsay ingredients business, and the ingredients and specialty products businesses conducted by Darling Ingredients International under the Sonac name (proteins, fats, technical fats and blood plasma products) and (ii) the Company's bakery residuals business. Feed Ingredients operations process animal by-products and used cooking oil into fats, protein and hides. Food Ingredients Food Ingredients consists principally of (i) the gelatin and hydrolyzed collagen business conducted by Darling Ingredients International under the Rousselot name, (ii) the natural casings and meat-by-products business conducted by Darling Ingredients International under the CTH name and (iii) certain specialty products businesses conducted by Darling Ingredients International under the Sonac name. Fuel Ingredients The Company's Fuel Ingredients segment consists of (i) the Company's biofuel business conducted under the Dar Pro® and Rothsay names (ii) the bioenergy business conducted by Darling Ingredients International under the Ecoson and Rendac names and (iii) the Company's investment in the DGD Joint Venture. Business Segments (in thousands):
| Feed Ingredients | Food Ingredients | Fuel Ingredients | Corporate | Total
Fiscal Year Ended January 2, 2016 |  |  |  |  |
Net Sales | $ | 2,074,333 |  | $ | 1,094,918 |  | $ | 228,195 |  | $ | — |  | $ | 3,397,446 |
Cost of sales and operating expenses | 1,613,402 |  | 863,562 |  | 177,061 |  | — |  | 2,654,025 |
Gross Margin | 460,931 |  | 231,356 |  | 51,134 |  | — |  | 743,421 |
Selling, general and administrative expense | 178,624 |  | 103,301 |  | 7,264 |  | 33,385 |  | 322,574 |
Acquisition costs | — |  | — |  | — |  | 8,299 |  | 8,299 |
Depreciation and amortization | 165,854 |  | 66,817 |  | 26,711 |  | 10,522 |  | 269,904 |
Segment operating income/(loss) | 116,453 |  | 61,238 |  | 17,159 |  | (52,206 | ) | 142,644 |
Equity in net income of unconsolidated subsidiaries | 1,521 |  | — |  | 71,895 |  | — |  | 73,416 |
Segment income | 117,974 |  | 61,238 |  | 89,054 |  | (52,206 | ) | 216,060 |
Total other expense |  |  |  |  | (117,280 | )
Income before income taxes |  |  |  |  | $ | 98,780 |
Segment assets at January 2, 2016 | $ | 2,439,444 |  | $ | 1,448,014 |  | $ | 631,968 |  | $ | 270,176 |  | $ | 4,789,602 |
| Feed Ingredients | Food Ingredients | Fuel Ingredients | Corporate | Total
Fiscal Year Ended January 3, 2015 |  |  |  |  |
Net Sales | $ | 2,421,462 |  | $ | 1,248,352 |  | $ | 286,629 |  | $ | — |  | $ | 3,956,443 |
Cost of sales and operating expenses | 1,864,835 |  | 1,029,488 |  | 228,848 |  | — |  | 3,123,171 |
Gross Margin | 556,627 |  | 218,864 |  | 57,781 |  | — |  | 833,272 |
Selling, general and administrative expense | 205,484 |  | 118,716 |  | 8,596 |  | 41,784 |  | 374,580 |
Acquisition costs | — |  | — |  | — |  | 24,667 |  | 24,667 |
Depreciation and amortization | 158,871 |  | 73,274 |  | 27,898 |  | 9,474 |  | 269,517 |
Segment operating income/(loss) | 192,272 |  | 26,874 |  | 21,287 |  | (75,925 | ) | 164,508 |
Equity in net income of unconsolidated subsidiaries | 1,842 |  | — |  | 63,767 |  | — |  | 65,609 |
Segment income | 194,114 |  | 26,874 |  | 85,054 |  | (75,925 | ) | 230,117 |
Total other expense |  |  |  |  | (148,665 | )
Income before income taxes |  |  |  |  | $ | 81,452 |
Segment assets at January 3, 2015 | $ | 2,667,601 |  | $ | 1,730,794 |  | $ | 693,921 |  | $ | 34,231 |  | $ | 5,126,547 |
| Feed Ingredients | Food Ingredients | Fuel Ingredients | Corporate | Total
Fiscal Year Ended December 28, 2013 |  |  |  |  |
Net Sales | $ | 1,788,563 |  | $ | — |  | $ | 13,705 |  | $ | — |  | $ | 1,802,268 |
Cost of sales and operating expenses | 1,329,057 |  | — |  | 10,762 |  | — |  | 1,339,819 |
Gross Margin | 459,506 |  | — |  | 2,943 |  | — |  | 462,449 |
Selling, general and administrative expense | 149,160 |  | — |  | 928 |  | 20,737 |  | 170,825 |
Acquisition costs | — |  | — |  | — |  | 23,271 |  | 23,271 |
Depreciation and amortization | 93,120 |  | — |  | 368 |  | 5,299 |  | 98,787 |
Segment operating income/(loss) | 217,226 |  | — |  | 1,647 |  | (49,307 | ) | 169,566 |
Equity in net income of unconsolidated subsidiaries | — |  | — |  | 7,660 |  | — |  | 7,660 |
Segment income | 217,226 |  | — |  | 9,307 |  | (49,307 | ) | 177,226 |
Total other expense |  |  |  |  | (13,548 | )
Income before income taxes |  |  |  |  | $ | 163,678 |
Business Segment Property, Plant and Equipment (in thousands):
| January 2, 2016 |  | January 3, 2015 |  | December 28, 2013
Depreciation and amortization: |  |  |  |  |
Feed Ingredients | $ | 165,854 |  |  | $ | 158,871 |  |  | $ | 93,120 |
Food Ingredients | 66,817 |  |  | 73,274 |  |  | — |
Fuel Ingredients | 26,711 |  |  | 27,898 |  |  | 368 |
Corporate Activities | 10,522 |  |  | 9,474 |  |  | 5,299 |
Total | $ | 269,904 |  |  | $ | 269,517 |  |  | $ | 98,787 |
Capital expenditures: |  |  |  |  |
Feed Ingredients | $ | 153,894 |  |  | $ | 135,923 |  |  | $ | 84,616 |
Food Ingredients | 49,066 |  |  | 61,657 |  |  | — |
Fuel Ingredients | 19,478 |  |  | 21,392 |  |  | 162 |
Corporate Activities | 7,410 |  |  | 9,946 |  |  | 33,529 |
Total (a) | $ | 229,848 |  |  | $ | 228,918 |  |  | $ | 118,307 |
(a) | Excludes the capital assets acquired in an immaterial acquisition in fiscal 2015, the VION Acquisition and Custom Blenders acquisition in fiscal 2014 of approximately $984.2 million, the Terra Transaction and the Rothsay Acquisition in fiscal 2013 of approximately $167.0 million.
Geographic Area Net Trade Revenues (in thousands):
| January 2, 2016 |  | January 3, 2015 |  | December 28, 2013
North America | $ | 1,951,421 |  |  | $ | 2,131,978 |  |  | $ | 1,802,268 |
Europe | 1,066,779 |  |  | 1,438,320 |  |  | — |
China | 234,978 |  |  | 229,876 |  |  | — |
South America | 68,226 |  |  | 73,241 |  |  | — |
Other | 76,042 |  |  | 83,028 |  |  | — |
Total | $ | 3,397,446 |  |  | $ | 3,956,443 |  |  | $ | 1,802,268 |
The Company attributes revenues from external customers to individual foreign countries based on the origin of the Company's shipments. Prior to fiscal 2014, the Company did not have operations outside of North America. During fiscal 2014, the Company acquired operations in Europe, China, South America and other countries of the world. Long-lived assets related to the Company's operations in North America, Europe, China, South American and other were as follows (in thousands):
| FY 2015 | FY 2014
| Long-Lived Assets | Long-Lived Assets
North America | $ | 2,394,197 |  | $ | 2,422,050 |
Europe | 1,226,046 |  | 1,408,237 |
China | 169,832 |  | 186,994 |
South America | 60,396 |  | 93,264 |
Other | 7,343 |  | 7,390 |
Total | $ | 3,857,814 |  | $ | 4,117,935 |

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- Definition The entire disclosure for reporting segments including data and tables. Reportable segments include those that meet any of the following quantitative thresholds a) it's reported revenue, including sales to external customers and intersegment sales or transfers is 10 percent or more of the combined revenue, internal and external, of all operating segments b) the absolute amount of its reported profit or loss is 10 percent or more of the greater, in absolute amount of 1) the combined reported profit of all operating segments that did not report a loss or 2) the combined reported loss of all operating segments that did report a loss c) its assets are 10 percent or more of the combined assets of all operating segments. + References Reference 1: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 34 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8981-108599 Reference 2: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 41 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e9038-108599 Reference 3: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 33 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8971-108599 Reference 4: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 12 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8595-108599 Reference 5: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 1 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8380-108599 Reference 6: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 32 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8933-108599 Reference 7: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 26 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8844-108599 Reference 8: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 35 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8984-108599 Reference 9: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 40 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e9031-108599 Reference 10: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 42 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e9054-108599 Reference 11: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 10 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8538-108599 Reference 12: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 29 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8864-108599 Reference 13: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 31 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8924-108599 Reference 14: http://www.xbrl.org/2003/role/presentationRef -Publisher FASB -Name Accounting Standards Codification -Topic 280 -SubTopic 10 -Section 50 -Paragraph 30 -URI http://asc.fasb.org/extlink&oid=51669610&loc=d3e8906-108599 + Details
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