Table of Contents

UNITED STATES

SECURITIES AND EXCHANGE COMMISSION

WASHINGTON, D.C. 20549

 


 

FORM 10-Q

 


 

(Mark One)

x QUARTERLY REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934

 

For the quarterly period ended September 30, 2005

 

¨ TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES EXCHANGE ACT OF 1934 [NO FEE REQUIRED]

 

For the transition period from              to             

 

Commission File Number 0-20646

 


 

Caraustar Industries, Inc.

(Exact name of registrant as specified in its charter)

 


 

North Carolina   58-1388387

(State or other jurisdiction of

incorporation or organization)

 

(I.R.S. Employer

Identification Number)

 

5000 Austell Powder Springs Road, Suite 300,

Austell, Georgia

  30106
(Address of principal executive offices)   (Zip Code)

 

(770) 948-3101

(Registrant’s telephone number, including area code)

 


 

Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days.    Yes  x    No  ¨

 

Indicate by check mark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Exchange Act).    Yes  x    No  ¨

 

Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act).    Yes  ¨    No  x

 

Indicate the number of shares outstanding of each of issuer’s classes of common stock, as of the latest practicable date, October 31, 2005.

 

Common Stock, $.10 par value   28,789,494
(Class)   (Outstanding)

 



Table of Contents

FORM 10-Q FOR THE QUARTER ENDED SEPTEMBER 30, 2005

 

CARAUSTAR INDUSTRIES, INC.

 

TABLE OF CONTENTS

 

         Page

PART I — FINANCIAL INFORMATION     
Item 1.   Condensed Consolidated Financial Statements (unaudited):     
    Condensed Consolidated Balance Sheets as of September 30, 2005 and December 31, 2004    3
    Condensed Consolidated Statements of Operations for the three-month and nine-month periods ended September 30, 2005 and 2004    4
    Condensed Consolidated Statements of Cash Flows for the nine-month periods ended September 30, 2005 and 2004    5
    Notes to Condensed Consolidated Financial Statements    6
Item 2.   Management’s Discussion and Analysis of Financial Condition and Results of Operations    24
Item 3.   Quantitative and Qualitative Disclosures About Market Risk    40
Item 4.   Controls and Procedures    40
PART II — OTHER INFORMATION     
Item 1.   Legal Proceedings    40
Item 2.   Unregistered Sales of Equity Securities and Use of Proceeds    40
Item 5.   Other Information    40
Item 6.   Exhibits    40
Signatures    41
Exhibit Index    42

 

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ITEM 1. Condensed Consolidated Financial Statements

 

CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

 

CONDENSED CONSOLIDATED BALANCE SHEETS (UNAUDITED)

(In thousands, except share data)

 

     September 30,
2005


    December 31,
2004


 
ASSETS                 

CURRENT ASSETS:

                

Cash and cash equivalents

   $ 90,670     $ 89,756  

Receivables, net of allowances for doubtful accounts, returns, and discounts of $3,937 and $4,418 as of September 30, 2005 and December 31, 2004, respectively

     119,485       102,644  

Inventories

     86,134       89,044  

Refundable income taxes

     399       409  

Current deferred tax asset

     9,060       11,035  

Other current assets

     14,138       11,059  
    


 


Total current assets

     319,886       303,947  
    


 


PROPERTY, PLANT AND EQUIPMENT:

                

Land

     11,802       11,856  

Buildings and improvements

     139,103       138,872  

Machinery and equipment

     629,245       616,791  

Furniture and fixtures

     16,583       15,725  
    


 


       796,733       783,244  

Less accumulated depreciation

     (411,783 )     (395,110 )
    


 


Property, plant and equipment, net

     384,950       388,134  
    


 


GOODWILL

     183,130       183,130  

INVESTMENT IN UNCONSOLIDATED AFFILIATES

     58,246       59,676  

OTHER ASSETS

     22,979       24,818  
    


 


     $ 969,191     $ 959,705  
    


 


LIABILITIES AND SHAREHOLDERS’ EQUITY                 

CURRENT LIABILITIES:

                

Current maturities of debt

   $ 80     $ 80  

Accounts payable

     90,505       84,890  

Accrued interest

     20,113       8,810  

Accrued compensation

     11,042       11,742  

Capital lease obligations

     510       79  

Other accrued liabilities

     33,153       34,880  
    


 


Total current liabilities

     155,403       140,481  
    


 


LONG-TERM DEBT, less current maturities

     502,800       506,141  

LONG-TERM CAPITAL LEASE OBLIGATIONS

     721       —    

DEFERRED INCOME TAXES

     59,411       57,320  

PENSION LIABILITY

     26,898       32,897  

OTHER LIABILITIES

     5,303       5,614  

COMMITMENTS AND CONTINGENCIES (Note 13)

                

SHAREHOLDERS’ EQUITY:

                

Preferred stock, $.10 par value; 5,000,000 shares authorized, no shares issued

     —         —    

Common stock, $.10 par value; 60,000,000 shares authorized, 28,783,384 and 28,753,390 shares issued and outstanding at September 30, 2005 and December 31, 2004, respectively

     2,878       2,875  

Additional paid-in capital

     192,023       191,903  

Unearned compensation

     (3,690 )     (4,334 )

Retained earnings

     49,165       48,552  

Accumulated other comprehensive (loss) income:

                

Minimum pension liability adjustment

     (22,621 )     (22,621 )

Foreign currency translation

     900       877  
    


 


Total accumulated other comprehensive loss

     (21,721 )     (21,744 )
    


 


Total Shareholders’ Equity

     218,655       217,252  
    


 


     $ 969,191     $ 959,705  
    


 


 

The accompanying notes are an integral part of these condensed consolidated financial statements.

 

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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

 

CONDENSED CONSOLIDATED STATEMENTS OF OPERATIONS (UNAUDITED)

(In thousands, except per share data)

 

     For the Three Months Ended
September 30,


    For the Nine Months Ended
September 30,


 
     2005

    2004

    2005

    2004

 

SALES

   $ 267,761     $ 273,789     $ 806,597     $ 799,355  

COST OF SALES

     234,475       232,900       694,156       678,481  
    


 


 


 


Gross Profit

     33,286       40,889       112,441       120,874  

SELLING, GENERAL AND ADMINISTRATIVE EXPENSES

     33,589       33,831       105,453       103,098  

RESTRUCTURING AND IMPAIRMENT

     (566 )     5,121       342       10,654  
    


 


 


 


Income from operations

     263       1,937       6,646       7,122  

OTHER (EXPENSE) INCOME:

                                

Interest expense

     (10,466 )     (10,336 )     (31,568 )     (31,597 )

Interest income

     748       249       1,811       596  

Equity in income of unconsolidated affiliates

     9,615       7,746       27,531       16,810  

Other, net

     35       (81 )     381       (400 )
    


 


 


 


       (68 )     (2,422 )     (1,845 )     (14,591 )
    


 


 


 


INCOME (LOSS) BEFORE INCOME TAXES AND MINORITY INTEREST

     195       (485 )     4,801       (7,469 )

(PROVISION) BENEFIT FOR INCOME TAXES

     (118 )     (79 )     (4,050 )     1,988  

MINORITY INTEREST IN INCOME

     (32 )     (32 )     (138 )     (145 )
    


 


 


 


NET INCOME (LOSS)

   $ 45     $ (596 )   $ 613     $ (5,626 )
    


 


 


 


OTHER COMPREHENSIVE INCOME (LOSS):

                                

Foreign currency translation adjustment

     236       175       23       (126 )
    


 


 


 


COMPREHENSIVE INCOME (LOSS)

   $ 281     $ (421 )   $ 636     $ (5,752 )
    


 


 


 


BASIC

                                

NET INCOME (LOSS) PER COMMON SHARE

   $ 0.00     $ (0.02 )   $ 0.02     $ (0.20 )
    


 


 


 


WEIGHTED AVERAGE NUMBER OF SHARES OUTSTANDING

     28,780       28,506       28,769       28,449  
    


 


 


 


DILUTED

                                

NET INCOME (LOSS) PER COMMON SHARE

   $ 0.00     $ (0.02 )   $ 0.02     $ (0.20 )
    


 


 


 


WEIGHTED AVERAGE NUMBER OF SHARES OUTSTANDING

     28,878       28,506       28,887       28,449  
    


 


 


 


 

The accompanying notes are an integral part of these condensed consolidated financial statements.

 

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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

 

CONDENSED CONSOLIDATED STATEMENTS OF CASH FLOWS (UNAUDITED)

(In thousands)

 

     For the Nine Months Ended
September 30,


 
     2005

    2004

 

OPERATING ACTIVITIES:

                

Net income (loss)

   $ 613     $ (5,626 )

Depreciation and amortization

     21,305       22,558  

Stock-based compensation expense

     640       1,610  

(Gain) loss on repurchase of debt

     (121 )     301  

Restructuring and impairment

     (171 )     2,967  

Deferred income taxes

     3,936       (3,413 )

Equity in income of unconsolidated affiliates

     (27,531 )     (16,810 )

Distributions from unconsolidated affiliates

     24,328       11,500  

Changes in operating assets and liabilities

     (9,810 )     15,795  
    


 


Net cash provided by operating activities

     13,189       28,882  
    


 


INVESTING ACTIVITIES:

                

Purchases of property, plant and equipment

     (17,982 )     (15,644 )

Proceeds from disposal of property, plant and equipment

     2,811       2,041  

Return of investment in unconsolidated affiliate

     4,672       —    

Investment in unconsolidated affiliates

     (40 )     (150 )
    


 


Net cash used in investing activities

     (10,539 )     (13,753 )
    


 


FINANCING ACTIVITIES:

                

Repayments of long-term debt

     (2,413 )     (14,176 )

Payments for capital lease obligations

     (380 )     (139 )

Proceeds from swap agreement unwind

     826       380  

Issuances of stock, net of forfeitures

     231       2,450  
    


 


Net cash used in financing activities

     (1,736 )     (11,485 )
    


 


NET INCREASE IN CASH AND CASH EQUIVALENTS

     914       3,644  

CASH AND CASH EQUIVALENTS AT BEGINNING OF PERIOD

     89,756       85,551  
    


 


CASH AND CASH EQUIVALENTS AT END OF PERIOD

   $ 90,670     $ 89,195  
    


 


SUPPLEMENTAL DISCLOSURES:

                

Cash payments for interest

   $ 23,268     $ 22,441  
    


 


Income tax payments, net of refunds

   $ 370     $ 1,264  
    


 


Property acquired under capital leases

   $ 1,532     $ —    
    


 


 

The accompanying notes are an integral part of these condensed consolidated financial statements.

 

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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

 

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

September 30, 2005

(UNAUDITED)

 

Note 1. Basis of Presentation

 

The financial information included herein is unaudited; however, such information reflects all adjustments (consisting of normal recurring adjustments) which are, in the opinion of management, necessary to present fairly, in all material respects, the financial position of the Company as of September 30, 2005, and the results of operations for the three months and nine months ended September 30, 2005 and 2004 and the cash flows for the nine months ended September 30, 2005 and 2004, respectively. The results of operations for the three months and nine months ended September 30, 2005 and 2004 and the cash flows for the nine months ended September 30, 2005 and 2004 are not, and should not be, construed as necessarily indicative of the results of the operations or cash flows which may be reported for the remainder of 2005.

 

The accompanying unaudited condensed financial statements have been prepared pursuant to the rules and regulations of the Securities and Exchange Commission for reporting on Form 10-Q. Pursuant to such rules and regulations, certain footnote disclosures and other information normally included in financial statements prepared in accordance with principles generally accepted in the United States of America have been condensed or omitted. These unaudited condensed financial statements should be read in conjunction with the Company’s Annual Report on Form 10-K for the fiscal year ended December 31, 2004. The accounting policies followed for interim financial reporting are the same as those disclosed in Note 1 of the notes to the financial statements included in the Company’s Form 10-K.

 

Note 2. New Accounting Pronouncements

 

On April 14, 2005, the Securities and Exchange Commission announced that the required effective date for adopting Statement of Financial Accounting Standards (“SFAS”) No. 123 (R), “Share-Based Payment” has been deferred to fiscal years beginning after June 15, 2005 instead of an effective date beginning July 1, 2005. The Company will be required to adopt this statement January 1, 2006.

 

Note 3. Accounting for Stock-Based Compensation

 

The Company has elected to follow Accounting Principles Board Opinion No. 25, “Accounting for Stock Issued to Employees” and related interpretations (“APB No. 25”) in accounting for its employee stock options. However, pro forma information regarding net income and earnings per share is required by SFAS No. 148, “Accounting For Stock-Based Compensation - Transition and Disclosure” which requires that the information be determined as if the Company has accounted for its employee stock options granted under the fair value method of that statement. The fair values of the options granted during 2004 were estimated as of the grant dates using a Black-Scholes option pricing model with the following weighted average assumptions:

 

Risk-free interest rate

   3.88% — 4.31 %

Expected dividend yield

   0 %

Expected option lives

   8-10 years  

Expected volatility

   40 %

 

The total fair value of the options granted during the year ended December 31, 2004 was computed to be approximately $2.3 million. The Company granted no options during the nine-month period ended September 30, 2005. The Company granted 23,440 options with an approximate value of $183 thousand during the nine-month period ended September 30, 2004. If the Company had accounted for these plans in accordance with SFAS No. 123, “Accounting for Stock-Based Compensation” and included the amortization expense related to options vesting each year, the Company’s reported and pro forma net income (loss) and net income (loss) per share for the three and nine months ended September 30, 2005 and 2004 would have been as follows (in thousands, except per share data):

 

     Three Months Ended
September 30,


    Nine Months Ended
September 30,


 
     2005

    2004

    2005

    2004

 

Net income (loss):

                                

As reported

   $ 45     $ (596 )   $ 613     $ (5,626 )

Incremental stock based compensation expense determined pursuant to SFAS No. 123, net of related tax effects

     (244 )     (159 )     (857 )     (959 )
    


 


 


 


Pro forma net loss

   $ (199 )   $ (755 )   $ (244 )   $ (6,585 )
    


 


 


 


Diluted (loss) income per common share:

                                

As reported

   $ 0.00     $ (0.02 )   $ 0.02     $ (0.20 )

Pro forma

     (0.01 )     (0.03 )     (0.01 )     (0.23 )

 

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Note 4. Inventory

 

Inventories are carried at the lower of cost or market. The costs included in inventory include raw materials (recovered fiber for paperboard products and paperboard for converted products), direct and indirect labor and employee benefits, energy and fuel, depreciation, chemicals, general manufacturing overhead and various other costs of manufacturing. General and administrative costs are not included in inventory costs.

 

Market, with respect to all inventories, is replacement cost or net realizable value. The Company reviews inventory at least quarterly to determine the necessity of write-offs for excess, obsolete or unsaleable inventory. The Company estimates reserves for inventory obsolescence and shrinkage based on management’s judgment of future realization. These reviews require management to assess customer and market demand. All inventories are valued using the first-in, first-out method.

 

Inventories at September 30, 2005 and December 31, 2004, were as follows (in thousands):

 

     September 30,
2005


   December 31,
2004


Raw materials and supplies

   $ 39,783    $ 40,094

Finished goods and work in process

     46,351      48,950
    

  

Total inventory

   $ 86,134    $ 89,044
    

  

 

Note 5. Senior Credit Facility and Long-Term Debt

 

At September 30, 2005 and December 31, 2004, total long-term debt consisted of the following (in thousands):

 

     September 30,
2005


    December 31,
2004


 

9 7/8 % senior subordinated notes

   $ 262,500     $ 265,000  

7 3/8 % senior notes

     189,750       189,750  

7 1/4 % senior notes

     29,000       29,000  

Other notes payable

     9,735       9,735  

Net premiums (1)

     11,895       12,736  
    


 


Total debt

     502,880       506,221  

Less current maturities

     (80 )     (80 )
    


 


Total long-term debt

   $ 502,800     $ 506,141  
    


 



(1) These amounts consist of realized interest rate swap gains less the original issuance discounts and accumulated discount amortization related to the senior and senior subordinated notes. As described below under “Interest Rate Swap Agreements,” realized gains resulting from unwinding interest rate swaps are recorded as a component of debt and will be accreted as a reduction to interest expense over the remaining term of the debt.

 

Senior Credit Facility

 

The Company’s senior credit facility provides for a revolving line of credit of $75.0 million and is secured primarily by a first priority security interest in the Company’s accounts receivable and inventory. The facility includes a subfacility of $50.0 million for letters of credit, usage of which reduces availability under the facility. As of September 30, 2005 and December 31, 2004, no borrowings were outstanding under the facility; however, an aggregate of $38.3 million and $38.4 million in letter of credit obligations were outstanding, respectively. Availability under the facility at September 30, 2005 was $36.7 million after taking into consideration outstanding letter of credit obligations.

 

Effective March 1, 2005 the Company amended its senior credit facility to increase the aggregate amount of permitted asset sales from $5.0 million to $15.0 million, to reduce the unused facility fee from 0.50% to 0.375%, and to reduce the applicable interest margins above the Base Rate and LIBOR Rate for borrowings and outstanding letters of credit under the facility. The interest margin for Base Rate borrowings was reduced from 0.50% to a range from (0.25%) to 0.25%, and the margin for LIBOR

 

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Rate borrowings and outstanding letters of credit was reduced from 2.50% to a range from 1.50% to 2.00%, with the applicable margin to be set based on the Company’s levels of available cash. At September 30, 2005, the applicable interest margin for Base Rate borrowings was (0.25%) and the applicable interest margin for LIBOR Rate borrowings was 1.50%.

 

Effective September 20, 2005, the Company amended its senior credit facility to permit the issuance of a $29.5 million letter of credit in favor of Standard Gypsum, L.P.’s lender, with an expiration date no later than October 29, 2006. This amendment was made in connection with the refinancing of Standard Gypsum’s debt facilities as described under Note 11, “Equity Interests in Unconsolidated Affiliates.”

 

Senior and Senior Subordinated Notes

 

On June 1, 1999, the Company issued $200.0 million in aggregate principal amount of 7 3/8% senior notes due June 1, 2009. The 7 3/8% senior notes were issued at a discount to yield an effective interest rate of 7.47% and pay interest semiannually. After taking into account realized gains from unwinding various interest rate swap agreements, the current effective interest rate of the 7 3/8% senior notes is 6.3%. The 7 3/8% senior notes are unsecured obligations of the Company. During the year ended December 31, 2004, the Company purchased an aggregate of $10.3 million of these notes in the open market.

 

On March 29, 2001, the Company issued $285.0 million of 9 7/8% senior subordinated notes due April 1, 2011 and $29.0 million of 7 1/4% senior notes due May 1, 2010. These senior subordinated notes and senior notes were issued at a discount to yield effective interest rates of 10.5% and 9.4%, respectively. After taking into account realized gains from unwinding various interest rate swap agreements, the current effective interest rate of the 9 7/8% senior subordinated notes is 9.2%. These publicly traded senior subordinated and senior notes are unsecured, but are guaranteed, on a joint and several basis, by all but one of the Company’s wholly-owned domestic subsidiaries. The Company purchased $20.0 million of the 9 7/8% senior subordinated notes during the year ended December 31, 2004. During May 2005, the Company purchased $2.5 million of the 9 7/8% senior subordinated notes in the open market. The Company’s board of directors has authorized purchases of up to an additional $10.0 million of the 9 7/8% senior subordinated notes as market conditions warrant; however, purchases of senior notes or senior subordinated notes may be limited by the terms of the Company’s senior credit facility.

 

See Note 14, “Subsequent Events” regarding the purchase of an additional $5.0 million of the Company’s 9 7/8% senior subordinated notes in the open market.

 

Interest Rate Swap Agreements

 

From time to time, the Company has entered into interest rate swap agreements related to its senior notes and its senior subordinated notes. The payment and expiration date for these interest rate swaps correspond to the terms of the note obligations they cover. These interest rate swap agreements effectively convert an amount of the Company’s fixed debt into variable rate obligations. Typically, the variable amounts are based upon a three-month or six-month LIBOR plus a fixed margin. When the Company has unwound these agreements and recognized a gain, the amount is classified as a component of debt and is accreted to interest expense over the remaining life of the notes. As of September 30, 2005 the Company had no outstanding interest rate swap agreements.

 

In March 2004, the Company unwound a $50.0 million interest rate swap agreement related to the 9 7/8% senior subordinated notes and received approximately $380 thousand from the bank counter party. The $380 thousand gain was classified as a component of debt, and is being accreted over the remaining life of the notes and will partially offset the increase in interest expense.

 

In April 2004, the Company entered into an interest rate swap agreement in the notional amount of $50.0 million. This agreement effectively converted $50.0 million of the Company’s fixed rate 9 7/8 % senior subordinated notes into variable rate obligations. The variable rates were based on six-month LIBOR plus a fixed margin.

 

In March 2005, the Company entered into an interest rate swap agreement in the notional amount of $50.0 million. This agreement, effectively converted $50.0 million of the Company’s fixed rate 7 3/8 % senior notes into variable rate obligations. The variable rates were based on three-month LIBOR plus a fixed margin.

 

In June 2005, the Company unwound the March 2005 $50.0 million interest rate swap agreement related to the 7 3/8% senior notes and received approximately $826 thousand from the bank counter party. The $826 thousand gain was classified as a component of debt, and is being accreted over the remaining life of the notes and will partially offset the increase in interest expense.

 

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Under the provisions of SFAS No. 133 “Accounting for Derivative Instruments and Hedging Activities,” as amended, the Company has designated and accounted for its interest rate swap agreements as fair value hedges. The Company has assumed no ineffectiveness with regard to these agreements as they qualified for the short-cut method of accounting for fair value hedges of debt obligations, as prescribed by SFAS No. 133.

 

Note 6. Segment Information

 

The Company operates principally in four business segments organized by products. The paperboard segment consists of facilities that manufacture 100% recycled uncoated and clay-coated paperboard. The recovered fiber segment consists of facilities that collect and sell recycled paper and broker recycled paper and other paper rolls. The tube, core, and composite container segment is principally made up of facilities that produce spiral and convolute-wound tubes, cores, and composite cans. The carton and custom packaging segment consists of facilities that produce printed and unprinted folding cartons and set-up boxes and facilities that provide contract manufacturing and contract packaging services. Intersegment sales are recorded at prices which approximate market prices.

 

Operating results include all costs and expenses directly related to the segment involved. Corporate expenses include corporate, general, administrative and unallocated information systems expenses.

 

The following table presents certain business segment information for the periods indicated (in thousands):

 

     Three Months Ended
September 30,


    Nine Months Ended
September 30,


 
     2005

    2004

    2005

    2004

 

Sales (external customers):

                                

Paperboard

   $ 69,358     $ 71,944     $ 207,052     $ 215,059  

Recovered fiber

     20,766       23,070       62,359       61,261  

Tube, core, and composite container

     98,600       99,872       299,357       293,234  

Carton and custom packaging

     79,037       78,903       237,829       229,801  
    


 


 


 


Total

   $ 267,761     $ 273,789     $ 806,597     $ 799,355  
    


 


 


 


Sales (intersegment):

                                

Paperboard

   $ 47,562     $ 49,483     $ 147,822     $ 139,879  

Recovered fiber

     23,456       16,650       61,063       44,991  

Tube, core, and composite container

     1,352       1,686       3,978       4,075  

Carton and custom packaging

     215       278       744       814  
    


 


 


 


Total

   $ 72,585     $ 68,097     $ 213,607     $ 189,759  
    


 


 


 


Income (loss) from operations:

                                

Paperboard (A)

   $ 2,186     $ 7,745     $ 14,103     $ 18,439  

Recovered fiber (B)

     (151 )     1,167       616       2,524  

Tube, core, and composite container (C)

     1,816       1,765       5,092       9,591  

Carton and custom packaging (D)

     951       (2,648 )     4,354       (6,711 )
    


 


 


 


       4,802       8,029       24,165       23,843  

Corporate expense (E)

     (4,539 )     (6,092 )     (17,519 )     (16,721 )
    


 


 


 


Income from operations

     263       1,937       6,646       7,122  

Interest expense

     (10,466 )     (10,336 )     (31,568 )     (31,597 )

Interest income

     748       249       1,811       596  

Equity in income of unconsolidated affiliates

     9,615       7,746       27,531       16,810  

Other, net

     35       (81 )     381       (400 )
    


 


 


 


Income (loss) before income taxes and minority interest

   $ 195     $ (485 )   $ 4,801     $ (7,469 )
    


 


 


 



(A) Results for the three-month periods ended September 30, 2005 and 2004 include credits to operations of $1.5 million and charges to operations of $591 thousand, respectively, for restructuring and impairment costs. Results for the nine-month periods ended September 30, 2005 and 2004 include credits to operations of $1.5 million and charges to operations of $2.5 million respectively, for restructuring and impairment costs. These costs relate to closing and consolidating operations within the paperboard segment.
(B)

Results for the three-month periods ended September 30, 2005 and 2004 include charges to operations of $36 thousand and $458 thousand respectively, for restructuring and impairment costs. Results for the nine-month periods ended September 30,

 

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2005 and 2004 include credits to operations of $28 thousand and charges to operations of $488 thousand respectively, for restructuring and impairment costs. These costs relate to closing and consolidating operations within the recovered fiber segment.

(C) Results for the three-month periods ended September 30, 2005 and 2004 include charges to operations of $89 thousand and $520 thousand, respectively, for restructuring and impairment costs. Results for the nine-month periods ended September 30, 2005 and 2004 include charges to operations of $194 and $742 thousand respectively, for restructuring and impairment costs. These costs relate primarily to the disposition of machinery and equipment within the tube, core and composite segment.
(D) Results for the three-month periods ended September 30, 2005 and 2004 include charges to operations of $856 thousand and $3.3 million, respectively, for restructuring and impairment costs. Results for the nine-month periods ended September 30, 2005 and 2004 include charges to operations of $1.7 million and $5.0 million respectively, for restructuring and impairment costs. These costs relate to closing and consolidating operations within the carton and custom packaging segment.
(E) Results for the three-month periods ended September 30, 2005 and 2004 include credits to operations of $2 thousand and charges to operations of $259 thousand, respectively, for centralizing the accounting and finance operations. Results for the nine-month periods ended September 30, 2005 and 2004 include charges to operations of $27 thousand and $1.9 million, respectively for centralizing the accounting and finance operations.

 

Note 7. Goodwill and Other Intangible Assets

 

Goodwill

 

The Company accounts for goodwill and other intangible assets pursuant to SFAS No. 142, “Goodwill and Other Intangible Assets.” Under this pronouncement the Company performs an impairment test at least annually. The Company’s most recent impairment test was performed during the fourth quarter of 2004 and did not result in an impairment charge. There were no changes in goodwill during the nine months ended September 30, 2005.

 

Intangible Assets

 

As of September 30, 2005 and December 31, 2004, respectively, the Company had an intangible asset of $6.8 million, net of $1.8 million of accumulated amortization, and $7.2 million, net of $1.4 million of accumulated amortization which is classified with other assets. Amortization expense was $426 thousand for each nine month period ended September 30, 2005 and 2004. The intangible asset is associated with the acquisition of certain assets of the Smurfit Industrial Packaging Group, which was completed in 2002, and is attributable to the acquired customer relationships. This intangible asset is being amortized over 15 years. Scheduled amortization of the intangible asset for the next five years is as follows (in thousands):

 

2006

   $ 568

2007

     568

2008

     568

2009

     568

2010

     568
    

Five year total

   $ 2,840
    

 

Note 8. Restructuring and Impairment Costs

 

Restructuring has been a primary component of management’s strategy to address the decrease in industry demand and excess capacity. In response to these issues the Company has closed and consolidated seven facilities since 2000 within its paperboard segment, four facilities within its carton and custom packaging segment and one facility in its tube, core and composite segment. These initiatives are designed to enhance the Company’s competitiveness through reduced costs, reduction of geographic overlap, duplicative capabilities, and differentiated quality products and services to the Company’s customers.

 

In addition to the Company’s restructuring initiatives for its operations, the Company implemented a plan to centralize its accounting and finance operations to its headquarters located in Austell, Georgia. This action was initiated to enhance the accounting control environment and mitigate the cost of complying with the Sarbanes-Oxley Act.

 

In September 2005, the Company announced the permanent closure of its Mobile tube plant located in Mobile, Alabama. In the third quarter of 2005 the Company recorded a charge of approximately $69 thousand for severance and other benefits in

 

10


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connection with this closure. The Company expects to incur an additional $96 thousand of severance and other benefit expense and $1.0 million in other exit costs related to the closure of this facility. The Mobile tube plant is expected to cease operations by the end of the year in order to facilitate customer transition to the Company’s other tube facilities.

 

In June 2005, the Company announced the permanent closure of its Palmer carton plant located in Thorndike, Massachusetts. For the nine months ended September 30, 2005 the Company had recorded charges of approximately $427 thousand for severance and other benefits and $42 thousand in other exit costs in connection with this closure. The Company expects to incur an additional $135 thousand in other exit costs related to the closure of this facility. The Palmer carton plant ceased operations in mid-July in order to facilitate customer transition to the Company’s other carton operations.

 

In September 2005, the Company sold the real estate associated with its Chesapeake paperboard mill, which permanently closed in February 2000, for $1.7 million, net of expenses, and recorded a gain of approximately $1.0 million.

 

In September 2005, the Company negotiated and settled its long term lease obligation related to the closure of its Carolina Converting, Inc. facility, which was permanently closed in December 2002, for $872 thousand, net of expenses, and recorded a $580 thousand reversal of the restructuring accrual.

 

See Note 14, “Subsequent Events”, for discussion on the closure of the Company’s DeQuincy tube plant, located in DeQuincy, Louisiana and its plan to sell the Company’s Hunt Valley carton plant, located in Hunt Valley, Maryland.

 

The following is a summary of restructuring and impairment costs and the restructuring liability from December 31, 2004 to September 30, 2005 (in thousands):

 

     Asset
Impairment
Charges and
(Gain) Loss
on Disposals


    Severance and
Other
Termination
Benefits Costs


    Other Exit
Costs


    Restructuring
Liability Total


    Total (1)

 

Liability balance, December 31, 2004

           $ 3,716     $ 2,750     $ 6,466          

First quarter 2005 costs

   $ 183       —         420       420     $ 603  
    


                         


Expenditures

             (791 )     (887 )     (1,678 )        
            


 


 


       

Liability balance, March 31, 2005

           $ 2,925     $ 2,283     $ 5,208          

Second quarter 2005 costs

   $ 66       90       149       239     $ 305  
    


                         


Expenditures

             (351 )     (470 )     (821 )        
            


 


 


       

Liability balance, June 30, 2005

           $ 2,664     $ 1,962     $ 4,626          

Third quarter 2005 (gain) costs

   $ (420 )     295       (441 )     (146 )   $ (566 )
    


                         


Expenditures

             (566 )     (1,241 )     (1,807 )        
            


 


 


       

Liability balance, September 30, 2005

           $ 2,393     $ 280     $ 2,673          
            


 


 


       

(1) Asset impairment charges, gain or loss on disposals, severance and other termination benefit costs and other exit costs are aggregated and reported as restructuring and impairment costs on the statement of operations.

 

The following table summarizes restructuring and impairment costs by segment for those plans initiated since January 1, 2003 and accounted for under SFAS No. 146, “Accounting for Costs Associated with Exit or Disposal Activities” (in thousands):

 

Segment


  

Cumulative Costs as
of

December 31, 2004 (1)


   Costs for the Nine
Months Ended
September 30,
2005 (2)


    Estimated Costs
to Complete
Initiatives as of
September 30,
2005


  

Total Estimated
Costs of Initiatives
as of

September 30, 2005


Paperboard

   $ 15,103    $ —       $ —      $ 15,103

Recovered fiber

     1,023      (59 )     —        964

Carton and custom packaging

     12,349      1,082       410      13,841

Tube, core and composite container

     528      49       1,246      1,823

Corporate

     1,945      26       —        1,971
    

  


 

  

Total

   $ 30,948    $ 1,098     $ 1,656    $ 33,702
    

  


 

  


(1) Of the total $30.9 million in cumulative restructuring costs, $22.6 million were non-cash charges.
(2) The total restructuring and impairment costs of $342 thousand as reported in the Company’s unaudited financial statements for the nine months ended September 30, 2005, does not agree with the nine month total of $1.1 million from the table above, because some of the costs are related to plans initiated prior to January 1, 2003 and are not subject to the disclosure requirements of SFAS No. 146.

 

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Note 9. Pension Plan and Other Postretirement Benefits

 

Pension Plan and Supplemental Executive Retirement Plan

 

Substantially all of the Company’s employees participate in a noncontributory defined benefit pension plan (the “Pension Plan”). The Pension Plan calls for benefits to be paid to all eligible employees at retirement based primarily on years of service with the Company and compensation rates in effect near retirement. The Pension Plan’s assets consist of shares held in collective trust funds, pooled separate accounts, money market funds, and futures contracts. The Company’s policy is to fund benefits attributed to employees’ service to date, as well as service expected to be earned in the future. The Company made a $13.1 million contribution in September 2005. No additional contributions are required within the next twelve months.

 

Certain executives participate in a supplemental executive retirement plan (“SERP”), which provides retirement benefits to participants based on average compensation. The SERP is unfunded at September 30, 2005.

 

Pension expense for the Pension Plan and the SERP includes the following components for the three and nine months ended September 30, 2005 and 2004 (in thousands):

 

     Three Months Ended
September 30,


    Nine Months Ended
September 30,


 
       2005       2004       2005       2004  
    


 


 


 


Service cost of benefits earned

   $ 835     $ 1,483     $ 2,505     $ 4,450  

Interest cost on projected benefit obligation

     1,797       1,509       5,392       4,526  

Estimated return on plan assets

     (1,607 )     (1,595 )     (4,823 )     (4,785 )

Net amortization and deferral

     1,295       881       3,886       2,644  
    


 


 


 


Net pension expense

   $ 2,320     $ 2,278     $ 6,960     $ 6,835  
    


 


 


 


 

Other Postretirement Benefits

 

The Company provides postretirement medical benefits to retired employees of certain of its subsidiaries. The Company accounts for these postretirement medical benefits in accordance with SFAS No. 106, “Employer’s Accounting for Postretirement Benefits Other than Pensions.”

 

Net periodic postretirement benefit cost for the three and nine months ended September 30, 2005 and 2004 included the following components (in thousands):

 

     Three Months Ended
September 30,


   Nine Months Ended
September 30,


     2005

   2004

   2005

   2004

Service cost of benefits earned

   $ 8    $ 5    $ 23    $ 14

Interest cost on accumulated postretirement benefit obligation

     78      83      235      248

Amortization

     17      70      50      211
    

  

  

  

Net postretirement benefit cost

   $ 103    $ 158    $ 308    $ 473
    

  

  

  

 

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Note 10. Income (Loss) Per Share

 

The following is a reconciliation of the numerators and denominators of the basic and diluted income (loss) per share computations for net income (loss) (in thousands, except per share information):

 

     Three Months Ended
September 30,


    Nine Months Ended
September 30,


 
     2005

   2004

    2005

   2004

 

Net income (loss)

   $ 45    $ (596 )   $ 613    $ (5,626 )
    

  


 

  


Weighted average number of common shares outstanding - basic

     28,780      28,506       28,769      28,449  

Common share equivalents

     98      —         118      —    
    

  


 

  


Weighted average number of common shares outstanding – diluted

     28,878      28,506       28,887      28,449  
    

  


 

  


Income (loss) per share - basic

   $ 0.00    $ (0.02 )   $ 0.02    $ (0.20 )
    

  


 

  


Income (loss) per share - diluted

   $ 0.00    $ (0.02 )   $ 0.02    $ (0.20 )
    

  


 

  


 

The impact of the dilutive effect of the stock options has been included in the three months ended September 30, 2005 and the nine months ended September 30, 2005; however, since the three and nine months ended September 30, 2004 were net losses, the impact of the dilutive effect of stock options, if any, was not added to the weighted average shares for these periods. The number of antidilutive options not included in the computation of diluted weighted average shares for the nine months ended September 30, 2005 and 2004 were 1,046,430 and 1,650,437, respectively.

 

Note 11. Equity Interests in Unconsolidated Affiliates

 

The Company owns 50% of Standard Gypsum, L.P. (“Standard”). Standard is a joint venture, accounted for under the equity method, that operates two gypsum wallboard manufacturing facilities. One facility is located in McQueeny, Texas and the other is in Cumberland City, Tennessee. The joint venture is managed by Temple-Inland, Inc., which is the owner of the remaining 50% interest in the joint venture. Because of the significance of Standard’s operating results to the Company, Standard’s summarized balance sheets and income statements are presented below (in thousands):

 

     September 30,
2005 *


   December 31,
2004 *


Current assets

   $ 39,523    $ 27,995

Noncurrent assets

     61,699      61,968

Current liabilities

     17,958      11,631

Current debt

     56,200      56,200

Net assets

     27,064      22,132

 

     Three Months Ended
September 30,


  

Nine Months Ended

September 30,


     2005

   2004

   2005

   2004

Sales

   $ 50,689    $ 45,584    $ 146,154    $ 123,018

Gross profit

     18,174      14,385      50,937      35,581

Income from operations

     16,751      13,144      46,864      32,148

Net income

   $ 15,135    $ 12,472    $ 42,931    $ 30,514

* The actual dates of Standard’s financial statements are October 1, 2005 and January 1, 2005 for the periods ending September 30, 2005 and December 31, 2004, respectively.

 

The Company received $19.0 million and $11.5 million in cash distributions from Standard during the nine months ended September 30, 2005 and 2004, respectively. The Company’s equity interest in the earnings of Standard for the three months ended September 30, 2005 and September 30, 2004, were approximately $7.6 million and $6.2 million in earnings, respectively. The Company’s equity interest in the earnings of Standard for the nine months ended September 30, 2005 and September 30, 2004, were approximately $21.5 million and $15.2 million, respectively.

 

On September 22, 2005 Standard refinanced its outstanding letter of credit reimbursement obligations with borrowings under a new term loan in the principal amount of $56.2 million, from a replacement lender. The term loan matures in full one year from the agreement date. The Company is severally obligated for 50% of Standard’s obligations for principal, interest, fees and

 

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Table of Contents

other amounts with respect to the term loan. The other Standard partner, Temple-Inland, has guaranteed 50% of Standard’s obligations. As of September 2005, the outstanding principal balance under the term loan totaled $56.2 million, for one half of which the Company is obligated ($28.1 million). The Company’s obligation with respect to the Standard term loan is supported by a letter of credit in the face amount of $29.5 million, issued in favor of the Standard lender. This letter of credit was issued under the Company’s senior credit facility and expires in October 2006. In connection with the term loan the Company amended its senior credit facility effective September 20, 2005 to permit the issuance of this letter of credit.

 

The Company owns 50% of Premier Boxboard Limited (“PBL”). PBL is a joint venture with Temple-Inland, Inc., which owns the remaining 50% interest, and is accounted for under the equity method. PBL produces lightweight gypsum facing paper, along with containerboard grades, and is managed by the Company. Because of the significance of PBL’s operating results to the Company, PBL’s summarized balance sheets and income statements are presented below (in thousands):

 

     September 30,
2005


   December 31,
2004


Current assets

   $ 18,159    $ 20,845

Noncurrent assets

     136,570      140,434

Current liabilities

     15,326      13,676

Long-term liabilities

     295      698

Long-term debt

     50,000      50,000

Net assets

     89,108      96,905

 

     Three Months Ended
September 30,


  

Nine Months Ended

September 30,


     2005

   2004

   2005

   2004

Sales

   $ 29,332    $ 28,512    $ 91,671    $ 77,971

Gross profit

     7,340      6,422      22,481      12,996

Income from operations

     5,125      4,069      15,244      6,098

Net income

   $ 4,124    $ 2,993    $ 12,203    $ 2,846

 

The Company received $10.0 million in cash distributions from PBL for the nine months ended September 30, 2005, and no distributions for the nine months ended September 30, 2004. The Company’s equity interest in the earnings of PBL for the three months ended September 30, 2005 and September 30, 2004, were approximately $2.1 million and $1.5 million, respectively. The Company’s equity interest in the earnings of PBL for the nine months ended September 30, 2005 and September 30, 2004, were approximately $6.1 million and $1.5 million, respectively.

 

As of December 31, 2004, Premier Boxboard was the borrower under a credit facility with an aggregate outstanding principal amount of $632 thousand, consisting solely of an undrawn letter of credit. On January 5, 2005, Premier Boxboard’s revolving credit facility expired. The only outstanding obligation under the facility at the time of expiration was the $632 thousand letter of credit balance, which expired on June 20, 2005 and was not renewed. Premier Boxboard placed $614 thousand of available cash into a trust account to replace the expired letter of credit.

 

Note 12. Guarantor Condensed Consolidating Financial Statements

 

These condensed consolidating financial statements reflect Caraustar Industries, Inc. and its Subsidiary Guarantors, which consist of all but one of the Company’s wholly-owned subsidiaries other than foreign subsidiaries. These nonguarantor subsidiaries are herein referred to as “Nonguarantor Subsidiaries.” Separate financial statements of the Subsidiary Guarantors are not presented because the subsidiary guarantees are joint and several and full and unconditional, and the Company believes that the condensed consolidating financial statements presented are more meaningful in understanding the financial position of the Subsidiary Guarantors.

 

14


Table of Contents

CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING BALANCE SHEETS

(In thousands)

 

     As of September 30, 2005

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

    Consolidated

 
ASSETS  

CURRENT ASSETS:

                                        

Cash and cash equivalents

   $ 90,085     $ 141     $ 444     $ —       $ 90,670  

Intercompany funding

     (91,942 )     105,836       (13,894 )     —         —    

Receivables, net of allowances

     —         113,916       5,569       —         119,485  

Intercompany accounts receivable

     —         213       208       (421 )     —    

Inventories

     —         82,419       3,715       —         86,134  

Refundable income taxes

     399       —         —         —         399  

Current deferred tax asset

     9,060       —         —         —         9,060  

Other current assets

     8,622       3,336       2,180       —         14,138  
    


 


 


 


 


Total current assets

     16,224       305,861       (1,778 )     (421 )     319,886  
    


 


 


 


 


PROPERTY, PLANT, AND EQUIPMENT

     18,796       751,745       26,192       —         796,733  

Less accumulated depreciation

     (10,510 )     (387,532 )     (13,741 )     —         (411,783 )
    


 


 


 


 


Property, plant, and equipment, net

     8,286       364,213       12,451       —         384,950  
    


 


 


 


 


GOODWILL

     —         179,628       3,502       —         183,130  
    


 


 


 


 


INVESTMENT IN CONSOLIDATED SUBSIDIARIES

     572,865       131,669       —         (704,534 )     —    
    


 


 


 


 


INVESTMENT IN UNCONSOLIDATED AFFILIATES

     58,246       —         —         —         58,246  
    


 


 


 


 


OTHER ASSETS

     15,032       7,831       116       —         22,979  
    


 


 


 


 


     $ 670,653     $ 989,202     $ 14,291     $ (704,955 )   $ 969,191  
    


 


 


 


 


LIABILITIES AND SHAREHOLDERS’ EQUITY  

CURRENT LIABILITIES:

                                        

Current maturities of debt

   $ 80     $ —       $ —       $ —       $ 80  

Accounts payable

     19,367       67,176       3,962       —         90,505  

Intercompany accounts payable

     —         208       213       (421 )     —    

Accrued interest

     19,918       195       —         —         20,113  

Accrued compensation

     1,146       9,723       173       —         11,042  

Capital lease obligations

     489       21       —         —         510  

Other accrued liabilities

     1,415       29,836       1,902       —         33,153  
    


 


 


 


 


Total current liabilities

     42,415       107,159       6,250       (421 )     155,403  
    


 


 


 


 


LONG-TERM DEBT, less current maturities

     494,600       8,200       —         —         502,800  
    


 


 


 


 


LONG-TERM CAPITAL LEASE OBLIGATIONS

     682       39       —         —         721  
    


 


 


 


 


DEFERRED INCOME TAXES

     45,768       12,165       1,478       —         59,411  
    


 


 


 


 


PENSION LIABILITY

     26,898       —         —         —         26,898  
    


 


 


 


 


OTHER LIABILITIES

     911       3,566       —         826       5,303  
    


 


 


 


 


SHAREHOLDERS’ EQUITY:

                                        

Common stock

     2,764       772       523       (1,181 )     2,878  

Additional paid-in capital

     197,175       671,229       9,167       (685,548 )     192,023  

Unearned compensation

     (3,690 )     —         —         —         (3,690 )

Retained (deficit) earnings

     (114,249 )     186,072       (4,027 )     (18,631 )     49,165  

Accumulated other comprehensive (loss) income

     (22,621 )     —         900       —         (21,721 )
    


 


 


 


 


Total Shareholders’ Equity

     59,379       858,073       6,563       (705,360 )     218,655  
    


 


 


 


 


     $ 670,653     $ 989,202     $ 14,291     $ (704,955 )   $ 969,191  
    


 


 


 


 


 

15


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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING BALANCE SHEETS

(In thousands)

 

     As of December 31, 2004

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

    Consolidated

 
ASSETS  

CURRENT ASSETS:

                                        

Cash and cash equivalents

   $ 88,998     $ 125     $ 633     $ —       $ 89,756  

Intercompany funding

     (65,837 )     79,577       (13,740 )     —         —    

Receivables, net of allowances

     —         96,933       5,711       —         102,644  

Intercompany accounts receivable

     —         175       272       (447 )     —    

Inventories

     —         84,808       4,236       —         89,044  

Refundable income taxes

     409       —         —         —         409  

Current deferred tax asset

     11,035       —         —         —         11,035  

Other current assets

     4,502       5,094       1,463       —         11,059  
    


 


 


 


 


Total current assets

     39,107       266,712       (1,425 )     (447 )     303,947  
    


 


 


 


 


PROPERTY, PLANT, AND EQUIPMENT

     14,169       743,218       25,857       —         783,244  

Less accumulated depreciation

     (9,140 )     (373,279 )     (12,691 )     —         (395,110 )
    


 


 


 


 


Property, plant, and equipment, net

     5,029       369,939       13,166       —         388,134  
    


 


 


 


 


GOODWILL

     —         179,628       3,502       —         183,130  
    


 


 


 


 


INVESTMENT IN CONSOLIDATED SUBSIDIARIES

     572,865       131,669       —         (704,534 )     —    
    


 


 


 


 


INVESTMENT IN UNCONSOLIDATED AFFILIATES

     59,676       —         —         —         59,676  
    


 


 


 


 


OTHER ASSETS

     16,138       8,564       116       —         24,818  
    


 


 


 


 


     $ 692,815     $ 956,512     $ 15,359     $ (704,981 )   $ 959,705  
    


 


 


 


 


LIABILITIES AND SHAREHOLDERS’ EQUITY  

CURRENT LIABILITIES:

                                        

Current maturities of debt

   $ 80     $ —       $ —       $ —       $ 80  

Accounts payable

     20,352       59,880       4,658       —         84,890  

Intercompany accounts payable

     —         272       175       (447 )     —    

Accrued interest

     8,743       67       —         —         8,810  

Accrued compensation

     2,002       9,583       157       —         11,742  

Capital lease obligation

     79       —         —         —         79  

Other accrued liabilities

     4,030       29,970       880       —         34,880  
    


 


 


 


 


Total current liabilities

     35,286       99,772       5,870       (447 )     140,481  
    


 


 


 


 


LONG-TERM DEBT, less current maturities

     497,941       8,200       —         —         506,141  
    


 


 


 


 


DEFERRED INCOME TAXES

     43,599       12,240       1,481       —         57,320  
    


 


 


 


 


PENSION LIABILITY

     32,897       —         —         —         32,897  
    


 


 


 


 


OTHER LIABILITIES

     1,080       3,846       —         688       5,614  
    


 


 


 


 


SHAREHOLDERS’ EQUITY:

                                        

Common stock

     2,761       772       523       (1,181 )     2,875  

Additional paid-in capital

     197,055       671,229       9,167       (685,548 )     191,903  

Unearned compensation

     (4,334 )     —         —         —         (4,334 )

Retained (deficit) earnings

     (90,849 )     160,453       (2,559 )     (18,493 )     48,552  

Accumulated other comprehensive (loss) income

     (22,621 )     —         877       —         (21,744 )
    


 


 


 


 


Total Shareholders’ Equity

     82,012       832,454       8,008       (705,222 )     217,252  
    


 


 


 


 


     $ 692,815     $ 956,512     $ 15,359     $ (704,981 )   $ 959,705  
    


 


 


 


 


 

16


Table of Contents

CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING STATEMENTS OF OPERATIONS

(In thousands)

 

     For the Three Months Ended September 30, 2005

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

    Consolidated

 

SALES

   $ —       $ 332,661     $ 10,655     $ (75,555 )   $ 267,761  

COST OF SALES

     —         299,946       10,084       (75,555 )     234,475  
    


 


 


 


 


Gross profit

     —         32,715       571       —         33,286  

SELLING, GENERAL AND ADMINISTRATIVE EXPENSES

     4,536       27,690       1,363       —         33,589  

RESTRUCTURING AND IMPAIRMENT

     (2 )     (564 )     —         —         (566 )
    


 


 


 


 


(Loss) income from operations

     (4,534 )     5,589       (792 )     —         263  

OTHER (EXPENSE) INCOME:

                                        

Interest expense

     (10,377 )     (88 )     (1 )     —         (10,466 )

Interest income

     749       (1 )     —         —         748  

Equity in income of unconsolidated affiliates

     9,615       —         —         —         9,615  

Other, net

     —         80       (45 )     —         35  
    


 


 


 


 


       (13 )     (9 )     (46 )     —         (68 )
    


 


 


 


 


(LOSS) INCOME BEFORE INCOME TAXES AND MINORITY INTEREST

     (4,547 )     5,580       (838 )     —         195  

PROVISION FOR INCOME TAXES

     (118 )     —         —         —         (118 )

MINORITY INTEREST IN INCOME

     —         —         —         (32 )     (32 )
    


 


 


 


 


NET (LOSS) INCOME

   $ (4,665 )   $ 5,580     $ (838 )   $ (32 )   $ 45  
    


 


 


 


 


 

17


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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING STATEMENTS OF OPERATIONS

(In thousands)

 

     For the Three Months Ended September 30, 2004

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

    Consolidated

 

SALES

   $ —       $ 336,079     $ 9,258     $ (71,548 )   $ 273,789  

COST OF SALES

     —         295,291       9,157       (71,548 )     232,900  
    


 


 


 


 


Gross profit

     —         40,788       101       —         40,889  

SELLING, GENERAL AND ADMINISTRATIVE EXPENSES

     5,843       27,599       389       —         33,831  

RESTRUCTURING AND IMPAIRMENT

     259       4,862       —         —         5,121  
    


 


 


 


 


(Loss) income from operations

     (6,102 )     8,327       (288 )     —         1,937  

OTHER (EXPENSE) INCOME:

                                        

Interest expense

     (10,256 )     (79 )     (116 )     115       (10,336 )

Interest income

     364       —         —         (115 )     249  

Equity in income of unconsolidated affiliates

     7,746       —         —         —         7,746  

Other, net

     (172 )     (37 )     128       —         (81 )
    


 


 


 


 


       (2,318 )     (116 )     12       —         (2,422 )
    


 


 


 


 


(LOSS) INCOME BEFORE INCOME TAXES AND MINORITY INTEREST

     (8,420 )     8,211       (276 )     —         (485 )

PROVISION FOR INCOME TAXES

     (79 )     —         —         —         (79 )

MINORITY INTEREST IN INCOME

     —         —         —         (32 )     (32 )
    


 


 


 


 


NET (LOSS) INCOME

   $ (8,499 )   $ 8,211     $ (276 )   $ (32 )   $ (596 )
    


 


 


 


 


 

18


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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING STATEMENTS OF OPERATIONS

(In thousands)

 

     For the Nine Months Ended September 30, 2005

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

    Consolidated

 

SALES

   $ —       $ 997,362     $ 32,852     $ (223,617 )   $ 806,597  

COST OF SALES

     —         886,732       31,041       (223,617 )     694,156  
    


 


 


 


 


Gross profit

     —         110,630       1,811       —         112,441  

SELLING, GENERAL AND ADMINISTRATIVE EXPENSES

     17,486       84,689       3,278       —         105,453  

RESTRUCTURING AND IMPAIRMENT

     27       315       —         —         342  
    


 


 


 


 


(Loss) income from operations

     (17,513 )     25,626       (1,467 )     —         6,646  

OTHER (EXPENSE) INCOME:

                             —            

Interest expense

     (31,300 )     (266 )     (2 )     —         (31,568 )

Interest income

     1,811       —         —         —         1,811  

Equity in income of unconsolidated affiliates

     27,531       —         —         —         27,531  

Other, net

     121       259       1       —         381  
    


 


 


 


 


       (1,837 )     (7 )     (1 )     —         (1,845 )
    


 


 


 


 


(LOSS) INCOME BEFORE INCOME TAXES AND MINORITY INTEREST

     (19,350 )     25,619       (1,468 )     —         4,801  

PROVISION FOR INCOME TAXES

     (4,050 )     —         —         —         (4,050 )

MINORITY INTEREST IN INCOME

     —         —         —         (138 )     (138 )
    


 


 


 


 


NET (LOSS) INCOME

   $ (23,400 )   $ 25,619     $ (1,468 )   $ (138 )   $ 613  
    


 


 


 


 


 

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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING STATEMENTS OF OPERATIONS

(In thousands)

 

     For the Nine Months Ended September 30, 2004

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

    Consolidated

 

SALES

   $ —       $ 977,233     $ 28,715     $ (206,593 )   $ 799,355  

COST OF SALES

     —         858,852       26,222       (206,593 )     678,481  
    


 


 


 


 


Gross profit

     —         118,381       2,493       —         120,874  

SELLING, GENERAL AND ADMINISTRATIVE EXPENSES

     14,877       85,000       3,221       —         103,098  

RESTRUCTURING AND IMPAIRMENT

     1,850       8,804       —         —         10,654  
    


 


 


 


 


(Loss) income from operations

     (16,727 )     24,577       (728 )     —         7,122  

OTHER (EXPENSE) INCOME:

                                        

Interest expense

     (31,355 )     (239 )     (318 )     315       (31,597 )

Interest income

     911       —         —         (315 )     596  

Equity in income of unconsolidated affiliates

     16,810       —         —         —         16,810  

Other, net

     (568 )     131       37       —         (400 )
    


 


 


 


 


       (14,202 )     (108 )     (281 )     —         (14,591 )
    


 


 


 


 


(LOSS) INCOME BEFORE INCOME TAXES AND MINORITY INTEREST

     (30,929 )     24,469       (1,009 )     —         (7,469 )

BENEFIT FOR INCOME TAXES

     1,988       —         —         —         1,988  

MINORITY INTEREST IN INCOME

     —         —         —         (145 )     (145 )
    


 


 


 


 


NET (LOSS) INCOME

   $ (28,941 )   $ 24,469     $ (1,009 )   $ (145 )   $ (5,626 )
    


 


 


 


 


 

20


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CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING STATEMENTS OF CASH FLOWS

(In thousands)

 

     For the Nine Months Ended September 30, 2005

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

   Consolidated

 

Net cash provided by operating activities

   $ 1,431     $ 11,634     $ 124     $ —      $ 13,189  
    


 


 


 

  


Investing activities:

                                       

Purchases of property, plant and equipment

     (3,244 )     (14,425 )     (313 )     —        (17,982 )

Proceeds from disposal of property, plant and equipment

     —         2,811       —         —        2,811  

Return of investment in unconsolidated affiliates

     4,672       —         —         —        4,672  

Investment in unconsolidated affiliates

     (40 )     —         —         —        (40 )
    


 


 


 

  


Net cash provided by (used in) investing activities

     1,388       (11,614 )     (313 )     —        (10,539 )
    


 


 


 

  


Financing activities:

                                       

Repayments of long-term debt

     (2,413 )     —         —         —        (2,413 )

Payments for capital lease obligations

     (376 )     (4 )     —         —        (380 )

Proceeds from swap agreement unwind

     826       —         —         —        826  

Issuances of stock, net of forfeitures

     231       —         —         —        231  
    


 


 


 

  


Net cash used in financing activities

     (1,732 )     (4 )     —         —        (1,736 )
    


 


 


 

  


Net increase (decrease) in cash and cash equivalents

     1,087       16       (189 )     —        914  

Cash and cash equivalents at beginning of period

     88,998       125       633       —        89,756  
    


 


 


 

  


Cash and cash equivalents at end of period

   $ 90,085     $ 141     $ 444     $ —      $ 90,670  
    


 


 


 

  


 

21


Table of Contents

CARAUSTAR INDUSTRIES, INC. AND SUBSIDIARIES

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

CONSOLIDATING STATEMENTS OF CASH FLOWS

(In thousands)

 

     For the Nine Months Ended September 30, 2004

 
     Parent

    Guarantor
Subsidiaries


    Nonguarantor
Subsidiaries


    Eliminations

   Consolidated

 

Net cash provided by (used in) operating activities

   $ 17,227     $ 11,832     $ (177 )   $ —      $ 28,882  
    


 


 


 

  


Investing activities:

                                       

Purchases of property, plant and equipment

     (1,330 )     (13,691 )     (623 )     —        (15,644 )

Proceeds from disposal of property, plant and equipment

     —         1,992       49       —        2,041  

Investment in unconsolidated affiliates

     (150 )     —         —         —        (150 )
    


 


 


 

  


Net cash used in investing activities

     (1,480 )     (11,699 )     (574 )     —        (13,753 )
    


 


 


 

  


Financing activities:

                                       

Repayments of long-term debt

     (14,159 )     (17 )     —         —        (14,176 )

Payments for capital lease obligations

     (139 )     —         —         —        (139 )

Proceeds from swap agreement unwind

     380       —         —         —        380  

Issuances of stock, net of forfeitures

     2,450       —         —         —        2,450  
    


 


 


 

  


Net cash used in financing activities

     (11,468 )     (17 )     —         —        (11,485 )
    


 


 


 

  


Net increase (decrease) in cash and cash equivalents

     4,279       116       (751 )     —        3,644  
    


 


 


 

  


Cash and cash equivalents at beginning of period

     84,303       —         1,248       —        85,551  
    


 


 


 

  


Cash and cash equivalents at end of period

   $ 88,582     $ 116     $ 497     $ —      $ 89,195  
    


 


 


 

  


 

22


Table of Contents

Note 13. Commitments and Contingencies

 

On August 11, 2005 Region V of the Environmental Protection Agency filed an administrative complaint against the Company for its alleged failure to timely file completed emergency and hazardous chemical inventory forms, pursuant to the Emergency Planning and Community Right-to-Know Act (EPCRA), for calendar years 2001 and 2002. The EPA proposed fines totaling $74 thousand. The Company was working with the EPA and had filed, prior to commencement of the administrative action, inventory forms for the relevant calendar years. The Company and the EPA reached an agreement in principle to resolve this matter. The Company agreed to accept these violations and pay a reduced penalty of $40 thousand. The Company has reviewed and updated its compliance activities and management believes this process will enable the Company to comply prospectively with EPCRA filing requirements.

 

Note 14. Subsequent Events

 

In October 2005 the Company purchased $5.0 million of its 9 7/8% senior subordinated notes in the open market for approximately $4.9 million.

 

In October 2005, the Company announced the permanent closure of its DeQuincy tube plant located in DeQuincy, Louisiana. The Company expects to incur a $165 thousand in severance and termination benefits and $25 thousand in other exit costs. The DeQuincy tube plant is expected to cease operations by the end of the year in order to facilitate customer transition to the Company’s other tube facilities.

 

On November 1, 2005, the Company announced the expected sale of its Hunt Valley carton and corrugated box plant located in Hunt Valley, Maryland. The sale is projected to be completed by December 31, 2005. The parties have not entered into a definitive agreement, but are in the process of negotiating the final terms.

 

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Table of Contents

ITEM 2. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS.

 

CARAUSTAR INDUSTRIES, INC.

 

MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION

AND RESULTS OF OPERATIONS

 

The following is management’s discussion and analysis of certain significant factors that have affected our financial condition and operating results during the periods included in the accompanying condensed consolidated financial statements.

 

General

 

We are a major manufacturer of recycled paperboard and converted paperboard products. We operate in four business segments. The paperboard segment manufactures 100% recycled uncoated and clay-coated paperboard. The recovered fiber segment collects and sells recycled paper and brokers recycled paper and other paper rolls. The tube, core and composite container segment produces spiral and convolute-wound tubes, cores and cans. The carton and custom packaging segment produces printed and unprinted folding carton and set-up boxes and provides contract manufacturing and packaging services.

 

Our business is vertically integrated to a large extent. This means that our converting operations consume a large portion of our own paperboard production, approximately 44% in the first nine months of 2005. The remaining 56% of our paperboard production is sold to external customers in any of the four recycled paperboard end-use markets: tube, core and composite containers; folding cartons; gypsum wallboard facing paper and other specialty products. These integration statistics do not include volume produced or converted by our 50% owned, unconsolidated, joint ventures, Premier Boxboard Limited and Standard Gypsum, LLP. As part of our strategy to optimize our operating efficiency, each of our mills can produce recycled paperboard for more than one end-use market. This allows us to shift production among mills in response to customer or market demands.

 

Historically, we have grown our business, revenues and production capacity to a significant degree through acquisitions. Based on the difficult operating climate for our industry and our financial position over the last three years, the pace of our acquisition activity, and correspondingly, our revenue growth, has slowed as we have focused on conserving cash and maximizing the productivity and efficiency of our existing facilities.

 

We are a holding company that operates our business through 25 subsidiaries as of September 30, 2005. We also own a 50% interest in two joint ventures with Temple-Inland, Inc. We have two additional joint ventures with unrelated entities in which our investment and share of earnings are immaterial. We account for these interests in our joint ventures under the equity method of accounting. See “–Liquidity and Capital Resources – Off - Balance Sheet Arrangements – Joint Venture Financings” below.

 

Key Business Indicator and Trends

 

Our industry has historically been closely correlated with the domestic economy in general, and with consumer nondurable consumption (packaging segment) and industrial production (tube, core and composite containers segment), specifically. These demand drivers tend to be cyclical in nature, with cycles lasting 3 – 5 years depending on such factors as gross domestic product, interest rates and other factors. As these demand drivers fluctuate, we typically experience variability in volume and revenue in our business. From late 1999 through 2002, the recycled paperboard and converted paperboard products industry was in a down cycle. While we believe that future operating results may improve, and improvements have been realized in 2004 and to a lesser extent for the nine months ended September 30, 2005, we cannot ascertain either the timing or extent of any such improvement, in light of its dependence on these demand drivers and other factors, such as changes in key operating costs like fiber and energy.

 

A key operating indicator of our business is paperboard mill operating rates. Mill operating rates are calculated as the ratio of production compared with capacity assuming a normalized mill schedule of 355 days per year. As paperboard mill operating rates increase, cost per ton of paperboard generally decreases. As these tons are sold, profitability increases, since fixed production costs are absorbed by more tons produced. Additionally, higher operating rates generally provide enhanced opportunity to recover material, energy and labor increases through improved pricing. This positively affects paperboard and converted products’ income from operations and cash flow. Paperboard mill operating rates are affected by demand and by mill

 

24


Table of Contents

closures. Industry demand decreased from 2000 – 2002 due primarily to a recessionary general economy, the continued migration of U.S. manufacturing offshore to lower labor cost environments and product substitution, such as the replacement of carton packaging with plastic standup pouches. The decrease in demand resulted in a decrease in operating rates for us and the industry as a whole. We expect the migration of U.S. manufacturing offshore and product substitution to continue, although at a slower rate, which could continue to negatively affect our income from operations and cash flow. We further expect these trends to be somewhat offset by the improving domestic economy and our own paperboard mill capacity reductions. Recent industry improvement in operating rates has been driven by paperboard mill closures, as over 1.7 million tons of capacity, or approximately 20% of the recycled paperboard mill total capacity, has been closed from 2001 through 2004. We have closed or idled approximately 323 thousand tons of our own paperboard mill capacity during this period to better match our supply capabilities to demand. The chart below shows a ten year history of operating rates for both Caraustar and the industry, as well as rates for the nine months ending September 30, 2005:

 

MILL OPERATING RATES

 

LOGO


(1) For the nine months ended September 30, 2005

 

Industry source: American Forest and Paper Association.

 

Restructuring has been a primary component of management’s strategy to address the decrease in demand resulting from secular trends, as discussed above, and generally weak domestic economic conditions. Between 2001 and September 30, 2005, restructuring charges have totaled $57.4 million, of which approximately $34.0 million have been noncash charges. We have also experienced increases in near-term manufacturing and selling, general and administrative costs as a result of our transitioning of business within our mill and converting systems to other company facilities. Our strategic initiatives are designed to enhance our competitiveness through reduced costs, increase revenue through delivery of differentiated quality products and services to our customers, and promote compliance with recent changes in legal and regulatory requirements. Our restructuring efforts have been directed toward reducing costs through manufacturing and converting facilities rationalization where we believed it was advantageous to do so due to geographic overlap, duplicative capabilities, changes in customer base and other factors. Rationalization of facilities typically results in initially increased cash outlays and expenses, such as severance costs. We believe that future earnings and cash flows will be favorably affected by our efforts to reconfigure our business to increase efficiency and better match supply with customer demand. However, should market conditions deteriorate, additional restructuring charges are possible.

 

Recovered fiber, which is derived from recycled paper stock, is our most significant raw material. Historically, the cost of recovered fiber has fluctuated significantly due to market and industry conditions. For example, our average recovered fiber cost per ton of paperboard produced increased $26 per ton, or 33%, from 1999 to 2000, decreased $39 per ton, or 38%, from 2000 to 2001 and then increased again $20 per ton, or 31%, from 2001 to 2002. Recovered fiber cost per ton averaged $107 during 2004 and $109 during the first nine months of 2005.

 

Excluding raw materials and labor, energy is our most significant manufacturing cost. Energy consists of fuel used to generate steam used in the paper making process and electrical purchases to operate our paperboard machines and all of our converting

 

25


Table of Contents

machinery. During the first nine months of 2005, energy costs were $73 per ton compared with $56 per ton in the first nine months of 2004, a 30.4% increase. The increase was due primarily to an increase in natural gas costs. Oil prices also affect our raw material costs because we use petroleum-based coatings, chemicals and resins in some of our products. Increases in gasoline prices can also affect our freight costs which can significantly impact our operating results. We primarily use contracted external freight haulers to deliver raw materials to our manufacturing facilities and deliver finished products to our customers. During 2004 we spent approximately $65.8 million on freight costs. During the nine-month period ending September 30, 2005 our freight costs increased $8.9 million compared with the same period in 2004. Until the last few years, our business had not been significantly affected by energy cost increases, and we historically have not passed increases in energy costs through to our customers. As the volatility of energy prices has increased, we have not been able to pass through to our customers all of the energy cost increases we have incurred. As a result, our operating margins have been adversely affected. Although we continue to evaluate our energy costs and consider ways to factor energy costs into our pricing, we cannot give assurance that our operating margins and results of operations will not continue to be adversely affected by rising energy costs.

 

We raise our selling prices in response to increases in raw material and energy costs. However, we often are unable to pass the full amount of these costs through to our customers on a timely basis due to supply and demand in the industry, and as a result often cannot maintain our operating margins in the face of rapid cost increases. In addition, our ability to implement price increases, even on a delayed basis, is contingent on competitive conditions and market acceptance of our stated price increases. Because of these conditions and the difficulty of estimating the market impact of announced price increases, from time to time we are only partially successful in implementing announced price increases. We experience margin shrinkage during all periods of cost increases due to customary time lags in implementing our price increases. We cannot give assurance that we will be able to recover any future increases in the cost of recovered fiber or energy by raising the prices of our products. Even if we are able to recover future cost increases, our operating margins and results of operations may still be materially and adversely affected by time delays in the implementation of price increases.

 

Critical Accounting Policies

 

Our accompanying condensed consolidated financial statements have been prepared in conformity with accounting principles generally accepted in the United States of America, which require management to make estimates that affect the amounts of revenues, expenses, assets and liabilities reported. The critical accounting matters that are very important to the portrayal of our financial condition and results of operations and require some of management’s most difficult, subjective and complex judgments are described in detail in our Annual Report on Form 10-K for the year ended December 31, 2004. The accounting for these matters involves forming estimates based on current facts, circumstances and assumptions which, in management’s judgment, could change in a manner that would materially affect management’s future estimates with respect to such matters and, accordingly, could cause future reported financial condition and results of operations to differ materially from financial results reported based on management’s current estimates. There have been no material changes in our critical accounting policies during the nine-month period ended September 30, 2005.

 

Results of Operations for the Three Months Ended September 30, 2005 and 2004

 

The following table shows paperboard shipment volume, average selling price per ton, average recovered fiber cost per ton for the paperboard mills, and average paperboard cost per ton for the tube and core operations for the periods indicated. The average selling price and average cost per ton, are presented below because management believes they are the most significant indicators of profitability for the paperboard segment and the tube, core and composite container segment. Historically, recovered fiber has been our largest raw material cost component and has fluctuated significantly due to market and industry conditions. However, these drivers are not the only factors that can affect these segments. Also, note that a portion of our sales do not have related paperboard volume, such as sales of contract packaging services and sales of recovered fiber. The volume information shown below includes shipments of unconverted paperboard and converted paperboard products. Tonnage volumes from our business segments, excluding tonnage produced or converted by our unconsolidated joint ventures, are combined and presented along end-use market lines.

 

26


Table of Contents
     Three Months Ended
September 30,


  

Change


   

%

Change


 
   2005

   2004

    

Paperboard tons shipped by production source (in thousands):

                          

From internal paperboard mill production

     238.8      251.1    (12.3 )   (4.9 )%

Purchases from external sources

     29.5      34.1    (4.6 )   (13.5 )%
    

  

  

 

Total paperboard tonnage

     268.3      285.2    (16.9 )   (5.9 )%
    

  

  

 

Paperboard tons shipped by end-use market (in thousands):

                          

Tube, core and composite container volume

                          

Paperboard (internal)

     57.9      63.5    (5.6 )   (8.8 )%

Purchases from external sources

     11.6      11.8    (0.2 )   (1.7 )%
    

  

  

 

Tube, core and composite container converted products

     69.5      75.3    (5.8 )   (7.7 )%

Unconverted paperboard shipped to external customers

     10.2      11.6    (1.4 )   (12.1 )%
    

  

  

 

Tube, core and composite container volume

     79.7      86.9    (7.2 )   (8.3 )%

Folding carton volume

                          

Paperboard (internal)

     22.0      22.7    (0.7 )   (3.1 )%

Purchases from external sources

     15.9      18.5    (2.6 )   (14.1 )%
    

  

  

 

Folding carton converted products

     37.9      41.2    (3.3 )   (8.0 )%

Unconverted paperboard shipped to external customers

     58.7      61.9    (3.2 )   (5.2 )%
    

  

  

 

Folding carton volume

     96.6      103.1    (6.5 )   (6.3 )%

Gypsum wallboard facing paper volume

                          

Unconverted paperboard shipped to external customers

     24.6      25.4    (0.8 )   (3.1 )%

Other specialty products volume

                          

Paperboard (internal)

     22.8      25.3    (2.5 )   (9.9 )%

Purchases from external sources

     2.0      3.8    (1.8 )   (47.4 )%
    

  

  

 

Other specialty converted products

     24.8      29.1    (4.3 )   (14.8 )%

Unconverted paperboard shipped to external customers

     42.6      40.7    1.9     4.7 %
    

  

  

 

Other specialty products volume

     67.4      69.8    (2.4 )   (3.4 )%
    

  

  

 

Total paperboard tonnage

     268.3      285.2    (16.9 )   (5.9 )%
    

  

  

 

Selling price and cost data ($/ton):

                          

Paperboard mills:

                          

Average selling price

   $ 474    $ 466    8     1.7 %

Average recovered fiber cost

     111      111    —       —    

Tube and core facilities:

                          

Average selling price

   $ 955    $ 901    54     6.0 %

Average paperboard cost

     485      487    (2 )   (0.4 )%

 

The following table shows paperboard shipment volume on our business segment basis (in thousands of tons).

 

    

Three Months Ended

September 30,


  

Change


   

%

Change


 
   2005

   2004

    

Paperboard

                      

Unconverted paperboard shipped to external customers

   136.1    139.7    (3.6 )   (2.6 )%

Paperboard shipped internally to converters in the paperboard segment

   13.1    14.5    (1.4 )   (9.7 )%

Paperboard purchased externally by converters in the paperboard segment

   0.1    0.1    0.0     0.0 %
    
  
  

 

Total volume

   149.3    154.3    (5.0 )   (3.2 )%

Tube, core and composite container

                      

Paperboard (internal)

   67.5    74.2    (6.7 )   (9.0 )%

Purchases from external sources

   13.5    15.5    (2.0 )   (12.9 )%
    
  
  

 

Total volume converted

   81.0    89.7    (8.7 )   (9.7 )%

Carton and custom packaging

                      

Paperboard (internal)

   22.1    22.7    (0.6 )   (2.6 )%

Purchases from external sources

   15.9    18.5    (2.6 )   (14.1 )%
    
  
  

 

Total volume converted

   38.0    41.2    (3.2 )   (7.8 )%
    
  
  

 

Total paperboard tonnage

   268.3    285.2    (16.9 )   (5.9 )%
    
  
  

 

 

Paperboard Tonnage. Total paperboard tonnage for the three months ended September 30, 2005, decreased 5.9% to 268.3 thousand tons from 285.2 thousand tons for the same period in 2004. Tons sold from paperboard mill production decreased 3.2% for the three months ended September 30, 2005, compared to the same period in 2004. Total tonnage converted decreased 9.2 % for the three months ended September 30, 2005.

 

Total paperboard tonnage decreased primarily due to the following factors:

 

    A decrease in internal conversion by our tube, core and composite container, and other specialty facilities resulting from a decline in industry demand in those markets.

 

    A decline in internal conversion by our folding carton facilities due primarily to shedding unprofitable customers.

 

    A decrease in sales of unconverted paperboard to the folding carton and tube, core and composite container end-use markets resulting from a decline in demand in those markets.

 

 

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Table of Contents

Sales. Our consolidated sales for the three months ended September 30, 2005 decreased 2.2% to $267.8 million from $273.8 million in the same period of 2004. The following table presents sales by business segment (in thousands):

 

     Three Months Ended
September 30,


  

$

Change


   

%

Change


 
     2005

   2004

    

Paperboard

   $ 69,358    $ 71,944    $ (2,586 )   (3.6 )%

Recovered fiber

     20,766      23,070      (2,304 )   (10.0 )%

Tube, core and composite container

     98,600      99,872      (1,272 )   (1.3 )%

Carton and custom packaging

     79,037      78,903      134     0.2 %
    

  

  


 

Total

   $ 267,761    $ 273,789    $ (6,028 )   (2.2 )%
    

  

  


 

 

Paperboard Segment

 

Sales for the paperboard segment decreased due to the following factors:

 

    Lower volume accounted for approximately $1.8 million of the decrease, primarily as a result of downtime and inefficiencies associated with equipment upgrade at our Sweetwater paperboard mill.

 

    Lower sales of approximately $1.9 million due to the June 2004 divestiture of the chemical sales operation combined with lower volume in the paperboard segment’s converting operations.

 

These factors were partially offset by higher selling prices for unconverted paperboard which accounted for an estimated $1.3 million increase in sales.

 

Recovered Fiber Segment

 

Sales for the recovered fiber segment decreased primarily due to lower selling prices, which were partially offset by higher volume.

 

Tube, Core and Composite Container Segment

 

Sales for the tube, core and composite container segment decreased due to the following factors:

 

    Lower volume accounted for approximately $4.0 million of the decrease.

 

    Lower volume for miscellaneous and forming sales accounted for approximately $1.5 million of the decrease.

 

These factors were partially offset by higher tube and core selling prices which accounted for an estimated $4.4 million increase in sales.

 

Carton and Custom Packaging Segment

 

Sales for the carton and custom packaging segment increased slightly due to higher carton selling prices, combined with higher contract packaging volume, partially offset by lower carton volume.

 

Gross Profit Margin. Gross profit margin for the three months ended September 30, 2005 decreased to 12.4% of sales from 14.9% in 2004. This margin decrease was due primarily to the following:

 

    Lower volume in the paperboard segment, primarily a result of downtime and inefficiencies associated with an equipment upgrade at our Sweetwater paperboard mill combined with uncharacteristic operating inefficiencies primarily in the uncoated mill group, which lowered gross profit by approximately $4.3 million.

 

    Higher energy costs in the paperboard segment of approximately $4.0 million.

 

    Higher freight costs of approximately $2.2 million.

 

    Lower sales volume combined with higher manufacturing costs in the tube, core and composite container segment, which accounted for approximately $2.9 million of the decrease.

 

    Higher other manufacturing costs of approximately $2.5 million. These cost increases were primarily driven by the increase in petroleum based products used in various manufacturing processes.

 

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Table of Contents

These factors were partially offset by the following:

 

    Higher selling prices, net of higher paperboard costs, in the tube and core segment, which accounted for approximately $4.3 million.

 

    An increase in paperboard mill selling prices and a decrease in recovered fiber costs, which accounted for approximately $1.9 million.

 

    Higher selling prices in the carton and custom packaging segment and higher contract packaging volume, which accounted for approximately $1.3 million.

 

Selling, General and Administrative Expenses. Selling, general and administrative expenses were $33.6 million for the three months ended September 30, 2005, a decrease of 0.7% for the same period in 2004. The decrease in selling, general and administrative expense is primarily due to:

 

    A $1.6 million expense related to the third quarter 2004 vesting of performance accelerated restricted stock.

 

    Lower fees for consultants related to Sarbanes-Oxley compliance of approximately $500 thousand.

 

These factors were partially offset by:

 

    Higher pension and other employee costs of approximately $1.1 million.

 

    Higher employee and administrative costs of approximately $540 thousand related to two initiatives: centralization of our accounting and finance operations and an investment in other back office functions in order to reduce professional fees, purchasing and other costs in the long term.

 

    Higher accounts receivable reserve expense of approximately $350 thousand.

 

Restructuring and Impairment .

 

In September 2005, we announced the permanent closure of our Mobile tube plant located in Mobile, Alabama. In the third quarter of 2005 we recorded a charge of approximately $69 thousand for severance and other benefits in connection with this closure. We expect to incur an additional $96 thousand of severance and other benefit expense and $1.0 million in other exit costs related to the closure of this facility. The Mobile tube plant is expected to cease operations by the end of the year in order to facilitate customer transition to our other tube facilities.

 

In September 2005, we sold the real estate associated with our Chesapeake paperboard mill, which permanently closed in February 2000, for $1.7 million, net of expenses, and recorded a gain of approximately $1.0 million.

 

In September 2005, we negotiated and settled our long term lease obligation related to our Carolina Converting, Inc. facility, which was permanently closed in December 2002, for $872 thousand, net of expenses, and recorded a reversal of the restructuring accrual of approximately $580 thousand.

 

See Note 14, “Subsequent Events”, for discussion on the closure of our DeQuincy tube plant, located in DeQuincy, Louisiana and our plan to sell our Hunt Valley carton plant, located in Hunt Valley, Maryland.

 

During the third quarter of 2005, we recorded a $420 thousand gain on disposal of fixed assets, incurred $295 thousand in severance and other benefit costs, and an expense reversal of $441 thousand of other exit costs. During the third quarter of 2004 we recorded asset impairment charges of $932 thousand, we incurred severance and other benefit costs of $3.4 million, and incurred $735 thousand of other exit costs. We paid $566 thousand in severance and other termination benefits and paid $1.2 million for other exit costs in the third quarter of 2005, leaving an accrual of $2.7 million at September 30, 2005.

 

Income (loss) from operations. Income from operations for the nine months ended September 30, 2005 was $263 thousand, a decrease of $1.7 million from the operating income of $1.9 million for the same period last year. The following table presents income (loss) from operations by business segment (in thousands):

 

     Three Months Ended
September 30,


   

$

Change


   

%

Change


 
     2005

    2004

     

Paperboard

   $ 2,186     $ 7,745     $ (5,559 )   (71.8 )%

Recovered fiber

     (151 )     1,167       (1,318 )   N/A  

Tube, core and composite container

     1,816       1,765       51     2.9 %

Carton and custom packaging

     951       (2,648 )     3,599     N/A  

Corporate expense

     (4,539 )     (6,092 )     1,553     25.5 %
    


 


 


 

Total

   $ 263     $ 1,937     $ (1,674 )   (86.4 )%
    


 


 


 

 

29


Table of Contents

Paperboard Segment

 

The decrease in income from operations was a result of the following:

 

    Lower volume, primarily a result of downtime and inefficiencies associated with an equipment upgrade at our Sweetwater paperboard mill, combined with uncharacteristic operating inefficiencies primarily in the uncoated mill group, lowered gross profit by approximately $4.3 million.

 

    Higher energy costs of approximately $4.0 million.

 

    Higher pension and other employee costs of approximately $1.1 million.

 

    Higher other manufacturing costs of approximately $830 thousand.

 

These factors were partially offset by:

 

    Lower restructuring costs and savings from closed facilities of approximately $2.1 million.

 

    An increase in paperboard mill selling prices and a decrease in recovered fiber cost accounted for an estimated $1.9 million increase in income from operations.

 

    Lower selling, general and administrative expenses of approximately $800 thousand resulting from restructured and closed facilities.

 

Recovered Fiber Segment

 

The decrease in income from operations was a result of higher freight costs of $1.1 million and higher accounts receivable reserve expense of approximately $200 thousand.

 

Tube, Core and Composite Container Segment

 

The increase in income from operations was a result of the higher selling tube and core prices, net of higher paperboard costs, which accounted for approximately $3.5 million of the increase.

 

This increase was almost completely offset by the following factors:

 

    Lower sales volume combined with higher manufacturing costs accounted for an estimated $2.1 million decrease in income from operations.

 

    Higher freight and other manufacturing costs of approximately $1.4 million.

 

Carton and Custom Packaging Segment

 

The increase in income from operations was a result of the following:

 

    Lower restructuring costs and savings from closed facilities of approximately $2.4 million.

 

    Higher selling prices and higher contract packaging volume accounted for approximately $1.3 million.

 

These factors were partially offset by accelerated depreciation and other expenses of approximately $450 thousand as a result of closing down Palmer carton plant located in Thorndike, Massachusetts.

 

Other (Expense)Income. Interest expense for the three months ended September 30, 2005 and September 30, 2004 was approximately $10.5 million and $10.4 million, respectively. See “—Liquidity and Capital Resources” for additional information regarding our debt, interest expense and interest rate swap agreements.

 

Equity in income from unconsolidated affiliates was $9.6 million for the three months ended September 30, 2005, an improvement of $1.9 million over equity in income from unconsolidated affiliates of $7.7 million for the three months ended September 30, 2004. This increase was due to a significant improvement in operating results for Standard Gypsum and Premier Boxboard Limited. These improved results were due primarily to an increase in selling prices and volume for both joint ventures, which were driven by the strong housing market.

 

30


Table of Contents

(Provision) Benefit for income taxes. The effective rate of income tax expense for the three months ended September 30, 2005 was 60.5%, compared to an effective rate of 16.3% for the three months ended September 30, 2004. The effective rates for both periods are different from the statutory rates due to permanent tax adjustments.

 

Net Income (Loss). Due to the factors discussed above, net income for the three months ended September 30, 2005 was $45 thousand, or $0.00 net income per common share, compared to a net loss of $596 thousand, or $(0.02) net loss per common share, for the same period last year.

 

Results of Operations for the Nine Months Ended September 30, 2005 and 2004

 

     Nine Months Ended
September 30,


  

Change


   

%

Change


 
     2005

   2004

    

Paperboard tons shipped by production source (in thousands):

                            

From internal paperboard mill production

     722.9      745.3      (22.4 )   (3.0 )%

Purchases from external sources

     91.3      101.4      (10.1 )   (10.0 )%
    

  

  


 

Total paperboard tonnage

     814.2      846.7      (32.5 )   (3.8 )%
    

  

  


 

Paperboard tons shipped by end-use market (in thousands):

                            

Tube, core and composite container volume

                            

Paperboard (internal)

     179.2      187.0      (7.8 )   (4.2 )%

Purchases from external sources

     32.1      33.7      (1.6 )   (4.8 )%
    

  

  


 

Tube, core and composite container converted products

     211.3      220.7      (9.4 )   (4.3 )%

Unconverted paperboard shipped to external customers

     35.2      36.5      (1.3 )   (3.6 )%
    

  

  


 

Tube, core and composite container volume

     246.5      257.2      (10.7 )   (4.2 )%

Folding carton volume

                            

Paperboard (internal)

     69.3      71.5      (2.2 )   (3.1 )%

Purchases from external sources

     52.3      58.3      (6.0 )   (10.3 )%
    

  

  


 

Folding carton converted products

     121.6      129.8      (8.2 )   (6.3 )%

Unconverted paperboard shipped to external customers

     179.6      179.3      0.3     0.2 %
    

  

  


 

Folding carton volume

     301.2      309.1      (7.9 )   (2.6 )%

Gypsum wallboard facing paper volume

                            

Unconverted paperboard shipped to external customers

     58.7      77.3      (18.6 )   (24.1 )%

Other specialty products volume

                            

Paperboard (internal)

     72.8      68.6      4.2     6.1 %

Purchases from external sources

     6.9      9.4      (2.5 )   (26.6 )%
    

  

  


 

Other specialty converted products

     79.7      78.0      1.7     2.2 %

Unconverted paperboard shipped to external customers

     128.1      125.1      3.0     2.4 %
    

  

  


 

Other specialty products volume

     207.8      203.1      4.7     2.3 %
    

  

  


 

Total paperboard tonnage

     814.2      846.7      (32.5 )   (3.8 )%
    

  

  


 

Selling price and cost data ($/ton):

                            

Paperboard mills:

                            

Average selling price

   $ 475    $ 453    $ 22     4.9 %

Average recovered fiber cost

     109      107      2     1.9 %

Tube and core facilities:

                            

Average selling price

   $ 948    $ 892    $ 56     6.3 %

Average paperboard cost

     497      474      23     4.9 %

 

The following table shows paperboard shipment volume on our business segment basis (thousands of tons).

 

     Nine Months Ended
September 30,


  

Change


   

%

Change


 
   2005

   2004

    

Paperboard segment

                      

Unconverted paperboard shipped to external customers

   401.6    418.3    (16.7 )   (4.0 )%

Paperboard shipped internally to converters in the paperboard segment

   45.6    44.6    1.0     2.2 %

Paperboard purchased externally by converters in the paperboard segment

   0.4    0.3    0.1     33.3 %
    
  
  

 

Total volume

   447.6    463.2    (15.6 )   (3.4 )%

Tube, core and composite container segment

                      

Paperboard (internal)

   206.4    211.0    (4.6 )   (2.2 )%

Purchases from external sources

   38.6    42.8    (4.2 )   (9.8 )%
    
  
  

 

Total volume converted

   245.0    253.8    (8.8 )   (3.5 )%

Carton and custom packaging segment

                      

Paperboard (internal)

   69.3    71.4    (2.1 )   (2.9 )%

Purchases from external sources

   52.3    58.3    (6.0 )   (10.3 )%
    
  
  

 

Total volume converted

   121.6    129.7    (8.1 )   (6.2 )%

Total paperboard tonnage

   814.2    846.7    (32.5 )   (3.8 )%
    
  
  

 

 

31


Table of Contents

Paperboard Tonnage. Total paperboard tonnage for the nine months ended September 30, 2005, decreased 3.8% to 814.2 thousand tons from 846.7 thousand tons for the same period in 2004. Tons sold from paperboard mill production decreased 3.4% for the nine months ended September 30, 2005, compared to the same period in 2004. Total tonnage converted decreased 3.7% for the nine months ended September 30, 2005.

 

Total paperboard tonnage decreased due to the following factors:

 

    A decrease in gypsum facing paper sales resulting from downtime and inefficiencies associated with equipment upgrade at our Sweetwater paperboard mill combined with a decrease in industry demand in the tube, core and composite container and folding carton markets.

 

    A decrease in internal conversion by our tube, core and composite container and folding carton operations resulting from the same industry demand declines mentioned above.

 

These decreases were partially offset by an increase in internal conversion by our other specialty operations.

 

Sales. Our consolidated sales for the nine months ended September 30, 2005, increased 0.9% to $806.6 million from $799.4 million for the same period in 2004. The following table presents sales by business segment (in thousands):

 

     Nine Months Ended
September 30,


  

$

Change


   

%

Change


 
   2005

   2004

    

Paperboard

   $ 207,052    $ 215,059    $ (8,007 )   (3.7 )%

Recovered fiber

     62,359      61,261      1,098     1.8 %

Tube, core and composite container

     299,357      293,234      6,123     2.1 %

Carton and custom packaging

     237,829      229,801      8,028     3.5 %
    

  

  


 

Total

   $ 806,597    $ 799,355    $ 7,242     0.9 %
    

  

  


 

 

Paperboard Segment

 

Sales for the paperboard segment decreased due to the following factors:

 

    Lower volume accounted for approximately $7.4 million of the decrease, primarily as a result of downtime and inefficiencies associated with equipment upgrade at our Sweetwater paperboard mill combined with uncharacteristic operating inefficiencies primarily at our uncoated mills.

 

    The June 2004 divestiture of the chemical sales operation and lower volume in the paperboard segment’s converting operation accounted for approximately $10.9 million of the decrease.

 

These factors were partially offset by higher selling prices which accounted for an estimated $9.2 million increase in sales combined with higher converting operations sales of approximately $700 thousand.

 

Recovered Fiber Segment

 

Sales increased $1.1 million for the recovered fiber segment due to higher volume primarily attributable to nine months of activity in 2005 for a new greenfield brokerage facility that began operations in the second quarter of 2004. These increases were partially offset by a decrease in selling price.

 

Tube, Core and Composite Container Segment

 

Sales for the tube, core and composite container segment increased due to higher selling prices for tubes and cores, which accounted for approximately $13.4 million of the increase.

 

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This increase was partially offset by the following factors:

 

    Lower volume accounted for an approximate $4.7 million decrease in sales.

 

    Lower miscellaneous and forming sales accounted for an approximate $3.1 million decrease in sales.

 

Carton and Custom Packaging Segment

 

Sales for the carton and custom packaging segment increased due to the following factors:

 

    Higher contract packaging volume accounted for approximately $8.9 million of the increase.

 

    Higher carton pricing accounted for approximately $10.4 million of the increase.

 

These increases were partially offset by lower volume which accounted for an approximate $11.7 million decrease in sales.

 

Gross Profit Margin. Gross profit margin for the nine months ended September 30, 2005, decreased to 13.9% of sales from 15.1% for the same period in 2004. This margin decrease was due to the following factors:

 

    Higher freight costs of approximately $8.9 million.

 

    Higher manufacturing and other costs of approximately $8.6 million.

 

    Higher paperboard costs in our carton and custom packaging segment of approximately $5.3 million.

 

    Higher energy costs in the paperboard segment of approximately $4.2 million.

 

    Accelerated depreciation and other expenses of approximately $1.1 million as a result of closing the Palmer carton plant located in Thorndike, Massachusetts.

 

These factors were partially offset by:

 

    Higher selling prices in the carton and custom packaging segment accounted for an estimated $8.9 million increase in gross profit.

 

    Higher selling prices, net of higher paperboard costs, in the tube and core segment accounted for an estimated $7.7 million increase in gross profit.

 

    An increase in paperboard mill selling prices and a decrease in recovered fiber costs accounted for an estimated $4.1 million increase in gross profit.

 

    In 2004, we recorded a $2.1 million inventory reserve for a specific carton customer that filed Chapter 11 bankruptcy. We reversed $1.1 million of this reserve during the first nine months of 2005 resulting in a $3.2 million year over year increase in gross profit.

 

Selling, General and Administrative Expenses. Selling, general and administrative expenses were $105.5 million for the nine months ended September 30, 2005, an increase of 2.3% from the same period in 2004. Selling, general and administrative expenses increased due to the following factors:

 

    Higher employee and administrative costs of approximately $3.5 million related to two initiatives: centralization of our accounting and finance operations and an investment in other back office functions in order to reduce professional fees, purchasing and other costs in the long term.

 

    Higher pension and other employee costs of approximately $3.0 million.

 

    Higher information technology costs of approximately $1.4 million related to Sarbanes-Oxley compliance and consulting fees related to the implementation of an enterprise resource planning software.

 

    The carton and custom packaging segment recorded a reserve of approximately $1.0 million for costs related to a product recall.

 

These factors were partially offset by:

 

    Lower selling, general and administrative expenses of approximately $3.5 million as a result of restructured and closed facilities.

 

    Expense of approximately $1.6 million related to the 2004 vesting of performance accelerated restricted stock.

 

    Lower accounts receivable reserve expense of $1.1 million.

 

    Lower fees for consultants related to Sarbanes-Oxley compliance of approximately $500 thousand.

 

Restructuring and Impairments.

 

In September 2005, we announced the permanent closure of our Mobile tube plant located in Mobile, Alabama. In the third quarter of 2005 we recorded a charge of approximately $69 thousand for severance and other benefits in connection with this closure. We expect to incur an additional $96 thousand of severance and other benefit expense and $1.0 million in other exit costs related to the closure of this facility. The Mobile tube plant is expected to cease operations by the end of the year in order to facilitate customer transition to our other tube facilities.

 

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In September 2005, we sold the real estate associated with our Chesapeake paperboard mill, which permanently closed in February 2000, for $1.7 million, net of expenses, and recorded a gain of approximately $1.0 million.

 

In September 2005, we negotiated and settled our long term lease obligation related to our Carolina Converting, Inc. facility, which was permanently closed in December 2002, for $872 thousand, net of expenses, and recorded a $580 thousand reversal of the restructuring accrual.

 

See Note 14, “Subsequent Events” for discussion on the closure of our DeQuincy tube plant, located in DeQuincy, Louisiana and our plan to sell our Hunt Valley carton plant, located in Hunt Valley, Maryland.

 

During the nine months ended September 30, 2005, we recorded a $171 thousand gain on disposal of fixed assets, incurred $385 thousand for severance and other termination benefits and $128 thousand for other exit costs. During the nine months ended September 30, 2004 we recorded asset impairment charges of $2.9 million, incurred severance and other benefit costs of $3.9 million, and incurred $3.8 million in other exit costs. During the nine months ended September 30, 2005 we paid $1.7 million in severance and other termination benefits and paid $2.6 million for other exit costs leaving an accrual of $2.7 million at September 30, 2005.

 

Income (Loss) From Operations. Income from operations for the nine months ended September 30, 2005 was $6.6 million, a decrease of $476 thousand compared with operating income of $7.1 million for the same period in 2004. The following table presents income (loss) from operations by business segment (in thousands):

 

     Nine Months Ended
September 30,


   

$

Change


   

%

Change


 
     2005

    2004

     

Paperboard

   $ 14,103     $ 18,439     $ (4,336 )   (23.5 )%

Recovered fiber

     616       2,524       (1,908 )   (75.6 )%

Tube, core and composite container

     5,092       9,591       (4,499 )   (46.9 )%

Carton and custom packaging

     4,354       (6,711 )     11,065     N/A  

Corporate expense

     (17,519 )     (16,721 )     (798 )   (4.8 )%
    


 


 


 

Total

   $ 6,646     $ 7,122     $ (476 )   (6.7 )%
    


 


 


 

 

Paperboard Segment

 

Income from operations decreased due to the following factors:

 

    Higher energy costs of approximately $8.1 million.

 

    Lower volume in the paperboard segment reduced operating income by approximately $3.2 million primarily as a result of downtime and inefficiencies associated with an equipment upgrade at our Sweetwater paperboard mill.

 

    Higher freight costs of approximately $3.1 million.

 

    Higher other manufacturing costs of approximately $1.0 million.

 

These factors were partially offset by:

 

    Lower restructuring costs and savings from closed facilities of approximately $5.8 million.

 

    An increase in paperboard mill selling prices and a decrease in recovered fiber costs accounted for an estimated $5.1 million increase.

 

Recovered Fiber Segment

 

Income from operations decreased due to higher freight costs of approximately $2.7 million, partially offset by lower restructuring costs and savings from closed facilities of approximately $500 thousand.

 

Tube, Core and Composite Container Segment

 

Income from operations decreased due to the following factors:

 

    Higher tube core and composite container manufacturing costs of approximately $7.5 million. These cost increases were generally driven by higher adhesives, resins, metals and employee costs.

 

    Higher freight costs of approximately $3.1 million.

 

    Higher resin and other manufacturing costs in our plastics facilities of approximately $1.1 million.

 

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These factors were partially offset by the following:

 

    Higher selling prices, net of higher paperboard costs, and lower volume which accounted for an approximate $6.7 million increase in income from operations.

 

    Lower restructuring costs and savings from closed facilities of approximately $525 thousand.

 

Carton and Custom Packaging Segment

 

The increase in income from operations was a result of the following:

 

    Higher selling price and contract packaging volume accounted for approximately $8.9 million of the increase.

 

    Lower restructuring costs and savings related to closed facilities costs of approximately $4.8 million.

 

    In 2004, we recorded a $2.1 million inventory reserve for a specific carton customer that filed Chapter 11 bankruptcy. We reversed $1.1 million of this reserve during the first nine months of 2005 resulting in a $3.2 million year over year increase in income from operations.

 

    Lower accounts receivable reserve expense of approximately $800 thousand.

 

    Lower other manufacturing costs of approximately $700 thousand.

 

These factors were partially offset by the following:

 

    Higher paperboard costs of approximately $5.4 million.

 

    Accelerated depreciation and other expenses of approximately $1.1 million as a result of closing the Palmer carton plant located in Thorndike, Massachusetts.

 

    A reserve of approximately $1.0 million for costs related to a product recall.

 

Other (Expense) Income. Interest expense for the nine months ended September 30, 2005 and 2004 was approximately $31.6 million. See “—Liquidity and Capital Resources” for additional information regarding our debt, interest expense and interest rate swap agreements.

 

Equity in income from unconsolidated affiliates was $27.5 million for the nine months ended September 30, 2005, an improvement of $10.7 million over equity in income from unconsolidated affiliates of $16.8 million for the same period in 2004. This increase was primarily due to a $6.3 million improvement in operating results for Standard Gypsum, our gypsum wallboard joint venture with Temple-Inland. The improved results were due primarily to an increase in selling prices and volume driven by the strong housing and remodeling markets. Premier Boxboard’s results improved $4.6 million for the nine month period ended September 30, 2005 compared to 2004, also due to higher volume and selling prices.

 

(Provision) Benefit for Income Taxes. The effective rate of income tax expense for the nine months ended September 30, 2005 was 84.4%, compared to an effective rate of income tax benefit of 26.61% for the nine months ended September 30, 2004. The effective rates for both periods are different from the statutory rates due to permanent tax adjustments. In addition, the income tax expense for the nine months ended September 30, 2005 includes tax expense of $1.9 million related to an increase in the valuation allowance for state net operating losses resulting from a change in Ohio tax law. On June 30, 2005, significant changes to the tax system of the State of Ohio were signed into law which will eliminate the Ohio franchise tax over the five year period ending December 31, 2010. The valuation allowance was recorded in its entirety at June 30, 2005 since the benefits of the net operating losses are not expected to be realized.

 

Net Income (loss). Due to the factors discussed above, net income for the nine months ended September 30, 2005 was $613 thousand, or $0.02 net income per common share, compared to a net loss of $5.6 million, or $0.20 net loss per common share, for the same period in 2004.

 

Liquidity and Capital Resources

 

Liquidity Sources and Risks. Our primary sources of liquidity are cash from operations and borrowings under our senior credit facility, described below. Downturns in operations can significantly affect our ability to generate cash. Factors that can affect our operating results and liquidity are discussed further in our 2004 Annual Report on Form 10-K under “—Risk Factors” in Part I, Item 1. For the nine-month period ended September 30, 2005, we generated $13.2 million in cash from operating activities compared with $28.9 million during the same period in 2004. We believe that our cash on hand at September 30, 2005 of $90.7 million and borrowing availability under our senior credit facility will be sufficient to meet our cash requirements for the next twelve months and the foreseeable future. Additionally, based on our historical ability to generate cash, we believe we will

 

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be able to meet our long-term cash requirements. However, if we are unable to generate cash at levels prior to the downturn beginning in 2000, our ability to generate sufficient cash to meet long-term requirements is uncertain. The following are factors that could adversely affect our future ability to generate cash from operations:

 

    a contraction in domestic demand for recycled paperboard and related packaging products similar to what our industry experienced in 2000, 2001 and 2002;

 

    increased market acceptance of alternative products, such as flexible packaging and plastics, that have replaced or can replace certain of our packaging products;

 

    continued export of domestic industrial manufacturing operations

 

    continued increase in fuel costs

 

    market acceptance of price increases and energy surcharges in response to rising operating costs; and

 

    significant unforeseen adverse conditions in our industry or the markets we serve.

 

The occurrence, continuation or exacerbation of these conditions could require us to seek additional funds from external sources in order to meet our liquidity requirements. In such event, our ability to obtain additional funds would depend on the various business and credit market conditions prevailing at the time, which are difficult to predict and many of which are out of our control. Our ability to secure additional funds could also be materially adversely affected by our substantial indebtedness. Additional risks related to our substantial indebtedness are discussed under “Risk Factors — Our substantial indebtedness could adversely affect our cash flow and our ability to fulfill our obligations under our indebtedness” in our Annual Report on Form 10-K for the year ended December 31, 2004.

 

The availability of liquidity from our senior credit facility is primarily affected by our continued compliance with the terms of the senior credit facility agreement governing our senior credit facility, including the payment of interest and compliance with various covenants and financial maintenance tests. We were in compliance with the covenants under our senior credit facility during the nine months ended September 30, 2005. Absent a deterioration of the U.S. economy as a whole or the specific sectors on which our business depends, we believe we will be in compliance with our covenants under the senior credit agreement during the remainder of 2005.

 

Borrowings. At September 30, 2005 and December 31, 2004, total debt (consisting of current maturities of debt and long-term debt, as reported on our condensed consolidated balance sheets) was as follows (in thousands):

 

     September 30,
2005


   December 31,
2004


9 7/8% senior subordinated notes

   $ 262,500    $ 265,000

7 3/8% senior notes

     189,750      189,750

7 1/4% senior notes

     29,000      29,000

Other notes payable

     9,735      9,735

Mark-to-market value of interest swap agreements

     —        —  

Net premiums (1)

     11,895      12,736
    

  

Total debt

   $ 502,880    $ 506,221
    

  


(1) These amounts consist of realized interest rate swap gains less the original issuance discounts and accumulated discount amortization related to the senior and senior subordinated notes. As described below under “Interest Rate Swap Agreements,” realized gains resulting from unwinding interest rate swaps are recorded as a component of debt and will be accreted as a reduction to interest expense over the remaining term of the debt.

 

Our senior credit facility provides for a revolving line of credit of $75.0 million and is secured primarily by a first priority security interest in our accounts receivable and inventory. The facility includes a subfacility of $50.0 million for letters of credit, usage of which reduces availability under the facility. As of September 30, 2005 and December 31, 2004, no borrowings were outstanding under the facility; however, an aggregate of $38.3 million and $38.4 million in letter of credit obligations were outstanding, respectively. Availability under the facility at September 30, 2005 was $36.7 million after taking into consideration outstanding letter of credit obligations.

 

Effective March 1, 2005 we amended our senior credit facility to increase the aggregate amount of permitted asset sales from $5.0 million to $15.0 million, to reduce the unused facility fee from 0.50% to 0.375%, and to reduce the applicable interest margins above the Base Rate and LIBOR Rate for borrowings and outstanding letters of credit under the facility. The interest margin for Base Rate borrowings was reduced from 0.50% to a range from (0.25%) to 0.25%, and the margin for LIBOR Rate

 

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borrowings and outstanding letters of credit was reduced from 2.50% to a range from 1.50% to 2.00%, with the applicable margin to be set based on our levels of available cash. At September 30, 2005, the applicable interest margin for Base Rate borrowings was (0.25%) and the applicable interest margin for LIBOR Rate borrowings was 1.50%.

 

Effective September 20, 2005 we amended our senior credit facility to permit the issuance of a $29.5 million letter of credit in favor of Standard Gypsum, L.P.’s lender with an expiration date no later than October 29, 2006. This amendment was made in connection with the refinancing of Standard Gypsum’s debt facilities, as described below under “Off-Balance Sheet Arrangements – Joint Venture Financings.”

 

See Note 14, “Subsequent Events” regarding the purchase of an additional $5.0 million of our 9 7/8% senior subordinated notes in the open market.

 

Interest Rate Swap Agreements. From time to time, we have entered into interest rate swap agreements related to our senior notes and senior subordinated notes. The payment and expiration date for these interest rate swaps correspond to the terms of the note obligations they cover. These interest rate swap agreements effectively convert an amount of our fixed debt into variable rate obligations. Typically, the variable amounts are based upon a three-month or six-month LIBOR plus a fixed margin. When we have unwound these agreements and recognized a gain, the amount is classified as a component of debt and is accreted to interest expense over the remaining life of the notes and partially offsets an increase in interest expense. As of September 30, 2005 we had no outstanding interest rate swaps.

 

In March 2004, we unwound a $50.0 million interest rate swap agreement related to our 9 7/8% senior subordinated notes and received approximately $380 thousand from the bank counter-party. The $380 thousand gain, classified as a component of debt, is being accreted over the remaining life of the notes and will partially offset the increase in interest expense.

 

In April 2004, we entered into an interest rate swap agreement in the notional amount of $50.0 million. This agreement effectively converted $50.0 million of the Company’s fixed rate 9 7/8% senior subordinated notes into variable rate obligations. The variable rates were based on six-month LIBOR plus a fixed margin.

 

In March 2005, we entered into an interest rate swap agreement in the notional amount of $50.0 million. This agreement effectively converted $50.0 million of our fixed rate 7 3/8 % senior notes into variable rate obligations. The variable rates were based on three-month LIBOR plus a fixed margin.

 

In June 2005, we unwound the March 2005 $50.0 million interest rate swap agreement related to the 7 3/8% senior notes and received approximately $826 thousand from the bank counter-party. The $826 thousand gain was classified as a component of debt, and is being accreted over the remaining life of the notes and will partially offset the increase in interest expense.

 

Off-Balance Sheet Arrangements Joint Venture Financings. As noted above, we own a 50% interest in two joint ventures with Temple-Inland, Inc.: Standard Gypsum, L.P. and Premier Boxboard Limited LLC. Because we account for these interests in our joint ventures under the equity method of accounting, the indebtedness of these joint ventures is not reflected in the liabilities included on our consolidated balance sheets.

 

On September 22, 2005 Standard refinanced its outstanding letter of credit reimbursement obligations with borrowings under a new term loan in the principal amount of $56.2 million, from a replacement lender. The term loan matures in full one year from the agreement date. We are severally obligated for 50% of Standard’s obligations for principal, interest, fees and other amounts with respect to the term loan. The other Standard partner, Temple-Inland, has guaranteed 50% of Standard’s obligations. As of September 2005, the outstanding principal balance under the term loan totaled $56.2 million, for one half of which we are obligated ($28.1 million). Our obligation with respect to the Standard term loan is supported by a letter of credit in the face amount of $29.5 million, issued in favor of the Standard lender. This letter of credit was issued under our senior credit facility and expires in October 2006. In connection with the term loan we amended our senior credit facility effective September 20, 2005 to permit the issuance of this letter of credit.

 

At December 31, 2004, Premier Boxboard was the borrower under a credit facility with an aggregate outstanding principal amount of $632 thousand, consisting solely of an undrawn letter of credit. On January 5, 2005, Premier Boxboard’s revolving credit facility expired. The only outstanding obligation under the facility at the time of expiration was the $632 thousand letter of credit balance, which expired on June 20, 2005 and was not renewed. Premier Boxboard placed $614 thousand of available cash into a trust account to replace the expired letter of credit.

 

Since December 31, 2004, except as described above, there have been no material changes in our obligations with respect to the debt obligations of these joint ventures, or any additional contingencies related to buy-sell agreements for our interests in the joint ventures. For more information about these obligations and contingencies, see “Management’s Discussion and Analysis of Financial Condition and Results of Operations — Liquidity and Capital Resources — Off-Balance Sheet Arrangements” in our Annual Report on Form 10-K for the year ended December 31, 2004.

 

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Cash from Operations. Cash generated from operations was $13.2 million for the nine months ended September 30, 2005, compared with $28.9 million from operations for the same period of 2004. The decrease in 2005 compared to the same period in 2004 was due primarily to a $13.1 million pension contribution made in September 2005, $3.8 million in payments in 2005 for bonuses earned in 2004, $4.3 million in payments for restructuring costs, and changes in working capital of $6.1 million. The changes in working capital are primarily due to changes in inventory, accounts payable and accrued liabilities. These decreases were partially offset by an increase in distributions of earnings from our joint venture partners, Standard Gypsum and Premier Boxboard, of $10.7 million.

 

Capital Expenditures. Capital expenditures were $17.9 million for the nine months ended September 30, 2005 versus $15.6 million for the same period of 2004. Aggregate capital expenditures of approximately $25.0 million are anticipated for 2005. To conserve cash, we intend to limit capital expenditures for 2005 to cost reduction, productivity improvement and replacement projects.

 

Inflation

 

Raw material and energy cost changes have had, and continue to have, a material negative effect on our operations. We do not believe that general economic inflation is a significant determinant of our raw material and energy cost increases or that it has a material effect on our operations.

 

New Accounting Pronouncements

 

On April 14, 2005, the Securities and Exchange Commission announced that the required effective date for adopting SFAS No. 123 (R), “Share-Based Payment” has been deferred to fiscal years beginning after June 15, 2005 instead of an effective date beginning July 1, 2005. The Company will be required to adopt this statement January 1, 2006.

 

Contractual Obligations

 

For a discussion of our contractual obligations, see “Management’s Discussion and Analysis of Financial Condition and Results of Operations —Liquidity and Capital Resources — Contractual Obligations” and Note 7 of “Notes to Consolidated Financial Statements” in our Annual Report on Form 10-K for the fiscal year ended December 31, 2004. There have been no significant developments with respect to our contractual obligations since December 31, 2004 other than the addition of capital lease obligations in the approximate amount of $1.7 million for the nine months ended September 30, 2005. The expected lease payments in 2006 and 2007 are approximately $557 thousand and $557 thousand, respectively.

 

Subsequent Events

 

In October 2005 we purchased $5.0 million of our 9 7/8% senior subordinated notes in the open market for approximately $4.9 million.

 

In October 2005, we announced the permanent closure of our DeQuincy tube plant located in DeQuincy, Louisiana. We expect to incur $165 thousand in severance and termination benefits and $25 thousand in other exit costs. The DeQuincy tube plant is expected to cease operations by the end of the year in order to facilitate customer transition to our other tube facilities.

 

On November 1, 2005, we announced the expected sale of our Hunt Valley carton plant located in Hunt Valley, Maryland. The sale is projected to be completed by December 31, 2005. The parties have not entered into a definitive agreement, but are in the process of negotiating the final terms.

 

Forward-Looking Information

 

This quarterly report on Form 10-Q, including “Management’s Discussion and Analysis of Financial Condition and Results of Operations,” contains certain “forward-looking statements,” within the meaning of Section 27A of the Securities Act of 1933 and Section 21E of the Securities Exchange Act of 1934, that represent our expectations, anticipations or beliefs about future events, including our operating results, financial condition, liquidity, expenditures, and compliance with legal and regulatory requirements. For this purpose, any statements that are not statements of historical fact may be deemed to be forward-looking statements. These statements involve risks and uncertainties that could cause actual results to differ materially depending on a variety of important factors, including, but not limited to, fluctuations in raw material prices and energy costs, increases in pension and insurance costs, downturns in industrial production, housing and construction and the consumption of durable and nondurable goods, the degree and nature of competition, the degree of market receptiveness to price increases and energy

 

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surcharges, demand for our products, the degree of success achieved by our new product initiatives, changes in government regulations, the application or interpretation of those regulations or in the systems, personnel, technologies or other resources we devote to compliance with regulations, our ability to complete acquisitions and successfully integrate the operations of acquired businesses, our ability to service our substantial indebtedness, unforeseen difficulties with the integration of our accounting and control operations, IT systems or legal function. Additional relevant risk factors that could cause actual results to differ materially are discussed in our most recent Annual Report on Form 10-K and in our other filings with the Securities and Exchange Commission. With respect to such forward-looking statements, we claim protection under the Private Securities Litigation Reform Act of 1995. Our SEC filings are available from us, and also may be examined at public reference facilities maintained by the Securities and Exchange Commission or, to the extent filed via EDGAR, accessed through the Web Site of the Securities and Exchange Commission (http://www.sec.gov). We do not undertake any obligation to update any forward-looking statements we make.

 

Risk Factors

 

For a discussion of our risk factors, see Risk Factors in “Management’s Discussion and Analysis of Financial Condition and Results of Operations” in our Annual Report on Form 10-K for the fiscal year ended December 31, 2004. There have been no significant developments with respect to our risk factors since December 31, 2004.

 

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PART I

 

ITEM 3. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

 

For a discussion of certain market risks related to us, see Part II, Item 7A, “Quantitative and Qualitative Disclosures about Market Risk,” in our Annual Report on Form 10-K for the fiscal year ended December 31, 2004. There have been no significant developments with respect to our exposure to interest rate market risks. See Note 5 to the condensed consolidated financial statements for additional information about our interest rate swap agreements.

 

ITEM 4. CONTROLS AND PROCEDURES

 

Changes in Internal Control Over Financial Reporting. There was no change to our internal control over financial reporting during the three months ended September 30, 2005 that has materially affected, or is reasonably likely to materially affect, our internal control over financial reporting.

 

Disclosure Controls and Procedures. Our management, with the participation of our chief executive officer and chief financial officer, evaluated the effectiveness of our disclosure controls and procedures (as defined in Rule 13a-15(e) under the Securities Exchange Act of 1934) as of September 30, 2005. Based on this evaluation, our chief executive officer and chief financial officer concluded that, as of September 30, 2005, our disclosure controls and procedures were effective in recording, processing, summarizing and reporting, on a timely basis, information required to be disclosed by the Company’s reports that it files or submits under the Securities Exchange Act of 1934.

 

PART II. OTHER INFORMATION

 

ITEM 1. LEGAL PROCEEDINGS

 

On August 11, 2005 Region V of the Environmental Protection Agency filed an administrative complaint against the Company for its alleged failure to timely file completed emergency and hazardous chemical inventory forms, pursuant to the Emergency Planning and Community Right-to-Know Act (EPCRA), for calendar years 2001 and 2002. The EPA proposed fines totaling $74 thousand. The Company was working with the EPA and had filed, prior to commencement of the administrative action, inventory forms for the relevant calendar years. The Company and the EPA reached an agreement in principle to resolve this matter. The Company agreed to accept these violations and pay a reduced penalty of $40 thousand. The Company has reviewed and updated its compliance activities and management believes this process will enable the Company to comply prospectively with EPCRA filing requirements.

 

ITEM 2. UNREGISTERED SALES OF EQUITY SECURITIES AND USE OF PROCEEDS

 

There were no transactions to report for the three months ended September 30, 2005.

 

In February 2002, we announced that we would suspend future dividend payments on our common stock until our earnings performance and cash flow performance improve. Our debt agreements contain certain limitations on the payment of dividends and currently preclude us from doing so.

 

ITEM 5. OTHER INFORMATION

 

On November 7, 2005 the Company amended its existing Change in Control Severance Agreements with its named Executives in connection with the Compensation and Benefits Committee’s (of the Company’s Board of Directors) annual review of agreements with management. The Change in Control Severance Agreements generally afford the Company continuity of operations in the event of a change in control, which may otherwise result in the departure or distraction of management personnel to the detriment of the Company and its shareholders.

 

The amendments will, in the event that the there is a change in control precipitating the termination of an Executive’s employment, additionally require the Company to: issue cash payments to Senior Management for projected incentive plan payments equal to the average annual incentive bonus paid to the Executive in the last two years; continue health and welfare benefits to the Executive and the Executive’s dependents on substantially the same basis as the health and welfare benefits offered to the Executive immediately before termination; and ensure compliance with Internal Revenue Code Section 280 G.

 

On November 7, 2005 the Company amended its Supplemental Executive Retirement Plan (SERP) in connection with the Compensation and Benefits Committee’s (of the Company’s Board of Directors) annual review of agreements with management. The SERP generally supplements the Company’s other retirement benefits by providing to certain Executives additional retirement benefits to which they otherwise would be entitled under the registrant’s pension plan in the absence of limitations imposed by the Internal Revenue Code.

 

The November 7th amendments will: ensure compliance with Internal Revenue Code Section 409A; diminishing risks for Executives in the Plan, caused in part by the Company’s decision to freeze its qualified defined benefits plan as of January 1, 2005, by adding optional forms of payment; and clarify certain plan provisions to conform with procedures and calculations under the Company’s defined contribution plan and more clearly define the operation of the plan.

 

ITEM 6. EXHIBITS

 

  a) Exhibits

 

The Exhibits to this Report on Form 10-Q are listed in the accompanying Exhibit Index.

 

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SIGNATURES

 

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.

 

CARAUSTAR INDUSTRIES, INC.
By:  

/s/ Ronald J. Domanico


    Ronald J. Domanico
    Senior Vice President and Chief Financial Officer

 

Date: November 8, 2005

 

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EXHIBIT INDEX

 

Exhibit No.

       

Description


3.01       Amended and Restated Articles of Incorporation of the Company (Incorporated by reference — Exhibit 3.01 to Annual Report for 1992 on Form 10-K [SEC File No. 0-20646])
3.02       Third Amended and Restated Bylaws of the Company (Incorporated by reference — Exhibit 3.02 to Annual Report for 2001 on Form 10-K [SEC File No. 0-20646])
10.1†       Caraustar Industries, Inc. Restoration Plan Amendment, dated as of August 11, 2005
10.2†       Caraustar Industries, Inc. Restoration Plan Amendment, dated as of November 7, 2005
10.3†       Sixth Amendment to Credit Agreement, dated as of September 20, 2005, by and among the Company and certain subsidiaries identified therein, as borrower, certain subsidiaries of the Company identified as guarantors listed therein, and Bank of America, N.A., as Administrative Agent
10.4†#       Change is Control Severance Agreement, dated November 7, 2005 between the Company and the officers of the Company
31.01†       Certification of CEO — Pursuant to Rule 13a-14(a)/15d-14(a), as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002
31.02†       Certification of CFO — Pursuant to Rule 13a-14(a)/15d-14(a), as adopted pursuant to Section 302 of the Sarbanes-Oxley Act of 2002
32.01†       Certification of CEO — Pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002
32.02†       Certification of CFO — Pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002

Filed herewith

 

# This exhibit is substantially identical to Change in Control Severance Agreements for the following individuals: Michael J. Keough, Ronald J. Domanico, William A. Nix, III, Jimmy A. Russell, Thomas C. Dawson, John R. Foster, Steven L. Kelchen, Gregory B. Cottrell, Barry A. Smedstad

 

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