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SECURITIES AND EXCHANGE COMMISSION

Washington, D.C. 20549

 


 

FORM 10-Q

 

(Mark One)

 

ý

 

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

 

 

 

 

 

For the quarterly period ended March 31, 2004

 

 

 

 

 

OR

 

 

 

o

 

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

 

 

 

 

 

For the transition period from                   to                  

 

 

 

 

 

Commission file number 333-40067

 

PLIANT CORPORATION

(Exact name of registrant as specified in its charter)

 

Utah

 

87-0496065

(State or other jurisdiction of
incorporation or organization)

 

(I.R.S. Employer
Identification No.)

 

1475 Woodfield Road, Suite 700

Schaumburg, IL 60173

(847) 969-3300

(Address of principal executive offices and telephone number)

 

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

 

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

 

APPLICABLE ONLY TO CORPORATE ISSUERS:

 

Indicate the number of shares outstanding of each of the issuer’s classes of common stock, as of the latest practicable date.  On May 14, 2004, there were 571,711 outstanding shares of the registrant’s Common Stock.

 



 

PLIANT CORPORATION AND SUBSIDIARIES

 

TABLE OF CONTENTS

 

PART I. FINANCIAL INFORMATION

 

 

 

 

 

 

ITEM 1. FINANCIAL STATEMENTS

 

 

 

 

 

 

 

CONDENSED CONSOLIDATED BALANCE SHEETS AS OF MARCH 31,
2004 AND DECEMBER 31, 2003

 

 

 

 

 

 

 

CONDENSED CONSOLIDATED STATEMENTS OF OPERATIONS FOR
THE THREE MONTHS ENDED MARCH 31, 2004 AND 2003

 

 

 

 

 

 

 

CONDENSED CONSOLIDATED STATEMENTS OF CASH FLOWS FOR
THE THREE MONTHS ENDED MARCH 31, 2004 AND 2003

 

 

 

 

 

 

 

CONDENSED CONSOLIDATED STATEMENT OF STOCKHOLDERS’
DEFICIT FOR THE THREE MONTHS ENDED MARCH 31, 2004

 

 

 

 

 

 

 

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS

 

 

 

 

 

 

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

 

 

 

 

 

 

ITEM 3. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

 

 

 

 

 

 

ITEM 4. CONTROLS AND PROCEDURES

 

 

 

 

 

PART II. OTHER INFORMATION

 

 

 

 

ITEM 1. LEGAL PROCEEDINGS

 

 

 

 

 

 

ITEM 2. CHANGES IN SECURITIES, USE OF PROCEEDS AND
ISSUER PURCHASES OF EQUITY SECURITIES

 

 

 

 

 

 

ITEM 3.  DEFAULTS UPON SENIOR SECURITIES

 

 

 

 

 

 

ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITYHOLDERS 

 

 

 

 

 

 

ITEM 5. OTHER INFORMATION

 

 

 

 

 

 

ITEM 6. EXHIBITS AND REPORTS ON FORM 8-K

 

 

2



 

PART I.  FINANCIAL INFORMATION

 

ITEM 1.  FINANCIAL STATEMENTS

 

PLIANT CORPORATION AND SUBSIDIARIES

CONDENSED CONSOLIDATED BALANCE SHEETS

AS OF MARCH 31, 2004 AND DECEMBER 31, 2003 (DOLLARS IN THOUSANDS) (UNAUDITED)

 

 

 

March 31, 2004

 

December 31, 2003

 

ASSETS

 

 

 

 

 

CURRENT ASSETS:

 

 

 

 

 

Cash and cash equivalents

 

$

3,346

 

$

3,308

 

Receivables, net of allowances of $5,530 and $5,776 respectively

 

123,209

 

111,942

 

Inventories

 

90,568

 

95,219

 

Prepaid expenses and other

 

3,076

 

3,809

 

Income taxes receivable, net

 

794

 

1,436

 

Deferred income taxes

 

9,362

 

9,417

 

Total current assets

 

230,355

 

225,131

 

 

 

 

 

 

 

PLANT AND EQUIPMENT, net

 

311,394

 

319,569

 

GOODWILL

 

182,158

 

182,162

 

INTANGIBLE ASSETS, net

 

19,227

 

19,752

 

OTHER ASSETS

 

40,283

 

40,172

 

TOTAL ASSETS

 

$

783,417

 

$

786,786

 

 

 

 

 

 

 

LIABILITIES AND STOCKHOLDERS’ DEFICIT

 

 

 

 

 

CURRENT LIABILITIES:

 

 

 

 

 

Trade accounts payable

 

$

88,031

 

$

89,800

 

Accrued liabilities:

 

 

 

 

 

Interest payable

 

18,624

 

19,775

 

Customer rebates

 

5,698

 

7,924

 

Other

 

40,207

 

35,947

 

Current portion of long-term debt

 

412

 

1,033

 

Total current liabilities

 

152,972

 

154,479

 

LONG-TERM DEBT, net of current portion

 

799,905

 

782,624

 

OTHER LIABILITIES

 

28,497

 

27,493

 

DEFERRED INCOME TAXES

 

28,645

 

27,792

 

SHARES SUBJECT TO MANDATORY REDEMPTION (Note 9)

 

202,953

 

 

Total Liabilities

 

1,212,972

 

992,388

 

Minority  Interest

 

232

 

291

 

REDEEMABLE PREFERRED STOCK – 200,000 shares authorized, designated as Series A, no par value, with a redemption and liquidation value of $1,000 per share; 140,973 shares outstanding at December 31, 2003

 

 

188,223

 

REDEEMABLE COMMON STOCK – no par value; 60,000 shares authorized; 10,873 shares outstanding as of March 31, 2004 and 29,073 shares outstanding as of December 31, 2003, net of related stockholders’ notes receivable of  $1,827 at March 31, 2004 and $4,258 at December 31, 2003

 

6,645

 

13,008

 

STOCKHOLDERS’ DEFICIT:

 

 

 

 

 

Common stock – no par value; 10,000,000 shares authorized, 542,638  shares outstanding at March 31, 2004 and December 31, 2003

 

103,376

 

103,376

 

Warrants to purchase common stock

 

39,133

 

39,133

 

Accumulated deficit

 

(567,811

)

(537,052

)

Stockholders’ notes receivable

 

(660

)

(660

)

Accumulated other comprehensive income (loss)

 

(10,470

)

(11,921

)

Total stockholders’ deficit

 

(436,432

)

(407,124

)

TOTAL LIABILITIES AND STOCKHOLDERS’ DEFICIT

 

$

783,417

 

$

786,786

 

 

See notes to condensed consolidated financial statements.

 

3



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATED STATEMENTS OF OPERATIONS

FOR THE THREE MONTHS ENDED MARCH 31, 2004 AND 2003 (IN THOUSANDS) (UNAUDITED)

 

 

 

2004

 

2003

 

 

 

 

 

 

 

NET SALES

 

$

244,167

 

$

240,511

 

 

 

 

 

 

 

COST OF SALES

 

207,375

 

197,714

 

 

 

 

 

 

 

Gross profit

 

36,792

 

42,797

 

 

 

 

 

 

 

OPERATING EXPENSES:

 

 

 

 

 

Sales, General and Administrative

 

20,983

 

21,316

 

Research and Development

 

1,832

 

1,377

 

Restructuring and Other Costs

 

 

6,064

 

 

 

 

 

 

 

Total operating expenses

 

22,815

 

28,757

 

 

 

 

 

 

 

OPERATING INCOME

 

13,977

 

14,040

 

 

 

 

 

 

 

INTEREST EXPENSE-Current and Long-term debt (note 4, 9)

 

(34,599

)

(19,856

)

 

 

 

 

 

 

INTEREST EXPENSE-Dividends and accretion on Redeemable Preferred Stock (note 9)

 

(8,367

)

 

OTHER INCOME(EXPENSE) – Net

 

(118

)

496

 

 

 

 

 

 

 

INCOME(LOSS) BEFORE INCOME TAXES

 

(29,107

)

(5,320

)

 

 

 

 

 

 

INCOME TAX EXPENSE

 

1,652

 

2,023

 

 

 

 

 

 

 

NET LOSS

 

$

(30,759

)

$

(7,343

)

 

See notes to condensed consolidated financial statements.

 

4



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATED STATEMENTS OF CASH FLOWS

FOR THE THREE MONTHS ENDED MARCH 31, 2004 AND 2003 (IN THOUSANDS) (UNAUDITED)

 

 

 

2004

 

2003

 

CASH FLOWS FROM OPERATING ACTIVITIES:

 

 

 

 

 

Net  income (loss)

 

$

(30,759

)

$

(7,343

)

Adjustments to reconcile net income (loss) to net cash (used in)/ provided by operating activities:

 

 

 

 

 

Depreciation and amortization

 

11,362

 

11,156

 

Amortization of deferred financing costs and accretion of debt discount

 

12,227

 

1,408

 

Deferred dividends and accretion on preferred shares

 

8,367

 

 

Deferred income taxes

 

715

 

(657

)

Provision for losses on accounts receivable

 

(246

)

(479

)

Non-cash plant closing costs

 

 

3,260

 

Gain or loss on disposal of assets

 

48

 

96

 

Changes in assets and liabilities:

 

 

 

 

 

Receivables

 

(11,132

)

(15,417

)

Inventories

 

4,950

 

(5,744

)

Prepaid expenses and other

 

738

 

(654

)

Income taxes payable/receivable

 

767

 

1,141

 

Other assets

 

(532

)

(259

)

Trade accounts payable

 

(1,812

)

4,807

 

Accrued liabilities

 

3,157

 

5,982

 

Other liabilities

 

1,005

 

1,329

 

Other

 

(59

)

(146

)

Net cash (used in) / provided by operating activities

 

(1,204

)

(1,520

)

 

 

 

 

 

 

CASH FLOWS FROM INVESTING ACTIVITIES:

 

 

 

 

 

Capital expenditures for plant and equipment

 

(3,114

)

(3,622

)

 

 

 

 

 

 

Net cash used in investing activities

 

(3,114

)

(3,622

)

 

 

 

 

 

 

CASH FLOWS FROM FINANCING ACTIVITIES:

 

 

 

 

 

Net proceeds from issuance of preferred stock

 

 

9,988

 

Net proceeds from issuance of senior secured discount notes

 

225,299

 

 

Payment of financing fees

 

(8,664

)

(2,200

)

Repayments/Payments of term debt and revolver

 

(219,575

)

(10,000

)

Repayment of Capital Leases and other, net

 

(470

)

(1,783

)

Proceeds from revolving debt - net

 

8,300

 

11,700

 

 

 

 

 

 

 

Net cash provided by (used in)  financing activities

 

4,890

 

7,705

 

 

 

 

 

 

 

EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

 

(534

)

281

 

 

 

 

 

 

 

NET INCREASE (DECREASE) IN CASH AND CASH EQUIVALENTS

 

38

 

2,844

 

 

 

 

 

 

 

CASH AND CASH EQUIVALENTS, BEGINNING OF THE PERIOD

 

3,308

 

1,635

 

CASH AND CASH EQUIVALENTS, END OF THE PERIOD

 

$

3,346

 

$

4,479

 

 

 

 

 

 

 

SUPPLEMENTAL DISCLOSURES OF CASH FLOW INFORMATION:

 

 

 

 

 

Cash paid (received) during the period for:

 

 

 

 

 

Interest

 

$

20,854

 

$

6,401

 

Income taxes

 

819

 

1,802

 

Other non-cash disclosure:

 

 

 

 

 

Preferred Stock dividends accrued but not paid

 

$

7,922

 

$

6,321

 

 

See notes to condensed consolidated financial statements.

 

5



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONSOLIDATED STATEMENTS OF STOCKHOLDERS’ DEFICIT

FOR THE THREE MONTHS ENDED MARCH 31, 2004   (IN THOUSANDS) (UNAUDITED)

 

 

 

 

 

 

 

Warrants
To Purchase
Common Stock

 

Accumulated
Deficit

 

Stockholders’
Notes
Receivable

 

Accumulated
Other
Comprehensive
Income (Loss)

 

Total

 

Common Stock

Shares

 

Amount

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BALANCE, DECEMBER 31, 2003

 

543

 

$

103,376

 

$

39,133

 

$

(537,052

)

$

(660

)

$

(11,921

)

$

(407,124

)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Net loss

 

 

 

 

 

 

 

(30,759

)

 

 

 

 

(30,759

)

Accumulated fair value change in interest rate derivatives charged to interest expense, net of taxes

 

 

 

 

 

 

 

 

 

 

 

2,220

 

2,220

 

Foreign currency translation adjustment

 

 

 

 

 

 

 

 

 

 

 

(769

)

(769

)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BALANCE, MARCH 31, 2004

 

543

 

$

103,376

 

$

39,133

 

$

(567,811

)

$

(660

)

$

(10,470

)

$

(436,432

)

 

See notes to condensed consolidated financial statements.

 

6



 

PLIANT CORPORATION AND SUBSIDIARIES

 

NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS (UNAUDITED)

 

1.                    BASIS OF PRESENTATION

 

The accompanying condensed consolidated financial statements have been prepared, without audit, in accordance with U.S. generally accepted accounting principles and pursuant to the rules and regulations of the Securities and Exchange Commission. The information reflects all normal recurring adjustments that, in the opinion of management, are necessary for a fair presentation of the financial position, results of operations and cash flows of Pliant Corporation and its subsidiaries (“Pliant,” the “Company” or “we”) as of the dates and for the periods presented. Results of operations for the period ended March 31, 2004 are not necessarily indicative of results of operations to be expected for the full fiscal year.

 

Certain information in footnote disclosures normally included in financial statements presented in accordance with U.S. generally accepted accounting principles has been condensed or omitted in accordance with the rules and regulations of the Securities and Exchange Commission. These statements should be read in conjunction with the Company’s Annual Report on Form 10-K for the year ended December 31, 2003 and the Company’s Registration Statement on Form S-4 (File No 333-114608). Certain reclassifications have been made to the condensed consolidated financial statements for the quarter ended March 31, 2003 for comparative purposes.

 

2.       INVENTORIES

 

Inventories are valued at the lower of cost (using the first-in, first-out method) or market value. Inventories as of March 31, 2004 and December 31, 2003 consisted of the following (in thousands):

 

 

 

March 31, 2004

 

December 31, 2003

 

 

 

 

 

 

 

Finished goods

 

$

52,908

 

$

55,858

 

Raw materials

 

27,741

 

28,551

 

Work-in-process

 

9,919

 

10,810

 

 

 

 

 

 

 

Total

 

$

90,568

 

$

95,219

 

 

3. RESTRUCTURING AND OTHER COSTS

 

Restructuring and other costs include plant closing costs (including costs related to relocation of manufacturing equipment), office closing costs and other costs related to workforce reductions.

 

The following table summarizes restructuring and other costs for the three months ended March 31 (in thousands):

 

 

 

2004

 

2003

 

Plant closing costs:

 

 

 

 

 

Severance

 

$

 

$

300

 

Relocation of production lines

 

 

1,294

 

Other plant closure costs

 

 

1,200

 

 

 

 

2,794

 

Office closing and workforce reduction costs:

 

 

 

 

 

Severance

 

 

10

 

Leases

 

 

3,260

 

 

 

 

3,270

 

 

 

$

 

$

6,064

 

 

7



 

2003 Accruals:

 

Plant Closing Costs During the first quarter of 2003, we continued to incur costs related to the closure of our facilities in Merced, California and Shelbyville, Indiana; production rationalizations in Toronto, Canada; and the relocation of certain lines from our Merced plant and Fort Edward plant to our other facilities.

 

Office Closing and Workforce Reduction Costs – During the first quarter of 2003, we accrued the present value of future lease payments on two  buildings that we do not currently occupy.  In connection with the 2001 restructuring plan, we vacated and subleased these facilities in 2001.  During the first quarter of 2003, the sublessees defaulted on the subleases.

 

The following table summarizes the roll-forward of the reserve from December 31, 2003 to March 31, 2004:

 

 

 

 

 

 

 

Accruals for the  Quarter ended March 31, 2004

 

 

 

 

 

 

 

 

 

 

 

Additional
Employees

 

Severance

 

Relocated
Production
Lines

 

Leases

 

Other
Plant
Closure
Costs

 

Total

 

Payments /
Charges

 

 

 

12/31/2003

3/31/ 04

 

# Employees
Terminated

 

Accrual
Balance

# Employees
Terminated

 

Accrual
Balance

 

Plant Closing Costs:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Merced

 

54

 

$

1,235

 

 

 

 

 

 

 

 

 

 

$

—-

 

$

(115

)

54

 

$

1,120

 

Shelbyville

 

8

 

 

 

 

 

 

 

 

 

8

 

 

Toronto

 

4

 

 

 

 

 

 

 

 

 

4

 

 

Pliant Solutions

 

148

 

541

 

 

 

 

 

 

 

(50

)

165

 

491

 

Mexico

 

17

 

 

 

 

 

 

 

 

 

 

 

Leases

 

 

2,004

 

 

 

 

 

 

 

(58

)

 

1,946

 

 

 

231

 

$

3,780

 

 

 

 

 

 

 

 

 

 

$

 

$

(223

)

231

 

$

3,557

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Office Closing and Workforce Reduction Costs:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Leases

 

 

$

1,129

 

 

 

 

 

 

 

 

 

 

$

 

$

(134

)

 

$

995

 

Severance

 

114

 

237

 

 

 

 

 

 

 

(119

)

114

 

118

 

Singapore

 

 

152

 

 

 

 

 

 

 

(4

)

 

148

 

 

 

114

 

$

1,518

 

 

 

 

 

 

 

 

 

 

$

 

$

(257

)

114

 

 

1,261

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

TOTAL

 

345

 

$

5,298

 

 

 

 

 

 

 

 

 

 

$

 

$

(480

)

345

 

$

4,818

 

 

Plant Closing Costs and Office Closing and Workforce Reduction Costs

 

 2004 accrualsThere were no accruals made in 2004.  The only activity during the quarter related to payments charged to the accrual.

 

8



 

4.       INTEREST  EXPENSE – Current and Long-term debt

 

Interest expense – current and long-term debt in the statement of operations for the quarters ended March 31, 2004 and 2003 are as follows:

 

 

 

2004

 

2003

 

Interest expense accrued, net

 

$

23,333

 

18,448

 

Recurring amortization of financing fees

 

1,148

 

1,408

 

Write-off of previously capitalized financing fees and interest rate  derivatives costs(a)

 

10,118

 

 

 

 

 

 

 

 

TOTAL

 

$

34,599

 

$

19,856

 

 


(a) This write-off resulted from the repayment of the old credit facilities in February 2004, from the net proceeds from the issuance of the senior secured discount notes and borrowings under the new revolving credit facility.

 

 

5.       STOCK OPTION PLANS

 

During the three months ended March 31, 2004, options to purchase 4,365 shares of our common stock were cancelled in connection with employee terminations.

 

We apply Accounting Principles Board Opinion No. 25 and related interpretations in accounting for stock-based compensation

plans as they relate to employees and directors.  We did not have compensation expense related to stock options for the three month periods ended March 31, 2004 and March 31, 2003.  Had the compensation cost for all the outstanding options been determined in accordance with SFAS No. 123, “Accounting for Stock-Based Compensation,” our net income (loss) for the quarters ended March 31, 2004 and 2003 would have been the following pro forma amounts (in thousands):

 

 

 

2004

 

2003

 

 

 

 

 

 

 

As reported

 

$

(30,759

)

$

(7,343

)

Pro forma stock compensation expense

 

(200

)

(188

)

Pro forma

 

$

(30,959

)

$

(7,531

)

 

5.                    INCOME TAXES

 

Income tax expense for the three months ended March 31, 2004 was $1.7 million on pretax losses of $29.1 million as compared to $2.0 million on pretax losses of $5.3 million for the same period in 2003. Income tax benefits related to net operating losses in the United States are offset by a valuation allowance as the realization of these tax benefits are not certain. Therefore, the income tax expense in the statements of operations primarily reflects foreign income taxes.

 

6.                    COMPREHENSIVE INCOME/(LOSS)

 

Other comprehensive income (loss) for the three months ended March 31, 2004 and 2003 was ($29.3) million and ($7.5) million, respectively. The components of other comprehensive income/(loss) are net income (loss), the change in cumulative unrealized losses on derivatives recorded in accordance with Statement of Financial Accounting Standards No. 133 and foreign currency translation.

 

9



 

7.                    NEW REVOLVING CREDIT FACILITY AND ISSUANCE OF SENIOR SECURED DISCOUNT NOTES DUE 2009

 

Long-term debt as of March 31, 2004 and December 31, 2003 consists of the following (in thousands):

 

 

 

March 31,
2004

 

December 31,
2003

 

Credit Facilities:

 

 

 

 

 

New revolving credit facility

 

$

8,300

 

$

 

Tranche A and B term loans under old credit facilities

 

 

219,575

 

Senior secured discount notes at 11 1/8%

 

228,405

 

 

Senior secured notes, interest at 11 1/8%

 

250,000

 

250,000

 

Senior subordinated notes, interest at 13.0% (net of unamortized issue discount, premium and discount related to warrants)

 

312,596

 

312,402

 

Obligations under capital leases

 

809

 

856

 

Insurance financing

 

207

 

824

 

Total

 

800,317

 

783,657

 

Less current portion

 

(412

)

(1,033

)

Long-term portion

 

$

799,905

 

$

782,624

 

 

On February 17, 2004 we repaid the balance outstanding on the existing credit facilities that existed on that date from the proceeds from the issuance of Senior Secured Discount Notes (discussed below) and the New Revolving Credit Facility (discussed below).

 

New Revolving Credit Facility

 

On February 17, 2004, we entered into a new revolving credit facility providing up to $100 million (subject to a borrowing base).  The new revolving credit facility includes a $15 million letter of credit sub-facility, with letters of credit reducing availability under the revolving credit facility.

 

The new revolving credit facility is secured by a first priority security interest in substantially all inventory, receivables, deposit accounts, 100% of capital stock of, or other equity interests in existing and future domestic subsidiaries and foreign subsidiaries that are note guarantors, and 65% of the capital stock of, or other equity interests in existing and future first-tier foreign subsidiaries, investment property and certain other assets of the Company and the note guarantors (the “Second Priority Collateral”).

 

The new revolving credit facility matures on February 17, 2009.  The Company is subject to periodic reporting of a borrowing base consisting of eligible accounts receivable and eligible inventory.  The interest rates will be at LIBOR plus 2.5% to 2.75% or ABR plus 1.5% - 1.75%.  The commitment fee for the unused portion of the new revolving credit facility is 0.50% per annum.

 

The borrowings under the new revolving credit facility may be limited to 75% of the lesser of the total commitment at such time and the borrowing base in effect at such time if the fixed coverage ratio defined in the new revolving credit facility is less than or equal to 1.10 to 1.00.  In addition, we were unable to borrow more than $45 million as of March 31, 2004 until we put in place certain deposit control agreements.  These deposit control agreements were put in place in April 2004.

 

Issuance of 11 1/8% Senior Secured Discount Notes due 2009

 

On February 17, 2004 we completed the sale of $306 million ($225.3 million of proceeds) principal amount at maturity of 11 1/8% Senior Secured Discount Notes due 2009.  The proceeds of this offering and the borrowing under the new revolving credit facility (discussed above) were used to repay and terminate the credit facilities that existed at December 31, 2003.

 

10



 

The Senior Secured Discount Notes are secured by a first priority security interest in substantially all of our real property, fixtures, equipment, intellectual property and other assets other than the Second-Priority Collateral (the “First-Priority Collateral”).

 

Unless we elect to pay cash interest as described below, and except under certain limited circumstances, the notes will accrete from the date of issuance at the rate of 11 1/8% until December 15, 2006, compounded semiannually on each June 15 and December 15 commencing June 15, 2004, to an aggregate principal amount of $1,000 per note ($306.0 million in the aggregate assuming no redemption or other repayments).  Commencing on December 15, 2006, interest on the notes will accrue at the rate of 11 1/8% per annum and will be payable in cash semiannually on June 15 and December 15, commencing on June 15, 2007.

 

On any interest payment date prior to December 15, 2006, we may elect to commence paying cash interest (from and after such interest payment date) in which case (i) we will be obligated to pay cash interest on each subsequent interest payment date, (ii) the notes will cease to accrete after such interest payment date and (iii) the outstanding principal amount at the stated maturity of each note will equal the accreted value of such note as of such interest payment date.

 

On or after June 15, 2007, we may redeem some or all of the notes at the following redemption prices (expressed as a percentage of principal amount), plus accrued and unpaid interest: 105.563% if redeemed prior to June 15, 2008; 102.781% if redeemed prior to June 15, 2009; and 100% if redeemed on or after June 15, 2009.  Prior to such date, we may not redeem the notes except as described in the following paragraph.

 

At any time prior to June 15, 2007, we may redeem up to 35% of the accreted value of the notes with the net cash proceeds of certain equity offerings by us at a redemption price equal to 111.125% of the accreted value thereof plus accrued interest, so long as (i) at least 65% of the accreted value of the notes remains outstanding after such redemption and (ii) any such redemption by us is made within 120 days after such equity offering.

 

8.       OPERATING  SEGMENTS

 

Operating segments are components of our business for which separate financial information is available that is evaluated regularly by our chief operating decision maker in deciding how to allocate resources and in assessing performance.  This information is reported on the basis that it is used internally for evaluating segment performance.

 

We have four operating segments: Pliant U.S., Pliant Flexible Packaging, Pliant International and Pliant Solutions.   Sales and transfers between our segments are eliminated in consolidation.  We evaluate the performance of our operating segments based on net sales (excluding inter-company sales) and segment profit.  The segment profit reflects income before interest expense, income taxes, depreciation, amortization, restructuring costs and other non-cash charges and net adjustments for certain unusual items.  Our reportable segments are managed separately with separate management teams, because each segment has differing products, customer requirements, technology and marketing strategies.

 

Segment profit and segment assets as of and for the periods ended March 31, 2004 and 2003 are presented in the following table (in thousands). Certain reclassifications have been made to the prior year amounts to be consistent with the 2004 presentation.

 

 

 

Pliant
U.S.

 

Pliant Flexible
Packaging

 

Pliant
International

 

Pliant
Solutions

 

Corporate/
Other

 

Total

 

2004

 

 

 

 

 

 

 

 

 

 

 

 

 

Net sales to customers

 

$

154,092

 

$

56,383

 

$

26,431

 

$

7,261

 

$

 

$

244,167

 

Intersegment sales

 

3,248

 

572

 

1,542

 

107

 

(5,469

)

 

Total net sales

 

157,340

 

56,955

 

27,973

 

7,368

 

(5,469

)

244,167

 

Depreciation and amortization

 

7,155

 

1,899

 

1,902

 

327

 

79

 

11,362

 

Interest expense

 

 

19

 

921

 

5

 

42,021

 

42,966

 

Segment profit

 

22,998

 

8,604

 

1,074

 

(2,274

)

(5,181

)

25,221

 

Segment total assets

 

459,408

 

139,594

 

88,778

 

17,445

 

78,192

 

783,417

 

Capital expenditures

 

1,497

 

143

 

1,260

 

35

 

179

 

(3,114

)

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2003

 

 

 

 

 

 

 

 

 

 

 

 

 

Net sales to customers

 

$

151,929

 

$

51,757

 

$

28,036

 

$

8,789

 

$

 

$

240,511

 

Intersegment sales

 

3,155

 

881

 

2,771

 

 

(6,807

)

 

Total net sales

 

155,084

 

52,638

 

30,807

 

8,789

 

(6,807

)

240,511

 

Depreciation and amortization

 

6,557

 

1,977

 

1,739

 

305

 

578

 

11,156

 

Interest expense

 

(2

)

13

 

577

 

5

 

19,263

 

19,856

 

Segment profit

 

26,761

 

7,675

 

2,880

 

(901

)

(4,356

)

32,059

 

Segment total assets

 

533,907

 

137,488

 

99,695

 

33,860

 

65,095

 

870,045

 

Capital expenditures

 

1,129

 

703

 

1,406

 

 

384

 

3,622

 

 

11



 

A reconciliation of the totals reported for the operating segments to the totals reported in the consolidated financial statements as of and for the three months ended March 31 is as follows (in thousands):

 

 

 

2004

 

2003

 

 

 

 

 

 

 

Profit or Loss

 

 

 

 

 

Total segment profit

 

$

25,221

 

$

32,059

 

Depreciation and amortization

 

(11,362

)

(11,156

)

Restructuring and other costs

 

 

(6,064

)

Interest expense

 

(42,966

)

(19,856

)

 

 

 

 

 

 

Other expenses and adjustments for non-cash charges and certain adjustments defined by our credit agreement

 

 

(303

)

Income (loss) before taxes

 

$

(29,107

)

$

(5,320

)

 

 

 

 

 

 

Assets

 

 

 

 

 

Total assets for reportable segments

 

$

705,225

 

$

804,950

 

Other unallocated assets

 

78,192

 

65,095

 

Total consolidated assets

 

$

783,417

 

$

870,045

 

 

12



 

9.   SHARES SUBJECT TO MANDATORY REDEMPTION

 

The Company adopted Statement of Financial Accounting Standard No. 150 ( “SFAS 150”) Accounting for Certain Financial Instruments with Characteristics of both Liabilities and Equity, effective January 1, 2004. As a result, the Redeemable Preferred Stock of the Company that contains an unconditional mandatory redemption feature was recorded as a liability on the date of adoption at fair market value. Fair market value was determined using the value of the securities on the date of issuance plus accretion of discount from the date of issuance through December 31,2003 and the unpaid dividends at the end of each quarter from the date of issuance through December 31, 2003. In addition, effective January 1, 2004 the dividends and accretion on the preferred shares are included as a part of interest expense in the statement of operations.

 

In addition, as a result of adopting SFAS 150, the Company’s redeemable common shares that have been put for redemption by the shareholder were recorded as a liability at fair value. The fair value was computed using the agreed upon price of the redemption times the number of shares put by the shareholder. As required by SFAS 150 prior periods were not restated.

 

The shares subject to mandatory redemption are as follow (in thousands):

 

 

 

As of January 1,
2004

 

As of March 31,
2004

 

Redeemable Preferred Shares 200,000 shares authorized, 140,973 shares outstanding as of March 31, 2004, designated as Series A, no par value with a redemption value of $1,000 per share plus accumulated dividends.

 

$

188,223

 

$

196,591

 

 

 

 

 

 

 

18,200 Redeemable Common Shares that have been put for redemption by a shareholder, net of a shareholder note of $2,431

 

6,362

 

6,362

 

Total shares subject to mandatory redemption

 

$

194,585

 

$

202,953

 

 

The cash settlement at the redemption date (assuming no cash dividends are paid through the redemption date) is  $ 680.6 million for the redeemable preferred shares and $ 6.4 million ( net of the note receivable of $ 2.4 million) for the redeemable common shares that have been put for redemption by the shareholder.

 

10.             DEFINED BENEFIT PLANS

 

We sponsor three noncontributory defined benefit pension plans (the “United States Plans”) covering domestic employees with 1,000 or more hours of service. We fund our plans in amounts to fulfill the funding requirements of the Employee Retirement Income Security Act of 1974. Contributions are intended to not only provide for benefits attributed to service to date but also for those expected to be earned in the future. We also sponsor a defined benefit plan in Germany (the “Germany Plan”). For information on the Germany Plan please refer to the Company’s Form 10-K for the year ended December 31,2003.

 

The consolidated accrued net pension expense for the quarters ended March 31, 2004 and 2003 includes the following components (in thousands):

 

 

 

2004

 

2003

 

United States Plans

 

 

 

 

 

Service cost-benefits earned during the period

 

$

1,189

 

$

1,119

 

Interest cost on projected benefit obligation

 

1,374

 

1,289

 

Expected return on assets

 

(1,105

)

(869

)

Other

 

184

 

130

 

Total accrued pension expense

 

$

1,642

 

$

1,669

 

 

 

 

 

 

 

Employer Contributions (a)

 

 

 

 

 

2004 Expected to plan trusts

 

$

7,261

 

 

 

 


(a)     Disclosed due to the change from Form 10-K for the year ended December 31, 2003 as a result of the minimum funding changes made under the Pension Funding Equity Act.

 

13



 

11.             CONTINGENCIES

 

Environmental Contingencies  Our operations are subject to extensive environmental laws and regulations concerning emissions to the air, discharges to surface and subsurface waters, and the generation, handling, storage, transportation, treatment, and disposal of waste materials, as adopted by various governmental authorities in the jurisdictions in which we operate. We believe we make every reasonable effort to remain in full compliance with existing governmental laws and regulations concerning the environment.

 

Litigation  On November 19, 2001, S.C. Johnson & Son, Inc. and S.C. Johnson Home Storage, Inc. (collectively, “S.C. Johnson”) filed a complaint against us in the U.S. District Court for the District of Michigan, Northern Division (Case No. 01-CV-10343-BC). The complaint alleges misappropriation of proprietary trade secret information relating to certain componentry used in the manufacture of reclosable “slider” bags. We counterclaimed alleging that S.C. Johnson misappropriated certain of our trade secrets relating to the extrusion of flange zipper and unitizing robotics. Both the S.C. Johnson complaint and our counterclaim seek damages and injunctive and declaratory relief. The S.C. Johnson complaint and our counterclaim have been voluntarily submitted to non-binding mediation for the purpose of potential settlement. The mediation took place on February 20, 2004.  Negotiations are still ongoing. We are unable to predict whether the case can be settled as a result of the mediation. Any amount we may agree to pay as a result of the mediation and any settlement, if any, we may agree to may be significant, but is not anticipated to have a material adverse effect on our financial condition or results of operations. If the case cannot be settled on a basis acceptable to us, we intend to continue resisting S.C. Johnson’s claims and to pursue our counterclaim vigorously.

 

On February 26, 2003, former employees of our Fort Edward, NY manufacturing facility, which we acquired as part of the Decora acquisition, named us as defendants in a complaint filed in the Supreme Court of the State of New York, County of Washington (Index No. 4417E). We received service of this complaint on April 2, 2003, and successfully removed the case to the United States District Court for the Northern District of New York (Case No. 1:03cv00533). The complaint alleges claims against us for conspiracy to defraud and breach of contract arising out of our court-approved purchase of the assets of Decora Industries, Inc. and Decora, Incorporated. Plaintiffs’ complaint seeks compensatory and punitive damages and a declaratory judgment nullifying severance agreements for lack of consideration and economic duress. We intend to resist the plaintiffs’ claims vigorously. We do not believe this proceeding will have a material adverse affect on our financial condition or results of operations.

 

We are involved in other litigation matters from time to time in the ordinary course of our business. In our opinion, none of such litigation is material to our financial condition or results of operations.

 

In the fourth quarter of 2003, we accrued $7.2 million for the estimated costs of certain litigation matters. This accrual as of March 31, 2004 was $ 7.1 million.

 

12.             CONDENSED CONSOLIDATING FINANCIAL  STATEMENTS

 

The following condensed consolidating financial statements present, in separate columns, financial information for (i) Pliant Corporation (on a parent only basis) with its investment in its subsidiaries recorded under the equity method, (ii) guarantor subsidiaries (as specified in the Indenture dated May 31, 2000 (the “2000 Indenture”) relating to Pliant Corporation’s $220 million senior subordinated notes due 2010 (the “2000 Notes”), the Indenture dated April 10, 2002 (the “2002 Indenture”) relating to Pliant’s $100 million senior subordinated notes due 2010 (the “2002 Notes”), the Indenture dated May 30, 2003 ( the “ 2003 Indenture”) relating to Pliant’s $ 250 million senior secured notes due 2009 (the “2003 Notes”) and Indenture dated February 17, 2004 ( the “2004 Indenture” and, together with the 2000 Indenture, the 2002 Indenture and the 2003 Indenture, the “Indentures”)  relating to Pliant’s $ 306 million senior secured discount notes due 2009 ( “ 2004 Notes” and, together with the 2000 Notes, the 2002 Notes and the 2003 Notes, the “Notes”) on a combined basis, with any investments in non-guarantor subsidiaries specified in the Indentures recorded under the equity method, (iii) direct and indirect non-guarantor subsidiaries on a combined basis, (iv) the eliminations necessary to arrive at the information for Pliant Corporation and its subsidiaries on a consolidated basis, and (v) Pliant Corporation on a consolidated basis, in each case as of March 31, 2004 and December 31, 2003 and for the three months ended March 31, 2004 and 2003.  The Notes are fully and unconditionally guaranteed on a joint and several basis by each guarantor subsidiary and each guarantor subsidiary is wholly owned, directly or indirectly, by Pliant Corporation.  There are no contractual restrictions limiting transfers of cash from guarantor and non-guarantor subsidiaries to Pliant Corporation except from our Alliant joint venture.  Alliant is a joint venture between us and Supreme Plastics Ltd., a company based in the United Kingdom.  We own a fifty-percent interest in Alliant.  The limited

 

14



 

liability company agreement governing the joint venture prohibits distributions to the members of the joint venture before July 27, 2004, other than annual distributions sufficient to pay taxes imposed upon the members as a result of the attribution to the members of income of the joint venture.  The condensed consolidating financial statements are presented herein, rather than separate financial statements for each of the guarantor subsidiaries, because management believes that separate financial statements relating to the guarantor subsidiaries are not material to investors.

 

In 2004, one of our subsidiaries in Canada, Uniplast Industries Co. became a guarantor subsidiary. As a result, all periods presented include Uniplast Industries Co. as a guarantor subsidiary.

 

15



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATING BALANCE SHEET

AS OF MARCH 31, 2004 (IN THOUSANDS) (UNAUDITED)

 

 

 

Pliant
Corporation
(Parent Only)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

Eliminations

 

Consolidated
Pliant
Corporation

 

 

 

 

 

 

 

 

 

 

 

 

 

ASSETS

 

 

 

 

 

 

 

 

 

 

 

CURRENT ASSETS:

 

 

 

 

 

 

 

 

 

 

 

Cash and cash equivalents

 

$

 

$

227

 

$

3,119

 

$

 

$

3,346

 

Receivables – net

 

89,103

 

16,270

 

17,836

 

 

123,209

 

Inventories

 

61,315

 

16,809

 

12,444

 

 

90,568

 

Prepaid expenses and other

 

2,058

 

390

 

628

 

 

 

3,076

 

Income taxes receivable

 

217

 

262

 

315

 

 

794

 

Deferred income taxes

 

10,366

 

(1,505

)

501

 

 

9,362

 

Total current  assets

 

163,059

 

32,453

 

34,843

 

 

230,355

 

PLANT AND EQUIPMENT – Net

 

246,878

 

23,750

 

40,766

 

 

311,394

 

INTANGIBLE ASSETS – Net

 

173,975

 

26,098

 

1,312

 

 

201,385

 

INVESTMENT IN SUBSIDIARIES

 

(4,520

)

(1,062

)

1,062

 

4,520

 

 

OTHER ASSETS

 

36,278

 

 

4,005

 

 

40,283

 

TOTAL ASSETS

 

$

615,670

 

$

81,239

 

$

81,988

 

$

4,520

 

783,417

 

 

 

 

 

 

 

 

 

 

 

 

 

LIABILITIES AND STOCKHOLDERS’ EQUITY (DEFICIT)

 

 

 

 

 

 

 

 

 

 

 

CURRENT LIABILITIES:

 

 

 

 

 

 

 

 

 

 

 

Current portion of long-term debt

 

$

412

 

$

 

$

 

$

 

$

412

 

Trade accounts payable

 

67,871

 

7,928

 

12,232

 

 

88,031

 

Accrued liabilities

 

54,678

 

5,018

 

4,833

 

 

64,529

 

Due to (from) affiliates

 

(128,685

)

80,747

 

47,938

 

 

 

Total current liabilities

 

(5,724

)

93,693

 

65,003

 

 

152,972

 

LONG-TERM DEBT – Net of current portion

 

799,905

 

 

 

 

799,905

 

OTHER LIABILITIES

 

25,791

 

 

2,706

 

 

28,497

 

DEFERRED INCOME TAXES

 

22,532

 

2,539

 

3,574

 

 

28,645

 

SHARES SUBJECT TO MANDATORY REDEMPTION

 

202,953

 

 

 

 

202,953

 

Total Liabilities

 

1,045,457

 

96,232

 

71,283

 

 

1,212,972

 

MINORITY INTEREST

 

 

 

232

 

 

232

 

REDEEMABLE COMMON STOCK

 

6,645

 

 

 

 

6,645

 

STOCKHOLDERS’ EQUITY (DEFICIT):

 

 

 

 

 

 

 

 

 

 

 

Common stock

 

103,376

 

 

9,650

 

(9,650

)

103,376

 

Additional paid-in capital

 

 

14,020

 

19,652

 

(33,672

)

 

Warrants

 

39,133

 

 

 

 

39,133

 

Retained earnings accumulated (deficit)

 

(567,811

)

(29,032

)

(12,240

)

41,272

 

(567,811

)

Stockholders’ note receivable

 

(660

)

 

 

 

(660

)

Accumulated other comprehensive loss

 

(10,470

)

19

 

(6,589

)

6,570

 

(10,470

)

Total stockholders’ equity (deficit)

 

(436,432

)

(14,993

)

10,473

 

4,520

 

(436,432

)

TOTAL LIABILITIES AND STOCKHOLDERS’ EQUITY (DEFICIT)

 

$

615,670

 

$

81,239

 

$

81,988

 

$

4,520

 

$

783,417

 

 

16



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATING BALANCE SHEET

AS OF DECEMBER 31, 2003 (IN THOUSANDS) (UNAUDITED)

 

 

 

Pliant
Corporation
Parent Only

 

Combined
Guarantors

 

Combined
Non-Guarantors

 

Eliminations

 

Consolidated
Pliant
Corporation

 

ASSETS

 

 

 

 

 

 

 

 

 

 

 

CURRENT ASSETS:

 

 

 

 

 

 

 

 

 

 

 

Cash and cash equivalents

 

$

 

$

1,192

 

$

2,116

 

$

 

$

3,308

 

Receivables

 

79,685

 

14,071

 

18,186

 

 

111,942

 

Inventories

 

63,954

 

19,567

 

11,698

 

 

95,219

 

Prepaid expenses and other

 

2,626

 

460

 

723

 

 

3,809

 

Income taxes receivable

 

167

 

806

 

463

 

 

1,436

 

Deferred income taxes

 

10,934

 

(1,521

)

4

 

 

9,417

 

Total current assets

 

157,366

 

34,575

 

33,190

 

 

225,131

 

PLANT AND EQUIPMENT, Net

 

253,601

 

24,576

 

41,392

 

 

319,569

 

GOODWILL

 

182,162

 

 

 

 

182,162

 

INTANGIBLE ASSETS, Net

 

19,752

 

 

 

 

19,752

 

INVESTMENT IN SUBSIDIARIES

 

(916

)

(1,062

)

1,062

 

916

 

 

OTHER ASSETS

 

36,125

 

 

4,047

 

 

40,172

 

TOTAL ASSETS

 

$

648,090

 

$

58,089

 

$

79,691

 

$

916

 

$

786,786

 

 

 

 

 

 

 

 

 

 

 

 

 

LIABILITIES AND STOCKHOLDERS’  EQUITY (DEFICIT)

 

 

 

 

 

 

 

 

 

 

 

CURRENT LIABILITIES:

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Trade accounts payable

 

$

66,839

 

$

8,520

 

$

14,441

 

$

 

$

89,800

 

Accrued liabilities

 

53,714

 

4,790

 

5,142

 

 

63,646

 

Current portion of long-term debt

 

1,033

 

 

 

 

1,033

 

Due to (from) affiliates

 

(72,692

)

56,423

 

16,269

 

 

 

 

Total current liabilities

 

48,894

 

69,733

 

35,852

 

 

154,479

 

LONG-TERM DEBT, Net of current portion

 

758,461

 

 

24,163

 

 

782,624

 

OTHER LIABILITIES

 

24,952

 

 

2,541

 

 

27,493

 

DEFERRED INCOME TAXES

 

21,676

 

2,502

 

3,614

 

 

27,792

 

Total liabilities

 

853,983

 

72,235

 

66,170

 

 

992,388

 

MINORITY INTEREST

 

 

 

291

 

 

291

 

REDEEMABLE STOCK:

 

 

 

 

 

 

 

 

 

 

 

Preferred stock

 

188,223

 

 

 

 

188,223

 

Common stock

 

13,008

 

 

 

 

13,008

 

Total redeemable stock

 

201,231

 

 

 

 

201,231

 

STOCKHOLDERS’ (DEFICIT):

 

 

 

 

 

 

 

 

 

 

 

Common stock

 

103,376

 

14,020

 

29,302

 

(43,322

)

103,376

 

Warrants to purchase common stock

 

39,133

 

 

 

 

39,133

 

Retained earnings (deficit)

 

(537,052

)

(28,155

)

(9,845

)

38,000

 

(537,052

)

Stockholders’ notes receivable

 

(660

)

 

 

 

(660

)

Accumulated other comprehensive loss

 

(11,921

)

(11

)

(6,227

)

6,238

 

(11,921

)

TOTAL STOCKHOLDERS’ EQUITY (DEFICIT)

 

(407,124

)

(14,146

)

13,230

 

916

 

(407,124

)

Total liabilities and stockholders’ (deficit)

 

$

648,090

 

$

58,089

 

$

79,691

 

$

916

 

$

786,786

 

 

17



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATING INCOME STATEMENT

FOR THE THREE MONTHS ENDED MARCH 31, 2004 (IN THOUSANDS) (UNAUDITED)

 

 

 

Pliant
Corporation
(Parent Only)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

Eliminations

 

Consolidated
Pliant
Corporation

 

 

 

 

 

 

 

 

 

 

 

 

 

SALES , Net

 

$

194,065

 

$

27,345

 

$

28,226

 

$

(5,469

)

$

244,167

 

COST OF SALES

 

160,059

 

25,942

 

26,843

 

(5,469

)

207,375

 

 

 

 

 

 

 

 

 

 

 

 

 

GROSS PROFIT

 

34,006

 

1,403

 

1,383

 

 

36,792

 

OPERATING EXPENSES

 

19,034

 

1,364

 

2,417

 

 

22,815

 

 

 

 

 

 

 

 

 

 

 

 

 

OPERATING INCOME

 

14,972

 

39

 

(1,034

)

 

13,977

 

INTEREST EXPENSE

 

(42,025

)

(163

)

(778

)

 

(42,966

)

EQUITY IN EARNINGS OF SUBSIDIARIES

 

(3,272

)

 

 

3,272

 

 

OTHER INCOME  (EXPENSE), Net

 

(305

)

26

 

161

 

 

(118

)

 

 

 

 

 

 

 

 

 

 

 

 

NET INCOME (LOSS) BEFORE INCOME TAXES

 

(30,630

)

(98

)

(1,651

)

3,272

 

(29,107

)

INCOME TAX PROVISION

 

129

 

779

 

744

 

 

1,652

 

NET INOME (LOSS)

 

$

(30,759

)

$

(877

)

$

(2,395

)

$

3,272

 

$

(30,759

)

 

18



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATING INCOME STATEMENT

FOR THE THREE MONTHS ENDED MARCH 31, 2003 (IN THOUSANDS) (UNAUDITED)

 

 

 

Pliant
Corporation
(Parent Only)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

Eliminations

 

Consolidated
Pliant
Corporation

 

 

 

 

 

 

 

 

 

 

 

 

 

SALES , Net

 

$

190,855

 

$

29,394

 

$

27,069

 

$

(6,807

)

$

240,511

 

COST OF SALES

 

155,514

 

25,249

 

23,758

 

(6,807

)

197,714

 

GROSS PROFIT

 

35,341

 

4,145

 

3,311

 

 

42,797

 

OPERATING EXPENSES

 

23,561

 

2,284

 

2,912

 

 

28,757

 

 

 

 

 

 

 

 

 

 

 

 

 

OPERATING INCOME

 

11,780

 

1,861

 

399

 

 

14,040

 

INTEREST EXPENSE

 

(19,269

)

(143

)

(444

)

 

(19,856

)

EQUITY IN EARNINGS OF SUBSIDIARIES

 

1,063

 

 

 

(1,063

)

 

OTHER INCOME  (EXPENSE), Net

 

(129

)

(52

)

677

 

 

496

 

 

 

 

 

 

 

 

 

 

 

 

 

INCOME (LOSS) BEFORE INCOME TAXES

 

(6,555

)

1,666

 

632

 

(1,063

)

(5,320

)

INCOME TAX PROVISION (BENEFIT)

 

788

 

555

 

680

 

 

2,023

 

NET INCOME (LOSS)

 

$

(7,343

)

$

1, 111

 

$

(48

)

$

(1,063

)

$

(7,343

)

 

19



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATING STATEMENT OF CASH FLOWS

FOR THE THREE MONTHS ENDED MARCH 31, 2004 (IN THOUSANDS) (UNAUDITED)

 

 

 

Pliant
Corporation
(Parent Only)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

Eliminations

 

Consolidated
Pliant
Corporation

 

 

 

 

 

 

 

 

 

 

 

 

 

CASH FLOWS PROVIDED BY (USED IN) OPERATING ACTIVITIES

 

$

(27,096

)

$

(439

)

$

26,331

 

$

 

$

(1,204

)

 

 

 

 

 

 

 

 

 

 

 

 

CASH FLOWS FROM INVESTING ACTIVITIES:

 

 

 

 

 

 

 

 

 

 

 

Capital expenditures for plant and equipment

 

(1,705

)

(63

)

(1,346

)

 

(3,114

)

Net cash used in investing activities

 

(1,705

)

(63

)

(1,346

)

 

(3,114

)

CASH FLOWS FROM FINANCING ACTIVITIES:

 

 

 

 

 

 

 

 

 

 

 

Net proceeds from issuance of senior secured discount notes

 

225,299

 

 

 

 

 

 

 

225,299

 

Payment of financing fees

 

(8,664

)

 

 

 

 

 

 

(8,664

)

Repayment of term debt and revolver

 

(195,412

)

 

(24,163

)

 

(219,575

)

Repayment of capital leases and other, net

 

(470

)

 

 

 

(470

)

Proceeds from revolving debt, net

 

8,300

 

 

 

 

8,300

 

Net cash used in financing activities

 

29,053

 

 

(24,163

)

 

4,890

 

 

 

 

 

 

 

 

 

 

 

 

 

EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

 

(252

)

(50

)

(232

)

 

(534

)

 

 

 

 

 

 

 

 

 

 

 

 

NET INCREASE (DECREASE) IN CASH AND CASH EQUIVALENTS

 

 

(552

)

590

 

 

38

 

 

 

 

 

 

 

 

 

 

 

 

 

CASH AND CASH EQUIVALENTS AT BEGINNING OF THE PERIOD

 

 

552

 

2,756

 

 

3,308

 

 

 

 

 

 

 

 

 

 

 

 

 

CASH AND CASH EQUIVALENTS AT END OF THE PERIOD

 

$

 

$

 

$

3,346

 

$

 

$

3,346

 

 

20



 

PLIANT CORPORATION AND SUBSIDIARIES

 

CONDENSED CONSOLIDATING STATEMENT OF CASH FLOWS

FOR THE THREE MONTHS ENDED MARCH 31, 2003 (IN THOUSANDS) (UNAUDITED)

 

 

 

Pliant
Corporation
(Parent Only)

 

Combined
Guarantor
Subsidiaries

 

Combined
Non-Guarantor
Subsidiaries

 

Eliminations

 

Consolidated
Pliant
Corporation

 

 

 

 

 

 

 

 

 

 

 

 

 

CASH FLOWS PROVIDED BY (USED IN) OPERATING ACTIVITIES

 

$

(4,225

)

$

3,730

 

$

(1,025

)

$

 

$

(1,520

)

 

 

 

 

 

 

 

 

 

 

 

 

CASH FLOWS FROM INVESTING ACTIVITIES:

 

 

 

 

 

 

 

 

 

 

 

Capital expenditures for plant and equipment

 

(1,333

)

(2,289

)

 

 

(3,622

)

Net cash used in investing activities

 

(1,333

)

(2,289

)

 

 

(3,622

)

CASH FLOWS FROM FINANCING ACTIVITIES:

 

 

 

 

 

 

 

 

 

 

 

Net proceeds from issuance of preferred stock

 

9,988

 

 

 

 

9,988

 

Payment of financing fees

 

(2,200

)

 

 

 

(2,200

)

Principal payments on long-term debt, net

 

546

 

 

(629

)

 

(83

)

Net cash used in financing  activities

 

8,334

 

 

(629

)

 

7,705

 

 

 

 

 

 

 

 

 

 

 

 

 

EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

 

430

 

(1,142

)

993

 

 

281

 

 

 

 

 

 

 

 

 

 

 

 

 

NET INCREASE (DECREASE) IN CASH AND CASH EQUIVALENTS

 

3,206

 

299

 

(661

)

 

2,844

 

 

 

 

 

 

 

 

 

 

 

 

 

CASH AND CASH EQUIVALENTS AT BEGINNING OF THE PERIOD

 

 

(21

)

1,656

 

 

1,635

 

 

 

 

 

 

 

 

 

 

 

 

 

CASH AND CASH EQUIVALENTS AT END OF THE PERIOD

 

$

3,206

 

$

278

 

$

995

 

$

 

$

4,479

 

 

21



 

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

 

The purpose of this section is to discuss and analyze our consolidated financial condition, liquidity and capital resources and results of operations. This analysis should be read in conjunction with Management’s Discussion and Analysis of Financial Condition and Results of Operations contained in our Annual Report on Form 10-K for the year ended December 31, 2003 (the “2003 10-K”) and our Registration Statement on Form S-4 (file No. 333-114608). This section contains certain forward-looking statements within the meaning of federal securities laws that involve risks and uncertainties, including statements regarding our plans, objectives, goals, strategies and financial performance. Our actual results could differ materially from the results anticipated in these forward-looking statements as a result of factors set forth under “Cautionary Statement for Forward-Looking Information” below and elsewhere in this report.

 

General

 

We generate our revenues, earnings and cash flows from the sale of film and flexible packaging products throughout the world. We manufacture these products at 25 facilities located in the United States, Australia, Canada, Germany and Mexico. Our sales have grown primarily as a result of strategic acquisitions made over the past several years, increased levels of production at acquired facilities, return on capital expenditures and the overall growth in the markets for film and flexible packaging products.

 

Results of Operations

 

The following table sets forth net sales, operating expenses, and operating income, and such amounts as a percentage of net sales, for the three months ended March 31, 2004 and 2003 (dollars in millions).

 

 

 

Three Months Ended March 31,

 

 

 

2004

 

2003

 

 

 

$

 

% of
Sales

 

$

 

% of
Sales

 

 

 

 

 

 

 

 

 

 

 

Net sales

 

$

244.2

 

100.0

%

$

240.5

 

100.0

%

Cost of sales

 

207.4

 

84.9

 

197.7

 

82.2

 

Gross profit

 

36.8

 

15.1

 

42.8

 

17.8

 

Operating expenses before restructuring and other costs

 

22.8

 

9.4

 

22.7

 

9.5

 

Restructuring and other costs

 

 

 

6.1

 

2.5

 

Total operating expenses

 

22.8

 

9.4

 

28.8

 

12.0

 

Operating income

 

$

14.0

 

5.7

%

$

14.0

 

5.8

%

 

Three Months Ended March 31, 2004 Compared with the Three Months Ended March 31, 2003

 

Net Sales

 

Net sales increased by $3.7 million, or 1.5%, to $244.2 million for the first quarter of 2004 from $240.5 million for the three months ended March 31, 2003. The increase was primarily due to a 3.9% increase in our average selling price resulting primarily from the pass through of increases in our raw material prices partially offset by a 2.2% decrease in sales volume.  See “Operating Segment Review” below for a detailed discussion of sales volumes and selling prices by segment and division.

 

22



 

Gross Profit

 

Gross profit decreased by $6.0 million, or 14%, to $36.8 million for the first quarter of 2004, from $42.8 million for the three months ended March 31, 2003. This decrease was primarily due to the effect of lower sales volumes. See “Operating Segment Review” below for a detailed discussion of the margin variances by segment.

 

Total Operating Expenses before Restructuring and Other Costs

 

Total operating expenses before restructuring and other costs increased $0.1 million, to $22.8 million for the first quarter of 2004 from $22.7 million for the first quarter of 2003.

 

Restructuring and Other Costs

 

Restructuring and other costs decreased by $6.1 million since there were no restructuring expenses incurred in the first quarter of 2004.

 

Operating Income

 

Operating income remained at $14.0 million for the three months ended March 31, 2004 as compared to the three months ended March 31, 2003, due to the factors discussed above.

 

Interest Expense

 

Interest expense on current and long-term debt increased by $14.7 million, or 73.9%, to $34.6 million for the three months ended March 31, 2004 from $19.9 million for the three months ended March 31, 2003. This increase was principally due to the higher interest costs resulting from the issuance of an additional $250 million of senior secured notes in May 2003 and the additional $ 225.3 million of senior secured discount notes in February 2004. The proceeds from the issuance of these notes were used to repay bank debt that carried a lower interest rate. In addition, the first quarter 2004 interest expense included a charge for the write-off of previously capitalized financing fees and losses related to interest rate derivatives totaling $ 10.1 million.

 

Interest expense on preferred stock reflects the dividends and accretion on the redeemable preferred stock of the Company that is classified as interest expense after adoption of SFAS 150, effective January 1, 2004.

 

Other Income(Expense)

 

Other expense was $0.1 million for the three months ended March 31, 2004, as compared to other income of $ 0.5 million for the three months ended March 31, 2003. The other income for the three months ended March 31, 2003 included primarily net proceeds from the realization of certain insurance policies.

 

Income Tax Expense (Benefit)

 

Income tax expense for the three months ended March 31, 2004 was $1.7 million on pretax losses of $29.1 million as compared to $2.0 million on pretax losses of $5.3 million for the same period in 2003. Income tax benefits related to net operating losses in the United States were offset by a valuation allowance as the realization of these tax benefits is not certain. Therefore, the income tax expense in the statements of operations primarily reflect foreign income taxes.

 

Operating Segment Review

 

General

 

Operating segments are components of our business for which separate financial information is available that is evaluated regularly by our chief operating decision maker in deciding how to allocate resources and in assessing performance.  We evaluate the performance of our operating segments based on net sales (excluding inter-company

 

23



 

sales) and segment profit.  The segment profit reflects income before interest expense, income taxes, depreciation, amortization, restructuring and other costs and other non-cash charges and net adjustments for certain unusual items.  For more information on our operating segments, including a reconciliation of segment profit to income before taxes, see Note 8 to the consolidated financial statements included elsewhere in this report.

 

We have  four reporting segments: Pliant U.S., Pliant Flexible Packaging, Pliant International and Pliant Solutions.

 

Summary of segment information (in millions of dollars):

 

 

 

Pliant
U.S.

 

Pliant Flexible
Packaging

 

Pliant
International

 

Pliant
Solutions

 

Unallocated
Corporate
Expenses

 

Total

 

Quarter ended March 31, 2004

 

 

 

 

 

 

 

 

 

 

 

 

 

Net sales

 

$

154.1

 

$

56.4

 

$

26.4

 

$

7.3

 

$

 

$

244.2

 

Segment profit (loss)

 

$

23.0

 

$

8.6

 

$

1.1

 

$

(2.3

)

$

(5.2

)

$

25.2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Quarter ended March 31, 2003

 

 

 

 

 

 

 

 

 

 

 

 

 

Net sales

 

$

151.9

 

$

51.8

 

$

28.0

 

$

8.8

 

$

 

$

240.5

 

Segment profit (loss)

 

$

26.8

 

$

7.7

 

$

2.9

 

$

(0.9

)

$

(4.4

)

$

32.1

 

 

Three Months Ended March 31, 2004 Compared with the Three Months Ended March 31, 2003

 

Pliant U.S.

 

Net sales.  The net sales of our Pliant U.S. segment increased $2.2 million, or 1.4%, to $154.1 million for the first quarter of 2004 from $151.9 million for the first quarter of 2003.  This increase was primarily due to an increase in our average selling prices of 3.3 cents per pound or 3.6% partially offset by a 2.1% decrease in sales volumes. The decrease in sales volumes is discussed for each Pliant U.S. division below. The increase in our average selling prices was principally due to the increase in raw material prices that were partially passed on to our customers.

 

Net sales in our Industrial Films division increased $0.8 million, or 1.6%, to $48.2 million for the first quarter of 2004 from $47.4 million for the first quarter of 2003.  This increase was principally due to an increase in our average selling prices of 6.6 cents per pound or 8.5% partially offset by a decrease in sales volumes of 3.9 million pounds, or 6.4%. The decrease in sales volume was primarily the result of the effects of down-gauging resulting from the introduction of new generation products, some customer rationalization and the timing of large shipments.  Net sales in our Specialty Films division increased $0.8 million, or 1.8%, to $48.9 million for the first quarter of 2004 from $48.1 million for the first quarter of 2003.  This increase was principally due to an increase in our sales volume of 1.1 million pounds, partially offset by a decrease in our average selling prices of 0.7 cents per pound, or 0.7%. The increase in sales volume was primarily the result of higher sales from our personal care business.  Net sales in our Converter Films division increased $0.6 million, or 1.0%, to $57.0 million for the first quarter of 2004 from $56.4 million for the first quarter of 2003.  This increase was principally due to an increase in our average selling prices of 2.0 cents per pound or 2.0% partially offset by the effect of lower sales volumes which decreased 1.0%.

 

Segment profit.  The Pliant U.S. segment profit decreased $ 3.8 million to $23.0 million for the first quarter of 2004 as compared to $26.8 million for the first quarter of 2003 principally due to the decreases in sales volumes discussed above and lower gross margins. The decrease in gross margins was principally due to the fact that the higher selling prices discussed above were not sufficient to offset the increase in raw material prices, principally in the specialty and converter divisions.

 

24



 

Pliant Flexible Packaging

 

Net sales. The net sales of our Pliant Flexible Packaging segment increased $4.6 million, or 8.9%, to $56.4 million for the first quarter of 2004 from $51.8 million for the first quarter of 2003.  This increase was principally due to an increase in our sales volumes of 2.0 million pounds, or 5.6%, and an increase in our average selling prices of 4.7 cents per pound, or 3.2%.  The sales volume increased principally due to additional sales to existing customers and sales from our new ten color press in Langley.

 

Segment profit.  The Pliant Flexible Packaging segment profit increased $0.9 million to $8.6 million for the first quarter of 2004 from $7.7 million for the first quarter of 2003.  This increase in segment profit was primarily due to an increase in gross margins and the effect of higher sales volumes discussed above partially offset by the effect of higher conversion costs. The increase in gross margins was principally due to the fact that selling prices increased at a rate higher than the increase in raw material prices in the first quarter of 2004. In addition, there is a delay in implementing price increases and decreases in this segment due to contracts with certain customers. Therefore, the margins for this quarter benefited from substantial increases in raw material prices in prior quarters.

 

Pliant International

 

Net sales. The net sales of our Pliant International segment decreased $1.6 million, or 5.7%, to $26.4 million for the first quarter of 2004 from $28.0 million for the first quarter of 2003.  This decrease was principally due to a 11.5% decrease in our sales volume, partially offset by an increase in our average selling prices of 6.2 cents per pound, or 6.5%.  Among other factors, our sales volumes were adversely affected by a reduction in sales at our plant in Mexico due to the loss of certain customers and products as a result of operating issues discussed below.

 

Segment profit.  The Pliant International segment profit decreased $1.8 million to $1.1 million for the first quarter of 2004 from $2.9 million for the first quarter of 2003.  The decrease was due principally to the operating losses in our plant in Mexico. Our plant in Mexico was affected by operating issues and the resulting loss of customers and products. Management changes have been made at this location and increases in sales volume and improved operating results are expected.

 

Pliant Solutions

 

Net sales. The net sales of our Pliant Solutions segment decreased $1.5 million, or 17.0%, to $7.3 million for the first quarter of 2004 from $8.8 million for the first quarter of 2003.  This decrease was principally due to a 11.9% decrease in our sales volume and a decrease in our average selling prices of 15.4 cents per pound, or 6.2%.  The decrease in sales volume was primarily due to several promotional programs in the first quarter of 2003 that were not repeated by our customers in the first quarter of 2004 and a reduction in sales to a major customer due to the closing of several stores. Average selling prices decreased due to a change in the sales mix.

 

Segment profit.  The Pliant Solutions segment profit decreased $1.4 million, to a loss of $(2.3) million for the first quarter of 2004 from a loss of $(0.9) million for the first quarter of 2003.  The decrease was due principally to the decrease in sales volumes and a decrease in gross margins due to a change in the sales mix.

 

Unallocated Corporate Expenses

 

Unallocated corporate expenses increased $0.8 million to $5.2 million for the first quarter of 2004 as compared to $ 4.4 million for the first quarter of 2003. The increase was principally due to an adjustment for $0.4 million related to employee benefits for an acquisition made in prior years, increase in legal fees and increases in labor costs.

 

25



 

Liquidity and Capital Resources

 

Sources of capital

 

Our principal sources of funds are cash generated by our operations and borrowings under our new revolving credit facility. In addition, we have raised funds through the issuance of our 13% Senior Subordinated Notes due 2010, 11 1/8% Senior Secured Notes due 2009, 11 1/8% Senior Secured Discount Notes due 2009 and the sale of shares of our preferred stock.

 

All of the term debt and revolver under the credit facilities that existed at December 31, 2003 had been at variable rates of interest, so payment of the term loans with the proceeds of our 11 1/8% Senior Secured Discount Notes and borrowings under our new revolving credit facility substantially reduced our exposure to interest rate risk. Although our new $100 million revolving credit facility is at a variable rate of interest, there are substantially fewer financial covenants than our credit facilities that existed at December 31, 2003, which will substantially reduce our exposure to covenant default risk. While the effective interest rate on the Senior Secured Discount Notes is higher than the term loans retired from the proceeds of the February 2004 offering, we will realize greater short-term liquidity and flexibility in our debt structure resulting from the elimination of a number of the financial and other covenants in our then existing credit facilities and the deferral of cash interest on the Senior Secured Discount Notes during the period in which they accrete.

 

Prior credit facilities

 

As of December 31, 2003, our credit facilities consisted of: tranche A term loans in an aggregate principal amount of $9.6 million outstanding; Mexico term loans in an aggregate principal amount of $24.2 million outstanding; tranche B term loans in an aggregate principal amount of $185.8 million outstanding; and a revolving credit facility in an aggregate principal amount of up to $100 million (excluding $6.7 million of outstanding letters of credit).

 

New Revolving Credit Facility

 

On February 17, 2004, we paid off and terminated our then existing credit facilities and entered into a new revolving credit facility providing up to $100.0 million (subject to a borrowing base).  The new revolving credit facility includes a $15.0 million letter of credit sub-facility, with letters of credit reducing availability under our revolving credit facility.

 

The new revolving credit facility is secured by a first-priority security interest in substantially all inventory, receivables, deposit accounts, 100% of capital stock of, or other equity interests in existing and future domestic subsidiaries and foreign subsidiaries that are guarantors of the Senior Secured Discount Notes, and 65% of the capital stock of, or other equity interests in existing and future first-tier foreign subsidiaries, investment property and certain other assets of the Company and the note guarantors (the “Second-Priority Collateral”), and a second-priority security interest in our real property, fixtures, equipment, intellectual property and other assets (the “First-Priority Collateral”).

 

The new revolving credit facility matures on February 17, 2009.  The Company is subject to periodic reporting of a borrowing base consisting of eligible accounts receivable and eligible inventory.  The interest rates will be at LIBOR plus 2.5% to 2.75 % or ABR plus 1.5% - - 1.75%.

 

The borrowings under the new revolving credit facility may be limited at any given time to 75% of the lesser of the total commitment at such time and the borrowing base in effect at such time if the fixed coverage ratio defined in the new revolving credit facility is less than or equal to 1.10 to 1.00.

 

Issuance of 11 1/8% Senior Secured Discount Notes due 2009

 

On February 17, 2004 we completed the sale of $306.0 million principal amount at maturity (gross proceeds of $225.3 million) of 11 1/8% Senior Secured Discount Notes due 2009.  The proceeds of the offering and

 

26



 

borrowings under the new revolving credit facility (discussed above) were used to repay and terminate the credit facilities that existed at December 31, 2003.

 

The Senior Secured Discount Notes are secured by a first-priority security interest in the First-Priority Collateral and a second-priority security interest in the Second-Priority Collateral.  The Senior Secured Discount Notes are guaranteed by our existing and future domestic restricted subsidiaries and certain foreign subsidiaries.

 

Unless we elect to pay cash interest as described below, and except under certain limited circumstances the Senior Secured Discount Notes will accrete from the date of issuance at the rate of 11 1/8% until December 15, 2006, compounded semiannually on each June 15 and December 15 commencing June 15, 2004, to an aggregate principal amount of $1,000 per note ($306.0 million in the aggregate assuming no redemption or other repayments).  Commencing on December 15, 2006, interest on the Senior Secured Discount Notes will accrue at the rate of 11 1/8% per annum and will be payable in cash semiannually on June 15 and December 15, commencing on June 15, 2007.

 

On any interest payment date prior to December 15, 2006, we may elect to commence paying cash interest (from and after such interest payment date) in which case (i) we will be obligated to pay cash interest on each subsequent interest payment date, (ii) the notes will cease to accrete after such interest payment date and (iii) the outstanding principal amount at the stated maturity of each note will equal the accreted value of such note as of such interest payment date.

 

On or after June 15, 2007, we may redeem some of all of the Senior Secured Discount Notes at the following redemption prices (expressed as a percentage of principal amount), plus accrued and unpaid interest: 105.563% if redeemed prior to June 15, 2008; 102.781% if redeemed prior to June 15, 2009; and 100% if redeemed on or after June 15, 2009.   Prior to such date, we may not redeem the notes except as described in the following paragraph.

 

At any time prior to June 15, 2007, we may redeem up to 35% of the accreted value of the Senior Secured Discount Notes with the net cash proceeds of certain equity offerings by us at a redemption price equal to 111.125% of the accreted value thereof plus accrued interest, so long as (i) at least 65% of the accreted value of the notes remains outstanding after such redemption and (ii) any such redemption by us is made within 120 days after such equity offering.

 

11 1/8% Senior Secured Notes due 2009

 

On May 30, 2003, we completed the sale of $250 million aggregate principal amount of our 11 1/8% Senior Secured Notes due 2009. The 11 1/8% Senior Secured Notes due 2009 mature on September 1, 2009, and interest is payable on March 1 and September 1 of each year. The net proceeds from the sale of the 11 1/8% Senior Secured Notes due 2009 were used to repay borrowings under our then existing credit facilities in accordance with an amendment to our then existing credit facilities. The 11 1/8% Senior Secured Notes due 2009 rank equally with our existing and future senior debt and rank senior to our existing and future subordinated indebtedness, including the 13% Senior Subordinated Notes due 2010. The 11 1/8% Senior Secured Notes due 2009 are secured, on a second-priority lien basis, by a substantial portion of our assets. Due to this second-priority status, the 11 1/8% Senior Secured Notes due 2009 effectively rank junior to our obligations secured by a first-priority lien on the collateral securing the 11 1/8% Senior Secured Notes due 2009 to the extent of the value of such collateral. These obligations secured by first-priority liens include our new revolving credit facility with respect to Second-Priority Collateral and the Senior Secured Discount Notes due 2009 with respect to First-Priority Collateral. In addition, the 11 1/8% Senior Secured Notes due 2009 effectively rank junior to any of our obligations that are secured by a lien on assets that are not part of the collateral securing the 11 1/8% Senior Secured Notes due 2009, to the extent of the value of such assets. The 11 1/8% Senior Secured Notes due 2009 are guaranteed by some of our subsidiaries.

 

Prior to June 1, 2007, we may, on one or more occasions, redeem up to a maximum of 35% of the original aggregate principal amount of the 11 1/8% Senior Secured Notes due 2009 with the net cash proceeds of one or more equity offerings by us at a redemption price equal to 111.125% of the principal amount thereof, plus accrued

 

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and unpaid interest. Otherwise, we may not redeem the 11 1/8% Senior Secured Notes due 2009 prior to June 1, 2007. On or after that date, we may redeem some or all of the 11 1/8% Senior Secured Notes due 2009 at the following redemption prices (expressed as a percentage of principal amount), plus accrued and unpaid interest: 105.563% if redeemed prior to June 1, 2008; 102.781% if redeemed prior to June 1, 2009; and 100% if redeemed on or after June 1, 2009.

 

13% Senior Subordinated Notes due 2010

 

In 2000, we issued $220 million aggregate principal amount of 13% Senior Subordinated Notes due 2010. In 2002, we issued an additional $100 million of 13% Senior Subordinated Notes due 2010. The 13% Senior Subordinated Notes due 2010 mature on June 1, 2010, and interest on the 13% Senior Subordinated Notes due 2010 is payable on June 1 and December 1 of each year. The 13% Senior Subordinated Notes due 2010 are subordinated to all of our existing and future senior debt, rank equally with any future senior subordinated debt, and rank senior to any future subordinated debt. The 13% Senior Subordinated Notes due 2010 are guaranteed by some of our subsidiaries. The 13% Senior Subordinated Notes due 2010 are unsecured. We may not redeem the 13% Senior Subordinated Notes due 2010 prior to June 1, 2005. On or after that date, we may redeem the 13% Senior Subordinated Notes due 2010, in whole or in part, at the following redemption prices (expressed as percentages of principal amount), plus accrued and unpaid interest: 106.5% if redeemed prior to June 1, 2006; 104.333% if redeemed prior to June 1, 2007; 102.167% if redeemed prior to June 1, 2008; and 100% if redeemed on or after June 1, 2008.

 

Preferred stock

 

We have approximately $196.6 million of Series A Cumulative Exchangeable Redeemable Preferred Stock outstanding. The Series A preferred stock accrues dividends at the rate of 14% per annum; however, our board of directors has never declared or paid any dividends on the Series A preferred stock. Unpaid dividends accumulate and are added to the liquidation amount of the Series A preferred stock. After May 31, 2005 the annual dividend rate increases to 16% unless we pay dividends in cash. The dividend rate also increases to 16% if we fail to comply with certain of our obligations or upon certain events of bankruptcy. The Series A preferred stock is mandatorily redeemable on May 31, 2011.

 

Net Cash Used in Operating Activities

 

Net cash used in operating activities was $1.2 million for the three months ended March 31, 2004, a decrease of $0.3 million, as compared to net cash used in operating activities of $1.5 million for the same period in 2003.  This decrease was largely due to changes in working capital items.

 

Net Cash Used in Investing Activities

 

Net cash used in investing activities decreased $0.5 million to $3.1 million for the three months ended March 31, 2004, from $3.6 million for the three months ended March 31, 2003.  These cash outflows were for capital expenditures for maintenance projects.

 

Net Cash Provided by Financing Activities

 

Net cash provided by financing activities was $4.9 million for the three months ended March 31, 2004, as compared to net cash provided by financing activities of $7.7 million for the three months ended March 31, 2003. The activity for the first quarter of 2004 includes the net proceeds from the issuance of senior secured discount notes for $225.3 million net of financing fees paid of $ 8.7 million and the repayment of the old credit facilities of $ 219.6 million. In addition we borrowed $ 8.3 million net of repayments under the new credit facility for operations and paid $0.5 million for capital leases.  The transactions in the first quarter of 2003 included the issuance of $ 10 million of

 

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redeemable preferred shares, net of issue costs, repayment of term debt and a part of the revolving debt under the old credit facility and borrowings under the revolving debt under the old credit facility for operations.

 

Liquidity

 

As of March 31, 2004, we had approximately $77.4 million of working capital.  We were unable to borrow more than $45.0 million under our new revolving credit facility as of March 31, 2004 until we put in place certain deposit control agreements.  These deposit control agreements were put in place in April 2004.  If these deposit control agreements had been in place as of March 31, 2004, subject to the next sentence, we would have had on a pro forma basis approximately $80.3 million available for borrowings under our new $100.0 million revolving credit facility, with outstanding borrowings of approximately $ 8.3 million and approximately $6.1 million of letters of credit issued under our revolving credit facility. The borrowings under the new revolving credit facility may be limited at any given time to 75% of the lesser of the total commitment at such time and the borrowing base in effect at such time if the fixed coverage ratio defined in the new revolving credit facility is less than or equal to 1.10 to 1.00.  Our outstanding borrowings under our revolving credit facility fluctuate significantly during each quarter as a result of the timing of payments for raw materials, capital and interest, as well as the timing of customer collections.

 

As of March 31, 2004, we had approximately $3.3 million in cash and cash equivalents.  A portion of this amount was held by our foreign subsidiaries.  Repatriation tax rates may limit our ability to access cash and cash equivalents generated by our foreign operations for use in our U.S. operations, including to pay principal and interest on outstanding borrowings.

 

We expect that our total capital expenditures will be approximately $20-$30 million in each of 2004 and 2005.  These expenditures will consist primarily of ongoing maintenance capital expenditures and limited capacity additions.

 

Our revolving credit facility and the indentures relating to our outstanding notes impose certain restrictions on us, including restrictions on our ability to incur indebtedness, pay dividends, make investments, grant liens, sell our assets and engage in certain other activities.

 

Cautionary Statement for Forward-Looking Information

 

Certain information set forth in this report contains “forward-looking statements” within the meaning of federal securities laws.  Forward-looking statements include statements concerning our plans, objectives, goals, strategies, future events, future revenues or performance, capital expenditures, financing needs, plans or intentions relating to acquisitions, business trends, and other information that is not historical information.  When used in this report, the words “estimates,” “expects,” “anticipates,” “forecasts,” “plans,” “intends,” “believes” and variations of such words or similar expressions are intended to identify forward-looking statements.  We may also make additional forward-looking statements from time to time.  All such subsequent forward-looking statements, whether written or oral, by us or on our behalf, are also expressly qualified by these cautionary statements.

 

All forward-looking statements, including, without limitation, management’s examination of historical operating trends, are based upon our current expectations and various assumptions.  Our expectations, beliefs and projections are expressed in good faith and we believe there is a reasonable basis for them.  But, there can be no assurance that management’s expectations, beliefs and projections will result or be achieved.  All forward-looking statements apply only as of the date made.  We undertake no obligation to publicly update or revise forward-looking statements which may be made to reflect events or circumstances after the date made or to reflect the occurrence of unanticipated events.

 

There are a number of risks and uncertainties that could cause our actual results to differ materially from the forward-looking statements contained in or contemplated by this report. These risks include, but are not limited to: general economic and business conditions, particularly an economic downturn; industry trends; increases in our leverage; interest rate increases; changes in our ownership structure; raw material costs and availability, particularly resin; competition; the loss of any of our significant customers; changes in the demand for our products; new technologies; changes in distribution channels or competitive conditions in the markets or countries in which we

 

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operate; costs of integrating any future acquisitions; loss of our intellectual property rights; foreign currency fluctuations and devaluations and political instability in our foreign markets; changes in our business strategy or development plans; availability, terms and deployment of capital; availability of qualified personnel; and increases in the cost of compliance with laws and regulations, including environmental laws and regulations. Each of these risks and certain other uncertainties are discussed in more detail in the 2003 Form 10-K and in our Registration Statement on Form S-4 (file no. 333-114608), as amended, filed with the Securities and Exchange Commission. There may be other factors, including those discussed elsewhere in this report that may cause our actual results to differ materially from the forward-looking statements.  Any forward-looking statements should be considered in light of these factors.

 

ITEM 3.  QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

 

We are exposed to resin price risks that arise in the normal course of business.  Significant increases in the price of resins could adversely affect our operating margins, results of operations and ability to service our indebtedness.

 

Since the repayment of $219.6 million of variable rate term debt with the proceeds of our Senior Secured Discount Notes and borrowings under our new revolving credit facility on February 17, 2004 our interest rate risk has decreased substantially.

 

Our new revolving credit facility is at a variable rate of interest.  An increase of 1% in interest rates would result in an additional $100,000 of annual interest expense for each $10.0 million in borrowings under our new revolving credit facility.  We will thus be exposed to interest rate risk to the extent of our borrowings under the new revolving credit facility.

 

ITEM 4. CONTROLS AND PROCEDURES

 

Evaluation of Disclosure Controls and Procedures

 

We maintain disclosure controls and procedures that are designed to ensure that information required to be disclosed in our filings under the Securities Exchange Act of 1934 is recorded, processed, summarized and reported within the periods specified in the rules and forms of the Securities and Exchange Commission.  This information is accumulated and communicated to our management, including our principal executive officer and our principal financial officer, as appropriate, to allow timely decisions regarding required disclosure.  Our management, including our principal executive officer and our principal financial officer, recognizes that any set of controls and procedures, no matter how well designed and operated, can provide only reasonable assurance of achieving the desired control objectives.

 

Under the supervision and with the participation of our management, including our principal executive officer and principal financial officer, we conducted an evaluation of our disclosure controls and procedures as of the end of the period covered by this report.  Based on this evaluation, our principal executive officer and principal financial officer concluded that our disclosure controls and procedures are effective in alerting them on a timely basis to material information required to be disclosed in our periodic filings.

 

Changes in Internal Controls

 

There were no significant changes in our internal controls or in other factors that could significantly affect these controls subsequent to the date of the evaluation referenced in the foregoing paragraph.

 

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PART II.  OTHER INFORMATION

 

ITEM 1. LEGAL PROCEEDINGS

 

There were no material developments during the quarter ended March 31, 2004 in the litigation described in Note 11 to the Consolidated Condensed Financial Statements contained in Item 1 of this report.

 

ITEM 2. CHANGES IN SECURITIES, USE OF PROCEEDS AND ISSUER PURCHASES OF EQUITY SECURITIES

 

On February 17, 2004, we issued $306 million in principal amount at maturity of our 11 1/8% Senior Secured Discount Notes due 2009.  The Senior Secured Discount Notes are secured by a first-priority security interest in the First-Priority Collateral and a second-priority security interest in the Second-Priority Collateral.  Due to the issuance of the Senior Secured Discount Notes, the right of payment of the holders of our 11 1/8% Senior Secured Notes due 2009 is effectively subordinated to the first-priority security interest of the Senior Secured Discount Notes in the First-Priority Collateral, to the extent of the value of that collateral.

 

ITEM 3. DEFAULTS UPON SENIOR SECURITIES

 

The Company received a waiver from the holders of its credit facilities in existence as of December 31, 2003 with respect to certain covenant defaults by the Company under those credit facilities.

 

ITEM 4. SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS

 

None.

 

ITEM 5. OTHER INFORMATION

 

None

 

ITEM 6. EXHIBITS AND REPORTS ON FORM 8-K

 

(a)                                  The following exhibits are filed with this report.

 

31.1                           Certification of Chief Executive Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.

 

31.2                           Certification of Chief Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.

 

32.1                           Certification of Chief Executive Officer furnished pursuant to 18 U.S.C. Section 1350, as Adopted Pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.

 

32.2                           Certification of Chief Financial Officer furnished pursuant to 18 U.S.C. Section 1350, as Adopted Pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.

 

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(b)                                  Reports on Form 8-K

 

We filed / furnished a Current Report on Form 8-K, dated January 29, 2004, under Items 5, 7 and 9 of such form, announcing our intention to offer the Senior Secured Discount Notes, terminate our then existing credit facilities and enter into a new revolving credit facility.  The information included in Item 9 of this Current Report was furnished and shall not be deemed to be filed.

 

We furnished a Current Report on Form 8-K, dated January 30, 2004, under Items 7 and 9 of such form, estimating the financial outlook for 2004.  The information included in Item 9 of this Current Report was furnished and shall not be deemed to be filed.

 

We filed a Current Report on Form 8-K, dated February 17, 2004, under Items 5 and 7 of such form, announcing the completion of the sale of our Senior Secured Discount Notes and the execution of our $100 million new revolving credit facility.

 

We furnished a Current Report on Form 8-K, dated March 25, 2004, under Items 9 and 12 of such form, reporting the scheduling of our earnings conference call and to provide certain information required by Regulation G.  The information included in Items 9 and 12 of this Current Report was furnished and shall not be deemed to be filed.

 

We furnished a Current Report on Form 8-K, dated March 26, 2004, under Item 9 of such form, announcing the Company’s position for growth in 2004 and beyond as stated in a letter from Harold Bevis, President and Chief Executive Officer of Pliant, to our customers, investors and employees.  The information included in Item 9 of this Current Report was furnished and shall not be deemed to be filed.

 

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SIGNATURES

 

 

Pursuant to the requirements 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.

 

 

 

PLIANT CORPORATION

 

 

 

 

 

/s/ BRIAN E. JOHNSON

 

 

BRIAN E. JOHNSON

 

Executive Vice President and

 

Chief Financial Officer

 

(Authorized Signatory and

 

Principal Financial and Accounting Officer)

 

 

 

 

Date:

May 14, 2004

 

 

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INDEX TO EXHIBITS

 

Exhibits

 

 

 

 

 

31.1

 

Certification of Chief Executive Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.

 

 

 

31.2

 

Certification of Chief Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002.

 

 

 

32.1

 

Certification of Chief Executive Officer furnished pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.

 

 

 

32.2

 

Certification of Chief Financial Officer furnished pursuant to 18 U.S.C. Section 1350, as adopted pursuant to Section 906 of the Sarbanes-Oxley Act of 2002.

 

34