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Consolidated Statements of Operations and Comprehensive Loss (USD $)
In Thousands, except Per Share data, unless otherwise specified
 12 Months Ended
Dec. 31, 2011
Jan. 01, 2011
Jan. 02, 2010
Consolidated Statements of Operations and Comprehensive Loss [Abstract]      
Net sales $ 1,755,431 $ 1,804,418 $ 1,646,108
Cost of sales 1,545,282 1,593,745 1,452,947
Gross profit 210,149 210,673 193,161
Operating expenses:      
Selling, general, and administrative 207,857 221,185 210,214
Net gain from terminating the Georgia-Pacific supply agreement     (17,772)
Depreciation and amortization 10,562 13,365 16,984
Total operating expenses 218,419 234,550 209,426
Operating loss (8,270) (23,877) (16,265)
Non-operating expenses (income):      
Interest expense 30,510 33,788 32,456
Changes associated with the ineffective interest rate swap (1,676) (4,603) 6,252
Write-off of debt issue costs   183 1,407
Other expense, net 501 587 519
Loss before provision for (benefit from) income taxes (37,605) (53,832) (56,899)
Provision for (benefit from) income taxes 962 (589) 4,564
Net loss (38,567) (53,243) (61,463)
Basic and diluted weighted average number of common shares outstanding 43,187 30,688 31,017
Basic and diluted net loss per share applicable to common shares outstanding $ (0.89) $ (1.73) $ (1.98)
Comprehensive loss:      
Net loss (38,567) (53,243) (61,463)
Other comprehensive loss:      
Foreign currency translation, net of taxes (92) 336 1,173
Unrealized (loss) gain from pension plan, net of taxes (14,969) (616) 941
Unrealized gain from ineffective interest rate swap, net of taxes 519 1,297 6,431
Comprehensive loss $ (53,109) $ (52,226) $ (52,918)