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UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
WASHINGTON, D.C. 20549


FORM 10-K

FOR ANNUAL AND TRANSACTION REPORTS PURSUANT TO SECTIONS 13 OR 15(d) OF THE
SECURITIES EXCHANGE ACT OF 1934


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

For the fiscal year ended December 31, 2004

OR

       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 1-10258


TREDEGAR CORPORATION

(Exact name of registrant as specified in its charter)

Virginia   54-1497771

(State or other jurisdiction
of incorporation or organization)
 
(I.R.S. Employer
Identification No.)

1100 Boulders Parkway, Richmond, Virginia   23225

(Address of principal executive offices)  
(Zip Code)

Registrant’s telephone number, including area code:   804-330-1000

Securities registered pursuant to Section 12(b) of the Act:


Title of Each Class   Name of Each Exchange on Which Registered

 
Common Stock
Preferred Stock Purchase Rights
  New York Stock Exchange
New York Stock Exchange

Securities registered pursuant to Section 12(g) of the Act: None

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 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 at least the past 90 days. Yes  No


Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K .

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

 

Aggregate market value of voting and non-voting common equity held by non-affiliates of the registrant as of June 30, 2004: $492,409,575*

Number of shares of Common Stock outstanding as of January 31, 2005: 38,607,611 (38,420,200 as of June 30, 2004)

*  In determining this figure, an aggregate of 7,892,638 shares of Common Stock beneficially owned by Floyd D. Gottwald, Jr., John D. Gottwald, William M. Gottwald and the members of their immediate families has been excluded because the shares are held by affiliates. The aggregate market value has been computed based on the closing price in the New York Stock Exchange Composite Transactions on June 30, 2004, as reported by The Wall Street Journal.





Documents Incorporated By Reference

                    Portions of the Tredegar Corporation (“Tredegar”) Proxy Statement for the 2005 Annual Meeting of Shareholders (the “Proxy Statement”) are incorporated by reference into Part III of this Form 10-K. We expect to file our Proxy Statement with the Securities and Exchange Commission and mail it to shareholders on or about March 25, 2005.


 

Index to Annual Report on Form 10-K
Year Ended December 31, 2004


Part I     Page  

Item 1. Business   1-4  

Item 2. Properties   4-5  

Item 3. Legal Proceedings   5  

Item 4. Submission of Matters to a Vote of Security Holders   None  

 
Part II

Item 5.

Market for Tredegar’s Common Equity, Related  
Stockholder Matters and Issuer Purchases of Equity Securities

  6-7  

Item 6. Selected Financial Data   7-14  

Item 7. Management’s Discussion and Analysis of Financial Condition
and Results of Operations
  15-39  

Item 7A. Quantitative and Qualitative Disclosures About Market Risk   39  

Item 8. Financial Statements and Supplementary Data   43-74  

Item 9. Changes In and Disagreements With Accountants on Accounting  and Financial Disclosures   None  

Item 9A. Controls and Procedures   39-40  

Item 9B. Other Information   None  

 
Part III

Item 10 Directors and Executive Officers of Tredegar*   40-41  

Item 11 Executive Compensation   *  

Item 12 Security Ownership of Certain Beneficial Owners and Management
and Related Stockholder Matters
  *  

Item 13 Certain Relationships and Related Transactions   42  

Item 14 Principal Accounting Fees and Services   *  

 
Part IV

Item 15 Exhibits and Financial Statement Schedules   43  


*  Items 11, 12 and 14 and portions of Item 10 are incorporated by reference from the Proxy Statement.

The Securities and Exchange Commission (the “SEC”) has not approved or disapproved of this report or passed upon its accuracy or adequacy.




PART I

Item 1.        BUSINESS

Description of Business

                    Tredegar Corporation (“Tredegar”) is engaged, through its subsidiaries, in the manufacture of plastic films and aluminum extrusions. We also operate Therics Inc. (“Therics”), which has developed and in 2004 launched an initial family of products used in bone grafting procedures. We sold our venture capital investment portfolio in the first half of 2003 and received tax refunds of about $55 million in the first quarter of 2004 related to the sale (see pages 37-39 for more information).

Film Products

                    Tredegar Film Products Corporation and its subsidiaries (together, “Film Products”) manufacture plastic films, elastics, nonwovens and laminate materials primarily for personal and household care products and packaging and surface protection applications. These products are produced at various locations throughout the United States and at plants in The Netherlands, Hungary, Italy, China and Brazil. Film Products competes in all of its markets on the basis of product innovation, quality, price and service.

Personal and Household Care Films.  Film Products is one of the largest global suppliers of apertured, breathable, elastic and embossed films, and nonwovens and laminate materials for personal care markets, including:

 
Apertured film and nonwoven materials for use as topsheet in feminine hygiene products, baby diapers and adult incontinent products (including materials sold under the ComfortQuilt® name);
 
Breathable, embossed and elastic materials for use as components for baby diapers, adult incontinent products and feminine hygiene products (including elastic components sold under the FabriflexTM, StretchTabTM and FlexaireTM names); and
 
Absorbent transfer layers for baby diapers and adult incontinent products sold under the AquiDryTM and AquiSoftTM names.
 

                    In each of the last three years, personal care products accounted for more than 30% of Tredegar’s consolidated net sales.

                    Film Products also makes apertured films, breathable barrier films and laminates that regulate vapor or fluid transmission. These products are typically used in industrial, medical, agricultural and household markets, including disposable mops, facial wipes, filter layers for personal protective suits, facial masks and landscaping fabric.

Packaging and Protective Films. Film Products produces a broad line of packaging films with an emphasis on paper, as well as laminating films for food packaging applications. These products give our customers a competitive advantage by providing cost savings with thin-gauge films that are readily printable and convertible on conventional processing equipment. Major end uses include overwrap for bathroom tissue and paper towels, and retort pouches.

                    Film Products also produces films that are disposable, protective coversheets for photopolymers used in the manufacture of circuit boards. Other films sold under the UltraMask® and ForceFieldTM names are used as protective films to protect flat panel display components such as glass during fabrication, shipping and handling.

Raw Materials.  The primary raw materials used by Film Products are low density, linear low density and high density polyethylene and polypropylene resins, which are obtained from domestic and foreign suppliers at competitive prices. We believe there will be an adequate supply of polyethylene and polypropylene resins in the immediate future. Film Products also buys nonwoven fabrics based on these same resins, and we believe there will be an adequate supply of these materials in the immediate future.




Customers.   Film Products sells to many branded product producers throughout the world. Its largest customer is The Procter & Gamble Company (“P&G”). Net sales to P&G totaled $226 million in 2004, $207 million in 2003 and $243 million in 2002 (these amounts include film sold to third parties that converted the film into materials used in products manufactured by P&G).

                    P&G and Tredegar have had a successful long-term relationship based on cooperation, product innovation and continuous process improvement. The loss or significant reduction in sales associated with P&G would have a material adverse effect on our business.

Research and Development and Intellectual Property. Film Products has technical centers in Terre Haute, Indiana; Lake Zurich, Illinois; Chieti, Italy; and Shanghai, China; and holds 220 issued patents (75 of which are issued in the U.S.) and 103 trademarks (5 of which are issued in the U.S.). Expenditures for research and development (“R&D”) have averaged $7.6 million per year over the past three years.

                    On September 13, 2004, we announced that our technical centers in Terre Haute, Indiana and Lake Zurich, Illinois would be moved to Richmond, Virginia, where a substantial portion of Film Products’ marketing, sales and senior management are located. We expect the move to be completed by the end of 2005. The technical facility in Terre Haute will continue to operate at reduced staffing levels. Technical operations at the plant in Lake Zurich will be discontinued. The centralized location of R&D, marketing, sales and senior management should help improve product development time and reduce expenses. Pretax cash expenditures associated with the restructuring are expected of approximately $8 million (consisting primarily of severance, relocation and hiring expenses, leasehold improvements and equipment costs). Once complete, the restructuring is expected to reduce annual operating expenses by approximately $2 million and result in a net reduction of approximately 20 positions.

Aluminum Extrusions

                    The William L. Bonnell Company, Inc. and its subsidiaries (together, “Aluminum Extrusions”) produce soft-alloy aluminum extrusions primarily for building and construction, distribution, transportation, machinery and equipment, electrical and consumer durables markets.

                    Aluminum Extrusions manufactures mill (unfinished), anodized (coated) and painted aluminum extrusions for sale directly to fabricators and distributors that use our extrusions to produce window components, curtain walls and storefronts, tub and shower doors, industrial and agricultural machinery and equipment, ladders, bus bars, automotive parts, snowmobiles and tractor-trailer shapes, among other products. Sales are made primarily in the United States and Canada, principally east of the Rocky Mountains. Aluminum Extrusions competes primarily on the basis of product quality, service and price.

                    Aluminum Extrusions sales volume by market segment over the last two years is shown below:


 
 
  % of Aluminum Extrusions Sales Volume
by Market Segment
 
 
 
  2004   2003  
   
 
 
  Building and construction:        
      Commercial   41     39  
      Residential   21     23  
  Distribution   13     14  
  Transportation   10     10  
  Machinery and equipment   7     6  
  Electrical   5     5  
  Consumer durables   3     3  
 
 
  Total   100     100  
 
 

2



Raw Materials.  The primary raw materials used by Aluminum Extrusions consist of aluminum ingot, aluminum scrap and various alloys, which are purchased from domestic and foreign producers in open-market purchases and under short-term contracts. We believe there will be an adequate supply of aluminum and other required raw materials and supplies in the immediate future.

Intellectual Property. Aluminum Extrusions holds two U.S. patents and three U.S. trademarks.

Therics

                    Located in Princeton, New Jersey, Therics currently employs 32 people. Therics began developing tissue-engineered products in 1996. Its primary focus is on commercializing products made from the TheriForm® process, a unique microfabrication technology used to create scaffolds in a variety of shapes and forms with precise internal architecture that permits tissue in-growth.

                    Therics’ initial synthetic bone graft implants, which have received clearance from the U.S. Food and Drug Administration (the “FDA”), are made from beta-tricalcium phosphate (“b -TCP”). b -TCP has proven effective as a reliable bone substitute in a variety of orthopaedic and neurosurgical applications. We believe there will be adequate supply of b -TCP in the immediate future.

                    Therics introduced its initial line of implants used in bone grafting procedures in 2004. The initial feedback from orthopaedic surgeons, neurosurgeons and others in the marketplace has generally been positive. Therics is working with selected surgeons and using patient-based case studies to improve existing products and develop more advanced product line extensions. Therics currently distributes through a network of independent distributors and is presently considering potential research and marketing collaborations with a variety of orthopaedic companies in an effort to broaden its scope and reach.

                    According to Knowledge Enterprises, Inc. (The Worldwide Orthopaedic Market, 2003-2004), global sales for the orthobiologics market, which includes bone graft substitutes, allograft distribution/processing, autogenous bone and soft tissue replacement products, growth factors and viscoelastics, were $1.37 billion in 2003 (a 29% increase over 2002) and one of the fastest growing segments in the orthopaedics industry.

                    Therics relies on a combination of patent, trademark, copyright and trade secret laws to protect the company’s proprietary technologies and products. Therics owns or holds exclusive rights to 36 issued patents (34 of which are issued in the U.S.) and has two U.S. trademarks. Therics has more than 34 U.S. and foreign patent applications pending and nine trademark applications pending. Therics spent approximately $7.8 million in 2004, $11.2 million in 2003 and $12.5 million in 2002 on R&D activities.

                    Therics had revenues of $380,000 and an operating loss of $9.8 million in 2004, no revenues and an operating loss of $11.7 million in 2003 and revenues of $208,000 and an operating loss of $13.1 million in 2002. Revenues in 2004 relate to the sale of Therics’ initial line of implants used in bone grafting procedures. Revenues recognized by Therics prior to 2004 relate entirely to payments received for R&D support. As of December 31, 2004, Tredegar had invested approximately $74 million in Therics compared with $65 million as of December 31, 2003. Therics’ identifiable assets included in Tredegar’s consolidated balance sheet were $8.6 million at December 31, 2004, including goodwill and intangible assets of $4.4 million. Therics also has future rental commitments under noncancelable operating leases through 2011 totaling $9.7 million at December 31, 2004, with partially offsetting sublease rental commitments relating to excess space totaling about $1 million.


3



General

Patents, Licenses and Trademarks. Tredegar considers patents, licenses and trademarks to be of significance for Film Products and Therics. We routinely apply for patents on significant developments in each of these businesses. Our patents have remaining terms ranging from 1 to 17 years. We also have licenses under patents owned by third parties.

Research and Development. Tredegar spent approximately $15.3 million in 2004, $18.8 million in 2003 and $20.3 million in 2002 on R&D activities related to continuing operations.

Backlog.  Backlogs are not material to our operations.

Government Regulation.  Laws concerning the environment that affect or could affect our domestic operations include, among others, the Clean Water Act, the Clean Air Act, the Resource Conservation Recovery Act, the Occupational Safety and Health Act, the National Environmental Policy Act, the Toxic Substances Control Act, the Comprehensive Environmental Response, Compensation and Liability Act (“CERCLA”), as amended, regulations promulgated under these acts, and any other federal, state or local laws or regulations governing environmental matters. We believe that we are in substantial compliance with all applicable laws, regulations and permits. In order to maintain substantial compliance with such standards, we may be required to incur expenditures, the amounts and timing of which are not presently determinable but which could be significant, in constructing new facilities or in modifying existing facilities.

Employees.  Tredegar employed approximately 3,100 people at December 31, 2004.

Available Information and Corporate Governance Documents.  Our Internet address is www.tredegar.com. We make available, free of charge through our web site, our annual report on Form 10-K, quarterly reports on Form 10-Q, current reports on Form 8-K and amendments to those reports filed or furnished pursuant to Section 13(a) or 15(d) of the Securities Exchange Act of 1934, as amended, as soon as reasonably practicable after such documents are electronically filed with, or furnished to, the SEC. In addition, our Corporate Governance Guidelines, Code of Conduct and the charters of our Audit, Executive Compensation and Nominating and Governance Committees are available on our web site and are available in print, without charge, to any shareholder upon request by contacting Tredegar’s Corporate Secretary at 1100 Boulders Parkway, Richmond, Virginia 23225. The information on our website is not, and shall not be deemed to be, a part of this report or incorporated into other filings we make with the SEC.

Item 2.        PROPERTIES

General

                    Most of the improved real property and the other assets used in our operations are owned, and none of the owned property is subject to an encumbrance that is material to our consolidated operations. We consider the plants, warehouses and other properties and assets owned or leased by us to be in generally good condition.

                    We believe that the capacity of our plants is adequate to meet our immediate needs. Our plants generally have operated at 50-95% of capacity. Our corporate headquarters, which is leased, is located at 1100 Boulders Parkway, Richmond, Virginia 23225.


4



                    Our principal plants and facilities are listed below:

 

Film Products Principal Operations
Locations in the United States Locations in Foreign Countries
LaGrange, Georgia (1)
Lake Zurich, Illinois (technical
   center & production
   facility) (2)
Pottsville, Pennsylvania
Terre Haute, Indiana
   (technical center &
   production facility) (2)
Chieti, Italy (technical center)
Guangzhou, China
Kerkrade, The Netherlands
Rétság, Hungary
Roccamontepiano, Italy
São Paulo, Brazil
Shanghai, China
Production of plastic films,
nonwovens and laminate materials

Aluminum Extrusions Principal Operations
Locations in the United States Locations in Canada
Carthage, Tennessee
Kentland, Indiana
Newnan, Georgia
Aurora, Ontario (3)
Pickering, Ontario
Richmond Hill, Ontario
Ste Thérèse, Québec
Woodbridge, Ontario
Production of aluminum extrusions, fabrication and finishing

————————————————
(1)    On January 10, 2005, we announced that we are exploring the sale of the Film Products’ plant in LaGrange, Georgia. This plant produces blown films used for adult incontinent and baby diaper backsheet, feminine hygiene pad pouch packaging, and other packaging and industrial applications. Annual revenues for the products that would be included in a sale are about $25 million. The proposed transaction is not expected to have a material impact on our financial results.
 
(2)    On September 13, 2004, we announced that our technical centers in Terre Haute, Indiana and Lake Zurich, Illinois would be moved to Richmond, Virginia, where a substantial portion of Film Products’ marketing, sales and senior management are located. More information on this restructuring is provided on page 2.
 
(3)    On April 13, 2004, we announced that the aluminum extrusions plant in Aurora, Ontario would be closed and that its business would be transferred to other extrusion facilities in Ontario. We expect the plant to close in the first quarter of 2005. The shutdown plan includes moving the Aurora plant’s largest press to the plant in Pickering, Ontario, and investing $8 million to upgrade the press and enlarge the facility. This consolidation is expected to reduce annual operating costs by approximately $2 million.
 

Therics

                    Therics leases space in Princeton, New Jersey.

Item 3.        LEGAL PROCEEDINGS

                    A consent order was entered into by the Environmental Protection Division, Department of Natural Resources, State of Georgia and The William L. Bonnell Company relating to alleged violations of the conditions and limitations contained in the National Pollutant Discharge Elimination System Permit No. GA0000507 (the “Permit”) for our wastewater treatment facility in Newnan, Georgia. The consent order was in effect through December 31, 2003. We agreed to pay penalties until the Permit issues associated with our wastewater treatment facility were resolved. We believe that the issues have been resolved and have made aggregate payments of $160,000 under the consent order.

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

                    None.


5



PART II

 
Item 5.   MARKET FOR TREDEGAR’S COMMON EQUITY, RELATED STOCKHOLDER MATTERS AND ISSUER PURCHASES OF EQUITY SECURITIES
 

Market Prices of Common Stock and Shareholder Data

                    Our common stock is traded on the New York Stock Exchange (“NYSE”) under the ticker symbol TG. We have no preferred stock outstanding. There were 38,597,522 shares of common stock held by 4,146 shareholders of record on December 31, 2004.

                    The following table shows the reported high and low closing prices of our common stock by quarter for the past two years.



 
  2004   2003  
 
 
 
High   Low   High   Low  
 
 
 
 
 
First quarter $ 17.80   $ 13.20   $ 15.08   $ 10.60  
Second quarter   16.13     13.00     15.67     11.96  
Third quarter   18.38     14.75     16.76     14.03  
Fourth quarter   20.25     16.68     16.52     14.62  


Dividend Information

 
                   We have paid a dividend every quarter since becoming a public company in July 1989. During 2002, 2003 and 2004, our quarterly dividend was 4 cents per share.
 

                    All decisions with respect to payment of dividends will be made by the Board of Directors based upon earnings, financial condition, anticipated cash needs and such other considerations as the Board deems relevant. See Note 8 beginning on page 60 for minimum shareholders’ equity required and aggregate dividends permitted.

Issuer Purchases of Equity Securities

                    During 2004, we did not purchase any shares of our common stock in the open market. During 2003, we purchased 406,400 shares of our common stock in the open market for $5.2 million (an average price of $12.72 per share). During 2002, we purchased 110,700 shares of our common stock in the open market for $1.4 million (an average price of $12.91 per share). Under a standing authorization from our board of directors, we may purchase an additional 3.4 million shares in the open market or in privately negotiated transactions at prices management deems appropriate.

Annual Meeting

                    Our annual meeting of shareholders will be held on April 28, 2005, beginning at 9:30 a.m. EDT at the University of Richmond’s Jepson Alumni Center in Richmond, Virginia. We expect to mail formal notice of the annual meeting, proxies and proxy statements to shareholders on or about March 25, 2005.


6



Inquiries

                    Inquiries concerning stock transfers, dividends, dividend reinvestment, consolidating accounts, changes of address, or lost or stolen stock certificates should be directed to:

National City Bank
Dept. 5352
Corporate Trust Operations
P.O. Box 92301
Cleveland, Ohio 44193-0900
Phone:  800-622-6757
E-mail:  shareholder.inquiries@nationalcity.com

                    All other inquiries should be directed to:

Tredegar Corporation
Investor Relations Department
1100 Boulders Parkway
Richmond, Virginia 23225
Phone:  800-411-7441
E-mail:  invest@tredegar.com
Web site:  www.tredegar.com

Quarterly Information

                    We do not generate or distribute quarterly reports to shareholders. Information on quarterly results can be obtained from our web site and from quarterly reports on Form 10-Q filed with the SEC.

 
Legal Counsel

Hunton & Williams LLP
Richmond, Virginia
Independent Registered Public Accounting Firm

PricewaterhouseCoopers LLP
Richmond, Virginia

 

Item 6.        SELECTED FINANCIAL DATA

                    The tables that follow on pages 8-14 present certain selected financial and segment information for the eight years ended December 31, 2004.


7



EIGHT-YEAR SUMMARY

Tredegar Corporation and Subsidiaries                                                                
                                                                 
Years Ended December 31 2004     2003     2002     2001     2000     1999     1998     1997    

(In thousands, except per-share data)                                                                
                                                                 
Results of Operations (a):                                                                
Sales $ 861,165     $ 738,651     $ 753,724     $ 779,157     $ 879,475     $ 828,015     $ 705,024     $ 586,466    
Other income (expense), net   15,604   (b)   7,853       546       1,255       1,914       972       1,749       3,135    

    876,769       746,504       754,270       780,412       881,389       828,987       706,773       589,601    

Cost of goods sold   717,120   (b)   606,242       582,658       618,323       706,817       648,254       553,184       457,896    
Freight   22,398       18,557       16,319       15,580       17,125       15,221       10,946       8,045    
Selling, general & administrative
    expenses
  60,030   (b)   53,341       52,252       47,954       47,321       44,675       37,127       36,659    
Research and development expenses   15,265       18,774       20,346       20,305       15,305       11,500       5,995       6,475    
Amortization of intangibles   330       268       100       4,914       5,025       3,430       205       50    
Interest expense   3,171       6,785       9,352       12,671       17,319       9,088       1,318       1,952    
Asset impairments and costs associated
    with exit and disposal activities
  22,973   (b)   11,426   (c)   3,884   (d)   16,935   (e)   23,791   (f)   4,628   (g)   664   (h)      
Unusual items         1,067   (c)   (6,147 ) (d)   (971 ) (e)   (762 ) (f)         (765 ) (h)   (2,250 ) (i)

    841,287       716,460       678,764       735,711       831,941       736,796       608,674       508,827    

Income from continuing operations
    before income taxes
  35,482       30,044       75,506       44,701       49,448       92,191       98,099       80,774    
Income taxes   9,222   (b)   10,717       26,881       13,950   (e)   18,135       32,728       32,094   (h)   28,339    

Income from continuing operations (a)   26,260       19,327       48,625       30,751       31,313       59,463       66,005       52,435    

Discontinued operations (a):                                                                
    Income (loss) from venture capital
        investment activities
  2,921       (46,569 )     (42,428 )     (16,627 )     83,640       (4,626 )     394       8,883    
    Income (loss) from operations
         of Molecumetics
        891       (8,728 )     (5,768 )     (3,577 )     (2,189 )     (2,243 )     (2,872 )  
    Income from discontinued energy segment                     1,396                   4,713          

Income (loss) from discontinued operations (a)   2,921       (45,678 )     (51,156 )     (20,999 )     80,063       (6,815 )     2,864       6,011    

Net income (loss) $ 29,181     $ (26,351 )   $ (2,531 )   $ 9,752     $ 111,376     $ 52,648     $ 68,869     $ 58,446    

                                                                 
Diluted earnings (loss) per share:                                                                
    Continuing operations (a) $ .68     $ .50     $ 1.25     $ .79     $ .80     $ 1.54     $ 1.71     $ 1.33    
    Discontinued operations (a)   .08       (1.19 )     (1.32 )     (.54 )     2.06       (.18 )     .07       .15    

    Net income (loss) $ .76     $ (.69 )   $ (.07 )   $ .25     $ 2.86     $ 1.36     $ 1.78     $ 1.48    


Refer to notes to financial tables on page 14.   


8



EIGHT-YEAR SUMMARY

Tredegar Corporation and Subsidiaries
 
Years Ended December 31 2004   2003   2002   2001   2000   1999   1998   1997  

(In thousands, except per-share data)                                                
                                                 
Share Data:                                                
Equity per share $ 12.45   $ 11.72   $ 12.08   $ 12.53   $ 13.07   $ 9.88   $ 8.46   $ 7.34  
Cash dividends declared per share   .16     .16     .16     .16     .16     .16     .15     .11  
Weighted average common shares
       outstanding during the period
  38,295     38,096     38,268     38,061     37,885     36,992     36,286     36,861  
Shares used to compute diluted
       earnings per share during
       the period
  38,507     38,441     38,869     38,824     38,908     38,739     38,670     39,534  
Shares outstanding at end of period   38,598     38,177     38,323     38,142     38,084     37,661     36,661     37,113  
Closing market price per share:                                                
       High   20.25     16.76     24.72     21.70     32.00     32.94     30.67     24.65  
       Low   13.00     10.60     12.25     15.30     15.00     16.06     16.13     12.54  
       End of year   20.21     15.53     15.00     19.00     17.44     20.69     22.50     21.96  
Total return to shareholders (j)   31.2 %   4.6 %   (20.2 )%   9.9 %   (14.9 )%   (7.3 )%   3.1 %   65.0 %
                 
 Financial Position:                                                
 Total assets   769,474     753,025     837,962     865,031     903,768     792,487     457,178     410,937  
 Cash and cash equivalents   22,994     19,943     109,928     96,810     44,530     25,752     25,409     120,065  
 Income taxes recoverable from sale of
       venture capital portfolio
      55,000                          
 Debt   103,452     139,629     259,280     264,498     268,102     270,000     25,000     30,000  
 Shareholders’ equity (net book value)   480,442     447,399     462,932     477,899     497,728     372,228     310,295     272,546  
 Equity market capitalization (k)   780,066     592,889     574,845     724,706     664,090     779,112     824,873     814,940  


Refer to notes to financial tables on page 14.   


9



SEGMENT TABLES
Tredegar Corporation and Subsidiaries

Net Sales (l)  

Segment 2004   2003   2002   2001   2000   1999   1998   1997  

(In thousands)                                                
                                                 
Film Products $ 413,257   $ 365,501   $ 376,904   $ 382,740   $ 380,202   $ 342,300   $ 286,965   $ 298,862  
Aluminum Extrusions   425,130     354,593     360,293     380,387     479,889     461,241     395,455     266,585  
Therics   380         208     450     403     161          

          Total ongoing operations (n)   838,767     720,094     737,405     763,577     860,494     803,702     682,420     565,447  
Divested operations (a):                                                
          Fiberlux                   1,856     9,092     11,629     10,596  
          Other (m)                           29     2,378  

          Total net sales   838,767     720,094     737,405     763,577     862,350     812,794     694,078     578,421  
Add back freight   22,398     18,557     16,319     15,580     17,125     15,221     10,946     8,045  

Sales as shown in Consolidated                                                
          Statements of Income $ 861,165   $ 738,651   $ 753,724   $ 779,157   $ 879,475   $ 828,015   $ 705,024   $ 586,466  


Refer to notes to financial tables on page 14.   


10



SEGMENT TABLES                                                                
Tredegar Corporation and Subsidiaries                                                                
                                                                 
Operating Profit                                                                

Segment   2004       2003       2002       2001       2000       1999       1998       1997    

(In thousands)                                                                
                                                                 
Film Products:                                                                
    Ongoing operations $ 43,259     $ 45,676     $ 72,307     $ 61,787     $ 47,112     $ 59,554     $ 53,786     $ 50,463    
    Plant shutdowns, asset impairments
      and restructurings
  (10,438)   (b)   (5,746 ) (c)   (3,397 ) (d)   (9,136 ) (e)   (22,163 ) (f)   (1,170 ) (g)            
    Unusual items               6,147   (d)                              

Aluminum Extrusions:                                                                
    Ongoing operations   22,637       15,117       27,304       25,407       52,953       56,501       47,091       32,057    
    Plant shutdowns, asset impairments
      and restructurings
  (10,553 ) (b)   (644 ) (c)   (487 ) (d)   (7,799 ) (e)   (1,628 ) (f)         (664 ) (h)      
    Gain on sale of land         1,385                                        
    Other   7,316   (b)                                          

Therics:                                                                
    Ongoing operations   (9,763 )     (11,651 )     (13,116 )     (12,861 )     (8,024 )     (5,235 )              
    Plant shutdowns, asset impairments
      and restructurings
  (2,041 ) (b)   (3,855 ) (c)                     (3,458 ) (g)            
    Unusual items         (1,067 ) (c)                                    

Divested operations (a):                                                                
    Fiberlux                           (264 )     57       1,433       845    
    Other (m)                                       (428 )     (267 )  
    Unusual items                           762   (f)         765   (h)   2,250   (i)

Total   40,417       39,215       88,758       57,398       68,748       106,249       101,983       85,348    
Interest income   350       1,183       1,934       2,720       2,578       1,419       2,279       4,959    
Interest expense   3,171       6,785       9,352       12,671       17,319       9,088       1,318       1,952    
Gain on sale of corporate assets   7,560       5,155                         712                
Corporate expenses, net   9,674       8,724   (c)   5,834       2,746   (e)   4,559       7,101       4,845       7,581    

Income from continuing operations
    before income taxes
  35,482       30,044       75,506       44,701       49,448       92,191       98,099       80,774    
Income taxes   9,222       10,717       26,881       13,950   (e)   18,135       32,728       32,094   (h)   28,339    

Income from continuing operations   26,260       19,327       48,625       30,751       31,313       59,463       66,005       52,435    
Income (loss) from discontinued
    operations (a)
  2,921       (45,678 )     (51,156 )     (20,999 )     80,063       (6,815 )     2,864       6,011    

                                                                 
Net income (loss) $ 29,181     $ (26,351 )   $ (2,531 )   $ 9,752     $ 111,376     $ 52,648     $ 68,869     $ 58,446    


Refer to notes to financial tables on page 14.   


11



SEGMENT TABLES
Tredegar Corporation and Subsidiaries

Identifiable Assets  

Segment 2004   2003   2002   2001   2000   1999   1998   1997  

(In thousands)                                                
                                                 
 Film Products $ 472,810   $ 422,321   $ 379,635   $ 367,291   $ 367,526   $ 360,517   $ 132,241   $ 123,613  
 Aluminum Extrusions   210,894     185,336     176,631     185,927     210,434     216,258     201,518     101,855  
 Therics   8,613     8,917     10,643     9,931     9,609     9,905          

            Subtotal   692,317     616,574     566,909     563,149     587,569     586,680     333,759     225,468  
 General corporate   54,163     61,508     52,412     40,577     30,214     22,419     23,905     21,357  
 Income taxes recoverable from sale of
            venture capital investment portfolio
      55,000                          
 Cash and cash equivalents   22,994     19,943     109,928     96,810     44,530     25,752     25,409     120,065  

            Identifiable assets from ongoing operations   769,474     753,025     729,249     700,536     662,313     634,851     383,073      366,890  
 Divested operations (a):                                                
            Fiberlux                       7,859     7,811     6,886  
            Other (m)                               983  
 Discontinued operations (a):
            Venture capital           108,713     158,887     236,698     145,028     61,098     33,628  
            Molecumetics               5,608     4,757     4,749     5,196     2,550  

            Total $ 769,474   $ 753,025   $ 837,962   $ 865,031   $ 903,768   $ 792,487   $ 457,178   $ 410,937  


Refer to notes to financial tables on page 14.   


12



SEGMENT TABLES
Tredegar Corporation and Subsidiaries

Depreciation and Amortization

Segment   2004     2003     2002     2001     2000     1999     1998     1997  

(In thousands)
                                                 
Film Products $ 21,967   $ 19,828   $ 20,085   $ 22,047   $ 23,122   $ 18,751   $ 11,993   $ 10,947  
Aluminum Extrusions   10,914     10,883     10,506     11,216     9,862     9,484     8,393     5,508  
Therics   1,300     1,641     463     2,262     1,782     1,195          

          Subtotal   34,181     32,352     31,054     35,525     34,766     29,430     20,386     16,455  
General corporate   241     270     353     329     315     253     254     313  

          Total ongoing operations   34,422     32,622     31,407     35,854     35,081     29,683     20,640     16,768  
Divested operations (a):                                                
          Fiberlux                   151     498     544     515  
          Other (m)                               135  
Discontinued operations (a):                 
          Venture capital                   18     22     21      
          Molecumetics           527     2,055     1,734     1,490     1,260     996  

          Total $ 34,422   $ 32,622   $ 31,934   $ 37,909   $ 36,984   $ 31,693   $ 22,465   $ 18,414  

Capital Expenditures, Acquisitions and Investments

Segment   2004     2003     2002     2001     2000     1999     1998     1997  

(In thousands)
Film Products $ 44,797   $ 57,203   $ 24,063   $ 24,775   $ 53,161   $ 25,296   $ 18,456   $ 15,354  
Aluminum Extrusions   10,007     8,293     4,799     8,506     21,911     16,388     10,407     6,372  
Therics   275     219     1,621     2,340     1,730     757          

          Subtotal   55,079     65,715     30,483     35,621     76,802     42,441     28,863     21,726  
General corporate   572     93     60     519     384     606     115     28  

          Capital expenditures for
               ongoing operations
  55,651     65,808     30,543     36,140     77,186     43,047     28,978     21,754  
Divested operations (a):                                                
          Fiberlux                   425     812     1,477     530  
          Other (m)                               5  
Discontinued operations (a):                 
          Venture capital                   86         54      
          Molecumetics           793     2,850     2,133     1,362     3,561     366  

          Total capital expenditures   55,651     65,808     31,336     38,990     79,830     45,221     34,070     22,655  
Acquisitions and other   1,420     1,579         1,918     6,316     215,227     72,102     13,469  
Novalux investment   5,000                              
Venture capital investments       2,807     20,373     24,504     93,058     81,747     35,399     20,801  

          Total $ 62,071   $ 70,194   $ 51,709   $ 65,412   $ 179,204   $ 342,195   $ 141,571   $ 56,925  


Refer to notes to financial tables on page 14.   


13



NOTES TO FINANCIAL TABLES

(In thousands, except per-share amounts)

(a)

In 2004, discontinued operations include a gain of $2,921 after-taxes primarily related to the reversal of a business and occupancy tax contingency accrual upon favorable resolution. The accrual was originally recorded in connection with our venture capital investment operation. In 2003, we sold substantially all of our venture capital investment portfolio. In 2002, we ceased operations at Molecumetics, one of our biotechnology units, and sold its tangible assets. The operating results associated with the venture capital investment portfolio and Molecumetics have been reported as discontinued operations. In 2003, discontinued operations also include a gain of $891 after-taxes on the sale of intellectual property of Molecumetics and a loss on the divestiture of the venture capital investment portfolio of $46,269 after-taxes. Discontinued operations in 2002 also include a loss on the disposal of Molecumetics of $4,875 after-taxes. In 2001, discontinued operations include a gain of $1,396 for the reversal of an income tax contingency accrual upon favorable conclusion of IRS examinations through 1997. The accrual was originally recorded in conjunction with the sale of The Elk Horn Coal Corporation. We divested our coal subsidiary, The Elk Horn Coal Corporation, and our remaining oil and gas properties in 1994. As a result of these events, we report the Energy segment as discontinued operations. In 1998, discontinued operations include gains for the reimbursement of payments made by us to the United Mine Workers of America Combined Benefit Fund (the “Fund”) and the reversal of a related accrued liability established to cover future payments to the Fund. On April 10, 2000, we sold Fiberlux. The operating results of Fiberlux were historically reported as part of the Plastics segment on a combined basis with Film Products.


(b)

Plant shutdowns, asset impairments and restructurings for 2004 include a charge of $10,127 related to the planned shutdown of the aluminum extrusions plant in Aurora, Ontario, a charge of $3,022 related to the sale of the films business in Argentina, charges of $2,572 related to accelerated depreciation from plant shutdowns and restructurings in Film Products, charges of $2,459 related to severance and other costs associated with plant shutdowns in Film Products, charges of $1,547 for severance and other employee-related costs associated with restructurings in Therics ($735), Film Products ($532) and Aluminum Extrusions ($280), a charge of $1,306 related to the estimated loss on the sub-lease of a portion of the Therics facility in Princeton, New Jersey, a charge of $1,278 (of this amount, $59 for employee relocation is included in “Selling, general & administrative expenses” in the consolidated statements of income) related to severance and other employee-related costs associated with the restructuring of the research and development operations in Film Products and charges of $575 in Film Products and $146 in Aluminum Extrusions related to asset impairments. Income taxes in 2004 include a tax benefit of $4,000 related to the reversal of income tax contingency accruals upon favorable conclusion of IRS and state examinations through 2000. The other pretax gain of $7,316 included in the Aluminum Extrusions section of the operating profit by segment table is comprised of the present value of an insurance settlement of $8,357 (future value of $8,455) associated with environmental costs related to prior years, partially offset by accruals for expected future environmental costs of $1,041. The company received $5,143 of the $8,455 insurance settlement in 2004 and recognized receivables at present value for future amounts due ($1,497 due in February of 2005 and $1,717 due in February 2006). The gain from the insurance settlement is included in “Other income (expense), net” in the consolidated statements of income, while the accruals for expected future environmental costs are included in “Cost of goods sold.”


(c)

Plant shutdowns, asset impairments and restructurings for 2003 include charges of $4,514 for severance costs in connection with restructurings in Film Products ($1,922), Aluminum Extrusions ($256), Therics ($1,155) and corporate headquarters ($1,181, included in “Corporate expenses, net” in the operating profit by segment table), charges of $2,776 for asset impairments in the films business, charges of $2,700 related to the estimated loss on the sub-lease of a portion of the Therics facility in Princeton, New Jersey, a charge of $611 primarily related to severance costs associated with the shutdown of the films plant in New Bern, North Carolina, a charge of $388 related to an early retirement program in our aluminum business and charges of $437 for additional costs incurred related to plant shutdowns in our films business. Unusual items for 2003 include a charge of $1,067 related to an adjustment for depreciation and amortization at Therics based on our decision to suspend divestiture efforts.


(d)

Plant shutdowns, asset impairments and restructurings for 2002 include a charge of $1,457 for asset impairments in the films business, a charge of $1,007 for additional costs related to the shutdown of the films plant in Carbondale, Pennsylvania, a charge of $541 for additional costs related to the shutdown of the films plant in Tacoma, Washington, a charge of $487 for additional costs related to the shutdown of the aluminum extrusions plant in El Campo, Texas, and a charge of $392 for additional costs related to the 2000 shutdown of the films plant in Manchester, Iowa. Unusual items for 2002 include a net gain of $5,618 for payments received from P&G related to terminations and revisions to contracts and related asset write-downs, and a gain of $529 related to the sale of assets.


(e)

Plant shutdowns, asset impairments and restructurings for 2001 include a charge of $7,799 for the shutdown of the aluminum extrusions plant in El Campo, Texas, a charge of $3,386 for the shutdown of the films plant in Tacoma, Washington, a charge of $2,877 for the shutdown of the films plant in Carbondale, Pennsylvania, a charge of $1,505 for severance costs related to further rationalization in the films business, and a charge of $1,368 for impairment of our films business in Argentina. Unusual items in 2001 include a gain of $971 (included in “Corporate expenses, net” in the operating profit by segment table) for interest received on tax overpayments. Income taxes in 2001 include a tax benefit of $1,904 related to the reversal of income tax contingency accruals upon favorable conclusion of IRS examinations through 1997.


(f)

Plant shutdowns, asset impairments and restructurings for 2000 include a charge of $17,870 related to excess capacity in the films business, a charge of $1,628 related to restructuring at our aluminum extrusions plant in El Campo, Texas, and a charge of $4,293 for the shutdown of the films plant in Manchester, Iowa. Unusual items in 2000 include a gain of $762 for the sale of Fiberlux.


(g)

Plant shutdowns, asset impairments and restructurings for 1999 include a charge of $3,458 related to a write-off of in-process research and development expenses associated with the Therics acquisition and a charge of $1,170 for the write-off of excess packaging film capacity.


(h)

Plant shutdowns, asset impairments and restructurings for 1998 include a charge of $664 related to the shutdown of the powder-coat paint line in our aluminum extrusions plant in Newnan, Georgia. Unusual items for 1998 include a gain of $765 on the sale of APPX Software. Income taxes in 1998 include a tax benefit of $2,001 related to the sale, including a tax benefit for the excess of APPX Software's income tax basis over its financial reporting basis.


(i) Unusual items for 1997 include a gain of $2,250 related to the redemption of preferred stock received in connection with the 1996 divestiture of Molded Products.

(j) Total return to shareholders is computed as the sum of the change in stock price during the year plus dividends per share, divided by the stock price at the beginning of the year.

(k) Equity market capitalization is the closing market price per share for the period times the shares outstanding at the end of the period.

(l) Net sales represent gross sales less freight. Net sales is the measure used by the chief operating decision maker of each segment for purposes of assessing performance.

(m) Other includes primarily APPX Software (sold in 1998 - see (h)).

(n) Net sales include sales to P&G totaling $226,122 in 2004, $207,049 in 2003, and $242,760 in 2002. These amounts include plastic film sold to others who converted the film into materials used in products manufactured by P&G.

14



Item 7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND
  RESULTS OF OPERATIONS
 

Executive Summary

                    Tredegar is a manufacturer of plastic films and aluminum extrusions. We also have developed and are marketing an initial line of bone graft substitutes through our Therics subsidiary. Descriptions of our businesses are provided on pages 1-4.

                    In Film Products, operating profit from ongoing operations was $43.3 million in 2004 compared with $45.7 million in 2003. The decline was primarily due to higher resin costs and the loss of certain domestic backsheet business at the end of the first quarter of 2003 (see the business segment review beginning on page 34 for more information), partially offset by the positive effects of sales growth for new value-added products. Average prices of low density polyethylene resin (a primary raw material for Film Products) in the U.S. increased by approximately 27% during the second half of 2004 (see the chart on page 28 for historical prices since 2000). Resin prices in Europe and Asia have exhibited similar trends. We estimate that resin price increases in the fourth quarter resulted in a negative operating profit impact of about $2 million compared with the third quarter of 2004. This is in addition to the $1 million adverse impact we estimate occurred between the second and third quarters.

                    To address fluctuating resin prices, we have pass-through or cost-sharing agreements covering about 65% of our sales, but many have a 90-day lag. We are implementing price increases for many customers that are currently not subject to pass-through arrangements. Most new customer contracts contain resin pass-through arrangements. However, if resin prices continue to rise at a faster rate than selling prices, the delayed pass-through of costs will exert downward pressure on near-term profits.

                    We remain optimistic about the global growth prospects in Film Products, especially sales of new apertured, elastic, protective and other specialty films. The chart below shows the growth that we have achieved in these areas during the past year.

 

15



                    We believe much of our sales growth is the result of investments made over the past two years. Aggregate capital expenditures in 2003 and 2004 totaled $102 million, and we expect to spend another $50 million in 2005, with about $10 million earmarked for a production line that will manufacture a new material that enhances the fit of personal care products. The new line is already contracted to SCA, a $12 billion global personal care market leader headquartered in Sweden. Approximately one-third of our capital expenditures during 2003 and 2004 and planned capital expenditures during 2005 relate to customer-specific opportunities that are covered by capital indemnification, take-or-pay or similar arrangements. Excluding these opportunities, we estimate that our ongoing capital expenditure requirement in Film Products is about $35 million annually.

                    On January 10, 2005, we announced that we are exploring the sale of the films plant in LaGrange, Georgia. This plant produces blown films used for adult incontinent and baby diaper backsheet, feminine hygiene pad pouch packaging, and other packaging and industrial applications. Annual revenues for the products that would be included in a sale are about $25 million. The proposed transaction is not expected to have a material impact on our financial results. On July 23, 2004, a subsidiary of Tredegar purchased the assets of Yaheng Perforated Film Material Co., Ltd. (“Yaheng”) for approximately $1.4 million. Yaheng, based in Shanghai, China, has 21 employees and manufactures apertured nonwovens used primarily in personal care markets.

                    In Aluminum Extrusions, operating profit from ongoing operations increased to $22.6 million in 2004 (volume of 243.4 million pounds) from $15.1 million in 2003 (volume of 228.2 million pounds). The $7.5 million or 50% increase in operating profit on 6.7% volume growth is primarily due to operating leverage and pricing improvements, partially offset by the adverse effects of appreciation of the Canadian Dollar (about $2.4 million). Based on existing operating levels, we expect future annual operating profits to change at 3 - 4 times the percentage change in volume. Volume in 2004 was up in most markets after declining by about 30% from the last cyclical peak around 1999. Volume in our largest market, commercial construction, improved by about 13% in 2004 compared with 2003. Our outlook for continued volume growth in 2005 remains favorable. Historically, cyclical upturns in the aluminum extrusions industry last several years with overall cross-cycle volume growth in the 3% range. We believe that our focus on end markets and products that require customization, customer service and quality make us less vulnerable to price competition from low-cost suppliers of stock-type products, including offshore manufacturers. Our most attractive end markets include residential and non-residential windows, curtain walls, louvers & vents, agricultural equipment, ladders, walkway covers, pre-engineered structures, pleasure boats, custom trailers, and displays.

                    We continue to focus on reducing costs and aligning our structure to meet the needs of our customers. Three areas that we believe will generate significant savings are the shutdown of the films plant in New Bern, North Carolina (the “New Bern Plant”) (which occurred in the fourth quarter of 2004), the restructuring over the next 12 months of the R&D function in Film Products, and the shutdown of the aluminum extrusions plant in Aurora, Ontario (the “Aurora Plant”) (expected in the first quarter of 2005). Annual cost savings from these moves are expected of about $4 million for the shutdown of the New Bern Plant, $2 million for the restructuring of the R&D function, and $2 million for the shutdown of Aurora Plant. Related incremental cash expenditures to achieve these savings are about $7 million, $8 million and $8 million, respectively.

                    More information on Film Products and Aluminum Extrusions is provided in the business segment review beginning on page 34.

                    At Therics, sales and marketing efforts are evolving more slowly than expected, and we took steps in early January 2005 to reduce its expected loss rate from approximately $2.5 million to $2 million per quarter. We are exploring potential collaborations with other companies aimed at accelerating market penetration across a broader array of market segments.

                    We sold our venture capital investment portfolio in the first quarter of 2003 for cash proceeds of approximately $21.5 million, and its activities have been reported as discontinued operations. The sale generated income taxes recoverable of approximately $55 million, which we received in the first quarter of 2004. At December 31, 2004, we had $91 million of available borrowings under our credit facility. Key terms for the facility are summarized in the financial condition review on pages 23-27.


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Critical Accounting Policies

                    In the ordinary course of business, we make a number of estimates and assumptions relating to the reporting of results of operations and financial position in the preparation of financial statements in conformity with generally accepted accounting principles. Actual results could differ significantly from those estimates under different assumptions and conditions. We believe the following discussion addresses our most critical accounting policies. These policies require management to exercise judgments that are often difficult, subjective and complex due to the necessity of estimating the effect of matters that are inherently uncertain.

Impairment and Useful Lives of Long-lived Identifiable Assets and Goodwill

                    We regularly assess our long-lived identifiable assets for impairment when events or circumstances indicate that their carrying value may not be recoverable from future cash flows. Any necessary impairment charges are recorded when we do not believe the carrying value of the long-lived asset will be recoverable. We also reassess the useful lives of our long-lived assets based on changes in our business and technologies.

                    We assess goodwill for impairment when events or circumstances indicate that the carrying value may not be recoverable, or, at a minimum, on an annual basis (December 1 of each year). We have made determinations as to what our reporting units are and what amounts of goodwill and intangible assets should be allocated to those reporting units.

                    In assessing the recoverability of long-lived identifiable assets and goodwill, we must make assumptions regarding estimated future cash flows, discount rates and other factors to determine if impairment tests are met or the fair value of the respective assets. If these estimates or their related assumptions change in the future, we may be required to record additional impairment charges. Based upon assessments performed, we recorded asset impairment losses for continuing operations related to long-lived identifiable assets of $14.1 million in 2004, $2.8 million in 2003 and $1.5 million in 2002.

Pension Benefits

                    We have noncontributory and contributory defined benefit (pension) plans that have significant net pension income developed from actuarial valuations. Inherent in these valuations are key assumptions including discount rates, expected return on plan assets and rate of future compensation increases. We are required to consider current market conditions, including changes in interest rates and plan asset investment returns, in determining these assumptions. Actuarial assumptions may differ materially from actual results due to changing market and economic conditions, higher or lower withdrawal rates or longer or shorter life spans of participants. These differences may result in a significant impact to the amount of net pension income recorded in future periods.

                    The discount rate is used to determine the present value of future payments. In general, our liability increases as the discount rate decreases and vice versa. We reduced our discount rate in each of the last three years (the rate was 6.00% at the end of 2004, 6.25% at the end of 2003 and 6.75% at the end of 2002) due to the decline in market interest rates. The compensation increase assumption affects the estimate of future payments, and was 4% at the end of 2004 and 2003 and 4.5% at the end of 2002. Compensation increases were lowered in 2003 as a result of expected lower inflation. A lower expected return on plan assets increases the amount of expense and vice versa. Decreases in the level of actual plan assets will also serve to increase the amount of pension expense. During 2004 and 2003, the value of our plan assets increased due to improved general market conditions after declining in 2002, 2001 and 2000. Last year we decreased our expected long-term return on plan assets to 8.4% and have maintained that rate based on current market and economic conditions and asset mix (our expected return was 8.6% in 2003 and 9% in 2002 and prior years).

                    We currently expect net pension income to decline in 2005 by approximately $2 million compared to 2004 after declining by $800,000 in 2004 compared to 2003. We expect our minimum cash-funding requirement to be about $600,000 in 2005.


17



Income Taxes

                    Many deductions for tax return purposes cannot be taken until the expenses are actually paid, rather than when the expenses are recorded for book purposes. In these circumstances, we accrue for the tax benefit expected to be received in future years if, in our judgment, it is more likely than not that we will receive such benefits. In addition, the amount and timing of certain current deductions (which reduce taxes currently payable or generate income tax refunds) require interpretation of tax laws. In these circumstances, we estimate and accrue income tax contingencies for differences in interpretation that may exist with tax authorities. On a quarterly basis, we review our judgments regarding income tax contingency accruals and the likelihood the benefits of a deferred tax asset will be realized. During the periodic reviews, we must consider a variety of factors, including the nature and amount of the tax income and expense items, the current tax statutes, the current status of audits performed by tax authorities and the projected future earnings. We believe the realization of our net deferred tax assets is reasonably assured and that our income tax contingency accruals are adequate. If circumstances change, our valuation allowances for deferred tax assets, income tax contingency accruals and net earnings are adjusted accordingly in that period.

Recently Issued Accounting Standards

                    In December 2004, the Financial Accounting Standards Board (“FASB”) revised Statement of Financial Accounting Standards (“SFAS”) No. 123, Share-Based Payment. This statement requires that the cost of employee services received in exchange for equity instruments be measured based on the fair value of the award on the grant date. The statement also requires that the cost be recognized over the employee service period required to receive the award. The statement applies to awards granted after the effective date and to awards modified, repurchased or cancelled after that date. The statement is effective as of the beginning of the first interim or annual reporting period that begins after June 15, 2005. Early adoption is permitted. The adoption of this standard will have no impact on cash flow. The primary impact of adoption on Tredegar will be the recognition of compensation expense for stock options granted. Currently, we disclose the pro forma effects of treating stock option grants as compensation expense under the fair value-based method (see pages 51-53). We expect to continue to use the Black-Scholes options-pricing model to determine the estimated fair value of option grants but are still evaluating our transition method. We believe that the pro forma effects that have been disclosed are not materially different from compensation expense that would have been recognized if this standard had been previously adopted.

                    In November 2004, the FASB issued SFAS No. 151, Inventory Costs – An Amendment of ARB No. 43, Chapter 4. This statement clarifies that abnormal amounts of idle facility expense, freight, handling costs and wasted material (spoilage) should be expensed as current-period charges. In addition, this statement requires that allocation of fixed production overheads to the costs of conversion be based on the normal capacity of the production facilities. The statement is effective for inventory costs incurred during the fiscal years beginning after June 15, 2005. Early adoption is permitted. The adoption of this standard will have no impact on cash flow, and we do not expect it to have a significant impact on amounts reported in the consolidated statement of income and balance sheet.

                    In October 2004, the American Jobs Creation Act of 2004 (“AJCA”) was signed into law. In December 2004, the FASB issued Staff Position No. 109-1 (“FSP 109-1”), Application of FASB Statement No. 109, Accounting for Income Taxes, to the Tax Deduction on Qualified Production Activities Provided by the American Jobs Creation Act of 2004 and Staff Position No. 109-2 (“FSP 109-2”), Accounting and Disclosure Guidance for the Foreign Earnings Repatriation Provision within the American Jobs Creation Act of 2004. FSP 109-1 clarifies that the manufacturer’s tax deduction provided for under the AJCA should be accounted for as a special deduction in accordance with SFAS No. 109 and not as a tax rate reduction. FSP 109-2 provides accounting and disclosure guidance for the repatriation of certain foreign earnings to a U.S. taxpayer as provided for in the AJCA. We do not expect that the tax benefits resulting from the AJCA will have a material impact on our financial statements.

Results of Operations

2004 versus 2003

Revenues.   Overall, sales for 2004 increased 17% compared with 2003. Net sales (sales less freight) for Film Products and Aluminum Extrusions increased primarily due to higher sales volume and mix, including sales of new value-added products in Film Products, and higher selling prices driven by higher raw material costs. For more information on net sales, see the business segment review beginning on page 34.


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Operating Costs and Expenses.  Gross profit (sales less cost of goods sold and freight) as a percentage of sales decreased to 14.1% from 15.4% in 2003. At Film Products, the lower gross profit margin was driven primarily by higher resin costs and the loss of certain domestic backsheet business at the end of the first quarter of 2003 (see the business segment review beginning on page 34 for more information), partially offset by higher overall gross profit. For more information on resin costs, see the executive summary beginning on page 15. At Aluminum Extrusions, the gross profit margin increased primarily due to higher volume, operating leverage (generally constant fixed costs until full capacity utilization is achieved) and selling price increases above raw material cost increases, partially offset by appreciation of the Canadian dollar.

                    As a percentage of sales, selling, general and administrative (“SG&A”) expenses decreased to 7.0% compared with 7.2% in 2003 primarily due to higher sales. Overall SG&A expenses were up by $6.7 million partially due to the classification of certain costs at Therics as operating versus R&D (see below) consistent with the commercialization of the company’s initial line of bone graft substitutes. SG&A expenses also increased in equivalent U.S. Dollars as a result of the appreciation of the Euro, Hungarian Forint and Canadian Dollar.

                    R&D expenses declined to $15.3 million in 2004 from $18.8 million in 2003. R&D spending at Therics declined to $7.8 million in 2004 from $11.2 million in 2003 due to cost reduction efforts and the classification of certain costs as operating versus R&D consistent with the commercialization of the company’s initial line of bone graft substitutes. R&D spending at Film Products was $7.5 million in 2004 compared with $7.6 million in 2003.

                    Losses associated with plant shutdowns, asset impairments and restructurings in 2004 totaled $23 million ($15.2 million after taxes) and included:

 
A fourth quarter charge of $84,000 ($56,000 after taxes), a third-quarter charge of $828,000 ($537,000 after taxes), a second-quarter charge of $994,000 ($647,000 after taxes) and a first-quarter charge of $666,000 ($432,000 after taxes) related to accelerated depreciation from plant shutdowns and restructurings in Film Products;
 
A fourth-quarter charge of $569,000 (of this amount, $59,000 for employee relocation is included in SG&A expenses in the consolidated statements of income) ($369,000 after taxes) and a third-quarter charge of $709,000 ($461,000 after taxes) related to severance for 30 people and other employee-related costs associated with the restructuring of the R&D operations in Film Products (we anticipate recognizing additional charges associated with this restructuring over the next 12 months of approximately $2.8 million ($1.8 million after taxes)), including costs associated with relocating R&D functions to Richmond, Virginia;
 
A fourth-quarter charge of $639,000 ($415,000 after taxes), a third-quarter charge of $617,000 ($401,000 after taxes), a second-quarter charge of $300,000 ($195,000 after taxes) and a first-quarter charge of $537,000 ($349,000 after taxes) primarily related to severance (63 people) and other employee-related costs associated with the shutdown of the New Bern Plant;
 
A third-quarter charge of $357,000 ($329,000 after taxes) and a second-quarter charge of $2.7 million ($1.9 million after taxes) for the loss on the sale of the films business in Argentina (proceeds net of transaction costs were $803,000 ($401,000 net of cash included in business sold));
 
A fourth-quarter charge of $352,000 ($228,000 after taxes), a third-quarter charge of $195,000 ($127,000 after taxes) and a first-quarter charge of $9.6 million ($6.2 million after taxes) related to the planned shutdown of the Aurora Plant, including asset impairment charges of $7.1 million and severance and other employee-related costs of $2.5 million (these costs are contractually-related for about 100 people and have been immediately accrued and we anticipate recognizing additional shutdown-related costs of about $2 million in the first quarter of 2005);
 
A third-quarter charge of $170,000 ($111,000 after taxes) for additional costs incurred related to a plant shutdown in Film Products;
 
A second-quarter charge of $300,000 ($195,000 after taxes), partially offset by a fourth-quarter gain of $104,000 ($68,000 after taxes), related to the loss on the sale of the previously shutdown films manufacturing facility in Manchester, Iowa (the “Manchester Plant”);
 
A fourth quarter charge of $427,000 ($277,000 after taxes) and a second-quarter charge of $879,000 ($571,000 after taxes) related to the estimated loss on the sub-lease of a portion of the Therics facility in Princeton, New Jersey;

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Second-quarter charges of $575,000 ($374,000 after taxes) in Film Products and $146,000 ($95,000 after taxes) in Aluminum Extrusions related to asset impairments; and
 
Fourth quarter charges of $1.4 million ($912,000 after taxes) related to severance and other employee-related costs associated with restructurings in Therics ($590,000 before taxes), Film Products ($532,000 before taxes) and Aluminum Extrusions ($280,000 before taxes) and a second-quarter charge of $145,000 ($94,000 after taxes) related to severance at Therics (an aggregate of 24 people were affected by these restructurings).
 

                    Remaining liabilities for exit and disposal activities at December 31, 2004 ($8.5 million), primarily include the shutdown of the Aurora Plant, the relocation of R&D functions in Film Products to Richmond, Virginia, the recent staff reductions at Therics and the estimated loss on the sub-lease at Therics.

                    Gain on sale of corporate assets in 2004 includes a fourth-quarter gain on the sale of land of $1 million ($649,000 after taxes and proceeds of $1.3 million), a second-quarter gain on the sale of land of $413,000 ($268,000 after taxes and proceeds of $647,000) and a first-quarter gain on the sale of public equity securities of $6.1 million ($4 million after taxes and proceeds of $7.2 million). There were no public equity securities held at December 31, 2004. These gains are included in “Other income (expense), net” in the consolidated statements of income and separately shown in the operating profit by segment table on page 11.

                    Income taxes in 2004 include a third-quarter tax benefit of $4 million related to the reversal of income tax contingency accruals upon the favorable conclusion of IRS and state examinations through 2000.

                    The other gain of $7.3 million ($4.8 million after taxes) included in the Aluminum Extrusions section of the operating profit by segment table on page 11 is comprised of the present value of an insurance settlement of $8.4 million (future value of $8.5 million) associated with environmental matters related to prior years, partially offset by accruals for expected future environmental costs of $1 million. The company received $5.2 million of the $8.5 million insurance settlement in September of 2004 and recognized receivables at present value for future amounts due ($1.5 million due in February of 2005 and $1.8 million due in February 2006). The gain from the insurance settlement is included in “Other income (expense), net” in the consolidated statements of income, while the accruals for expected future environmental costs are included in “Cost of goods sold.”

                    For more information on costs and expenses, see the business segment review beginning on page 34.

Interest Income and Expense. Interest income, which is included in “Other income (expense), net” in the consolidated statements of income, was $350,000 in 2004 and $1.2 million in 2003. Interest income was down primarily due to lower average cash and cash equivalents balances (excess cash was used to repay debt in conjunction with our debt refinancing in October 2003). Our policy permits investment of excess cash in marketable securities that have the highest credit ratings and maturities of less than one year with the primary objectives being safety of principal and liquidity.


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                    Interest expense declined to $3.2 million in 2004 compared with $6.8 million in 2003. Average debt outstanding and interest rates were as follows:



(In Millions) 2004   2003  

Floating-rate debt with interest charged on a rollover
   basis at one-month LIBOR plus a credit spread:
             
      Average outstanding debt balance   $ 105.2   $ 108.8  
      Average interest rate     2.7 %   2.0 %
Floating-rate debt fixed via interest rate swaps in the
   second quarter of 2001 and maturing in the second
             
   quarter of 2003:              
      Average outstanding debt balance   $   $ 28.9  
      Average interest rate       5.4 %
Fixed-rate and other debt:              
      Average outstanding debt balance   $ 5.6   $ 7.2  
      Average interest rate     6.0 %   6.4 %

Total debt:              
      Average outstanding debt balance   $ 110.8   $ 216.9  
      Average interest rate     2.8 %   2.6 %


Income Taxes.   The effective tax rate from continuing operations was 26.0% in 2004, down from 35.7% in 2003. The decrease is primarily due to a tax benefit of $4 million related to the reversal of income tax contingency accruals upon favorable conclusion of IRS and state examinations through 2000, partially offset by tax benefits of about $600,000 not recognized on 2004 operating losses of certain foreign subsidiaries that may not be recoverable in the carryforward period.

Discontinued Operations. On March 7, 2003, Tredegar Investments, Inc. (“Tredegar Investments”) reached definitive agreements to sell substantially all of its venture capital investment portfolio. For more information on the sale (including a summary of venture capital investment activities from 2002 through disposal in 2003), see the business segment review beginning on page 37. The results for venture capital investment activities have been reported as discontinued operations and include an after-tax gain of $2.9 million in 2004 primarily related to the reversal of business and occupancy tax contingency accruals upon favorable resolution.

2003 versus 2002

Revenues.   Overall, sales for 2003 decreased 2% compared with 2002. Net sales (sales less freight) for Film Products and Aluminum Extrusions declined primarily due to lower sales volume, partially offset by higher selling prices driven by higher raw material costs. For more information on net sales, see the business segment review beginning on page 34.

Operating Costs and Expenses.  Gross profit (sales less cost of goods sold and freight) as a percentage of sales decreased to 15.4% in 2003 from 20.5% in 2002. In Film Products, an overall lower gross profit margin was driven primarily by the loss of certain domestic backsheet business (lower overall contribution to cover fixed costs), higher raw material prices and higher manufacturing costs on certain new products. In Aluminum Extrusions, the gross profit margin declined primarily due to the impact of the Canadian Dollar appreciating against the U.S. Dollar, higher energy costs, lower volume and higher insurance costs. For more information on the loss of certain domestic backsheet business, see the business segment review for Film Products beginning on page 34.

                    As a percentage of sales, SG&A expenses increased to 7.2% compared with 6.9% in 2002, primarily due to lower sales, the appreciation of the Canadian Dollar and Euro against the U.S. Dollar, higher employee-related costs, and expenses associated with commencing the implementation of a new information system in Film Products.

                    R&D expenses declined to $18.8 million in 2003 ($11.2 million for Therics and $7.6 million for Film Products) from $20.3 million in 2002 ($12.5 million for Therics and $7.8 million for Film Products). The decline was primarily due to cost reduction efforts at Therics.


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                    Losses associated with plant shutdowns, asset impairments and restructurings in 2003 totaled $11.4 million ($7.4 million after taxes) and included:

 
A fourth-quarter charge of $875,000 ($560,000 after taxes) for asset impairments in the films business, including charges of $466,000 ($298,000 after taxes) relating to accelerated depreciation of assets at the New Bern Plant;
 
A fourth-quarter charge of $611,000 ($391,000 after taxes) for approximately 50% of the total severance costs and other employee-related costs in connection with the shutdown of the New Bern Plant;
 
A third-quarter charge of $945,000 ($605,000 after taxes) relating to accelerated depreciation of assets at the New Bern Plant;
 
A third-quarter charge of $299,000, a second quarter charge of $53,000 and a first-quarter charge of $85,000 (collectively $280,000 after taxes) for additional costs incurred related to the shutdown of the films plants in Tacoma, Washington, Carbondale, Pennsylvania and the Manchester Plant;
 
A third-quarter charge of $322,000 ($206,000 after taxes) for severance and other employee-related costs in connection with restructurings in Film Products;
 
A third-quarter charge of $2.2 million ($1.4 million after taxes) and a second-quarter charge of $549,000 ($357,000 after taxes) related to the estimated loss on the sub-lease of a portion of the Therics facility in Princeton, New Jersey;
 
A third-quarter charge of $256,000 ($163,000 after taxes) for severance and other employee-related costs in connection with restructurings in Aluminum Extrusions;
 
A second-quarter charge of $3.9 million ($2.5 million after taxes) for severance and other employee-related costs in connection with restructurings in Film Products ($1.6 million before taxes), corporate headquarters ($1.2 million before taxes and included in “Corporate expenses, net” in the operating profit by segment table on page 11) and Therics ($1.2 million before taxes);
 
A second-quarter charge of $956,000 ($612,000 after taxes) for asset impairments in the films business, including charges of $312,000 ($200,000 after taxes) related to accelerated depreciation of assets at the New Bern Plant; and
 
A second-quarter charge of $388,000 ($248,000 after taxes) related to an early retirement program in Aluminum Extrusions.
 

                    The loss from unusual items in 2003 of $1.1 million ($694,000 after taxes) relates to a first-quarter charge to adjust depreciation and amortization at Therics based on Tredegar’s decision to suspend divestiture efforts. Results for 2003 also included a fourth-quarter gain of $1.4 million ($886,000 after taxes) on the sale of land at the facility in Richmond Hill, Ontario (total proceeds of approximately $1.8 million), and gains totaling $5.2 million ($3.3 million after taxes) on the sale of corporate assets. The gains from the sale of corporate assets included:

 
A fourth-quarter gain of $2.6 million ($1.6 million after taxes) from the sale of 547,500 shares of Illumina, Inc. common stock (NASDAQ: ILMN) for total proceeds of $3.8 million; 
 
A fourth-quarter gain of $355,000 ($229,000 after taxes) from the sale of 64,150 shares of Vascular Solutions, Inc. common stock (NASDAQ: VASC) for total proceeds of $403,000;
 
A third-quarter gain of $942,000 ($608,000 after taxes) from the sale of 200,000 shares of VASC for total proceeds of $1.1 million; and
 
A third-quarter gain of $1.3 million and fourth-quarter gain of $15,000 (collectively $841,000 after taxes) from the sale of corporate real estate (total proceeds of approximately $1.8 million).
 

                    The gains from the sale of land and corporate assets are included in “Other income (expense), net” in the consolidated statements of income and separately shown in the segment operating profit table on page 11.

                    For more information on costs and expenses, see the business segment review beginning on page 34.

Interest Income and Expense. Interest income, which is included in “Other income (expense), net” in the consolidated statements of income, was $1.2 million in 2003 and $1.9 million in 2002. Despite a higher average cash and cash equivalents balance, interest income was down due to lower average tax equivalent yield earned on cash equivalents (1% in 2003 and 1.9% in 2002).

                    Interest expense was $6.8 million in 2003 (including a charge of $737,000 for the write-off of deferred financing costs associated with credit facilities replaced) compared with $9.4 million in 2002. Capitalized interest costs were $593,000 in 2003 compared with $674,000 in 2002. Average debt outstanding and interest rates for 2003 and 2002 were as follows:


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(In Millions) 2003   2002  

Floating-rate debt with interest charged on a rollover
   basis at one-month LIBOR plus a credit spread:
             
      Average outstanding debt balance   $ 180.8   $ 175.0  
      Average interest rate     2.0 %   2.5 %
Floating-rate debt fixed via interest rate swaps in the
   second quarter of 2001 and maturing in the second
   quarter of 2003:
             
      Average outstanding debt balance   $ 28.9   $ 75.0  
      Average interest rate     5.4 %   5.4 %
Fixed-rate and other debt:              
      Average outstanding debt balance   $ 7.2   $ 7.3  
      Average interest rate     6.4 %   7.2 %

Total debt:              
      Average outstanding debt balance   $ 216.9   $ 257.3  
      Average interest rate     2.6 %   3.5 %


Income Taxes.   The effective tax rate from continuing operations was 35.7% in 2003 and 35.6% in 2002.

Discontinued Operations. Discontinued operations in 2002 include results for venture capital investment activities and Molecumetics. For more information, see the business segment review beginning on page 37.

Financial Condition

Assets

                    Tredegar’s total assets increased to $769.5 million at December 31, 2004, from $753 million at December 31, 2003. In the first quarter of 2004, we received tax refunds of about $55 million related to the sale of the venture capital portfolio and used $50 million to repay revolver debt in April 2004. Other significant changes in balance sheet items since December 31, 2003, are summarized below:

 
Accounts receivable increased by $33.2 million (39%) due primarily to higher net sales for all businesses (net sales for the fourth quarter of 2004 were up $43.4 million compared to the fourth quarter of 2003) and foreign currency effects (about $3.5 million).
 
Days sales outstanding remains in the 50-day range in Film Products and 45-day range in Aluminum Extrusions.
 
Inventories increased by $15.8 million (32%) due primarily to higher raw material prices (low-density polyethylene resin prices are up around 18 cents per pound (about 30%) in the U.S. and Europe since the fourth quarter of 2003, and aluminum is also up about 18 cents per pound (about 25%) since that time), sales volume and foreign currency effects (about $2.5 million).
 
Inventory days are in the 45-day range in Film Products and 35-day range in Aluminum Extrusions consistent with the end of last year.
 
Income taxes recoverable declined by $61.5 million due primarily to the receipt in the first quarter of 2004 of income tax refunds related to the sale of the venture capital portfolio (about $55 million).
 
Other assets increased by $5.4 million primarily due to the $5 million investment in Novalux during the third quarter of 2004. Our ownership interest in Novalux is approximately 18% (15% on a fully diluted basis). Novalux, based in Sunnyvale, California, is developing and commercializing a laser technology for use in a variety of applications, including flat panel displays for home theaters. We are already participating in the growing flat panel display market with our surface protection films. The investment in Novalux, which is included in “Other assets and deferred charges” in the consolidated balance sheet, is being accounted for under the cost method, with an impairment loss recognized and a new cost basis established for any write-down to estimated fair value.

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Net property, plant and equipment was up $19.2 million due primarily to capital expenditures in excess of depreciation of $21.6 million and foreign exchange translation of $9.1 million, partially offset by the $7.1 million asset impairment recognized in the first quarter of 2004 on the planned shutdown of the Aurora Plant and other asset impairments and disposals during the year in Film Products totaling $3.3 million.
 

Liabilities, Credit and Long-Term Obligations

                    Total liabilities were $289.0 million at December 31, 2004, down from $305.6 million at December 31, 2003, primarily due to debt reduction ($36.2 million), partially offset by an increase in accounts payable (up $17.2 million or 37%) due to higher inventories and the timing of payments.

                    Debt outstanding at December 31, 2004 of $103.5 million consisted of $97.4 million borrowed under our credit facility (comprised of a term loan of $64.4 million and revolving credit borrowings of $33 million) and other debt of $6.1 million. The credit agreement, dated October 17, 2003, consists of a $125 million three-year revolving credit facility and a $75 million three-year term loan (required term loan payments of $10.6 million have been made since origination). At December 31, 2004, available credit under the revolving credit facility was $91 million. Remaining term loan installments are due as follows:



Term Loan Quarterly Repayment Schedule (In Thousands)

Installment due each quarter on March 31, June 30 and September 30, 2005     $ 3,125  
Installment due each quarter on December 31, 2005, and March 31 and
   June 30, 2006
      3,750  
Final payment due on September 30, 2006       43,750  


                    The credit spread over LIBOR and commitment fees charged on the unused amount under the credit agreement at various indebtedness-to-adjusted EBITDA levels is as follows:



Pricing Under Credit Agreement (Basis Points)

  Credit Spread Over LIBOR
     
Indebtedness-to-
Adjusted EBITDA
Ratio
Revolver
($33 Million
Outstanding
at 12/31/04)
  Term Loan
($64 Million
Outstanding
at 12/31/04)
  Commitment
Fee
 

> 2x but <= 3x     150   150   30  
> 1x but <= 2x     125   125   25  
<= 1x     100   100   20  


                    At December 31, 2004, we had no interest rate swaps outstanding and the interest cost on debt was priced at one-month LIBOR plus the applicable credit spread of 125 basis points.


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                    The computations of adjusted EBITDA, adjusted EBIT, the leverage ratio and interest coverage ratio as defined in the credit agreement are presented below along with the related most restrictive covenants. Adjusted EBITDA and adjusted EBIT as defined in the credit agreement are not intended to represent cash flow from operations as defined by GAAP and should not be considered as either an alternative to net income or to cash flow.



Computations of Adjusted EBITDA, Adjusted EBIT, Leverage Ratio and

Interest Coverage Ratio as Defined in Credit Agreement Along with Related Most

Restrictive Covenants

For the Year Ended December 31, 2004 (In Thousands)


Computations of adjusted EBITDA and adjusted EBIT as defined in
Credit Agreement:
   
   Net income     $ 29,181  
   Plus:    
      After-tax losses related to discontinued operations        
      Total income tax expense for continuing operations       9,222  
      Interest expense       3,171  
      Depreciation and amortization expense for continuing operations       34,422  
      All non-cash losses and expenses, plus cash losses and expenses not
         to exceed $10,000, for continuing operations that are classified as
         unusual, extraordinary or which are related to plant shutdowns, asset
         impairments and/or restructurings (cash-related of $10,262)
      23,811  
   Minus:    
      After-tax income related to discontinued operations       (2,921 )
      Total income tax benefits for continuing operations        
      Interest income       (350 )
      All non-cash gains and income, plus cash gains and income not to
         exceed $10,000, for continuing operations that are classified as unusual,
         extraordinary or which are related to plant shutdowns, asset
         impairments and/or restructurings (all cash-related of $15,917)
      (10,000 )
   Plus or minus, as applicable, pro forma EBITDA adjustments associated
      with acquisitions and asset dispositions
      (22 )
 
 
   Adjusted EBITDA as defined in Credit Agreement       86,514  
   Less: Depreciation and amortization expense for continuing operations
      (including pro forma for acquisitions and asset dispositions)
      (34,430 )
 
 
   Adjusted EBIT as defined in Credit Agreement     $ 52,084  
 
 
Indebtedness:    
   Total debt     $ 103,452  
   Face value of letters of credit       6,391  
 
 
   Indebtedness     $ 109,843  
 
 
Shareholders’ equity at December 31, 2004     $ 480,442  
     
Computations of leverage and interest coverage ratios as defined in
Credit Agreement:
   
   Leverage ratio (pro forma indebtedness-to-adjusted EBITDA)       1.27 x
   Interest coverage ratio (adjusted EBIT-to-interest expense)       16.43 x
Most restrictive covenants as defined in Credit Agreement:    
   Maximum permitted aggregate amount of dividends that can be paid
      by Tredegar during the term of the Credit Agreement
    $ 100,000  
   Minimum adjusted shareholders’ equity permitted (increases by
      50% of net income generated after September 30, 2003)
    $ 344,248  
   Maximum leverage ratio permitted:    
      Ongoing       3.00 x
      Pro forma for acquisitions       2.50 x
   Minimum interest coverage ratio permitted       2.50 x


25



                    Noncompliance with any one or more of the debt covenants may have an adverse effect on financial condition or liquidity in the event such noncompliance cannot be cured or should we be unable to obtain a waiver from the lenders. Renegotiation of the covenant through an amendment to the credit agreement may effectively cure the noncompliance, but may have an effect on financial condition or liquidity depending upon how the covenant is renegotiated.

                    We are obligated to make future payments under various contracts as set forth below:



  Payments Due by Period

(In Millions) 2005   2006   2007   2008   2009   Remainder   Total  

Debt $ 13.1   $ 88.9   $ .4   $ .3   $ .3   $ .5   $ 103.5  
Operating leases:
    Therics  

1.4

   

1.5

   

1.6

    1.6     1.6    

2.0

   

9.7

 
    Other  

1.5

   

1.4

   

1.1

    .9     .2    

.6

   

5.7

 
Capital expenditure commitments *  

16.1

                       

16.1

 

Total $ 32.1   $ 91.8   $ 3.1   $ 2.8   $ 2.1   $ 3.1   $ 135.0  


*Represents contractual obligations for plant construction and purchases of real property and equipment. See Note 13 on page 66.

                    We believe that existing borrowing availability, our current cash balances and our cash flow from operations will be sufficient to satisfy our working capital, capital expenditure and dividend requirements for the foreseeable future.

                    From time to time, we enter into transactions with third parties in connection with the sale of assets or businesses in which we agree to indemnify the buyers or third parties involved in the sale for certain liabilities or risks related to the assets or business. Also, in the ordinary course of our business, we may enter into agreements with third parties for the sale of goods or services that may contain indemnification provisions. In the event that an indemnification claim is asserted, liability for indemnification would be subject to an assessment of the underlying facts and circumstances under the terms of the applicable agreement. Further, any indemnification payments may be limited or barred by a monetary cap, a time limitation, or a deductible or basket. For these reasons, we are unable to estimate the maximum potential amount of the potential future liability under the indemnity provisions of these agreements. We do, however, accrue for losses for any known contingent liability, including those that may arise from indemnification provisions, when future payment is probable. We disclose contingent liabilities if the probability of loss is reasonably possible and significant.

Shareholders’ Equity

                    At December 31, 2004, we had 38,597,522 shares of common stock outstanding and a total market capitalization of $780.1 million, compared with 38,176,821 shares of common stock outstanding and a total market capitalization of $592.9 million at December 31, 2003.

                    During 2004, we did not purchase any shares of our common stock in the open market. During 2003, we purchased 406,400 shares of our common stock in the open market for $5.2 million (an average price of $12.72 per share). During 2002, we purchased 110,700 shares of our common stock in the open market for $1.4 million (an average price of $12.91 per share). Since becoming an independent company in 1989, we have purchased a total of 20.8 million shares for $122.8 million (an average price of $5.90 per share). Under a standing authorization from our board of directors, we may purchase an additional 3.4 million shares in the open market or in privately negotiated transactions at prices management deems appropriate.

Cash Flows

                    The discussion below supplements the information presented in the consolidated statements of cash flows on page 47.

                    In 2004, cash provided by operating activities was $93.8 million compared with $76.4 million in 2003. The increase is due primarily to the income tax refund related to the sale of the venture capital portfolio (see the business segment review beginning on page 34) partially offset by higher primary working capital (accounts receivable, inventories and accounts payable) needed to support higher sales.


26



 

                    Cash used in investing activities was $50.3 million in 2004 compared with $36.5 million in 2003. The change is primarily attributable to proceeds from the sale of venture capital investments, net of investments made, of $18.7 million in 2003, and the $5 million investment in Novalux made in the third quarter of 2004, partially offset by lower capital expenditures of $10.2 million. See the business segment review beginning on page 34 regarding capital expenditures in 2004 and 2003.

                    Net cash used in financing activities was $40.5 million in 2004 compared to $129.9 million in 2003. In 2004, we used $50 million from tax refunds related to the sale of the venture capital portfolio to pay down debt. Additional net borrowings of $13.8 million related primarily to capital expenditures and higher primary working capital needed to support higher sales. Net cash used in financing activities in 2003 was driven by scheduled debt payments and debt payments made in conjunction with our refinancing in 2003.

                    In 2003, net cash provided by operating activities was $76.4 million compared with $65.3 million in 2002. The increase is due to a decrease in the level of primary working capital partially offset by lower income from ongoing operations. Accounts receivable declined mainly from volume shortfall payments and contract terminations and revisions in Film Products accrued at the end of 2002 and received in 2003 (about $15 million in accounts receivable at the end of 2002 versus none at the end of 2003). Accounts payable increased due to the timing of payments. Inventories increased primarily due to the appreciation of the Euro and the Canadian Dollar.

                    Net cash used in investing activities was $36.5 million in 2003 compared to $42.1 million in 2002. This decrease was due to positive cash flow from venture capital activities in 2003 versus negative cash flow in 2002 and higher proceeds from the sale of corporate assets and property disposals (see Note 15 on page 69 for more information), partially offset by higher capital expenditures and acquisitions (up $36.1 million).

                    Net cash used in financing activities was $129.9 million in 2003 compared to $10.1 million in 2002. This increase was driven by scheduled debt payments and debt payments made in conjunction with our refinancing in 2003 (see pages 24-26 for more information).

                    In 2002, net cash provided by operating activities was $65.3 million compared to $74.9 million in 2001. The decrease is due to an increase in working capital in 2002 versus a decrease in working capital in 2001, partially offset by higher income from manufacturing operations (up $8.3 million). The increase in working capital in 2002 was mainly due to higher receivables, primarily from volume shortfall payments and contract terminations and revisions in Film Products (up $14.7 million). The decrease in working capital in 2001 was mainly due to lower receivables (down $17.4 million), primarily from a 15% drop in volume in Aluminum Extrusions in the fourth quarter of 2001.

                    Net cash used in investing activities was $42.1 million in 2002 compared to $13.4 million in 2001. The increase was driven by negative cash flow from venture capital activities in 2002 versus positive cash flow in 2001, partially offset by lower capital expenditures and acquisitions (down $9.6 million).

                    Net cash used in financing activities was about the same in 2002 and 2001.


27



Quantitative and Qualitative Disclosures about Market Risk

                    Tredegar has exposure to the volatility of interest rates, polyethylene and polypropylene resin prices, aluminum ingot and scrap prices, energy prices, foreign currencies and emerging markets. See the section on liabilities, credit and long-term obligations beginning on page 24 regarding credit agreements and interest rate exposures.

                    Changes in resin prices, and the timing of those changes, could have a significant impact on profit margins in Film Products. Profit margins in Aluminum Extrusions are sensitive to fluctuations in aluminum ingot and scrap prices as well as natural gas prices. There is no assurance of our ability to pass through higher raw material and energy costs to our customers.

                    We estimate that resin price increases in the fourth quarter resulted in a negative operating profit impact of about $2 million compared with the third quarter of 2004. This is in addition to the $1 million adverse impact we estimate occurred between the second and third quarters of 2004. The significant increases in the U.S. since 2002 in prices of low density polyethylene resin (a primary raw material for Film Products) are shown in the chart below.

 
 

                    Resin prices in Europe and Asia have exhibited similar trends. The price of resin is driven by several factors including supply and demand and the price of natural gas, oil and ethylene. To address fluctuating resin prices, we have pass-through or cost-sharing agreements covering about 65% of our sales, but many have a 90-day lag. We are implementing price increases for many customers that are currently not subject to pass-through arrangements. Most new customer contracts contain resin pass-through arrangements. However, if resin prices continue to rise at a faster rate than selling prices, the delayed pass-through of costs will exert downward pressure on near-term profits.


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                    In the normal course of business, we enter into fixed-price forward sales contracts with certain customers for the sale of fixed quantities of aluminum extrusions at scheduled intervals. In order to hedge our exposure to aluminum price volatility (see the chart below) under these fixed-price arrangements, which generally have a duration of not more than 12 months, we enter into a combination of forward purchase commitments and futures contracts to acquire or hedge aluminum, based on the scheduled deliveries. See Note 6 on page 58 for more information.
 
 

                    In Aluminum Extrusions, we hedge from time-to-time a portion of our exposure to natural gas price volatility by entering into fixed-price forward purchase contracts with our natural gas suppliers. As of December 31, 2004, we had forward contracts with natural gas suppliers covering 18% of our estimated future needs through March 31, 2005, with an average fixed price of $5.97 per mmBtu. We estimate that, in an unhedged situation, every $1 per mmBtu per month change in the market price of natural gas has a $150,000 impact on the monthly operating profit of Aluminum Extrusions. Substantially higher prices of natural gas in 2003 resulted in a reduction in operating profit in Aluminum Extrusions of approximately $3.2 million in 2003 compared with 2002.

 

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                    We sell to customers in foreign markets through our foreign operations and through exports from U.S. plants. The percentage of sales and total assets for manufacturing operations related to foreign markets for 2004 and 2003 are as follows:



Tredegar Corporation - Manufacturing Operations
Percentage of Net Sales and Total Assets Related to Foreign Markets

  2004
  2003
 
  % of Total
Net Sales*

  % Total
Assets -
Foreign
Oper-
ations*
  % of Total
Net Sales*

  % Total
Assets -
Foreign
Oper-
ations*
 
  Exports
From
U.S.
  Foreign
Oper-
ations
    Exports
From
U.S.
  Foreign
Oper-
ations
   
 
 
 
 
 
Canada   3     18     13     4     17     13  
Europe   2     14     17     4     12     15  
Latin America   2     2     1     3     2     2  
Asia   4     3     5     3     2     4  

 
Total % exposure
    to foreign
    markets
  11     37     36     14     33     34  

 

*

The percentages for foreign markets are relative to Tredegar’s total net sales and total assets from manufacturing operations (consolidated net sales and total assets from continuing operations excluding cash and cash equivalents, Therics and in 2003, income taxes recoverable from the sale of the venture capital portfolio).


                    We attempt to match the pricing and cost of our products in the same currency (except in Canada where about 70% of our sales of aluminum extrusions are U.S. Dollar-based) and generally view the volatility of foreign currencies (see the chart below) and emerging markets, and the corresponding impact on earnings and cash flow, as part of the overall risk of operating in a global environment. Exports from the U.S. are generally denominated in U.S. Dollars. Our foreign currency exposure on income from foreign operations in Europe primarily relates to the Euro and the Hungarian Forint.

                    The relatively high percentage of U.S. Dollar-priced sales in Canada is partly due to the shifting of a large portion of the customers previously served by the aluminum extrusions plant in El Campo, Texas, in 2001. The resulting mismatch between the currency denomination of sales and costs causes lower U.S. Dollar translated profits when the Canadian Dollar appreciates since our costs are higher in U.S. Dollar equivalent terms while sales are mostly unaffected (the opposite effect occurs when the Canadian Dollar depreciates in value relative to the U.S. Dollar). We estimate that the appreciation of the Canadian Dollar relative to the U.S. Dollar had an adverse impact on operating profit of $2.4 million in 2004 compared with 2003. In Film Products, where we have been able to better match the currency of our sales and costs, we estimate that the appreciation of the Euro and Hungarian Forint relative to the U.S. Dollar had a positive impact on operating profit of about $1 million in 2004 compared with 2003.


30



                    We are continuing to review the loading of our aluminum extrusions plants in North America to optimize production mix and minimize cost in light of the increase in the U.S. Dollar equivalent cost structure of our plants in Canada.
 
 

Forward-looking and Cautionary Statements

                    From time to time, we may make statements that may constitute “forward-looking statements” within the meaning of the “safe-harbor” provisions of the Private Securities Litigation Reform Act of 1995. Such statements are based on our then current expectations and are subject to a number of risks and uncertainties that could cause actual results to differ materially from those addressed in the forward-looking statements. Factors that may cause such a difference include, but are not limited to the following:

General

 
Our future performance is influenced by costs incurred by our operating companies including, for example, the cost of energy and raw materials. There is no assurance that we will be able to offset fully or on a timely basis the effects of higher raw material costs through price increases. Further, there is no assurance that cost control efforts will be sufficient to offset any additional future declines in revenue or increases in energy, raw material or other costs.
 
As part of our business strategy, we expect to pursue acquisitions of businesses or investments that we believe have unique and sustainable technologies, products and services in attractive end markets.  The success of this strategy will depend upon our ability to identify, acquire and finance on acceptable terms such businesses and on our ability to manage such businesses and achieve planned synergies and operating results, none of which can be assured.
 

Film Products

 
Film Products is highly dependent on sales associated with one customer, P&G.  P&G comprised 27% of Tredegar’s net sales in 2004, 29% in 2003 and 33% in 2002. The loss or significant reduction of sales associated with P&G would have a material adverse effect on our business, as would delays in P&G rolling out products utilizing new technologies developed by Tredegar. While we have undertaken efforts to expand our customer base, there can be no assurance that such efforts will be successful, or that they will offset any delay or loss of sales and profits associated with P&G.
 
Growth of Film Products depends on our ability to develop and deliver new products at competitive prices, especially in the personal care market .  Personal care products are now being made with a variety of new materials, replacing traditional backsheet and other components. While we have substantial technical resources, there can be no assurance that our new products can be brought to market successfully, or if brought to market successfully, at the same level of profitability and market share of replaced films. A shift in customer preferences away from our technologies, our inability to develop and deliver new profitable products, or delayed acceptance of our new products in domestic or foreign markets, could have a material adverse effect on our business.

31



Film Products operates in a field where our significant customers and competitors have substantial intellectual property portfolios .  The continued success of this business depends on our ability not only to protect our own technologies and trade secrets, but also to develop and sell new products that do not infringe upon existing patents. Although we are not currently involved in any patent litigation, an unfavorable outcome of any such action could have a significant adverse impact on Film Products.
 
As Film Products expands its personal care business, we have greater credit risk that is inherent in broadening our customer base.
 

Aluminum Extrusions

 
Sales volume and profitability of Aluminum Extrusions is cyclical and highly dependent on economic conditions of end-use markets in the United States and Canada, particularly in the construction, distribution and transportation industries. Our market segments are also subject to seasonal slowdowns during the winter months.  From 1992 to the second quarter of 2000, profits in Aluminum Extrusions grew as a result of positive economic conditions in the markets we serve and manufacturing efficiencies. However, a slowdown in these markets in the second half of 2000 resulted in a 13% decline in sales volume and 28% decline in ongoing operating profit compared with the second half of 1999. The aluminum extrusions industry continued to be affected by poor economic conditions in 2001 and 2002. In 2001, our sales volume declined 20% and operating profit declined 52% compared with 2000. Our sales volume declined 23% and operating profit declined 49% in 2002 compared with 2000. The decline in ongoing operating profit during these periods at approximately two to three times the rate of the decline in sales volume illustrates the operating leverage inherent in our operations (fixed operating costs). Moreover, in 2003 higher energy and insurance costs and the appreciation of the Canadian Dollar against the U.S. Dollar had an adverse impact on operating profits. Any benefits associated with cost reductions and productivity improvements may not be sufficient to offset the adverse effects on profitability from pricing and margin pressure and higher bad debts that usually accompany a downturn.
 
  In 2004, operating profit from ongoing operations in Aluminum Extrusions increased to $22.6 million from $15.1 million in 2003. The $7.5 million or 50% increase in operating profit on 6.7% volume growth is primarily due to operating leverage and pricing improvements. Based on existing operating levels, we expect future annual operating profits to change at 3 - 4 times the percentage change in volume.
 
The markets for our products are highly competitive with product quality, service, delivery performance and price being the principal competitive factors.  Aluminum Extrusions has over 1,700 customers in a variety of end-use markets within the broad categories of building and construction, distribution, transportation, machinery and equipment, electrical and consumer durables. No single customer exceeds 3% of Aluminum Extrusion’s net sales. Due to the diverse customer mix across many end-use markets, we believe the industry generally tracks the real growth of the overall economy (historical cross-cycle volume growth has been in the 3% range).
 
  During improving economic conditions, excess industry capacity is absorbed and pricing pressure becomes less of a factor in many of our end-use markets. Conversely, during an economic slowdown, excess industry capacity often drives increased pricing pressure in many end-use markets as competitors protect their position with key customers. Because the business is susceptible to these changing economic conditions, Aluminum Extrusions targets complex, customized, service-intensive business with more challenging requirements which is competitively more defensible compared to higher volume, standard extrusion applications.
 
  Foreign imports, primarily from China, currently represent less than 5% of the North American aluminum extrusion market. Foreign competition to date has been primarily large volume, standard extrusion profiles that impact some of our less strategic end-use markets. Market share erosion in other end-use markets remains possible.

32



 
 
  There can be no assurance that we will be able to maintain current margins and profitability. Our continued success and prospects depend on our ability to retain existing customers and participate in overall industry cross-cycle growth.
 

Therics

 
Therics has incurred losses since inception, and we are unsure when, or if, it will become profitable.  We are in the initial stages of commercializing certain orthobiologic products that have received FDA clearances. There can be no assurance that any of these products can be brought to market successfully.
 
  The commercialization of new future products will require significant research, development, preclinical and clinical testing, and regulatory approvals. Where potential new products do not advance beyond early product development or do not demonstrate preclinical or clinical efficacy, they will not likely be commercialized. In addition, there can be no assurance that the FDA and other regulatory authorities will clear our products in a timely manner.
 
Our ability to develop and commercialize products will depend on our ability to internally develop preclinical, clinical, regulatory, manufacturing and sales, distribution and marketing capabilities, or enter into arrangements with third parties to provide those functions. We may not be successful in developing these capabilities or entering into agreements with third parties on favorable terms. To the extent we rely on third parties for these capabilities, our control over such activities may be reduced which could make us dependent upon these parties. The inability to develop or contract for these capabilities would significantly impair our ability to develop and commercialize products and thus our ability to become profitable.
 
  Related factors that may impair our ability to develop and commercialize products include our reliance on pre-clinical and clinical data concerning our products and product introductions by competing companies. Likewise, in the event we are unable to manufacture our products efficiently or demonstrate to the relevant markets the value of our products or their advantages over competitive products, our ability to commercialize products and thus our operating results will be negatively affected.
 
  Sales and marketing efforts are evolving more slowly than expected. We have been relying to a significant degree on a sales force consisting of independent sales agents for the sale and marketing of our products. Market acceptance of our products, and thus our ability to become profitable, is largely dependent upon the competency of this sales force, whether they perform their duties in line with our expectations and their continued willingness to carry our products. We are exploring potential collaborations with other companies aimed at accelerating market penetration across a broader array of market segments, but we may not be able to enter into any such collaboration nor may such collaboration be successful even if we enter into one.
 
Our ability to develop and commercialize products will depend on market acceptance of those products. We are dependent upon the willingness of the medical community to learn about and try our products and then switch from currently used products to our products. In the event the community is reluctant or unwilling to utilize our products, our ability to generate profits will be significantly impaired. Commercial success is also dependent upon third party payor acceptance of our products.
 
Our ability to develop and commercialize certain products is dependent upon sufficient sources of supply for various raw materials.  We may not be successful in procuring the types and quantities of raw materials necessary to commercialize certain orthobiologic products, which would significantly impair our ability to become profitable.
 
Future sales and profits are dependent upon obtaining and maintaining all necessary regulatory approvals.  We have received clearances from the FDA for certain products as medical devices, which approvals must be maintained in order to commercialize these products. Similar FDA approval will need to be obtained for any new products in order to market those products. In addition, depending upon where we intend to engage in marketing activities, we may need to obtain the necessary approvals from the regulatory agencies of the applicable jurisdictions. Moreover, our manufacturing practices are regulated and periodically reviewed by the FDA. Failure to obtain and maintain the necessary regulatory approvals would significantly impair our ability to market our products and thus our ability to generate profits. Likewise, the marketing of our products and our profit generating capability would be impaired in the event approval of one or more of our products is limited or restricted by the FDA, either in conjunction with or subsequent to approval.

33



We are highly dependent on several principal members of our management and scientific staff. The loss of key personnel (or the inability to recruit key personnel) could have a material adverse effect on Therics’ business and results of operations, and could inhibit product research and development, commercialization and sales and marketing efforts. Failure to retain and recruit executive management in key areas, including sales and marketing and product research and development, could prevent us from achieving our business objectives.
 
We are dependent upon certain license rights, patents and other proprietary rights.  Future success is dependent in part on our ability to maintain and enforce license, patent and other proprietary rights. Complex legal and technical issues define the strength and value of our intellectual property portfolio. While we own or license certain patents, the issuance of a patent does not establish conclusively either validity or enforceability.
 
The patent positions of biotechnology firms generally are highly uncertain and involve complex legal and factual questions that can determine who has the right to develop a particular product. No clear policy has emerged regarding the breadth of claims covered by biotechnology patents in the U.S. The biotechnology patent situation outside the U.S. is even more uncertain and is currently undergoing review and revision in many countries. Changes in, or different interpretations of, patent laws in the U.S. and other countries might allow others to use our discoveries or to develop and commercialize our products without any compensation to us.
 
Our business exposes us to potential product liability claims.  The testing, manufacturing, marketing and sale of our products subject us to product liability risk, an inherent risk for our industry. A successful product liability action against us may have a material adverse effect on our business. Moreover, present insurance coverage may not be adequate to cover potential future product liability claims.
 

Business Segment Review

                    Net sales (sales less freight) and operating profit from ongoing operations are the measures of sales and operating profit used by the chief operating decision maker of each segment for purposes of assessing performance.

Film Products

Net Sales.  Net sales in Film Products were $413.3 million in 2004, $365.5 million in 2003 and $376.9 million in 2002. Net sales in 2002 include revenue related to volume shortfall payments of $9.3 million (none in 2003 and 2004). While we continue to have volume shortfall agreements in place for certain products, the majority of payments received in 2002 relate to older supply agreements for which volume commitments have expired. Total volume was 278.7 million pounds in 2004, 274.2 million pounds in 2003 and 303.2 million pounds in 2002. Total volume related to the business in Argentina sold in the third quarter of 2004 was 9.4 million pounds in 2004, 10.8 million pounds in 2003 and 10 million pounds in 2002.

                    See the executive summary beginning on page 15 for discussion of net sales and operating results for Film Products in 2004 compared with 2003.

                    Excluding the effects of volume shortfall payments, net sales and volume declines in 2003 compared with 2002 were primarily due to the loss of certain domestic backsheet business with P&G. Domestic backsheet net sales excluding volume shortfall payments were approximately $45 million in 2003 and $95 million in 2002.


34



                    We lost share in domestic backsheet as the market transitioned from products made from film to products made from laminates of film and nonwovens. We did not anticipate this market change and fell behind on the technology curve. Once initial business was lost, economies of scale began to increasingly favor the competition resulting in additional lost business. We have made a number of changes in response to losing this business, including increasing our marketing resources, conducting our own consumer research and selling to the broader marketplace. We also are continuously focused on reducing the cost of our products in light of competitive pricing pressures. While we continue to sell backsheet products on a global basis, our primary prospects for growth relate to:

 
Apertured films and nonwoven materials used as topsheets in feminine hygiene products (for example, our new apertured topsheet product for P&G’s sanitary napkin business);
 
Elastic materials used in baby diapers (for example, our elastic fastening components improve overall comfort and fit);
 
Materials used in adult incontinent products (for example, our elastic materials and transfer layers meet the growing need for adult incontinent products that improve the lifestyles of an aging population);
 
Films used for surface protection (for example, our protective film is used to protect automobiles and flat panel display components such as glass during fabrication, shipping and handling);
 
Films used for packaging (for example, our thin-gauge high density polyethylene film used as overwrap for tissue and towel products provides customers with cost savings and is readily printable and convertible on conventional processing equipment); and
 
Continued global expansion efforts.
 

                     Excluding domestic backsheet sales, net sales in Film Products grew at a compounded annual growth rate of approximately 12% from 2000-2004 (7% on a volume basis).

Operating Profit.  Operating profit in Film Products for 2004, 2003 and 2002 was as follows:



            (In Millions)  
  2004   2003   2002  

Operating profit as reported     $ 32.9   $ 39.9   $ 75.1  

Volume shortfall payments               9.3  
Unusual items:    
   Gain (loss) on terminations and revisions of contracts with P&G:    
      Proceeds from contract terminations and revisions               11.7  
      Related asset write-downs               (6.1 )

   Gain (loss) on terminations and revisions of contracts
      with P&G
              5.6  
Losses associated with plant shutdowns, asset
   impairments and restructurings and other unusual items
      (10.4 )   (5.8 )   (2.9 )

        (10.4 )   (5.8 )   2.7  

Operating profit excluding volume shortfall payments,
   losses associated with plant shutdowns, asset
   impairments and restructurings and unusual items
    $ 43.3   $ 45.7   $ 63.1  


                    See the executive summary beginning on page 15 for discussion of net sales and operating results for Film Products in 2004 compared to 2003.

                    The decline in operating profit from ongoing operations excluding volume shortfall payments was $17.4 million or 28% in 2003 compared with 2002, and was almost entirely due to the loss of the domestic backsheet business with P&G discussed above.

Identifiable Assets.  Identifiable assets in Film Products increased to $472.8 million at December 31, 2004, from $422.3 million at December 31, 2003, due primarily to capital expenditures in excess of depreciation of $22.9 million (see the depreciation, amortization and capital expenditures section below for more information), higher accounts receivable and inventories supporting higher sales and appreciation of the Euro and Hungarian Forint relative to the U.S. Dollar. See discussion regarding assets on page 23 for further information.


35



                    Identifiable assets in Film Products increased to $422.3 million at December 31, 2003, from $379.6 million at December 31, 2002, due primarily to capital expenditures in excess of depreciation of $37.4 million (see the depreciation, amortization and capital expenditures section below for more information) and appreciation of the Euro relative to the U.S. Dollar.

Depreciation, Amortization and Capital Expenditures.  Depreciation and amortization for Film Products was $22 million in 2004, up from $19.8 million in 2003 due to the relatively high level of capital expenditures in 2003 and 2004. We project depreciation expense for Film Products to increase to about $27 million in 2005.

                    Depreciation and amortization for Film Products was $19.8 million in 2003, down from $20.1 million in 2002. Depreciation expense in 2003 does not fully reflect significantly higher capital expenditures in 2003 since a large portion of the related assets were not placed in service by the end of the year.

                    Capital expenditures in Film Products in 2004 totaled $44.8 million and reflect the normal replacement of machinery and equipment and:

 
Expansion of production capacity at our films plant in Kerkrade, The Netherlands, including capacity for the new apertured topsheet product for P&G’s sanitary napkin business;
 
Construction of a new films plant in Guangzhou, China, including production capacity for apertured film used in feminine hygiene products;
 
Expansion of production capacity at our films plant in Shanghai, China, including capacity for breathable film used in personal care products and protective clothing;
 
Expansion of production capacity at our films plant in Lake Zurich, Illinois, including capacity for elastic materials used in diapers and photopolymer films used for surface protection;
 
Expansion of production capacity at our plant in Pottsville, Pennsylvania, including capacity for polyethylene film used for packaging and masking film used for surface protection; and
 
A new global information system.
 

                    Capital expenditures in Film Products in 2003 totaled $57.2 million and reflect the normal replacement of machinery and equipment and:

 
Machinery and equipment purchased to upgrade lines and expand capacity at our films plant in Kerkrade, The Netherlands, including adding capacity for the new apertured topsheet product for P&G’s sanitary napkin business;
 
Expansion of capacity at our films plant in Shanghai, China;
 
Construction of a new films plant in Guangzhou, China;
 
Expansion of our polypropylene and masking film capacity at our plant in Pottsville, Pennsylvania; and
 
Commencing the design and implementation of a new global information system.
 

                    See the executive summary beginning on page 15 for further discussion of historical and projected capital expenditures (including information on related capital indemnification, take-or-pay or similar arrangements) for Film Products.

Aluminum Extrusions

Net Sales and Operating Profit. Net sales in Aluminum Extrusions increased by 20% in 2004 (higher raw material-driven selling prices and higher volume) and declined 2% in 2003 (lower volume). Annual volume was 243.4 million pounds in 2004, 228.2 million pounds in 2003 and 234.3 million pounds in 2002 (see our market segments in the table on page 2).

                    See the executive summary beginning on page 15 for discussion of net sales and operating results for Aluminum Extrusions in 2004 compared with 2003.

                    Ongoing operating profit in Aluminum Extrusions declined by $12.2 million or 45% in 2003 due to appreciation of the Canadian Dollar against the U.S. Dollar (unfavorable impact of $3.8 million), higher energy costs (up $3.2 million), lower volume (unfavorable impact of $1.7 million) and higher insurance costs (up $1.6 million).


36



Identifiable Assets. Identifiable assets in Aluminum Extrusions increased to $210.9 million at December 31, 2004, from $185.3 million at December 31, 2003, due primarily to higher accounts receivable and inventories supporting higher sales and appreciation of the Canadian Dollar relative to the U.S. Dollar. See discussion regarding assets on page 23 for further information.

                      Identifiable assets in Aluminum Extrusions increased to $185.3 million at December 31, 2003, from $176.6 million at December 31, 2002, due primarily to the appreciation of the Canadian Dollar relative to the U.S. Dollar (positive impact of $6.8 million on the U.S. Dollar reported carrying value of property, plant and equipment).

Depreciation, Amortization and Capital Expenditures. Depreciation and amortization for Aluminum Extrusions was $10.9 million in 2004, $10.9 million in 2003 and $10.5 million in 2002.

                    Capital expenditures totaled $10 million in 2004, $8.3 million in 2003 and $4.8 million in 2002, and reflect the normal replacement of machinery and equipment. In addition, on November 21, 2003, we announced the acquisition of Apolo Tool and Die Manufacturing Inc. (“Apolo”) of Woodbridge, Ontario. The purchase price consisted of cash consideration of $1.6 million (including transaction costs of $110,000 and net cash acquired of $343,000). Apolo’s key capabilities include bending, CNC machining, drilling, mitering, punching, riveting, sawing and welding of aluminum extrusions and other materials. The company also has in-house tool and die design and manufacturing capability to support its fabrication services.

                    We project capital expenditures to be $13 million in 2005. We expect ongoing capital expenditures in Aluminum Extrusions in the $10 million range, with the excess in 2005 primarily relating to the shutdown of the Aurora Plant and the move of its largest press to our facility in Pickering, Ontario, including upgrading the press and enlarging the facility.

Therics

                    At Therics, sales and marketing efforts are evolving more slowly than expected, and we took steps in early January 2005 to reduce its expected loss rate from approximately $2.5 million to $2 million per quarter. We are exploring potential collaborations with other companies aimed at accelerating market penetration across a broader array of market segments.

Molecumetics

                    Operations at Molecumetics ceased on July 2, 2002, and results have been reported as discontinued operations. Cash flows relating to Molecumetics have not been separately disclosed in the consolidated statements of cash flows.

                    For the year ended December 31, 2002, the operating loss for Molecumetics was $5.9 million ($3.9 million after taxes), while revenues were $515,000. In addition to the operating loss, discontinued operations include a gain from the sale of intellectual property of $1.4 million ($891,000 after taxes) in 2003 and a loss on the disposal of $7.5 million ($4.9 million after taxes) in 2002. This loss on disposal is comprised of an impairment loss for assets of $4.9 million, severance and other employee-related costs of $1.4 million for 45 employees and estimated miscellaneous disposal costs of $1.2 million. The tangible assets were sold during the fourth quarter of 2002 for proceeds of $800,000.

Venture Capital Investment Activities

                    On March 7, 2003, Tredegar Investments reached definitive agreements to sell substantially all of its portfolio of private equity partnership interests to GS Vintage Funds II, which are investment partnerships managed by Goldman Sachs Asset Management’s Private Equity Group. On the same date and in a separate transaction, Tredegar Investments also agreed to sell to W Capital Partners, an independent private equity manager, the subsidiary funds that hold substantially all of Tredegar Investments’ direct venture capital investments. The sale of these fund interests included the assumption by the buyer of Tredegar Investments’ obligations to make additional capital contributions to those funds in the future.


37



                    The sale to W Capital Partners of the subsidiary funds that hold the direct investments occurred on March 7, 2003. The sale of the private equity fund interests occurred in a series of closings.

                    Net proceeds from the sales totaled approximately $21.5 million. Additionally, in the first quarter of 2004 we received income tax recoveries of approximately $55 million from the carry-back of 2003 capital losses generated by these sales against gains realized in 2000 by Tredegar Investments.

                    The agreements governing these transactions contain customary contingent indemnification provisions that Tredegar believes will not have a material effect on its financial position or results of operations.

                    The operating results from venture capital investment activities have been reported as discontinued operations. Cash flows from venture capital investment activities have not been separately disclosed in the consolidated statements of cash flows. A summary of venture capital investment activities from 2002 through disposal in 2003 is provided below:



                    (In Thousands)  
      2003   2002  

Carrying value of venture capital investments,
     beginning of period
    $ 93,765   $ 155,084  
Venture capital investment activity for period:
     (pre-tax amounts):
   
     New investments       2,807     20,373  
     Proceeds from the sale of investments, including
        broker receivables at end of period
      (21,504 )   (8,918 )
     Realized gains           4,454  
     Realized losses, write-offs and write-downs       (70,256 )   (65,154 )
     (Decrease) increase in unrealized gain on
        available-for-sale securities
      (917 )   (12,074 )
     Carrying value of public securities retained by
        Tredegar Investments*
      (3,895 )    

Carrying value of venture capital investments,
     end of period
    $   $ 93,765  

Summary of amounts reported as discontinued
operations in the consolidated statements of
income:
   
     Pretax gains (losses), net     $ (70,256 ) $ (60,700 )
     Operating expenses (primarily management fee
        expenses)
      (599 )   (5,594 )

     Loss before income taxes       (70,855 )   (66,294 )
     Income tax benefits       24,286     23,866  

     Loss from venture capital investment activities     $ (46,569 ) $ (42,428 )


* At December 31, 2003, Tredegar Investments held 596,492 shares of Vascular Solutions, Inc. (NASDAQ: VASC) and 265,955 shares of Illumina, Inc. (NASDAQ: ILMN). These securities, which were related to Tredegar Investments’ earlier venture capital investment activities, were sold in 2004 for $7.2 million, including gains recognized of $6.1 million ($4 million after taxes). At December 31, 2003, these securities were classified as available-for-sale, included in the consolidated balance sheets in “Other assets and deferred charges” ($5.4 million market value) and stated at market value with unrealized gains reported directly in shareholders’ equity net of related deferred income taxes.

38



                    Discontinued operations in 2004 include an after-tax gain associated with venture capital investment activities of $2.9 million primarily related to the reversal of business and occupancy tax contingency accruals upon favorable resolution.

Item 7A.     QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

                    See discussion of quantitative and qualitative disclosures about market risk beginning on page 28 in Management’s Discussion and Analysis.

Item 8.        FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA

                    See the index on page 43 for references to management’s report on internal control over financial reporting, report of the independent registered public accounting firm, the consolidated financial statements and selected quarterly financial data.

 
Item 9.       CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURES
 

                    None.

Item 9A.     CONTROLS AND PROCEDURES

Evaluation of Disclosure Controls and Procedures

                     Pursuant to Rule 13a-15(b) under the Securities Exchange Act of 1934, we carried out an evaluation, with the participation of our management, including our principal executive officer and principal financial officer, of the effectiveness of our disclosure controls and procedures (as defined under Rule 13a-15(e) under the Securities Exchange Act of 1934) as of the end of the period covered by this report. Based upon that evaluation, our principal executive officer and principal financial officer concluded that our disclosure controls and procedures are effective to ensure that information required to be disclosed by us in the reports that we file or submit under the Exchange Act, is recorded, processed, summarized and reported, within the time periods specified in the SEC's rules and forms, and that such information is accumulated and communicated to our management, including our principal executive officer and principal financial officer, as appropriate, to allow timely decisions regarding required disclosure.

                    There has been no change in our internal control over financial reporting during the quarter ended December 31, 2004, that has materially affected, or is reasonably likely to materially affect, our internal control over financial reporting.

Management’s Report on Internal Control Over Financial Reporting

                    Our management is responsible for establishing and maintaining adequate internal control over financial reporting, as such term is defined in Exchange Act Rule 13a-15(f) under the Securities Exchange Act of 1934, as amended. The Company’s internal control over financial reporting is designed to provide reasonable assurance to the Company’s management and board of directors regarding the reliability of financial reporting and the preparation and fair presentation of published financial statements in accordance with generally accepted accounting principles in the United States of America and includes policies and procedures that: 

 
Pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the transactions and dispositions of our assets; 
 
Provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with generally accepted accounting principles in the United States of America, and that our receipts and expenditures are being made only in accordance with authorization of our management and directors; and
 
Provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use or disposition of our assets that could have a material effect on the consolidated financial statements.
 


39



                    Internal control over financial reporting includes the controls themselves, monitoring (including internal auditing practices) and actions taken to correct deficiencies as identified.

                    Because of its inherent limitations, internal control over financial reporting may not prevent or detect misstatements. Also, projections of any evaluation of effectiveness to future periods are subject to the risk that controls may become inadequate because of changes in conditions, or that the degree of compliance with the policies or procedures may deteriorate.

                    Management conducted an evaluation of the effectiveness of our internal control over financial reporting based on the framework in Internal Control - Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission. Based on their evaluation under the framework in Internal Control — Integrated Framework, our management concluded that our internal control over financial reporting was effective as of December 31, 2004.

                    Our management’s assessment of the effectiveness of our internal control over financial reporting as of December 31, 2004, has been audited by PricewaterhouseCoopers LLP, an independent registered public accounting firm, as stated in their report which is included on pages 43-44.

Item 9B.     OTHER INFORMATION

                    None.

PART III

Item 10.     DIRECTORS AND EXECUTIVE OFFICERS OF TREDEGAR

                    The information concerning directors and persons nominated to become directors of Tredegar included in the Proxy Statement under the heading “Election of Directors” is incorporated herein by reference.

                    The information included in the Proxy Statement under the headings “Stock Ownership” and “Audit Committee Matters” is incorporated herein by reference.

                    Set forth below are the names, ages and titles of our executive officers:

 

Name

 

Age

 

Title


 
 
         

Norman A. Scher

 

67

 

President and Chief Executive Officer

         

Nancy M. Taylor

 

45

 

Senior Vice President of Strategy and Special Projects

         

Thomas G. Cochran

 

43

 

Vice President and President, Tredegar Film Products Corporation

         

Tammy H. Cummings

 

41

 

Vice President, Human Resources

         

D. Andrew Edwards

 

46

 

Vice President, Chief Financial Officer and Treasurer

         

Michael W. Giancaspro

 

49

 

Vice President, Business Development

         

Larry J. Scott

 

54

 

Vice President, Audit

         

W. Hildebrandt Surgner, Jr.

 

39

 

Vice President, General Counsel and Corporate Secretary

 

Norman A. Scher.   Mr. Scher was elected President and Chief Executive Officer effective September 10, 2001. Mr. Scher served as Executive Vice President and Chief Financial Officer from July 10, 1989 until September 10, 2001.


40



From July 10, 1989 until May 22, 1997, he served as Treasurer.

Nancy M. Taylor.   Ms. Taylor was elected Senior Vice President, Strategy and Special Projects effective November 1, 2004. Ms. Taylor served as Managing Director, European Operations, of Tredegar Film Products from January 1, 2003 until November 1, 2004. Ms. Taylor served as Vice President, Administration and Corporate Development from September 10, 2001 until February 12, 2003. Ms. Taylor served as Secretary from February 24, 1994 until February 12, 2003. She served as Vice President, Law, from November 18, 1998 until September 10, 2001, and served as General Counsel from May 22, 1997 until July 25, 2000.

Thomas G. Cochran.   Mr. Cochran was elected Vice President on November 28, 2001. Mr. Cochran has served as President of Tredegar Film Products since February 22, 2000. Mr. Cochran was the Managing Director of Tredegar Film Products’ European operations from January, 1998 until May, 1999, and Business Development Manager of those operations from September, 1996 until December, 1997. Mr. Cochran was President of Brudi, Inc., a former subsidiary of Tredegar, from January, 1995 until August, 1996.

Tammy H. Cummings.   Ms. Cummings was elected Vice President, Human Resources, on August 28, 2003. Ms. Cummings served as Director of Human Resources from June 1, 2002 until August 28, 2003. Prior to her employment with Tredegar, she served as Vice President, Human Resources/Organization Development for Luck Stone Corporation from 1998 until 2002 and served as Human Resources Director of Luck Stone Corporation from 1996 until 1998.

D. Andrew Edwards.   Mr. Edwards was elected Vice President, Chief Financial Officer and Treasurer on August 28, 2003. Mr. Edwards has served as Vice President, Finance since November 18, 1998. Mr. Edwards has served as Treasurer since May 22, 1997. From October 19, 1992 until July 10, 2000, Mr. Edwards served as Controller.

Michael W. Giancaspro.  Mr. Giancaspro was elected Vice President, Business Development, effective September 1, 2003. Prior to his current employment with Tredegar, Mr. Giancaspro served as Director of Finance and Treasurer at the Association for the Preservation of Virginia Antiquities from September 2002 until July 2003, and as Executive Vice President of Aim Technologies from October 2000 until August 2002. Mr. Giancaspro served as Vice President, Corporate Development, of Tredegar from January 1998 until April 2000, and Vice President, Corporate Planning, of Tredegar from February 1992 to January 1998.

Larry J. Scott.   Mr. Scott was elected Vice President, Audit, on May 24, 2000. Mr. Scott served as Director of Internal Audit from February 24, 1994 until May 24, 2000.

W. Hildebrandt Surgner, Jr.  Mr. Surgner was elected Corporate Secretary on February 12, 2003. He was elected Vice President and General Counsel on December 16, 2002. Prior to his employment with Tredegar, he served as Senior Counsel to Philip Morris U.S.A. in 2002 and served as Counsel to Philip Morris U.S.A. from 1999 until 2001. In this capacity, Mr. Surgner was employed by Philip Morris Management Corporation. He was an Associate at the law firm of Hunton & Williams LLP from 1994 until 1999.

                    We have adopted a Code of Conduct that applies to all of our directors, officers and employees (including our Chief Executive Officer, Chief Financial Officer and principal accounting officer) and have posted the Code of Conduct on our web site. We intend to satisfy the disclosure requirement under Item 10 of Form 8-K relating to amendments to or waivers from any provision of our Code of Conduct applicable to Chief Executive Officer, Chief Financial Officer and principal accounting officer by posting this information on our web site. Our Internet address is www.tredegar.com. The information on our website is not, and shall not be deemed to be, a part of this report or incorporated into other filings we make with the SEC.

                    Because our common stock is listed on the NYSE, our chief executive officer is required to make, and he has made, an annual certification to the NYSE stating that he was not aware of any violation by us of the corporate governance listing standards of the NYSE. Our chief executive officer made his annual certification to that effect to the NYSE as of May 12, 2004. In addition, we have filed, as exhibits to this Annual Report on Form 10-K, the certifications of our principal executive officer and principal financial officer required under Section 302 of the Sarbanes Oxley Act of 2002 to be filed with the SEC regarding the quality of our public disclosure.


41



Item 11.     EXECUTIVE COMPENSATION

                    The information included in the Proxy Statement under the headings “Compensation of Directors” and “Compensation of Executive Officers” is incorporated herein by reference.

 
Item 12.    SECURITY OWNERSHIP OF CERTAIN BENEFICIAL OWNERS AND MANAGEMENT AND RELATED STOCKHOLDER MATTERS
 

                    The information included in the Proxy Statement under the heading “Stock Ownership” and “Equity Compensation Plan Table” is incorporated herein by reference.

Item 13.     CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS

                    Thomas G. Slater, Jr., a member of our board of directors, is a partner of the law firm of Hunton & Williams LLP, which we engage for legal services.

Item 14.     PRINCIPAL ACCOUNTING FEES AND SERVICES

                    The following is incorporated herein by reference:

 
Information on accounting fees and services included in the Proxy Statement under the heading “Audit Fees;” and
 
Information on the Audit Committee’s procedures for pre-approving certain audit and non-audit services included in the Proxy Statement under the heading “Audit Committee Matters.”

42



PART IV

Item 15.     EXHIBITS AND FINANCIAL STATEMENT SCHEDULES

                    (a)       List of documents filed as a part of the report:

                                (1)            Financial statements:

Tredegar Corporation
Index to Financial Statements and Supplementary Data

 
Page

Management’s Report on Internal Control Over Financial Reporting 39-40

Report of Independent Registered Public Accounting Firm 43-44

Financial Statements:  

        Consolidated Statements of Income for the Years Ended
                December 31, 2004, 2003 and 2002
45

        Consolidated Balance Sheets as of December 31, 2004 and 2003 46

        Consolidated Statements of Cash Flows for the Years Ended
                December 31, 2004, 2003 and 2002
47

        Consolidated Statements of Shareholders’ Equity for
                the Years Ended December 31, 2004, 2003 and 2002
48

        Notes to Financial Statements 49-73

Selected Quarterly Financial Data (Unaudited) 74

 

                                (2)            Financial statement schedules:

                                                 None.

                                (3)            Exhibits:

                                                 See Exhibit Index on pages 81-82.

REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM


 

To the Board of Directors and Shareholders of
Tredegar Corporation

We have completed an integrated audit of Tredegar Corporation’s 2004 consolidated financial statements and of its internal control over financial reporting as of December 31, 2004 and audits of its 2003 and 2002 consolidated financial statements in accordance with the standards of the Public Company Accounting Oversight Board (United States). Our opinions, based on our audits, are presented below.

Consolidated Financial Statements

In our opinion, the consolidated financial statements listed in the index appearing under Item 15(a)(1) present fairly, in all material respects, the financial position of Tredegar Corporation and its subsidiaries at December 31, 2004 and 2003, and the results of their operations and their cash flows for each of the three years in the period ended December 31, 2004 in conformity with accounting principles generally accepted in the United States of America. These financial statements are the responsibility of the Company’s management. Our responsibility is to express an opinion on these financial statements based on our audits. We conducted our audits of these statements in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit of financial statements includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion.


43



Internal Control Over Financial Reporting

Also, in our opinion, management’s assessment, included in Management’s Report on Internal Control Over Financial Reporting appearing under Item 9A, that the Company maintained effective internal control over financial reporting as of December 31, 2004 based on criteria established in Internal Control – Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission (COSO), is fairly stated, in all material respects, based on those criteria. Furthermore, in our opinion, the Company maintained, in all material respects, effective internal control over financial reporting as of December 31, 2004 based on criteria established in Internal Control – Integrated Framework issued by the COSO. The Company’s management is responsible for maintaining effective internal control over financial reporting and for its assessment of the effectiveness of internal control over financial reporting. Our responsibility is to express opinions on management’s assessment and on the effectiveness of the Company’s internal control over financial reporting based on our audit. We conducted our audit of internal control over financial reporting in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether effective internal control over financial reporting was maintained in all material respects. An audit of internal control over financial reporting includes obtaining an understanding of internal control over financial reporting, evaluating management’s assessment, testing and evaluating the design and operating effectiveness of internal control, and performing such other procedures as we consider necessary in the circumstances. We believe that our audit provides a reasonable basis for our opinions.

A company’s internal control over financial reporting is a process designed to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with generally accepted accounting principles. A company’s internal control over financial reporting includes those policies and procedures that (i) pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the transactions and dispositions of the assets of the company; (ii) provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with generally accepted accounting principles, and that receipts and expenditures of the company are being made only in accordance with authorizations of management and directors of the company; and (iii) provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use, or disposition of the company’s assets that could have a material effect on the financial statements.

Because of its inherent limitations, internal control over financial reporting may not prevent or detect misstatements. Also, projections of any evaluation of effectiveness to future periods are subject to the risk that controls may become inadequate because of changes in conditions, or that the degree of compliance with the policies or procedures may deteriorate.

PricewaterhouseCoopers LLP
Richmond, Virginia
March 14, 2005


44



CONSOLIDATED STATEMENTS OF INCOME

Tredegar Corporation and Subsidiaries
 
Years Ended December 31 2004   2003   2002  

(In thousands, except per-share amounts)
           
Revenues:            
     Sales $ 861,165   $ 738,651   $ 753,724  
     Other income (expense), net   15,604     7,853     546  

    876,769     746,504     754,270  

 Costs and expenses:                  
     Cost of goods sold   717,120     606,242     582,658  
     Freight   22,398     18,557     16,319  
     Selling, general and administrative   60,030     53,341     52,252  
     Research and development   15,265     18,774     20,346  
     Amortization of intangibles   330     268     100  
     Interest   3,171     6,785     9,352  
     Asset impairments and costs associated
       with exit and disposal activities
  22,973     11,426     3,884  
     Unusual items       1,067     (6,147 )

       Total   841,287     716,460     678,764  

 Income from continuing operations
     before income taxes
  35,482     30,044     75,506  
 Income taxes   9,222     10,717     26,881  

 Income from continuing operations   26,260     19,327     48,625  

 Discontinued operations:                  
     Gain (loss) from venture capital investment activities (including an
       after-tax gain on a tax-related item of $2,275 in 2004 and an after-tax
       loss on the sale of the venture capital investment portfolio of
        $46,269 in 2003)
  2,921     (46,569 )   (42,428 )
     Income (loss) from operations of Molecumetics
       (including loss on disposal of $4,875 in 2002)
      891     (8,728 )

 Income (loss) from discontinued operations   2,921     (45,678 )   (51,156 )

 Net income (loss) $ 29,181   $ (26,351 ) $ (2,531 )

 Earnings (loss) per share:                  
     Basic:                  
       Continuing operations $ .69   $ .51   $ 1.27  
       Discontinued operations   .08     (1.20 )   (1.34 )

       Net income (loss) $ .77   $ (.69 ) $ (.07 )

     Diluted:
       Continuing operations $ .68   $ .50   $ 1.25  
       Discontinued operations   .08     (1.19 )   (1.32 )

       Net income (loss) $ .76   $ (.69 ) $ (.07 )

 
See accompanying notes to financial statements.

45



CONSOLIDATED BALANCE SHEETS

Tredegar Corporation and Subsidiaries
 
December 31 2004   2003  

(In thousands, except share amounts)      
 
Assets          
Current assets:            
    Cash and cash equivalents $ 22,994   $ 19,943  
    Accounts and notes receivable, net   117,314     84,110  
    Income taxes recoverable       61,508  
    Inventories   65,360     49,572  
    Deferred income taxes   10,181     10,998  
    Prepaid expenses and other   4,689     5,015  

      Total current assets   220,538     231,146  

Property, plant and equipment, at cost:
    Land and land improvements   12,637     12,739  
    Buildings   90,830     80,581  
    Machinery and equipment   518,258     486,767  

      Total property, plant and equipment   621,725     580,087  
    Less accumulated depreciation   305,033     282,611  

    Net property, plant and equipment   316,692     297,476  
Other assets and deferred charges   89,261     83,855  
Goodwill and other intangibles (other intangibles
    of $1,939 in 2004 and $1,297 in 2003)
  142,983     140,548  

      Total assets $ 769,474   $ 753,025  

 
Liabilities and Shareholders’ Equity            
Current liabilities:            
    Accounts payable $ 63,852   $ 46,706  
    Accrued expenses   38,141     42,456  
    Income taxes payable   1,446      
    Current portion of long-term debt   13,125     8,750  

      Total current liabilities   116,564     97,912  
Long-term debt   90,327     130,879  
Deferred income taxes   71,141     66,276  
Other noncurrent liabilities   11,000     10,559  

      Total liabilities   289,032     305,626  

Commitments and contingencies (Notes 13 and 16)
Shareholders’ equity:
           
    Common stock (no par value):            
      Authorized 150,000,000 shares;            
      Issued and outstanding - 38,597,522 shares
        in 2004 (including restricted stock) and 38,176,821 in 2003
  109,450     104,991  
    Common stock held in trust for savings restoration
      plan (57,489 shares in 2004 and 53,871 in 2003)
  (1,274 )   (1,212 )
    Unearned compensation on restricted stock (120,000
        shares in 2004)
  (1,402 )    
    Accumulated other comprehensive income (loss):            
      Unrealized gain on available-for-sale securities       2,770  
      Foreign currency translation adjustment   19,562     9,997  
      Gain on derivative financial instruments   884     444  
      Minimum pension liability   (1,156 )   (880 )
    Retained earnings   354,378     331,289  

      Total shareholders’ equity   480,442     447,399  

      Total liabilities and shareholders’ equity $ 769,474   $ 753,025  

 
See accompanying notes to financial statements.

46



CONSOLIDATED STATEMENTS OF CASH FLOWS

Tredegar Corporation and Subsidiaries
 
Years Ended December 31 2004   2003   2002  

(In thousands)       
 
Cash flows from operating activities:              
    Net income (loss) $ 29,181   $ (26,351 ) $ (2,531 )
    Adjustments for noncash items:                  
       Depreciation   34,092     32,354     31,834  
       Amortization of intangibles   330     268     100  
       Deferred income taxes   1,947     37,370     7,690  
       Accrued pension income and postretirement benefits   (3,999 )   (4,812 )   (9,101 )
       Loss on venture capital investments       70,256     60,700  
       Gain on sale of corporate assets   (7,560 )   (5,155 )    
       Loss on equipment writedowns and divestitures   13,811     2,456     12,514  
       Allowance for doubtful accounts           1,207  
    Changes in assets and liabilities, net of effects from
       acquisitions and divestitures:
                 
       Accounts and notes receivable   (31,711 )   14,649     (15,718 )
       Inventories   (13,962 )   (2,294 )   1,641  
       Income taxes recoverable   61,538     (48,737 )   (7,453 )
       Prepaid expenses and other   (258 )   (763 )   (1,579 )
       Accounts payable and accrued expenses   12,269     7,801     (12,686 )
    Other, net   (1,858 )   (661 )   (1,345 )

       Net cash provided by operating activities   93,820     76,381     65,273  

Cash flows from investing activities:                  
    Capital expenditures   (55,651 )   (65,808 )   (31,336 )
    Acquisitions (net of cash acquired of $343 in 2003)   (1,420 )   (1,579 )    
    Novalux investment in 2004 and venture
       capital investments in 2003 and 2002
  (5,000 )   (2,807 )   (20,373 )
    Proceeds from the sale of venture capital investments       21,504     8,918  
    Proceeds from the sale of corporate assets and
       property disposals
  10,209     9,602     2,020  
    Other, net   1,553     2,600     (1,317 )

       Net cash used in investing activities   (50,309 )   (36,488 )   (42,088 )

Cash flows from financing activities:                  
    Dividends paid   (6,154 )   (6,103 )   (6,134 )
    Debt principal payments   (72,750 )   (255,000 )   (5,218 )
    Borrowings   36,573     135,349      
    Repurchases of Tredegar common stock       (5,170 )   (1,429 )
    Proceeds from exercise of stock options   1,871     1,046     2,714  

       Net cash used in financing activities   (40,460 )   (129,878 )   (10,067 )

Increase (decrease) in cash and cash equivalents   3,051     (89,985 )   13,118  
Cash and cash equivalents at beginning of period   19,943     109,928     96,810  

Cash and cash equivalents at end of period $ 22,994   $ 19,943   $ 109,928  

Supplemental cash flow information:                  
    Interest payments (net of amount capitalized) $ 3,264   $ 6,709   $ 9,301  
    Income tax payments (refunds), net $ (50,006 ) $ (1,701 ) $ (3,660 )

 
See accompanying notes to financial statements.

47



CONSOLIDATED STATEMENTS OF SHAREHOLDERS’ EQUITY

Tredegar Corporation and Subsidiaries
 
          Accumulated Other
Comprehensive Income (Loss)
     
 
 
    Retained
Earnings
Trust for
Savings
Restora-
tion Plan
Unearned
Restricted
Stock
Compen-
sation
Unrealized
Gain on
Available-
for-Sale
Securities
Foreign
Currency
Trans-
lation
  Gain
(Loss) on
Derivative
Financial
Instruments
  Minimum
Pension
Liability
  Total
Share–
holders’
Equity
Common Stock

Shares Amount

(In thousands, except share and per-share data)                                      
                                     
Balance December 31, 2001 38,142,404 $ 107,104 $ 372,408 $ (1,212 ) $ $ 8,314 $ (6,007 ) $ (2,708 ) $   $ 477,899  

Comprehensive income (loss):                                      
   Net loss       (2,531 )                           (2,531 )
   Other comprehensive income (loss):                                      
      Available–for–sale securities adjustment,
         net of reclassification adjustment
         (net of tax of $4,346)
                  (7,728 )               (7,728 )
      Foreign currency translation adjustment
         (net of tax of $940)
                        1,585             1,585  
      Derivative financial instruments
         adjustment (net of tax of $1,041)
                            1,866         1,866  
      Minimum pension liability adjustment
         (net of tax of $1,821)
                                (3,310 )   (3,310 )
                                                     
   Comprehensive loss                                     (10,118 )
Cash dividends declared ($.16 per share)       (6,134 )                           (6,134 )
Repurchases of Tredegar common stock (110,700 ) (1,429 )                               (1,429 )
Issued upon exercise of stock options (including
   related income tax benefits of $1,250) & other
291,321 2,714                               2,714  

Balance December 31, 2002 38,323,025 108,389 363,743 (1,212 )     586   (4,422 )   (842 )   (3,310 )   462,932  

Comprehensive income (loss):                                      
   Net loss       (26,351 )                           (26,351 )
   Other comprehensive income (loss):                                      
      Available-for-sale securities adjustment,
         net of reclassification adjustment
         (net of tax of $1,228)
                  2,184               2,184  
      Foreign currency translation adjustment
         (net of tax of $7,788)
                        14,419             14,419  
      Derivative financial instruments
         adjustment (net of tax of $715)
                            1,286         1,286  
      Minimum pension liability adjustment
         (net of tax of $1,347)
                                2,430     2,430  
                                                     
   Comprehensive loss                                     (6,032 )
Cash dividends declared ($.16 per share)       (6,103 )                           (6,103 )
Repurchases of Tredegar common stock (406,400 ) (5,170 )                               (5,170 )
Issued upon exercise of stock options (including
   related income tax benefits of $726) & other
260,196 1,772                               1,772  

Balance December 31, 2003 38,176,821 104,991 331,289 (1,212 )     2,770   9,997     444     (880 )   447,399  

Comprehensive income (loss):                                      
      Net income       29,181                           29,181  
      Other comprehensive income (loss):                                      
         Available-for-sale securities adjustment,
            net of reclassification adjustment
            (net of tax of $1,556)
                  (2,770 )               (2,770 )
         Foreign currency translation adjustment
            (net of tax of $4,500)
                        8,404             8,404  
         Reclassification of foreign currency translation
            loss realized on the sale of the films business
            in Argentina (net of tax of $625)
                        1,161             1,161  
         Derivative financial instruments
            adjustment (net of tax of $247)
                            440         440  
         Minimum pension liability adjustment
            (net of tax of $149)
                                (276 )   (276 )
                                                     
   Comprehensive income                                     36,140  
Cash dividends declared ($.16 per share)       (6,154 )                           (6,154 )
Repurchases of Tredegar common stock                                      
Restricted stock grant, net of forfeitures 120,000 1,674         (1,674 )                    
Restricted stock amortization               272                   272  
Issued upon exercise of stock options (including
   related income tax benefits of $868) & other
300,701 2,785                               2,785  
Tredegar common stock purchased by trust
   for savings restoration plan
      62 (62 )                        

Balance December 31, 2004 38,597,522 $ 109,450 $ 354,378 $ (1,274 ) $ (1,402 ) $ $ 19,562   $ 884   $ (1,156 ) $ 480,442  

                                     
See accompanying notes to financial statements.                                 

48



NOTES TO FINANCIAL STATEMENTS

Tredegar Corporation and Subsidiaries
(In thousands, except Tredegar share and per-share amounts and unless otherwise stated)
 
1              SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES

 
Organization and Nature of Operations. Tredegar Corporation and subsidiaries (“Tredegar”) are engaged in the manufacture of plastic films and aluminum extrusions. We also have developed and are marketing an initial line of bone graft substitutes through our Therics subsidiary. See Note 17 regarding discontinued operations.

Basis of Presentation. The consolidated financial statements include the accounts and operations of Tredegar and all of its majority-owned subsidiaries. Intercompany accounts and transactions have been eliminated.

                The preparation of financial statements in conformity with generally accepted accounting principles requires us to make estimates and assumptions that affect the reported amounts of revenues, expenses, assets and liabilities and disclosure of contingent assets and liabilities at the date of the financial statements. Actual results could differ from those estimates.

Foreign Currency Translation. The financial statements of foreign subsidiaries, where the local currency is the functional currency, are translated into U.S. Dollars using exchange rates in effect at the period end for assets and liabilities and average exchange rates during each reporting period for results of operations. Adjustments resulting from the translation of these financial statements are reflected as a separate component of shareholders’ equity.

                The financial statements of foreign subsidiaries where the U.S. Dollar is the functional currency, and which have certain transactions in a local currency, are remeasured as if the functional currency were the U.S. Dollar. The remeasurement of local currencies into U.S. Dollars creates translation adjustments that are included in income.

                Transaction and remeasurement gains or losses included in income were not material in 2004, 2003 and 2002. These amounts do not include the effects between reporting periods that exchange rate changes have on income of our foreign locations that result from translation into U.S. Dollars.

Cash and Cash Equivalents. Cash and cash equivalents consist of cash on hand in excess of daily operating requirements and highly liquid investments with original maturities of three months or less. At December 31, 2004 and 2003, Tredegar had cash and cash equivalents of $22,994 and $19,943, respectively, including funds held in foreign locations of $21,410 and $16,188, respectively.

                Our policy permits investment of excess cash in marketable securities that have the highest credit ratings and maturities of less than one year. The primary objectives of the policy are safety of principal and liquidity.

Accounts and Notes Receivable.  Accounts receivable are stated at cash due from customers less allowances for doubtful accounts and sales returns. Accounts receivable are non-interest bearing and arise from the sale of product to customers under typical industry trade terms (average days sales outstanding are in the 50-day range for our plastic films business and 45-day range for our aluminum extrusions business). Notes receivable are not significant. Past due amounts are determined based on established terms and charged-off when deemed uncollectible. The allowance for doubtful accounts is determined based on our assessment of probable losses taking into account past due amounts, customer credit profile, historical experience and current economic conditions. Other receivables include insurance recoveries due within one year and value-added taxes related to certain foreign subsidiaries.

Inventories.   Inventories are stated at the lower of cost or market, with cost determined on the last-in, first-out (“LIFO”) basis, the weighted average cost or the first-in, first-out basis. Cost elements included in work-in-process and finished goods inventories are raw materials, direct labor and manufacturing overhead.

Property, Plant and Equipment.  Accounts include costs of assets constructed or purchased, related delivery and installation costs and interest incurred on significant capital projects during their construction periods. Expenditures for renewals and betterments also are capitalized, but expenditures for repairs and maintenance are expensed as incurred. The cost and accumulated depreciation applicable to assets retired or sold are removed from the respective accounts, and gains or losses thereon are included in income.


49



                Property, plant and equipment include capitalized interest of $762 in 2004, $593 in 2003 and $674 in 2002.

                Depreciation is computed primarily by the straight-line method based on the estimated useful lives of the assets, which range from 15 to 40 years for buildings and land improvements and 3 to 25 years for machinery and equipment.

Goodwill and Other Intangibles.  The excess of the purchase price over the fair value of identifiable net assets of acquired companies is allocated to goodwill. We assess goodwill for impairment when events or circumstances indicate the carrying value may not be recoverable, or, at a minimum, on an annual basis as of December 1 of each year. Impairment reviews may result in recognition of losses. We have made determinations as to what our reporting units are and what amounts of goodwill, intangible assets, other assets and liabilities should be allocated to those reporting units.

                The components of goodwill and other intangibles at December 31, 2004 and 2003, and related amortization periods are as follows:

 

December 31 2004   2003   Amortization Periods

Carrying value of goodwill:              
    Film Products $ 103,788   $ 102,962   Not amortized
    Aluminum Extrusions   33,764     32,797   Not amortized
    Therics   3,492     3,492   Not amortized

    Total carrying value of goodwill   141,044     139,251    

Carrying value of other intangibles:
    Film Products (cost basis of $1,575 & $603, respectively)   990     124   Not more than 17 yrs.
    Therics (cost basis of $2,236 in both years)   949     1,173   10 years

    Total carrying value of other intangibles   1,939     1,297    

Total carrying value of goodwill and other intangibles 142,983   $ 140,548    

 
                A reconciliation of the beginning and ending balances of goodwill and other intangibles for each of the three years in the period ended December 31, 2004 is as follows:
 

  2004   2003   2002  

Goodwill and other intangibles:                  
    Net carrying value, beginning of year $ 140,548   $ 137,339   $ 136,488  
       Amortization   (330 )   (268 )   (100 )
       Increase due to foreign currency translation and other   2,765     3,477     951  

    Net carrying value, end of year   142,983     140,548     137,339  
Goodwill and other intangibles related to Therics classified as
    non-current assets held for sale in the consolidated balance
    sheets
          (5,057 )

    Total carrying value of goodwill and other intangibles $ 142,983   $ 140,548   $ 132,282  

 

Impairment of Long-Lived Assets.  We review long-lived assets for possible impairment when events indicate that impairment may exist. For assets to be held and used in operations, if events indicate that an asset may be impaired, we estimate the future unlevered pre-tax cash flows expected to result from the use of the asset and its eventual disposition. Assets are grouped for this purpose at the lowest level for which there are identifiable and independent cash flows. If the sum of these undiscounted pre-tax cash flows is less than the carrying amount of the asset, an impairment loss is recognized. Measurement of the impairment loss is based on the estimated fair value of the asset, generally determined on a discounted after-tax cash flow basis.

                Assets to be disposed of are reported at the lower of their carrying amount or estimated fair value less cost to sell, with an impairment loss recognized for any writedown required.


50



Pension Costs and Postretirement Benefit Costs Other than Pensions.  Pension costs and postretirement benefit costs other than pensions are accrued over the period employees provide service to the company. Our policy is to fund our pension plans at amounts not less than the minimum requirements of the Employee Retirement Income Security Act of 1974 and to fund postretirement benefits other than pensions when claims are incurred.

Postemployment Benefits.  We periodically provide certain postemployment benefits purely on a discretionary basis. Related costs for these programs are accrued when it is probable that benefits will be paid. All other postemployment benefits are either accrued under current benefit plans or are not material to our financial position or results of operations.

Revenue Recognition.  Revenue from the sale of products, which is shown net of estimated sales returns and allowances, is recognized when delivery of product to the customer has occurred, the price of the product is fixed and determinable, and collectibility is reasonably assured. Amounts billed to customers related to freight have been classified as sales in the accompanying consolidated statements of income. The cost of freight has been classified as a separate line in the accompanying consolidated statements of income.

Research & Development (“R&D”) Costs.  R&D costs are expensed as incurred and include primarily salaries, wages, employee benefits, equipment depreciation, facility costs and the cost of materials consumed relating to R&D efforts. R&D costs include a reasonable allocation of indirect costs.

Income Taxes.   Income taxes are recognized during the period in which transactions enter into the determination of income for financial reporting purposes, with deferred income taxes being provided at enacted statutory tax rates on the differences between the financial reporting and tax bases of assets and liabilities (see Note 14). We accrue U.S. federal income taxes on unremitted earnings of our foreign subsidiaries.

Earnings Per Share.  Basic earnings per share is computed using the weighted average number of shares of common stock outstanding. Diluted earnings per share is computed using the weighted average common and potentially dilutive common equivalent shares outstanding, determined as follows:

 

  2004   2003   2002  

Weighted average shares outstanding used
    to compute basic earnings (loss) per share
  38,294,996     38,096,001     38,267,780  
Incremental shares attribute to stock
    options and restricted stock
  211,688     345,009     601,452  

Shares used to compute diluted
    earnings (loss) per share
  38,506,684     38,441,010     38,869,232  

 

                Incremental shares attributable to stock options and restricted stock are computed using the average market price during the related period. During 2004, 2003 and 2002, 2,073,990, 2,425,575 and 2,052,610 of average out-of-the-money options to purchase shares were excluded from the calculation of incremental shares attributable to stock options and restricted stock.

Stock-Based Employee Compensation Plans.  Stock options, stock appreciation rights (“SARs”) and restricted stock grants are accounted for using the intrinsic value method under APB Opinion No. 25, “Accounting for Stock Issued to Employees,” and related interpretations whereby:

 
No compensation cost is recognized for fixed stock option or restricted stock grants unless the quoted market price of the stock at the measurement date (ordinarily the date of grant or award) is in excess of the amount the employee is required to pay; and
 
Compensation cost for SARs is recognized and adjusted up through the date of exercise or forfeiture based on the estimated number of SARs expected to be exercised multiplied by the difference between the market price of our stock and the amount the employee is required to pay.

51



                Had compensation cost for stock option grants been determined in 2004, 2003 and 2002 based on the fair value at the grant dates, our income and diluted earnings per share from continuing operations would have been reduced to the pro forma amounts indicated below:
 

  2004   2003   2002  

Income from continuing operations:
     As reported
$ 26,260   $ 19,327   $ 48,625  
     Stock option-based employee
         compensation cost, net of tax, based
         on the fair value method
  (2,133 )   (2,194 )   (2,268 )

Pro forma income from continuing operations $ 24,127   $ 17,133   $ 46,357  

Basic earnings per share from
     continuing operations:
                 
     As reported $ .69   $ .51   $ 1.27  
     Pro forma   .63     .45     1.21  

Diluted earnings per share from
     continuing operations:
           
     As reported $ .68   $ .50   $ 1.25  
     Pro forma   .63     .45     1.19  

 

                Compensation cost related to stock-based compensation (restricted stock grants) included in determining net income from continuing operations was $272 in 2004, $95 in 2003 and $203 in 2002.

                The fair value of each option was estimated as of the grant date using the Black-Scholes options-pricing model. The assumptions used in this model for valuing Tredegar stock options granted during 2004, 2003 and 2002 are as follows:

 

      2004   2003   2002  

Dividend yield       1.2 %   1.0 %   .9 %
Volatility percentage       45.0 %   45.0 %   45.0 %
Weighted average risk-free interest rate       3.1 %   4.0 %   4.7 %
Holding period (years):                
     Officers       n/a     7.0     7.0  
     Management       5.0     5.0     5.0  
     Other employees       3.0     n/a     3.0  
Weighted average market prices at date of
     grant (market price equals exercise price):
               
     Officers and management     $ 13.97   $ 16.44   $ 18.71  
     Other employees       13.95     n/a     18.90  


52



                Tredegar Stock options granted during 2004, 2003 and 2002, and related estimated fair value at the date of grant, are as follows:

 

  2004   2003   2002  

Stock options granted (number of shares):                      
     Officers       n/a     10,000     181,000  
     Management       176,950     5,000     345,200  
     Other employees       161,675     n/a     98,300  

 
     Total       338,625     15,000     624,500  

Estimated weighted average fair value of
     options per share at date of grant (exercise
     price equaled market price on date of grant)
          Officers
      n/a   $ 7.93   $ 9.14  
          Management     $ 5.54     6.51     8.02  
          Other employees       4.32     n/a     6.20  

Total estimated fair value of stock
     options granted
    $ 1,679   $ 112   $ 5,033  

 

                The table above excludes stock options granted to a consultant in 2004. The estimated fair value related to that grant of $50 was expensed in 2004 in conjunction with services rendered. Additional disclosure of Tredegar stock options is included in Note 10.

                Therics stock options granted in 2004 and assumptions used in determining related pro forma compensation expense are as follows (there were no significant grants of Therics stock options in 2003 and 2002):

 

Assumptions Used in Determining Pro Forma Comp. Expense for Therics Stock Options Granted in 2004 & Other Data

Assumptions used in Black-Scholes       Other assumptions and items:        
options-pricing model:            Vesting period (years)     0.4 - 4  
     Dividend yield   0.0%        Therics stock options granted:        
     Volatility percentage (a)   95%           3rd quarter 2004     7,906,149  
     Weighted average risk-free interest rate   4.1%           1st quarter 2004     30,809,000  
     Holding period (years)   7.0        Aggregate estimated fair value of
        options at date of grant:
       
     Weighted average estimated fair value per share
          of underlying stock at date of grant (b)
  $ .090           3rd quarter 2004   $ 584  
     Weighted average estimated fair value of
          options per share at date of grant
  $ .074           1st quarter 2004   $ 2,271  
        Therics voting stock issued and outstanding
       at 12/31/04 (all held by Tredegar)
    202,829,760  
        Therics stock options outstanding at 12/31/04
       (all held by Therics employees)
    40,498,133  

(a) Volatility estimated for Therics based on Orthovita, Inc. (NASDAQ: VITA), a comparable company.
   
(b) Estimated fair value of underlying stock equaled the stock option exercise price at date of grant.

53



Financial Instruments.  We use derivative financial instruments for the purpose of hedging aluminum price volatility and interest rate exposures that exist as part of ongoing business operations. Our derivative financial instruments are designated as and qualify as cash flow hedges and are recognized in the balance sheet at fair value. A change in the fair value of the derivative that is highly effective as and that is designated and qualifies as a cash flow hedge is recorded in other comprehensive income. Gains and losses reported in other comprehensive income are reclassified to earnings in the periods in which earnings are affected by the variability of cash flows of the hedged transaction. Such gains and losses are reported on the same line as the underlying hedged item. Any hedge ineffectiveness (which represents the amount by which the changes in the fair value of the derivative exceed the variability in the cash flows of the forecasted transaction) is recorded in current period earnings. There was no hedge ineffectiveness recognized in earnings.

                Our policy requires that we formally document all relationships between hedging instruments and hedged items, as well as our risk management objective and strategy for undertaking various hedge transactions. We also formally assess (both at the hedge’s inception and on an ongoing basis) whether the derivatives that are used in hedging transactions have been highly effective in offsetting changes in the fair value or cash flows of hedged items and whether those derivatives may be expected to remain highly effective in future periods. When it is determined that a derivative is not (or has ceased to be) highly effective as a hedge, we discontinue hedge accounting prospectively.

                As a policy, we do not engage in speculative or leveraged transactions, nor do we hold or issue financial instruments for trading purposes.

                The cash flows related to financial instruments are classified in the statements of cash flows in a manner consistent with those of the transactions being hedged.

Comprehensive Income.  Comprehensive income, which is included in the consolidated statement of shareholders’ equity, is defined as net income and other comprehensive income. Other comprehensive income includes changes in unrealized gains and losses on available-for-sale securities, foreign currency translation adjustments, unrealized gains and losses on derivative financial instruments and minimum pension liability adjustments, all recorded net of deferred income taxes directly in shareholders’ equity.

                The available-for-sale securities adjustment included in the consolidated statement of shareholders’ equity is comprised of the following components:

 

  2004   2003   2002  

Available-for-sale securities adjustment:                  
    Unrealized net holding gains (losses)
       arising during the period
$ 1,872   $ 7,294   $ (9,419 )
    Income taxes   (655 )   (2,626 )   3,391  
    Reclassification adjustment for net
       losses (gains) realized in income
  (6,134 )   (3,851 )   (2,656 )
    Income taxes   2,147     1,367     956  

Available-for-sale securities adjustment $ (2,770 ) $ 2,184   $ (7,728 )

 

Recently Issued Accounting Standards.   In December 2004, the Financial Accounting Standards Board (“FASB”) revised Statement of Financial Accounting Standards (“SFAS”) No. 123, Share-Based Payment. This statement requires that the cost of employee services received in exchange for equity instruments be measured based on the fair value of the award on the grant date. The statement also requires that the cost be recognized over the employee service period required to receive the award. The statement applies to awards granted after the effective date and to awards modified, repurchased or cancelled after that date. The statement is effective as of the beginning of the first interim or annual reporting period that begins after June 15, 2005. Early adoption is permitted. The adoption of this standard will have no impact on cash flow. The primary impact of adoption on Tredegar will be the recognition of compensation expense for stock options granted. Currently, we disclose the pro forma effects of treating stock option grants as compensation expense under the fair value-based method (see the relevant section above). We expect to continue to use the Black-Scholes options-pricing model to determine the estimated fair value of option grants but are still evaluating our transition method. We believe that the pro forma effects that have been disclosed are not materially different from compensation expense that would have been recognized if this standard had been previously adopted.


54



                In November 2004, the FASB issued SFAS No. 151, Inventory Costs – An Amendment of ARB No. 43, Chapter 4. This statement clarifies that abnormal amounts of idle facility expense, freight, handling costs and wasted material (spoilage) should be expensed as current-period charges. In addition, this statement requires that allocation of fixed production overheads to the costs of conversion be based on the normal capacity of the production facilities. The statement is effective for inventory costs incurred during the fiscal years beginning after June 15, 2005. Early adoption is permitted. The adoption of this standard will have no impact on cash flow, and we do not expect it to have a significant impact on amounts reported in the consolidated statement of income and balance sheet.

                In October 2004, the American Jobs Creation Act of 2004 (“AJCA”) was signed into law. In December 2004, the FASB issued Staff Position No. 109-1 (“FSP 109-1”), Application of FASB Statement No. 109, Accounting for Income Taxes, to the Tax Deduction on Qualified Production Activities Provided by the American Jobs Creation Act of 2004 and Staff Position No. 109-2 (“FSP 109-2”), Accounting and Disclosure Guidance for the Foreign Earnings Repatriation Provision within the American Jobs Creation Act of 2004. FSP 109-1 clarifies that the manufacturer’s tax deduction provided for under the AJCA should be accounted for as a special deduction in accordance with SFAS No. 109 and not as a tax rate reduction. FSP 109-2 provides accounting and disclosure guidance for the repatriation of certain foreign earnings to a U.S. taxpayer as provided for in the AJCA. We do not expect that the tax benefits resulting from the AJCA will have a material impact on our financial statements.

2                  ACQUISITIONS AND INVESTMENTS


 
                On July 23, 2004, a subsidiary of Tredegar purchased the assets of Yaheng Perforated Film Material Co., Ltd. (“Yaheng”) for approximately $1,420. Yaheng, based in Shanghai, China, has 21 employees and manufactures apertured nonwovens used primarily in personal care markets. The purchase price was allocated to accounts receivable ($26), inventories ($45), property, plant and equipment ($288), patents ($822), employment agreements ($150), goodwill ($215), deferred income tax liabilities ($56) and accrued expenses ($70). Property, plant and equipment is being depreciated on a straight-line basis over approximately 10 years, patents are being amortized on a straight-line basis over approximately 7 years, and employment agreements are being amortized on a straight-line basis over approximately 3 years.
 
                 On November 21, 2003, Tredegar announced that its aluminum extrusions subsidiary, the William L. Bonnell Company, had acquired Apolo Tool and Die Manufacturing Inc. (“Apolo”) of Woodbridge, Ontario. The purchase price consisted of cash consideration of $1,579 (including transaction costs of $110 and net cash acquired of $343). Apolo’s key capabilities include bending, CNC machining, drilling, mitering, punching, riveting, sawing and welding of aluminum extrusions and other materials. The company also has in-house tool and die design and manufacturing capability to support its fabrication services. There was no goodwill (the excess of the purchase price over the estimated fair value of identifiable net assets acquired) associated with the Apolo acquisition.
 
                 The operating results for the acquired businesses have been included in the consolidated statements of income since the date acquired. Pro forma results for these acquisitions are immaterial.
 

                In August of 2004, we invested $5,000 in Novalux, Inc., representing an ownership interest of approximately 18% (15% on a fully diluted basis). Novalux, based in Sunnyvale, California, is developing and commercializing a laser technology for use in a variety of applications, including flat panel displays for home theaters. We are already participating in the growing flat panel display market with our surface protection films. The investment in Novalux, which is included in “Other assets and deferred charges” in the consolidated balance sheet, is being accounted for under the cost method, with an impairment loss recognized and a new cost basis established for any write-down to estimated fair value.


55



3              BUSINESS SEGMENTS

 

                Information by business segment and geographic area for the last three years is provided below. There are no accounting transactions between segments and no allocations to segments. Net sales (sales less freight) and operating profit from ongoing operations are the measures of sales and operating profit used by the chief operating decision maker of each segment for purposes of assessing performance. Film Products’ net sales to The Procter & Gamble Company (“P&G”) totaled $226,122 in 2004, $207,049 in 2003 and $242,760 in 2002. These amounts include plastic film sold to others that convert the film into materials used in products manufactured by P&G.

 

  Net Sales  
    2004     2003     2002  

Film Products $ 413,257   $ 365,501   $ 376,904  
Aluminum Extrusions   425,130     354,593     360,293  
Therics   380         208  

     Total net sales   838,767     720,094     737,405  
Add back freight   22,398     18,557     16,319  

Sales as shown in consolidated
     statements of income
$ 861,165   $ 738,651   $ 753,724  


  Operating Profit  
    2004     2003     2002  

Film Products:                  
     Ongoing operations $ 43,259   $ 45,676   $ 72,307  
     Plant shutdowns,
       asset impairments and
       restructurings (a)
  (10,438 )   (5,746 )   (3,397 )
     Unusual items (a)           6,147  

Aluminum Extrusions:                  
     Ongoing operations   22,637     15,117     27,304  
     Plant shutdowns,
       asset impairments and
       restructurings (a)
  (10,553 )   (644 )   (487 )
     Gain on sale of land (a)       1,385      
     Other (a)   7,316          

Therics:
     Ongoing operations   (9,763 )   (11,651 )   (13,116 )
     Restructurings (a)   (2,041 )   (3,855 )    
     Unusual items (a)       (1,067 )    

Total   40,417     39,215     88,758  
Interest income   350     1,183     1,934  
Interest expense   3,171     6,785     9,352  
Gain on sale of corporate assets (a)   7,560     5,155      
Corporate expenses, net (a)   9,674     8,724     5,834  

Income from operations continuing operations
     before income taxes
  35,482     30,044     75,506  
Income taxes (a)   9,222     10,717     26,881  

Income from continuing operations   26,260     19,327     48,625  
Income (loss) from discontinued operations (a)   2,921     (45,678 )   (51,156 )

Net income (loss) $ 29,181   $ (26,351 ) $ (2,531 )

   
(a) See Note 15 for more information on losses associated with plant shutdowns, asset impairments and restructurings, unusual items, gains from sale of assets and other items, and Note 17 for more information on discontinued operations.
   
(b) The difference between total consolidated sales as reported in the consolidated statements of income and segment and geographic net sales reported in this note is freight of $22,398 in 2004, $18,557 in 2003 and $16,319 in 2002.
   
(c) Information on exports and foreign operations are provided on the next page. Cash and cash equivalents includes funds held in foreign locations of $21,410, $16,188 and $16,550 at December 31, 2004, 2003, and 2002, respectively. Export sales relate almost entirely to Film Products. Foreign operations in The Netherlands, Hungary, China, Italy, Brazil and Argentina (operations in Argentina were sold in the third quarter of 2004) also relate to Film Products. Sales from our locations in The Netherlands, Hungary and Italy are primarily to customers located in Europe. Sales from our locations in China (Guangzhou and Shanghai) are primarily to customers located in China, but also include other customers in Asia. Foreign operations in Canada relate to Aluminum Extrusions. Sales from our locations in Canada are primarily to customers located in the U.S. and Canada. Certain previously reported amounts have been reclassified to conform to the current presentation.

56




  Identifiable Assets        
December 31 2004   2003   2002  

                 
Film Products     $ 472,810   $ 422,321   $ 379,635                    
Aluminum Extrusions       210,894     185,336     176,631                    
Therics       8,613     8,917     10,643                    

                 
     Subtotal       692,317     616,574     566,909                    
General corporate       54,163     61,508     52,412                    
Income taxes recoverable
     from sale of venture
     capital investment portfolio
          55,000                        
Cash and cash equivalents (c)       22,994     19,943     109,928                    

                 
     Continuing operations       769,474     753,025     729,249                    
Discontinued operations:                                        
     Venture capital               108,713                    
     Molecumetics                                  

                 
     Total     $ 769,474   $ 753,025   $ 837,962                    

                 

  Depreciation and Amortization   Capital Expenditures  
  2004   2003   2002   2004   2003   2002  

Film Products     $ 21,967   $ 19,828   $ 20,085   $ 44,797   $ 57,203   $ 24,063  
Aluminum Extrusions       10,914     10,883     10,506     10,007     8,293     4,799  
Therics       1,300     1,641     463     275     219     1,621  

     Subtotal       34,181     32,352     31,054     55,079     65,715     30,483  
General corporate       241     270     353     572     93     60  

     Continuing operations       34,422     32,622     31,407     55,651     65,808     30,543  
Discontinued operations:    
     Venture capital                            
     Molecumetics               527             793  

     Total     $ 34,422   $ 32,622   $ 31,934   $ 55,651   $ 65,808   $ 31,336  


  Net Sales by Geographic Area (c)        
  2004   2003   2002  

                 
United States     $ 441,891   $ 383,204   $ 416,189                    
Exports from the United States to:    
     Canada       27,663     25,188     24,026                    
     Latin America       16,668     17,915     20,711                    
     Europe       15,768     25,157     22,720                    
     Asia       31,617     21,510     27,480                    
Foreign operations:                                        
     Canada       147,145     125,347     130,356                    
     The Netherlands       66,856     43,954     28,720                    
     Hungary       34,721     32,204     31,156                    
     China       25,291     17,426     14,202                    
     Italy       12,423     12,698     9,402                    
     Brazil and Argentina       18,724     15,491     12,443                    

                 
     Total (b)     $ 838,767   $ 720,094   $ 737,405                    

                 

  Identifiable Assets
by Geographic Area (c)
  Property, Plant & Equipment,
Net by Geographic Area (c)
 
December 31 2004   2003   2002   2004   2003   2002  

United States     $ 427,240   $ 394,415   $ 515,542   $ 163,383   $ 159,127   $ 158,979  
Foreign operations:    
     Canada       92,290     86,564     78,544     38,610     44,179     38,383  
     The Netherlands       75,449     47,809     15,843     58,370     38,956     10,036  
     Hungary       27,308     26,815     27,022     19,371     20,449     21,596  
     China       38,713     29,233     15,565     25,684     22,577     10,597  
     Italy       20,785     20,951     14,486     3,991     3,826     2,351  
     Brazil and Argentina       10,532     10,787     8,620     5,037     5,295     4,751  
General corporate       54,163     61,508     52,412     2,246     3,067     3,910  
Income taxes recoverable
     from sale of venture
     capital investment portfolio
          55,000         n/a     n/a     n/a  
Cash and cash equivalents (c)       22,994     19,943     109,928     n/a     n/a     n/a  

     Total     $ 769,474   $ 753,025   $ 837,962   $ 316,692   $ 297,476   $ 250,603  

 
See footnotes on prior page and a reconciliation of net sales to sales as shown in the consolidated statements of income.

57



4              ACCOUNTS AND NOTES RECEIVABLE

 
                Accounts and notes receivable consist of the following:
 

December 31 2004   2003  

                 
Trade, less allowance for doubtful
    accounts and sales returns of $5,313
    in 2004 and $4,448 in 2003
    $ 109,347   $ 79,409  
Other       7,967     4,701  

    Total     $ 117,314   $ 84,110  

 

5              INVENTORIES


 
                Inventories consist of the following:
 

December 31 2004   2003  

Finished goods     $ 13,452   $ 9,190  
Work-in-process       3,097     3,294  
Raw materials       36,567     25,730  
Stores, supplies and other       12,244     11,358  

    Total     $ 65,360   $ 49,572  

 
                Inventories stated on the LIFO basis amounted to $20,837 at December 31, 2004 and $18,030 at December 31, 2003, which are below replacement costs by approximately $20,867 at December 31, 2004 and $16,289 at December 31, 2003.
 
6              FINANCIAL INSTRUMENTS   

 

                 In the normal course of business, we enter into fixed-price forward sales contracts with certain customers for the sale of fixed quantities of aluminum extrusions at scheduled intervals. In order to hedge our exposure to aluminum price volatility under these fixed-price arrangements, which generally have a duration of not more than 12 months, we enter into a combination of forward purchase commitments and futures contracts to acquire or hedge aluminum, based on the scheduled deliveries. The futures contracts are designated as and accounted for as cash flow hedges. These contracts involve elements of credit and market risk that are not reflected on our balance sheet, including the risk of dealing with counterparties and their ability to meet the terms of the contracts. The counterparties to our forward purchase commitments are major aluminum brokers and suppliers, and the counterparties to our futures contracts are major financial institutions. Fixed-price forward sales contracts are only made available to our best and most credit-worthy customers. The amount of aluminum futures contracts that hedged fixed-price forward sales contracts was $11,253 (14,410 pounds of aluminum) at December 31, 2004, and $8,137 (12,210 pounds of aluminum) at December 31, 2003.

                We use interest rate swaps to manage interest rate exposure. There were no interest rate swaps outstanding at December 31, 2004 and 2003. Interest rate swaps outstanding during 2003 and 2002 (there were none outstanding in 2004) were designated as and accounted for as cash flow hedges (see Note 8). Counterparties to our interest rate swaps consisted of large major financial institutions.

                After-tax gains of $1,230 in 2004 and $395 in 2003 and after-tax losses of $1,512 in 2002, were reclassified from other comprehensive income to earnings and were offset by losses or gains, respectively, from transactions relating to the underlying hedged item. As of December 31, 2004, we expect $884 of unrealized after-tax gains on derivative instruments reported in accumulated other comprehensive income to be reclassified to earnings within the next twelve months. We also expect that these gains will be offset by losses from transactions relating to the underlying hedged item.


58



7              ACCRUED EXPENSES

 
                Accrued expenses consist of the following:
 

December 31 2004   2003  

Payrolls, related taxes and medical and
    other benefits
    $ 7,946   $ 12,830  
Workmen’s compensation and disabilities       3,806     3,566  
Vacation       4,560     4,435  
Plant shutdowns and divestitures       8,485     5,192  
Other       13,344     16,433  

    Total     $ 38,141   $ 42,456  

 
                A reconciliation of the beginning and ending balances of accrued expenses associated with plant shutdowns and divestitures for each of the three years in the period ended December 31, 2004 is as follows:
 

Severance   Asset
Impairments
  Accelerated
Depreciation*
  Other   Total  

 Balance at December 31, 2001 $ 538   $   $   $ 4,385   $ 4,923  
 2002:
    Charges   826     1,457         1,601     3,884  
    Cash spent   (893 )           (4,952 )   (5,845 )
    Charged against assets       (1,457 )           (1,457 )
    Reversed to income   (97 )               (97 )

 Balance at December 31, 2002   374             1,034     1,408  
 2003:
    Charges   5,505     1,051     1,733     3,137     11,426  
    Cash spent   (3,773 )           (1,085 )   (4,858 )
    Charged against assets       (1,051 )   (1,733 )       (2,784 )
    Reversed to income                    

 Balance at December 31, 2003   2,106             3,086     5,192  
 2004:
    Charges   6,456     11,554     2,572     2,450     23,032  
    Cash spent   (3,732 )           (2,112 )   (5,844 )
    Charged against assets       (11,554 )   (2,572 )       (14,126 )
    Foreign currency translation   261                 261  
    Reversed to income               (30 )   (30 )

 Balance at December 31, 2004 $ 5,091   $   $   $ 3,394   $ 8,485  

   
* Represents depreciation accelerated due to plant shutdowns based on a remaining useful life of less than one year.
 
See Note 15 for more information on plant shutdowns, asset impairments and restructurings.

59



8              DEBT AND CREDIT AGREEMENTS

 
                On October 17, 2003, we refinanced our debt with a new $250,000 credit agreement (the “Credit Agreement”) consisting of a $175,000 three-year revolving credit facility and a $75,000 three-year term loan. The amount available under the revolving credit facility was reduced by $50,000 (from $175,000 to $125,000) in the first quarter of 2004 upon the receipt of the approximately $55,000 in income tax recoveries related to the sale of the venture capital portfolio (see Note 17). At December 31, 2004, available credit under the revolving credit facility was approximately $91,000. Total debt due and outstanding at December 31, 2004 is summarized below:
 

Debt Due and Outstanding at December 31, 2004

  Credit Agreement
         
Year
Due
    Revolver   Term
Loan
  Other   Total Debt
Due
 

   2005      $   $ 13,125   $   $ 13,125  
   2006        33,000     51,250     4,637     88,887  
   2007                361     361  
   2008                264     264  
   2009                269     269  
 Remainder               546     546  

   Total     $ 33,000   $ 64,375   $ 6,077   $ 103,452  

 
                 The credit spread over LIBOR and commitment fees charged on the unused amount under the credit agreement at various indebtedness-to-adjusted EBITDA levels are as follows:
 

Pricing Under Credit Agreement (Basis Points)

      Credit Spread Over LIBOR
     
Indebtedness-to-
Adjusted EBITDA
Ratio
Revolver
($33 Million
Outstanding
at 12/31/04)
  Term Loan
($64 Million
Outstanding
at 12/31/04)
  Commitment
Fee
 

> 2x but <= 3x       150     150     30  
> 1x but <= 2x       125     125     25  
<= 1x       100     100     20  

 

                At December 31, 2004 and 2003, we had no interest rate swaps outstanding and the interest cost on debt was priced at one-month LIBOR plus the applicable credit spread of 125 basis points.

                The most restrictive covenants in the Credit Agreement include:

 
Maximum aggregate dividends over the term of the Credit Agreement of $100,000;
 
Minimum shareholders’ equity ($344,248 as of December 31, 2004);
 
Maximum indebtedness-to-adjusted EBITDA of 3x (2.5x on a pro forma basis for acquisitions); and
 
Minimum adjusted EBIT-to-interest expense of 2.5x.
 

                We believe we were in compliance with all of our debt covenants as of December 31, 2004. Noncompliance with any one or more of the debt covenants may have an adverse effect on financial condition or liquidity in the event such noncompliance cannot be cured or should we be unable to obtain a waiver from the lenders. Renegotiation of the covenant through an amendment to the credit agreement may effectively cure the noncompliance, but may have an effect on financial condition or liquidity depending upon how the covenant is renegotiated.

                On April 27, 2001, we entered into a two-year interest rate swap agreement, with a notional amount of $50,000, under which we paid to a counterparty a fixed interest rate of 4.85% and the counterparty paid us a variable interest rate based on one-month LIBOR reset each month. This swap was designated as and accounted for as a cash flow hedge. It effectively fixed the rate on $50,000 of our $250,000 term loan then outstanding at 4.85% plus the applicable credit spread (generally 62.5 basis points at that time).


60



 

                On June 22, 2001, we entered into another two-year interest rate swap agreement, with a notional amount of $25,000, under which we paid to a counterparty a fixed interest rate of 4.64% and the counterparty paid us a variable interest rate based on one-month LIBOR reset each month. This swap was designated as and accounted for as a cash flow hedge. It effectively fixed the rate on $25,000 of our $250,000 term loan then outstanding at 4.64% plus the applicable credit spread (generally 62.5 basis points at that time).

 
9              SHAREHOLDER RIGHTS AGREEMENT

 

                Pursuant to a Rights Agreement dated as of June 30, 1999 (as amended), between Tredegar and National City Bank as Rights Agent, one Right is attendant to each share of our common stock. Each Right entitles the registered holder to purchase from Tredegar one one-hundredth of a share of Participating Cumulative Preferred Stock, Series A (the “Preferred Stock”), at an exercise price of $150 (the “Purchase Price”). The Rights will become exercisable, if not earlier redeemed, only if a person or group acquires 10% or more of the outstanding shares of our common stock or announces a tender offer which would result in ownership by a person or group of 10% or more of our common stock. Any action by a person or group whose beneficial ownership is reported on Amendment No. 4 to the Schedule 13D filed with respect to Tredegar on May 20, 1997, cannot cause the Rights to become exercisable.

                Each holder of a Right, upon the occurrence of certain events, will become entitled to receive, upon exercise and payment of the Purchase Price, Preferred Stock (or in certain circumstances, cash, property or other securities of Tredegar or a potential acquirer) having a value equal to twice the amount of the Purchase Price.

                The Rights will expire on June 30, 2009.


61



10           STOCK OPTION AND STOCK AWARD PLANS

 
                We have two stock option plans under which stock options may be granted to purchase a specified number of shares of common stock at a price no lower than the fair market value on the date of grant and for a term not to exceed 10 years. One of those option plans is a directors’ stock plan. In addition, we have three other stock option plans under which there are options that remain outstanding, but no future grants can be made. Employee options ordinarily vest one to two years from the date of grant. The outstanding options granted to directors vest over three years. The option plans also permit the grant of stock appreciation rights (“SARs”), stock, restricted stock, stock unit awards and incentive awards. No SARs have been granted since 1992. All SARs outstanding at December 31, 2001, were exercised during 2002.

                A summary of our stock options outstanding at December 31, 2004, 2003 and 2002, and changes during those years, is presented below:

 

      Option Exercise Price/Share
 
  Number of Shares  
 
 
        Wgted.  
  Options
  SARs
  Range
    Ave.  

Outstanding at 12/31/01   2,877,020     104,100   $ 2.70   to   $ 46.63   $ 18.94  
Granted in 2002   624,500         14.56   to     18.90     18.74  
Lapsed in 2002   (57,150 )       18.90   to     21.50     19.36  
Exercised in 2002   (283,490 )   (104,100 )   2.70   to     23.13     4.87  

Outstanding at 12/31/02   3,160,880         3.37   to     46.63     20.16  
Granted in 2003   15,000         16.19   to     16.57     16.44  
Lapsed in 2003   (179,970 )       16.55   to     46.63     24.75  
Exercised in 2003   (273,300 )       3.37   to     8.38     4.68  

Outstanding at 12/31/03   2,722,610         3.37   to     46.63     21.39  
Granted in 2004   348,425         13.95   to     14.50     13.97  
Lapsed in 2004   (102,175 )       7.38   to     46.63     23.28  
Exercised in 2004   (306,870 )       3.37   to     19.75     6.99  

Outstanding at 12/31/04   2,661,990       $ 4.17   to   $ 46.63   $ 22.01  

 

               The following table summarizes additional information about stock options outstanding and exercisable at December 31, 2004:

 

    Options Outstanding at
December 31, 2004
  Options Exercisable at
December 31, 2004
   
 
          Weighted Average          
         
         
Range of
Exercise Prices
  Shares     Remaining
Contract-
ual Life
(Years)
  Exercise
Price
  Shares   Weighted
Average
Exercise
Price
 

$ 4.17   to   $ 9.67   199,735     1.0   $ 7.81     199,735   $ 7.81  
  9.68   to     17.88   617,650     4.6     15.12     272,050     16.45  
  17.89   to     19.75   831,600     3.1     19.22     831,600     19.22  
  19.76   to     25.65   401,650     1.7     22.95     401,650     22.95  
  25.66   to     34.97   347,355     1.6     31.52     347,355     31.52  
  34.98   to     46.63   264,000     1.0     43.72     264,000     43.72  

$ 4.17   to   $ 46.63   2,661,990     2.7   $ 22.01     2,316,390   $ 23.19  

 

                Stock options exercisable totaled 2,127,610 shares at December 31, 2003 and 2,556,980 shares at December 31, 2002. Stock options available for grant totaled 2,030,300 shares at December 31, 2004, 642,625 shares at December 31, 2003 and 618,125 shares at December 31, 2002.

                During the first quarter of 2004, we also granted 125,000 shares of restricted Tredegar common stock to senior management (5,000 shares were cancelled when an employee left the company prior to vesting). The price on the date of grant was $13.95 per share, and compensation expense of approximately $1,674 is being amortized over the vesting period of five years, subject to accelerated vesting based on meeting certain financial targets.


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11           RETIREMENT PLANS AND OTHER POSTRETIREMENT BENEFITS


 

                We have noncontributory and contributory defined benefit (pension) plans covering most employees. The plans for salaried and hourly employees currently in effect are based on a formula using the participant’s years of service and compensation or using the participant’s years of service and a dollar amount.

                In addition to providing pension benefits, we provide postretirement life insurance and health care benefits for certain groups of employees. Tredegar and retirees share in the cost of postretirement health care benefits, with employees retiring after July 1, 1993, receiving a fixed subsidy to cover a portion of their health care premiums. On December 8, 2003, the Medicare Prescription Drug Improvement and Modernization Act of 2003 (the “Act”) was signed into law. We believe our prescription drug benefits are not actuarially equivalent to the Act and therefore do not expect that any federal subsidies will apply.

                 Assumptions used for financial reporting purposes to compute net benefit income or cost and benefit obligations, and the components of net periodic benefit income or cost, are as follows:

 

  Pension Benefits     Other Post-
Retirement Benefits
 
   
  2004   2003   2002   2004   2003   2002  

Weighted-average assumptions used
    to determine benefit obligations:
                        
    Discount rate   6.00 %   6.25 %   6.75 %   6.00 %   6.25 %   6.75 %
    Rate of compensation increases   4.00 %   4.00 %   4.50 %   4.00 %   4.00 %   4.50 %
Weighted-average assumptions used
    to determine net periodic benefit
    cost:
                                   
    Discount rate   6.25 %   6.75 %   7.25 %   6.25 %   6.75 %   7.25 %
    Rate of compensation increases   4.00 %   4.50 %   5.00 %   4.00 %   4.50 %   5.00 %
    Expected long-term return on
       plan assets, during the year
  8.40 %   8.60 %   9.00 %   n/a     n/a     n/a  
Rate of increase in per-capita cost
    of covered health care benefits:
                                   
    Indemnity plans, end of year   n/a     n/a     n/a     6.00 %   6.00 %   6.00 %
    Managed care plans, end of year   n/a     n/a     n/a     6.00 %   6.00 %   6.00 %
Components of net periodic benefit
    income (cost):
                                   
    Service cost $ (5,519 ) $ (5,851 ) $ (4,397 ) $ (115 ) $ (101 ) $ (103 )
    Interest cost   (12,283 )   (11,842 )   (11,680 )   (562 )   (584 )   (578 )
    Employee contributions   443     323     220              
    Other   (212 )   (98 )   (87 )            
    Expected return on plan assets   22,678     23,003     23,701              
    Amortization of:                                  
       Net transition asset   7     8     20              
       Prior service costs and gains
           or losses
  (491 )   (89 )   1,941     53     43     64  

    Net periodic benefit income (cost) $ 4,623   $ 5,454   $ 9,718   $ (624 ) $ (642 ) $ (617 )


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                The following tables reconcile the changes in benefit obligations and plan assets in 2004 and 2003, and reconcile the funded status to prepaid or accrued cost at December 31, 2004 and 2003:

 

  Pension Benefits   Other Post-
Retirement Benefits
 
 
  2004   2003   2004   2003  

Change in benefit obligation:                
    Benefit obligation, beginning of year $ 196,460   $ 179,118   $ 9,440   $ 8,994  
    Service cost   5,519     5,851     115     101  
    Interest cost   12,283     11,842     562     584  
    Plan amendments   88     263          
    Effect of discount rate change   6,997     12,621     377     522  
    Employee contributions   443     323          
    Other   2,087     (4,368 )   25     (318 )
    Benefits paid   (9,840 )   (9,190 )   (525 )   (443 )

    Benefit obligation, end of year $ 214,037   $ 196,460   $ 9,994   $ 9,440  

Change in plan assets:                        
    Plan assets at fair value,
       beginning of year
$ 233,759   $ 208,473   $   $  
    Actual return on plan assets   22,428     32,270          
    Employee contributions   443     323          
    Employer contributions   830     1,982     525     443  
    Other   (115 )   (99 )        
    Benefits paid   (9,840 )   (9,190 )   (525 )   (443 )

    Plan assets at fair value, end of year $ 247,505   $ 233,759   $   $  

Reconciliation of prepaid (accrued) cost:                        
    Funded status of the plans $ 33,468   $ 37,300   $ (9,993 ) $ (9,440 )
    Unrecognized net transition
       (asset) obligation
      (8 )        
    Unrecognized prior service cost   3,421     3,689          
    Unrecognized net (gain) loss   44,859     34,994     (20 )   (448 )

    Prepaid (accrued) cost, end of year $ 81,748   $ 75,975   $ (10,013 ) $ (9,888 )

Amounts recognized in the consolidated
    balance sheets:
                       
    Prepaid benefit cost $ 81,748   $ 75,975   $   $  
    Accrued benefit liability   (3,000 )   (2,650 )   (10,013 )   (9,888 )
    Intangible asset   1,222     1,296          
    Deferred tax liability   622     474          
    Accumulated other comprehensive
       loss
  1,156     880          

Net amount recognized $ 81,748   $ 75,975   $ (10,013 ) $ (9,888 )

 

                Net benefit income or cost is determined using assumptions at the beginning of each year. Funded status is determined using assumptions at the end of each year.

                At December 31, 2004, the effect of a 1% change in the health care cost trend rate assumptions would be immaterial.


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                Expected benefit payments over the next five years and in the aggregate for 2010-2014 are as follows:
 

Years Pension
Benefits
  Other
Post-
Retirement
Benefits
 

2005 $ 9,404   $ 489  
2006   9,763     510  
2007   10,123     534  
2008   10,966     559  
2009   11,654     594  
2010 - 2014   69,713     3,384  

 

                Prepaid pension cost of $81,748 at December 31, 2004 and $75,975 at December 31, 2003, is included in “Other assets and deferred charges” in the consolidated balance sheets. The accrued benefit liability of $3,000 and the intangible asset of $1,222 at December 31, 2004, and the accrued benefit liability of $2,650 and the intangible asset of $1,296 at December 31, 2003, are also included in “Other assets and deferred charges” in the consolidated balance sheets. Accrued postretirement benefit cost of $10,013 at December 31, 2004 and $9,888 at December 31, 2003, is included in “Other noncurrent liabilities” in the consolidated balance sheets.

                The percentage composition of assets held by pension plans at December 31, 2004 and 2003, and the current expected long-term return on assets are as follows:

 

December 31 % Composition
of Plan Assets
Expected
Long-term
Return %

2004   2003

Pension plans related to operations in the U.S.:      
     Low-risk fixed income securities 18.1 % 23.3 % 5.3 %

     Large capitalization equity securities 19.6   18.7   9.0  
     Mid-capitalization equity securities 7.3   6.6   9.3  
     Small-capitalization equity securities 4.1   3.4   10.2  
     International equity securities 19.1   17.6   10.2  

     Total equity securities 50.1   46.3   9.6  

     Hedge and private equity funds 20.9   20.1   9.3  
     Other assets 2.5   2.6   4.0  

     Total for pension plans related to operations in the U.S. 91.6   92.3   8.5  

Pension plans related to operations in Canada 8.4   7.7   7.0  

Total 100.0 % 100.0 % 8.4 %

 

                Our targeted allocation percentage for pension plan assets is in the range of the percentage composition that existed at December 31, 2004. Expected long-term returns are estimated by asset class and generally are based on inflation-adjusted historical returns, volatilities and risk premiums. For pension plans related to operations in the U.S., the portfolio of fixed income securities is structured with maturities that generally match estimated benefit payments over the next five years. We believe that over the long term a diversified portfolio of equity securities, hedge funds and private equity funds have a better risk-return profile than fixed income securities. The average remaining duration of benefit payments for our pension plans is about 14 years. We expect our required contributions to be about $600 in 2005.

                The accumulated benefit obligation was $196,715 at December 31, 2004 and $180,432 at December 31, 2003. The projected benefit obligation, accumulated benefit obligation and fair value of plan assets for plans with accumulated benefit obligations in excess of plan assets were $10,132, $10,132 and $8,199, respectively, at December 31, 2004, and $8,753, $8,753 and $6,409, respectively, at December 31, 2003.


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                We also have a non-qualified supplemental pension plan covering certain employees. The plan is designed to restore all or a part of the pension benefits that would have been payable to designated participants from our principal pension plans if it were not for limitations imposed by income tax regulations. The projected benefit obligation relating to this unfunded plan was $2,081 at December 31, 2004 and $2,197 at December 31, 2003. Pension expense recognized was $275 in 2004, $249 in 2003 and $255 in 2002. This information has been included in the preceding pension benefit tables.

12           SAVINGS PLAN


 

                We have a savings plan that allows eligible employees to voluntarily contribute a percentage (generally 10%) of their compensation. Under the provisions of the plan, we match a portion (generally 50%) of the employee’s contribution to the plan with shares of our common stock. We also have a non-qualified plan that restores matching benefits for employees suspended from the savings plan due to certain limitations imposed by income tax regulations. Charges recognized for these plans were $2,716 in 2004, $2,697 in 2003 and $2,573 in 2002. Our liability under the restoration plan was $1,288 at December 31, 2004 (consisting of 63,730 phantom shares of common stock) and $1,057 at December 31, 2003 (consisting of 68,068 phantom shares of common stock) valued at the closing market price on those dates.

                The Tredegar Corporation Benefits Plan Trust (the “Trust”) purchased 7,200 shares of our common stock in 1998 for $192 and 46,671 shares of our common stock in 1997 for $1,020, as a partial hedge against the phantom shares held in the restoration plan. There have been no shares purchased since 1997 except for re-invested dividends. The cost of the shares held by the Trust is shown as a reduction to shareholders’ equity in the consolidated balance sheets.

13           RENTAL EXPENSE AND CONTRACTUAL COMMITMENTS


 
                Rental expense for continuing operations was $4,549 in 2004, $3,822 in 2003 and $3,744 in 2002. Rental commitments under all non-cancelable operating leases as of December 31, 2004, are as follows:
 

Year Amount  

2005 $ 2,925  
2006   2,847  
2007   2,717  
2008   2,488  
2009   1,760  
Remainder   2,645  

Total $ 15,382  

 

                Therics has future rental commitments under noncancelable operating leases through 2011 (most of which contain sublease options) totaling $9,663. These future rental commitments are included in the above table. Sublease rental commitments relating to excess space at Therics total about $1,000 (excluded from the above table).

                Contractual obligations for plant construction and purchases of real property and equipment amounted to $16,108 at December 31, 2004 and $7,726 at December 31, 2003.


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14           INCOME TAXES

 
                Income from continuing operations before income taxes and income taxes are as follows:
 

2004   2003   2002  

Income from continuing operations before income taxes:            
    Domestic $ 27,875   $ 16,605   $ 61,850  
    Foreign   7,607     13,439     13,656  

      Total $ 35,482   $ 30,044   $ 75,506  

Current income taxes:                  
    Federal $ (2 ) $ 4,345   $ (430 )
    State   1,105     368     1,318  
    Foreign   6,996     2,689     1,954  

      Total   8,099     7,402     2,842  

Deferred income taxes:                  
    Federal   3,385     649     20,421  
    State   1,198     936     943  
    Foreign   (3,460 )   1,730     2,675  

      Total   1,123     3,315     24,039  

      Total income taxes $ 9,222   $ 10,717   $ 26,881  

 
                The significant differences between the U.S. federal statutory rate and the effective income tax rate for continuing operations are as follows:
 

Percent of Income Before Income
Taxes for Continuing Operations
 
 
2004   2003   2002  

Income tax expense at federal statutory rate 35.0   35.0   35.0  
State taxes, net of federal income tax benefit 4.2   2.8   1.9  
Unremitted earnings from foreign operations (.1 ) 1.5   (.6 )
Non-deductible expenses .8   1.0   .3  
Research and development tax credit (1.9 ) (1.7 ) (.5 )
Extraterritorial Income Exclusion (2.3 ) (2.8 ) (.8 )
Reversal of income tax contingency accruals (11.3 )    
Foreign rate differences and other 1.6   (.1 ) .3  

    Effective income tax rate 26.0   35.7   35.6  


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                Deferred tax liabilities and deferred tax assets at December 31, 2004 and 2003, are as follows:
 

December 31       2004     2003  

Deferred tax liabilities:                
                 
    Depreciation     $ 37,057   $ 32,317  
    Pensions       29,885     26,434  
    Foreign currency translation gain adjustment       10,619     5,494  
    Amortization of goodwill       7,975     3,750  
    Unrealized gain on available-for-sale securities           1,556  
    Income on derivative financial instruments       497     249  
    Inventory           194  
    Other       779     3,911  

        Total deferred tax liabilities       86,812     73,905  

Deferred tax assets:                
    Employee benefits       5,810     5,028  
    Tax benefit on U.S. foreign and R&D tax credits and
        NOL carryforwards
      10,979     7,052  
    Asset write-offs, divestitures and environmental
        accruals
      4,547     2,148  
    Allowance for doubtful accounts and sales returns       1,119     1,254  
    Tax in excess of book basis for venture capital
        investments
      638     902  
    Inventory       131      
    Other       2,628     2,243  

        Total deferred tax assets       25,852     18,627  

Net deferred tax liability     $ 60,960   $ 55,278  

Included in the balance sheet:                
    Noncurrent deferred tax liabilities in excess of assets     $ 71,141   $ 66,276  
    Current deferred tax assets in excess of liabilities       10,181     10,998  

        Net deferred tax liability     $ 60,960   $ 55,278  

 
                As of December 31, 2004, Tredegar had net operating loss, foreign tax credit and R&D tax credit carry- forwards in the U.S. that expire as follows:
 

U.S. Tax Carry-Forward Items at December 31, 2004 by Year of Expiration  

      Deferred Income Tax Assets   Estimated Minimum Future Taxable
Income Required to Realize Deferred
Income Tax Assets
 
     
 
Year of
Expiration
      Foreign
Tax
Credits
   

R&D Tax
Credits

   

Net
Operating
Losses

    Total    

Foreign
Tax
Credits

   

R&D Tax
Credits

   

Net
Operating
Losses

    Total  

2012     $ 1,209   $   $   $ 1,209   $ 3,454   $   $   $ 3,454  
2013       1,555             1,555     4,443             4,443  
2014       2,818             2,818     8,051             8,051  
2021           1,403         1,403         4,009         4,009  
2022           1,185         1,185         3,386         3,386  
2023           690     1,429     2,119         1,971     4,083     6,054  
2024           690         690         1,971         1,971  

Total     $ 5,582   $ 3,968   $ 1,429   $ 10,979   $ 15,948   $ 11,337   $ 4,083   $ 31,368  

 
                We believe that it is more likely than not that the timing of future taxable income in the U.S. will be sufficient to cover future tax deductible amounts related to the deferred income tax assets shown in the table above. Accordingly, no valuation allowance has been recognized for these items. However, a valuation allowance of approximately $600,000 is included in other deferred tax assets that offsets an amount included in that line item relating to possible future tax benefits on operating losses generated in 2004 by certain foreign subsidiaries that may not be recoverable in the carryforward period.

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15            LOSSES ASSOCIATED WITH PLANT SHUTDOWNS, ASSET IMPAIRMENTS AND RESTRUCTURINGS, UNUSUAL ITEMS, GAINS FROM SALE OF ASSETS AND OTHER ITEMS

 

                Losses associated with plant shutdowns, asset impairments and restructurings in 2004 totaled $23,032 ($15,192 after taxes) and include:

 
A fourth quarter charge of $84 ($56 after taxes), a third-quarter charge of $828 ($537 after taxes), a second-quarter charge of $994 ($647 after taxes) and a first-quarter charge of $666 ($432 after taxes) related to accelerated depreciation from plant shutdowns and restructurings in Film Products;
 
A fourth-quarter charge of $569 (of this amount, $59 for employee relocation is included in selling, general and administrative expenses in the consolidated statements of income) ($369 after taxes) and a third-quarter charge of $709 ($461 after taxes) related to severance for 30 people and other employee-related costs associated with the restructuring of the R&D operations in Film Products (we anticipate recognizing additional charges associated with this restructuring over the next 12 months of approximately $2,800 ($1,820 after taxes)), including costs associated with relocating R&D functions to Richmond, Virginia;
 
A fourth-quarter charge of $639 ($415 after taxes), a third-quarter charge of $617 ($401 after taxes), a second-quarter charge of $300 ($195 after taxes) and a first-quarter charge of $537 ($349 after taxes) primarily related to severance (63 people) and other employee-related costs associated with the shutdown of the films manufacturing facility in New Bern, North Carolina (the “New Bern Plant”) (the shut down was completed in the fourth quarter of 2004);
 
A third-quarter charge of $357 ($329 after taxes) and a second-quarter charge of $2,665 ($1,858 after taxes) for the loss on the sale of the films business in Argentina (proceeds net of transaction costs were $803 ($401 net of cash included in business sold));
 
A fourth-quarter charge of $352 ($228 after taxes), a third-quarter charge of $195 ($127 after taxes) and a first-quarter charge of $9,580 ($6,228 after taxes) related to the planned shutdown of an aluminum extrusions facility in Aurora, Ontario (the “Aurora Plant”), including asset impairment charges of $7,130 and severance and other employee-related costs of $2,450 (these costs are contractually-related for about 100 people and have been immediately accrued and we anticipate recognizing additional shutdown-related costs of about $2,000 in the first quarter of 2005);
 
A third-quarter charge of $170 ($111 after taxes) for additional costs incurred related to a plant shutdown in Film Products;
 
A second-quarter charge of $300 ($195 after taxes), partially offset by a fourth-quarter gain of $104 ($68 after taxes), related to the loss on the sale of the previously shutdown films manufacturing facility in Manchester, Iowa (the “Manchester Plant”);
 
A fourth quarter charge of $427 ($277 after taxes) and a second-quarter charge of $879 ($571 after taxes) related to the estimated loss on the sub-lease of a portion of the Therics facility in Princeton, New Jersey;
 
Second-quarter charges of $575 ($374 after taxes) in Film Products and $146 ($95 after taxes) in Aluminum Extrusions related to asset impairments; and
 
Fourth quarter charges of $1,402 ($912 after taxes) related to severance and other employee-related costs associated with restructurings in Therics ($590 before taxes), Film Products ($532 before taxes) and Aluminum Extrusions ($280 before taxes) and a second-quarter charge of $145 ($94 after taxes) related to severance at Therics (an aggregate of 24 people were affected by these restructurings).
 

                Gain on sale of corporate assets in 2004 includes a fourth-quarter gain on the sale of land of $1,013 ($649 after taxes and proceeds of $1,271), a second-quarter gain on the sale of land of $413 ($268 after taxes and proceeds of $647) and a first-quarter gain on the sale of public equity securities of $6,134 ($3,987 after taxes and proceeds of $7,182). There were no public equity securities held at December 31, 2004. These gains are included in “Other income (expense), net” in the consolidated statements of income and separately shown in the operating profit by segment table in Note 3.

                Income taxes in 2004 include a third-quarter tax benefit of $4,000 related to the reversal of income tax contingency accruals upon the favorable conclusion of IRS and state examinations through 2000.


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                The other gain of $7,316 ($4,756 after taxes) included in the Aluminum Extrusions section of the operating profit by segment table in Note 3 is comprised of the present value of an insurance settlement of $8,357 (future value of $8,455) associated with environmental matters related to prior years, partially offset by accruals for expected future environmental costs of $1,041. The company received $5,143 of the $8,455 insurance settlement in September of 2004 and recognized receivables at present value for future amounts due ($1,497 due in February of 2005 and $1,717 due in February 2006). The gain from the insurance settlement is included in “Other income (expense), net” in the consolidated statements of income, while the accruals for expected future environmental costs are included in “Cost of goods sold.”

                In 2003, losses associated with plant shutdowns, asset impairments and restructurings totaling $11,426 ($7,350 after taxes) included:

 
A fourth-quarter charge of $875 ($560 after taxes) for asset impairments in the films business, including charges of $466 ($298 after taxes) relating to accelerated depreciation of assets at the New Bern Plant;
 
A fourth-quarter charge of $611 ($391 after taxes) for approximately 50% of the total severance costs for 63 people and other employee-related costs in connection with the shutdown of the New Bern Plant;
 
A third-quarter charge of $945 ($605 after taxes) relating to accelerated depreciation of assets at the New Bern Plant;
 
A third-quarter charge of $299, a second quarter charge of $53 and a first-quarter charge of $85 (collectively $280 after taxes) for additional costs incurred related to the shutdown of the films plants in Tacoma, Washington (the “Tacoma Plant”), Carbondale, Pennsylvania (the “Carbondale Plant”) and the Manchester Plant;
 
A third-quarter charge of $322 ($206 after taxes) for additional severance and other employee-related costs in connection with a previously announced restructuring in Film Products;
 
A third-quarter charge of $2,151 ($1,398 after taxes) and a second-quarter charge of $549 ($357 after taxes) related to the estimated loss on the sub-lease of a portion of the Therics facility in Princeton, New Jersey;
 
A third-quarter charge of $256 ($163 after taxes) for severance for seven people and other employee-related costs in connection with restructurings in Aluminum Extrusions;
 
A second-quarter charge of $3,936 ($2,530 after taxes) for severance for 47 people and other employee-related costs in connection with restructurings in Film Products ($1,600 before taxes), corporate headquarters ($1,181 before taxes and included in “Corporate expenses, net” in the operating profit by segment table in Note 3) and Therics ($1,155 before taxes);
 
A second-quarter charge of $956 ($612 after taxes) for asset impairments in the films business, including charges of $312 ($200 after taxes) related to accelerated depreciation of assets at the New Bern Plant; and
 
A second-quarter charge of $388 ($248 after taxes) related to an early retirement program for 10 people in Aluminum Extrusions.
 

                The loss from unusual items in 2003 of $1,067 ($694 after taxes) relates to a first-quarter charge to adjust depreciation and amortization at Therics based on Tredegar’s decision to suspend divestiture efforts. Results for 2003 also included a fourth-quarter gain of $1,385 ($886 after taxes) on the sale of land at the facility in Richmond Hill, Ontario (total proceeds of approximately $1,800), and gains totaling $5,155 ($3,325 after taxes) on the sale of corporate assets. The gains from the sale of corporate assets included:

 
A fourth-quarter gain of $2,554 ($1,647 after taxes) from the sale of 547,500 shares of Illumina, Inc. common stock (NASDAQ: ILMN) for total proceeds of $3,791; 
 
A fourth-quarter gain of $355 ($229 after taxes) from the sale of 64,150 shares of Vascular Solutions, Inc. common stock (NASDAQ: VASC) for total proceeds of $403;
 
A third-quarter gain of $942 ($608 after taxes) from the sale of 200,000 shares of VASC for total proceeds of $1,092; and
 
A third-quarter gain of $1,289 and fourth-quarter gain of $15 (collectively $841 after taxes) from the sale of corporate real estate (total proceeds of approximately $1,800).
 

                The gains from the sale of land and corporate assets are included in “Other income (expense), net” in the consolidated statements of income and separately shown in the segment operating profit table in Note 3.

                At December 31, 2003, we held 265,955 shares of ILMN with a closing aggregate market value of $1,875 ($601 adjusted cost basis), and held 596,492 shares of VASC with a closing aggregate market value of $3,501 ($447 adjusted cost basis). These holdings, which are included in the consolidated balance sheets in “Other assets and deferred charges” at December 31, 2003, are stated at market value with unrealized gains reported directly in shareholders’ equity net of related deferred income taxes.


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                In 2002, losses associated with plant shutdowns, asset impairments and restructurings totaling $3,884 ($2,486 after taxes) primarily included:

 
A fourth-quarter charge of $1,457 ($932 after taxes) for asset impairments in the films business;
 
A fourth-quarter charge of $392 ($251 after taxes) for additional costs incurred related to the 2000 shutdown of the Manchester Plant;
 
A fourth-quarter charge of $318 ($204 after taxes) for additional costs incurred related to the shutdown of the aluminum extrusions plant in El Campo, Texas (the “El Campo Plant”);
 
A fourth-quarter charge of $259 ($166 after taxes) for additional costs incurred related to the shutdown of the Tacoma Plant;
 
A third-quarter charge of $178 ($114 after taxes) primarily for relocation and employee-related costs in connection with the shutdown of the Carbondale Plant;
 
A second-quarter charge of $268 ($172 after taxes) primarily for relocation and employee-related costs in connection with the shutdown of the Tacoma Plant;
 
A first-quarter charge of $800 ($512 after taxes) for severance for approximately 70 people and other employee-related costs in connection with the shutdown of the Carbondale Plant; and
 
A first-quarter charge of $196 ($125 after taxes) for costs incurred in the transfer of business related to the shutdown of the El Campo Plant.
 

                In 2002, the gain from unusual items (net) totaling $6,147 ($3,934 after taxes) included:

 
A fourth-quarter net gain of $5,618 ($3,596 after taxes) for payments received from P&G related to terminations and revisions to contracts of $11,718 and related asset write-downs of $6,100; and
 
A fourth-quarter gain of $529 ($338 after taxes) related to the sale of assets acquired in a prior acquisition.
 
16           CONTINGENCIES

 

                We are involved in various stages of investigation and remediation relating to environmental matters at certain plant locations. Where we have determined the nature and scope of any required environmental remediation activity, estimates of cleanup costs have been obtained and accrued. As we continue efforts to maintain compliance with applicable environmental laws and regulations, additional contingencies may be identified. If additional contingencies are identified, our practice is to determine the nature and scope of those contingencies, obtain and accrue estimates of the cost of remediation, and perform remediation. We do not believe that additional costs that could arise from those activities will have a material adverse effect on our financial position. However, those costs could have a material adverse effect on quarterly or annual operating results at that time.

                We are involved in various other legal actions arising in the normal course of business. After taking into consideration legal counsels’ evaluation of these actions, we believe that we have sufficiently accrued for probable losses and that the actions will not have a material adverse effect on our financial position. However, the resolution of the actions in a future period could have a material adverse effect on quarterly or annual operating results at that time.

                From time to time, we enter into transactions with third parties in connection with the sale of assets or businesses in which we agree to indemnify the buyers or third parties involved in the sale for certain liabilities or risks related to the assets or business. Also, in the ordinary course of our business, we may enter into agreements with third parties for the sale of goods or services that may contain indemnification provisions. In the event that an indemnification claim is asserted, liability for indemnification would be subject to an assessment of the underlying facts and circumstances under the terms of the applicable agreement. Further, any indemnification payments may be limited or barred by a monetary cap, a time limitation, or a deductible or basket. For these reasons, we are unable to estimate the maximum potential amount of the potential future liability under the indemnity provisions of these agreements. We do, however, accrue for losses for any known contingent liability, including those that may arise from indemnification provisions, when future payment is probable. We disclose contingent liabilities if the probability of loss is reasonably possible and significant.


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17           DISCONTINUED OPERATIONS


 

                On March 7, 2003, Tredegar Investments, Inc. (“Tredegar Investments”) reached definitive agreements to sell substantially all of its portfolio of private equity partnership interests to GS Vintage Funds II, which are investment partnerships managed by Goldman Sachs Asset Management’s Private Equity Group. On the same date and in a separate transaction, Tredegar Investments also agreed to sell to W Capital Partners, an independent private equity manager, the subsidiary funds that hold substantially all of Tredegar Investments’ direct venture capital investments. The sale of these fund interests included the assumption by the buyer of Tredegar Investments’ obligations to make additional capital contributions to those funds in the future.

                The sale to W Capital Partners of the subsidiary funds that hold the direct investments occurred on March 7, 2003. The sale of the private equity fund interests occurred in a series of closings.

                Net proceeds from the sales totaled $21,504. Additionally, in the first quarter of 2004 we received income tax recoveries of approximately $55,000 from the carry-back of 2003 capital losses generated by these sales against gains realized in 2000 by Tredegar Investments.

                The agreements governing these transactions contain customary contingent indemnification provisions that Tredegar believes will not have a material effect on its financial position or results of operations.

                The operating results associated with venture capital investment activities have been reported as discontinued operations.


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                A summary of venture capital investment activities from 2002 through disposal in 2003 is provided below:
 

  (In Thousands)  
  2003   2002  

Carrying value of venture capital investments,        
    beginning of period $ 93,765   $ 155,084  
Venture capital investment activity for period:            
    (pre-tax amounts):            
    New investments   2,807     20,373  
    Proceeds from the sale of investments, including
       broker receivables at end of period   (21,504 )   (8,918 )
    Realized gains       4,454  
    Realized losses, write-offs and write-downs   (70,256 )   (65,154 )
    (Decrease) increase in unrealized gain on
       available-for-sale securities   (917 )   (12,074 )
    Carrying value of public securities retained by
       Tredegar Investments*   (3,895 )    

Carrying value of venture capital investments,            
    end of period $   $ 93,765  

Summary of amounts reported as discontinued            
operations in the consolidated statements of            
income:            
    Pretax gains (losses), net $ (70,256 ) $ (60,700 )
    Operating expenses (primarily management fee            
       expenses)   (599 )   (5,594 )

    Loss before income taxes   (70,855 )   (66,294 )
    Income tax benefits   24,286     23,866  

    Loss from venture capital investment activities $ (46,569 ) $ (42,428 )

   
* At December 31, 2003, Tredegar Investments held 596,492 shares of Vascular Solutions, Inc. (NASDAQ: VASC) and 265,955 shares of Illumina, Inc. (NASDAQ: ILMN). These securities, which were related to Tredegar Investments’ earlier venture capital investment activities, were sold in 2004 for $7,182, including gains recognized of $6,134 ($3,987 after taxes). At December 31, 2003, these securities were classified as available-for-sale, included in the consolidated balance sheets in “Other assets and deferred charges” ($5,376 market value) and stated at market value with unrealized gains reported directly in shareholders' equity net of related deferred income taxes.
 

                Loss from venture capital investment activities in 2003 of $70,855 ($46,569 after taxes) includes a loss on the sale of $70,256 ($46,269 after taxes). Discontinued operations in 2004 include an after-tax gain associated with venture capital investment activities of $2,921 primarily related to the reversal of business and occupancy tax contingency accruals upon favorable resolution.

                On July 2, 2002, the operations at Molecumetics ceased. The operating results of Molecumetics have been reported as discontinued operations. For the year ended December 31, 2002, operating losses for Molecumetics were $5,928 ($3,853 after taxes), while revenues were $515. Discontinued operations also include a gain of $1,393 ($891 after taxes) in 2003 on the sale of intellectual property of Molecumetics and a charge of $7,500 ($4,875 after taxes) in 2002 for the loss on the disposal of Molecumetics. This charge is comprised of an impairment loss for assets of $4,860, severance and other employee related costs of $1,390 and miscellaneous disposal costs of $1,250. The tangible assets were sold during the fourth quarter of 2002 for proceeds of $800.

                Cash flows for discontinued operations have not been separately disclosed in the accompanying statement of cash flows.


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SELECTED QUARTERLY FINANCIAL DATA

 
Tredegar Corporation and Subsidiaries
(In thousands, except per-share amounts)
(Unaudited)
 

First
Quarter
  Second
Quarter
  Third
Quarter
  Fourth
Quarter
  Year  

2004                              

 Sales $ 195,919   $ 216,053   $ 222,515   $ 226,678   $ 861,165  
 Gross profit   27,348     33,102     31,669     29,528     121,647  
 Income from continuing operations   2,429     5,179     15,292     3,360     26,260  
 Income (loss) from discontinued operations               2,921     2,921  

 Net income (loss)   2,429     5,179     15,292     6,281     29,181  
 Earnings (loss) per share:                              
       Basic:                              
          Continuing operations   .06     .14     .40     .09     .69  
          Discontinued operations               .08     .08  

          Net income (loss)   .06   .14   .40   .17     .77  
       Diluted:                              
          Continuing operations   .06     .14     .40     .09     .68  
          Discontinued operations               .07     .08  

          Net income (loss)   .06   .14   .40   .16     .76  
 Shares used to compute earnings (loss) per share                            
       Basic   38,229     38,235     38,317     38,398     38,295  
       Diluted   38,435     38,427     38,519     38,655     38,507  

2003    

 Sales $ 182,045   $ 181,574   $ 193,125   $ 181,907   $ 738,651  
 Gross profit   28,356     27,206     30,798     27,492     113,852  
 Income from continuing operations   4,859     1,681     6,419     6,368     19,327  
 Income (loss) from discontinued operations   (49,516 )   891         2,947     (45,678 )

 Net income (loss)   (44,657 ) 2,572   6,419     9,315     (26,351 )
 Earnings (loss) per share:
       Basic:                              
          Continuing operations   .13     .04     .17     .17     .51  
          Discontinued operations   (1.30 )   .02         .08     (1.20 )

          Net income (loss)   (1.17 ) .06   .17   .25     (.69 )
       Diluted:                              
          Continuing operations   .12     .04     .17     .17     .50  
          Discontinued operations   (1.28 )   .02         .07     (1.19 )

          Net income (loss)   (1.16 ) .06   .17   .24     (.69 )
 Shares used to compute earnings (loss) per share                            
       Basic   38,179     38,047     38,058     38,101     38,096  
       Diluted   38,578     38,418     38,383     38,389     38,441  


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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.

 
  TREDEGAR CORPORATION
(Registrant)
     
Dated:  March 15, 2005 By /s/ N. A. Scher
   
    Norman A. Scher
     
    President and Chief Executive Officer
 

                Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed below by the following persons on behalf of the registrant and in the capacities indicated on March 15, 2005.

 
Signature   Title

 
 
/s/ John D. Gottwald   Chairman of the Board of Directors

   
    (John D. Gottwald)    
     
/s/ N. A. Scher   President, Chief Executive Officer and Director
(Principal Executive Officer)

 
    (Norman A. Scher)  
     
/s/ D. Andrew Edwards   Vice President, Chief Financial Officer and Treasurer
(Principal Financial and Accounting Officer)

 
    (D. Andrew Edwards)  
     
/s/ Austin Brockenbrough, III   Director

   
    (Austin Brockenbrough, III)    
     
/s/ Phyllis Cothran   Director

   
    (Phyllis Cothran)    
     
/s/ Donald T. Cowles   Director

   
    (Donald T. Cowles)    
     
/s/ R. W. Goodrum   Director

   
    (R. W. Goodrum)    
     
/s/ Floyd D. Gottwald, Jr.   Director

   
    (Floyd D. Gottwald, Jr.)    
     

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/s/ William M. Gottwald   Director

   
    (William M. Gottwald)    
     
/s/ Richard L. Morrill   Director

   
    (Richard L. Morrill)    
     
/s/ Thomas G. Slater, Jr.   Director

   
    (Thomas G. Slater, Jr.)    
     
/s/ R. Gregory Williams   Director

   
    (R. Gregory Williams)    

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EXHIBIT INDEX

 
3.1 Amended and Restated Articles of Incorporation of Tredegar (previously filed as Exhibit 3.1 to Tredegar’s Quarterly Report on Form 10-Q for the quarter ended June 30, 1989, and refiled herewith)
 
3.2 Amended By-laws of Tredegar (filed as Exhibit 3 to Tredegar’s Quarterly Report on Form 10-Q for the quarter ended June 30, 2003, and incorporated herein by reference)
 
3.3 Articles of Amendment (previously filed as Exhibit 3.3 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1999, and refiled herewith)
 
4.1 Form of Common Stock Certificate (previously filed as Exhibit 4.3 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1989, and refiled herewith)
 
4.2 Rights Agreement, dated as of June 30, 1999, by and between Tredegar and American Stock Transfer & Trust Company, as Rights Agent (previously filed as Exhibit 99.1 to the Registration Statement on Form 8-A, filed June 16, 1999, as amended, and refiled herewith)
 
4.2.1 Amendment and Substitution Agreement (Rights Agreement) dated as of December 11, 2002, by and among Tredegar, American Stock Transfer and Trust Company and National City Bank (filed as Exhibit 4.2.1 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 2002, and incorporated herein by reference).
 
4.3 Credit Agreement, dated as of October 17, 2003, by and among Tredegar Corporation, as borrower, its domestic subsidiaries, as guarantors, and the lenders (Wachovia Bank National Association, as administrative agent, SunTrust Bank, as syndication agent, and Bank of America, N.A., as documentation agent) (filed as Exhibit 4 to Tredegar’s Quarterly Report on Form 10-Q for the quarter ended September 30, 2003, and incorporated herein by reference)
 
10.1 Reorganization and Distribution Agreement dated as of June 1, 1989, between Tredegar and Ethyl (previously filed as Exhibit 10.1 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1989, and refiled herewith)
 
*10.2 Employee Benefits Agreement dated as of June 1, 1989, between Tredegar and Ethyl (previously filed as Exhibit 10.2 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1989, and refiled herewith)
 
10.3 Tax Sharing Agreement dated as of June 1, 1989, between Tredegar and Ethyl (previously filed as Exhibit 10.3 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1989, and refiled herewith)
 
10.4 Indemnification Agreement dated as of June 1, 1989, between Tredegar and Ethyl (previously filed as Exhibit 10.5 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1989, and refiled herewith)
 
*10.5 Tredegar 1989 Incentive Stock Option Plan (previously included as Exhibit A to the Prospectus contained in the Form S-8 Registration Statement No. 33-31047, and refiled herewith)
 
*10.5.1 Amendment to the Tredegar 1989 Incentive Stock Option Plan (previously filed as Exhibit 10.5.1 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1998, and refiled herewith)
 
*10.6 Tredegar 1992 Omnibus Stock Incentive Plan (previously filed as Exhibit 10.12 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1991, and refiled herewith)
 
*10.6.1 Amendment to the Tredegar 1992 Omnibus Incentive Plan (previously filed as Exhibit 10.7.1 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1998, and refiled herewith)
   
*10.7 Tredegar Industries, Inc. Retirement Benefit Restoration Plan (previously filed as Exhibit 10.13 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1993, and refiled herewith)
 
*10.7.1 Amendment to the Tredegar Retirement Benefit Restoration Plan (previously filed as Exhibit 10.8.1 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1998, and refiled herewith)
   
*10.8 Tredegar Industries, Inc. Savings Plan Benefit Restoration Plan (previously filed as Exhibit 10.14 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1993, and refiled herewith)
 
*10.8.1 Resolutions of the Executive Committee of the Board of Directors of Tredegar Corporation adopted on December 28, 2004 (effective as of December 31, 2004) amending the Tredegar Corporation Retirement Savings Plan Benefit Restoration Plan (filed as Exhibit 10.9.1 to Tredegar’s Current Report on Form 8-K, filed on December 30, 2004, and incorporated herein by reference)

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*10.9 Tredegar Industries, Inc. Amended and Restated Incentive Plan (previously included as Exhibit 99.2 to the Form S-8 Registration Statement No. 333-88177, filed on September 30, 1999, and incorporated herein by reference)
 
*10.10 Consulting Agreement made as of April 1, 2000 between Tredegar and Richard W. Goodrum (filed as Exhibit 10 to Tredegar’s Quarterly Report on Form 10-Q for the quarter ended June 30, 2000, and incorporated herein by reference)
 
*10.11 Tredegar Industries, Inc. Directors’ Stock Plan (previously filed as Exhibit 10.12 to Tredegar’s Annual Report on Form 10-K for the year ended December 31, 1998, and refiled herewith)
 
*10.12 Tredegar Corporation’s 2004 Equity Incentive Plan (filed as Exhibit 10.13 to the Form S-8 Registration Statement No. 333-115423, filed on May 12, 2004 (incorporating from the Annex to Tredegar Corporation’s Definitive Proxy Statement on Schedule 14A filed on March 4, 2004 (No. 1-10258) and incorporated herein by reference)
 
*10.13 Summary of Compensation for the President and Chief Executive Officer and each of the Named Executive Officers for Fiscal 2005 (filed as Item 1.01 to Tredegar’s Current Report on Form 8-K, filed on February 8, 2005, and incorporated herein by reference)
 
*10.14 Description of Cash Incentive Plan for fiscal 2005 (filed as Item 1.01 to Tredegar’s Current Report on Form 8-K, filed on December 16, 2004, and incorporated herein by reference)
   
*10.15 Summary of Director Compensation for Fiscal 2005
   
21 Subsidiaries of Tredegar
   
23.1 Consent of Independent Registered Public Accounting Firm
   
31.1 Section 302 Certification of Principal Executive Officer
   
31.2  Section 302 Certification of Principal Financial Officer
   
32.1 Section 906 Certification of Principal Executive Officer
   
32.2 Section 906 Certification of Principal Financial Officer
   
*  Denotes compensatory plans or arrangements or management contracts.

78