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Table of Contents

SECURITIES AND EXCHANGE COMMISSION

Washington, D.C. 20549

 


 

FORM 10-Q

 


 

x Quarterly Report Pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934

 

For the quarterly period ended July 31, 2004

 

¨ Transition Report Pursuant to Section 13 or 15(d) of the Securities Exchange Act of 1934

 

Commission File Number 000-22791

 


 

COLLINS & AIKMAN FLOORCOVERINGS, INC.

(Exact name of registrant as specified in its charter)

 


 

Delaware   58-2151061

(State or other jurisdiction of

incorporation or organization)

 

(IRS Employer

Identification No.)

311 Smith Industrial Boulevard, Dalton, Georgia   30721
(Address of principal executive offices)   (Zip Code)

 

Registrant’s telephone number: (706) 259-9711

 


 

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

 

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 of 1934 during the preceding 12 months (or for such shorter period that the Registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days.    Yes  x    No  ¨.

 

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

 

The Registrant has 1,000 shares of Common Stock, par value $.01 per share, issued and outstanding as of September 10, 2004.

 



Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

 

INDEX

 

               Page No.

Part I.

  

Financial Information

    
     Item 1.   

Financial Statements

    
         

Consolidated Balance Sheets – As of January 31, 2004 and July 31, 2004

   3
         

Consolidated Statements of Income – Thirteen Weeks and Twenty-Six Weeks Ended July 26, 2003 and July 31, 2004

   4
         

Consolidated Statements of Stockholder’s Equity – Twenty-Six Weeks Ended July 31, 2004

   5
         

Consolidated Statements of Cash Flows – Twenty-Six Weeks Ended July 26, 2003 and July 31, 2004

   6
         

Notes to Consolidated Financial Statements

   7
     Item 2.   

Management’s Discussion and Analysis of Financial Condition and Results of Operations

   25
     Item 3.   

Quantitative and Qualitative Disclosures About Market Risk

   33
     Item 4.   

Controls and Procedures

   33

Part II.

  

Other Information

    
     Item 1.   

Legal Proceedings

   33
     Item 6.   

Exhibits and Reports on Form 8-K

   34

Signature

   35

 

2


Table of Contents

PART 1 – FINANCIAL INFORMATION

 

Item 1. Financial Statements

 

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

CONSOLIDATED BALANCE SHEETS

(In Thousands)

 

     January 31,
2004


   

July 31,

2004


 
           (Unaudited)  
ASSETS                 

CURRENT ASSETS:

                

Cash and cash equivalents

   $ 11,041     $ 10,024  

Accounts receivable, net of allowances of $918 and $856 in fiscal 2003 and 2004, respectively

     36,019       51,269  

Inventories

     35,463       43,916  

Deferred tax assets

     4,013       4,850  

Prepaid expenses and other

     4,961       2,449  
    


 


Total current assets

     91,497       112,508  

PROPERTY, PLANT AND EQUIPMENT, net

     66,062       64,243  

GOODWILL

     98,378       98,378  

OTHER INTANGIBLE ASSETS, net

     34,255       32,722  

OTHER ASSETS

     8,956       8,562  
    


 


TOTAL ASSETS

   $ 299,148     $ 316,413  
    


 


LIABILITIES AND STOCKHOLDER’S EQUITY                 

CURRENT LIABILITIES:

                

Accounts payable

   $ 17,722     $ 19,464  

Accrued expenses

     20,298       29,177  

Current portion of long-term debt

     1,791       1,553  
    


 


Total current liabilities

     39,811       50,194  

OTHER LIABILITIES, including post-retirement benefit obligation

     4,768       4,306  

DEFERRED TAX LIABILITIES

     19       1,615  

LONG-TERM DEBT, net of current portion

     207,516       206,121  

MINORITY INTEREST

     342       320  

COMMITMENTS AND CONTINGENCIES

                

STOCKHOLDER’S EQUITY:

                

Common stock; $.01 par value per share, 1,000 shares authorized, issued, and outstanding in fiscal 2003 and 2004

     —         —    

Paid-in capital

     72,648       72,648  

Retained deficit

     (24,509 )     (17,313 )

Accumulated other comprehensive loss:

                

Foreign currency translation adjustment

     (493 )     (524 )

Minimum pension liability adjustment, net of tax

     (954 )     (954 )
    


 


Total stockholder’s equity

     46,692       53,857  
    


 


TOTAL LIABILITIES AND STOCKHOLDER’S EQUITY

   $ 299,148     $ 316,413  
    


 


 

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

 

3


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF INCOME

(Unaudited and In Thousands)

 

    

Thirteen Weeks

Ended


  

Twenty-Six Weeks

Ended


 
     July 26,
2003


   July 31,
2004


   July 26,
2003


  

July 31,

2004


 

NET SALES

   $ 93,931    $ 99,602    $ 165,500    $ 177,287  
    

  

  

  


COST OF GOODS SOLD

     59,169      60,567      107,501      111,983  

SELLING, GENERAL & ADMINISTRATIVE EXPENSES

     19,452      20,130      36,910      41,134  

AMORTIZATION

     1,528      765      3,056      1,531  
    

  

  

  


OPERATING EXPENSES

     80,149      81,462      147,467      154,648  
    

  

  

  


OPERATING INCOME

     13,782      18,140      18,033      22,639  

MINORITY INTEREST IN INCOME (LOSS) OF SUBSIDIARY

     32      14      16      (22 )

EQUITY IN EARNINGS OF AFFILIATE

     326      365      687      776  

NET INTEREST EXPENSE

     5,199      5,150      10,605      10,273  
    

  

  

  


INCOME BEFORE INCOME TAXES

     8,877      13,341      8,099      13,164  

INCOME TAX EXPENSE

     3,799      5,390      3,118      5,968  
    

  

  

  


NET INCOME

   $ 5,078    $ 7,951    $ 4,981    $ 7,196  
    

  

  

  


 

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

 

4


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF STOCKHOLDER’S EQUITY

FOR THE TWENTY-SIX WEEKS ENDED JULY 31, 2004

(Unaudited and In Thousands, Except Share Amounts)

 

     Common Stock

  

Paid - in

Capital


  

Retained
Earnings

(Deficit)


   

Accumulated Other

Comprehensive

Income (Loss)


   

Total


 
     Shares

   Amount

       

Foreign Currency

Translation
Adjustment


   

Minimum

Pension

Liability


   

BALANCE, January 31, 2004

   1,000    $ —      $ 72,648    $ (24,509 )   $ (493 )   $ (954 )   $ 46,692  
    
  

  

  


 


 


 


Net income

   —        —        —        7,196       —         —         7,196  

Foreign currency translation Adjustment

   —        —        —        —         (31 )     —         (31 )
    
  

  

  


 


 


 


Total Comprehensive Income (Loss)

   —        —        —        7,196       (31 )     —         7,165  
    
  

  

  


 


 


 


BALANCE, July 31, 2004

   1,000    $ —      $ 72,648    $ (17,313 )   $ (524 )   $ (954 )   $ 53,857  
    
  

  

  


 


 


 


 

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

 

5


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF CASH FLOWS

(Unaudited and In Thousands)

 

    

Twenty-Six Weeks

Ended


 
     July 26,
2003


    July 31,
2004


 

CASH FLOWS FROM OPERATING ACTIVITIES:

                

Net income

   $ 4,981     $ 7,196  
    


 


Adjustments to reconcile net income to net cash provided by operating activities:

                

Depreciation and leasehold amortization

     5,024       5,119  

Amortization of other intangible assets

     3,056       1,531  

Amortization and write-off of deferred financing fees

     630       840  

Change in deferred income tax

     (616 )     759  

Equity in earnings of affiliate

     (687 )     (776 )

Minority interest in income (loss) of subsidiary

     16       (22 )

Changes in operating assets and liabilities:

                

Accounts receivable

     (13,726 )     (15,250 )

Inventories

     (8,830 )     (8,453 )

Accounts payable

     6,193       1,742  

Accrued expenses

     7,010       8,879  

Other, net

     (683 )     1,695  
    


 


Total adjustments

     (2,613 )     (3,936 )
    


 


Net cash provided by operating activities

     2,368       3,260  
    


 


CASH FLOWS FROM INVESTING ACTIVITIES:

                

Equity distribution from affiliate

     2,282       922  

Additions to property, plant, and equipment

     (4,130 )     (3,411 )
    


 


Net cash used in investing activities

     (1,848 )     (2,489 )
    


 


CASH FLOWS FROM FINANCING ACTIVITIES:

                

Proceeds from revolving credit facility

     3,500       15,280  

Repayments of revolving credit facility

     (3,500 )     (15,280 )

Repayments of long-term debt

     (11,130 )     (1,573 )

Cash dividends to Tandus Group, Inc.

     (2,263 )     —    

Financing costs

     (18 )     (237 )
    


 


Net cash used in financing activities

     (13,411 )     (1,810 )
    


 


EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

     318       22  
    


 


NET CHANGE IN CASH AND CASH EQUIVALENTS

     (12,573 )     (1,017 )

CASH AND CASH EQUIVALENTS, beginning of period

     20,907       11,041  
    


 


CASH AND CASH EQUIVALENTS, end of period

   $ 8,334     $ 10,024  
    


 


 

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

 

6


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

1. General

 

The accompanying unaudited consolidated financial statements have been prepared in accordance with accounting principles generally accepted in the United States for interim financial information and the instructions to Form 10-Q and Rule 10-01 of Regulation S-X. Accordingly, they do not include all of the information and footnotes required by accounting principles generally accepted in the United States for complete financial statements. These consolidated financial statements should be read in conjunction with the audited consolidated financial statements and related notes thereto included in the Company’s Form 10-K for the year ended January 31, 2004, which was filed in May 2004 with the Securities and Exchange Commission. The accompanying unaudited consolidated financial statements, in the opinion of management, include all adjustments necessary for fair presentation. All such adjustments are of a normal and recurring nature.

 

2. Organization

 

Based on annual sales and product brands, Collins & Aikman Floorcoverings, Inc. (the “Company”), a Delaware corporation, is a leading manufacturer of floorcovering products for the North American specified commercial carpet market. The Company’s floorcovering products include (i) vinyl-backed six-foot roll carpet and modular carpet tile, and (ii) high style tufted and woven broadloom carpet. The Company designs, manufactures and markets its C&A, Monterey and Crossley brands for a wide variety of end markets, including corporate offices, education, healthcare, government facilities and retail stores. The ability to provide a “package of product offerings” in various forms, coupled with flexible distribution channels, allows the Company to provide a wide array of floorcovering solutions tailored for each of its customers. The Company is headquartered in Georgia, with additional locations in California, Canada, the United Kingdom, Singapore and China.

 

The Company is a wholly owned subsidiary of Tandus Group, Inc. (“Tandus Group”). Subsequent to a recapitalization transaction on January 25, 2001, investment funds managed by Oaktree Capital Management, LLC (“Oaktree”) and Banc of America Capital Investors (“BACI”) control a majority of the outstanding capital stock of Tandus Group.

 

3. Reclassifications

 

Certain prior period amounts have been reclassified to conform to the current period’s presentation.

 

4. Cash and Cash Equivalents

 

Cash and cash equivalents include all cash balances and investments with an original maturity of three months or less.

 

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Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

5. Inventories

 

Net inventory balances are summarized below (in thousands):

 

     January 31,
2004


  

July 31,

2004


          (Unaudited)

Raw materials

   $ 16,074    $ 21,942

Work in process

     5,153      7,458

Finished goods

     14,236      14,516
    

  

     $ 35,463    $ 43,916
    

  

 

6. Revenue Recognition

 

Revenue is recognized when goods are shipped, which is when legal title passes to the customer. For product installations subject to customer approval, revenue is recognized upon acceptance by the customer. The Company provides certain installation services to customers utilizing independent third-party contractors. The billings and expenses for these services are included in net sales and cost of goods sold, respectively. These billings and expenses were $6.0 million and $5.7 million for the twenty-six weeks ended July 31, 2004 and July 26, 2003, respectively, and $3.5 million and $3.4 million for the thirteen weeks ended July 31, 2004 and July 26, 2003, respectively.

 

A customer claims reserve and allowance for product returns is established based upon historical claims experience as a percent of gross sales. The allowance for customer claims is recorded upon shipment of goods and is recorded as a reduction of sales. While we believe the customer claims reserve and allowance for product returns is adequate and the judgment applied is appropriate based upon historical experience for these items, actual amounts determined to be due and payable could differ and additional allowances may be required.

 

7. Accrued Expenses

 

Accrued expenses are summarized below (in thousands):

 

     January 31,
2004


  

July 31,

2004


          (Unaudited)

Payroll and employee benefits

   $ 5,952    $ 8,385

Accrued taxes

     —        5,068

Customer claims

     2,206      2,716

Accrued interest

     8,145      8,172

Accrued professional fees

     2,862      3,197

Other

     1,133      1,639
    

  

     $ 20,298    $ 29,177
    

  

 

8


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

8. Goodwill and Other Intangible Assets

 

The Company adopted the provisions of Statement of Financial Accounting Standard No. 142, “Goodwill and Other Intangible Assets” (“SFAS No. 142”) on January 27, 2002.

 

The gross carrying amount and accumulated amortization of the intangible assets subject to amortization as of July 31, 2004 are as follows:

 

     July 31, 2004

 
     Gross Carrying
Amount


   Accumulated
Amortization


 

Amortized intangible assets:

               

Non-compete

   $ 12,000    $ (12,000 )

Patent

     27,000      (18,383 )

Supply Agreement

     8,000      (7,508 )
    

  


Total

   $ 47,000    $ (37,891 )
    

  


 

The Company’s non-compete with its former parent was being amortized over a seven-year period using the double-declining balance method and was fully amortized as of January 31, 2004. The patent is being amortized over an eleven-year period using the straight-line method. The supply agreement is being amortized over a three-year period using the straight-line method. In the fourth quarter of fiscal 2003, CAF Extrusion, Inc. (“Extrusion”), a wholly-owned subsidiary, recorded a non-cash impairment charge of $1.6 million, net of tax, related to the supply agreement with the seller. The impairment charge was to reduce the net carrying value of the supply agreement to its fair value.

 

Unamortized intangible assets:

      

Trade name

   $ 23,613
    

 

    

Thirteen Weeks

Ended


  

Twenty-Six Weeks

Ended


    

July 26,

2003


  

July 31,

2004


  

July 26,

2003


  

July 31,

2004


Aggregate amortization expense

   $ 1,528    $ 765    $ 3,056    $ 1,531
    

  

  

  

 

Estimated amortization expense:

      

Fiscal 2004

   $ 3,090

Fiscal 2005

   $ 2,639

Fiscal 2006

   $ 2,450

Fiscal 2007

   $ 2,455

Fiscal 2008

   $ —  

 

For the period ended July 31, 2004, there were no changes to the carrying value of goodwill.

 

9


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

9. Stock Based Compensation

 

As of July 31, 2004, the Company had one stock-based employee compensation plan, which is described more fully in Note 13 of the audited consolidated financial statements included in the Company’s Form 10-K for the year ended January 31, 2004, which was filed in May 2004 with the Securities and Exchange Commission. The Company accounts for this plan under the recognition and measurement principles of APB Opinion No. 25, “Accounting for Stock Issued to Employees,” and related interpretations. The Company accounts for these options as variable options and records expense based on increases and decreases in the fair market value of the Company’s common stock at the end of each reporting period. These options vest only upon the achievement of certain earnings targets, as defined. As of July 31, 2004 and July 26, 2003, the Company had not recorded any expense related to this plan as the Company had not achieved its earnings targets, and the fair market value of the Company’s common stock has not increased from the date of grant. The following table illustrates the effect on net income if the Company had applied the fair value recognition provisions of Financial Accounting Standards Board (“FASB”) Statement No. 123, “Accounting for Stock-Based Compensation,” to the stock-based employee compensation (in thousands).

 

    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
    

July 26,

2003


   

July 31,

2004


   

July 26,

2003


   

July 31,

2004


 

Net income as reported

   $ 5,078     $ 7,951     $ 4,981     $ 7,196  

Deduct: Total stock-based employee compensation expense determined under the fair value based method for all awards, net of tax

     (7 )     (10 )     (15 )     (18 )
    


 


 


 


Proforma net income

   $ 5,071     $ 7,941     $ 4,966     $ 7,178  
    


 


 


 


 

10. Recent Accounting Pronouncements

 

In May 2003, the FASB issued Statement of Financial Accounting Standards No. 150, “Accounting for Certain Financial Instruments with Characteristics of Both Liabilities and Equity” (“SFAS No. 150”). SFAS No. 150 modifies the accounting for certain financial instruments, that under previous guidance could be accounted for as either a liability or equity, to require liability treatment for those instruments in a company’s statement of financial position. This statement is effective for our interim periods beginning after December 15, 2003. The adoption of SFAS 150 did not have an impact on our financial position, results of operations or cash flows.

 

In December 2003, the FASB issued SFAS No. 132 (revised 2003), “Employers’ Disclosure about Pensions and Other Postretirement Benefits, an amendment of FASB Statements No. 87, 88 and 106” (“SFAS No. 132”). The revision of SFAS No. 132 provides for additional disclosures including the description of the types of plan assets, investment strategy, measurement date(s), plan obligations, cash flows and components of net periodic benefit cost recognized in interim periods. The revision of SFAS No. 132 is effective for our consolidated financial statements as of January 31, 2004 and did not have an impact on our financial position, results of operations or cash flows.

 

11. Long-Term Debt

 

On August 18, 2004, the Company executed Amendment No. 3 (the “Amendment”) to its Senior Credit Facility. The Amendment provides for, among other things, 1) the transfer of certain of the broadloom manufacturing fixed assets located in Santa Ana, California to the Company’s facility located in Truro, Nova Scotia, 2) the disposal of and/or transfer to Collins & Aikman Floorcoverings, Inc. of substantially all of the remaining Santa Ana, California fixed assets and transfer all or substantially all of the accounts receivable, inventory and other liquid current assets from its Monterey Carpets, Inc. legal entity to Collins & Aikman Floorcoverings, Inc., 3) the release of Monterey Carpets as a subsidiary guarantor under the

 

10


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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

subsidiary guarantee agreement and the security agreement and any other loan documents to which it is a party, 4) the exclusion from the calculation of covenants of the costs incurred in connection with the consolidation of up to $10.0 million, and 5) the reduction of the credit spread to Libor plus 2.75 on the Term B Loan. The Amendment further authorizes the collateral agent to release any and all liens held by the collateral agent in or on the assets to be transferred from Santa Ana, California to Truro, Nova Scotia.

 

Effective May 1, 2004, the Company amended its Senior Credit Facility to revise certain covenants. The amended principal financial covenants are as follows:

 

     Q1

   Q2

   Q3

   Q4

   Thereafter

Fixed charge coverage ratio

   1.00:1.00    1.00:1.00    1.00:1.00    1.10:1.00    1.10:1.00

Interest coverage ratio

   1.75:1.00    1.75:1.00    1.85:1.00    2.00:1.00    2.25:1.00

 

The Company’s fixed charge coverage ratio and interest coverage ratio were 1.49:1.00 and 2.29:1.00, respectively, at July 31, 2004. As is customary in debt agreements, in the event the Company is not in compliance with the covenants of the Senior Credit Facility, the Company will also be subject to the provisions of a cross-default for the 9.75% Senior Subordinated Notes. The Company was in compliance with all covenants as of July 31, 2004 and expects to remain in compliance throughout fiscal 2004, although no assurances to that effect can be given.

 

Total net interest expense was $5.2 million and $5.2 million for the thirteen weeks ended July 31, 2004 and July 26, 2003, respectively, which included minimal interest income. Total net interest expense was $10.3 and $10.6 million for the twenty-six weeks ended July 31, 2004 and July 26, 2003, respectively, which included minimal interest income.

 

12. Segment Information

 

The Company has adopted SFAS No. 131, “Disclosures about Segments of an Enterprise and Related Information” (“SFAS No. 131”). This statement addresses reporting of operating segment information and disclosures about products, services, geographic areas, and major customers. Management has reviewed the requirements of SFAS No. 131 concluding that the Company operates its business as two reportable segments: Floorcoverings and Extrusion.

 

Accounting policies of the segments are the same as those described in the summary of significant accounting policies. Performance of the segments is evaluated on Adjusted EBITDA, which represents earnings before interest, taxes, depreciation and amortization plus Chroma cash dividends and minority interest in income (loss) of subsidiary, less equity in earnings of Chroma.

 

The Floorcoverings segment represents all floorcovering products. These products are six-foot roll carpet, modular carpet tile and tufted and woven broadloom carpet. The Extrusion segment represents the Company’s extrusion plant, which was acquired on May 8, 2002. Products in this segment are nylon and polypropylene extruded yarn.

 

No single customer amounted to or exceeded 10.0% of the Floorcovering segment’s sales for any period presented. The Extrusion segment’s largest customer accounted for 15.8% and 37.0% of sales and its second largest customer accounted for 10.2% and 10.3% of sales in the thirteen weeks and twenty-six weeks ended July 31, 2004, respectively.

 

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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

The table below provides certain financial information by segment (in thousands):

 

    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
    

July 26,

2003


   

July 31,

2004


   

July 26,

2003


   

July 31,

2004


 

Net Sales to External Customers

                                

Floorcoverings

   $ 86,743     $ 94,917     $ 150,540     $ 164,927  

Extrusion

     7,188       4,685       14,960       12,360  
    


 


 


 


Total Sales to External Customers

   $ 93,931     $ 99,602     $ 165,500     $ 177,287  
    


 


 


 


    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
     July 26,
2003


    July 31,
2004


    July 26,
2003


    July 31,
2004


 

Adjusted EBITDA

                                

Floorcoverings

   $ 16,881     $ 21,484     $ 25,662     $ 28,133  

Extrusion

     1,346       598       2,733       2,078  
    


 


 


 


Total Adjusted EBITDA

   $ 18,227     $ 22,082     $ 28,395     $ 30,211  
    


 


 


 


    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
     July 26,
2003


    July 31,
2004


    July 26,
2003


   

July 31,

2004


 

Net income

   $ 5,078     $ 7,951     $ 4,981     $ 7,196  

Income taxes

     3,799       5,390       3,118       5,968  

Net interest expense

     5,199       5,150       10,605       10,273  

Depreciation

     2,512       2,533       5,024       5,119  

Amortization

     1,528       765       3,056       1,531  

Chroma cash dividends

     405       644       2,282       922  

Equity in earnings in Chroma

     (326 )     (365 )     (687 )     (776 )

Minority interest in income (loss) of subsidiary

     32       14       16       (22 )
    


 


 


 


Adjusted EBITDA

   $ 18,227     $ 22,082     $ 28,395     $ 30,211  
    


 


 


 


 

    

As of

January 31,

2004


  

As of

July 31,

2004


Consolidated Assets

             

Floorcoverings

   $ 267,090    $ 287,470

Extrusion

     32,058      28,943
    

  

Total Consolidated Assets

   $ 299,148    $ 316,413
    

  

 

12


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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

13. Investment in Equity Affiliate

 

Monterey Color Systems, Inc., a wholly owned subsidiary of Monterey Carpets, Inc. (“Monterey Carpets”), has a fifty percent (50%) ownership interest in Chroma Systems Partners (“Chroma”), which operates a carpet dyeing and finishing plant. Because the Company does not exercise control over Chroma, the Company accounts for its interest in Chroma under the equity method of accounting. The unaudited condensed financial information of Chroma for the twenty-six weeks ended July 31, 2004 and July 26, 2003, and as of July 31, 2004 and January 31, 2004 are summarized below:

 

    

As of

January 31,

2004


  

As of
July 31,

2004


Current Assets

   $ 2,203    $ 2,094

Non-current Assets

     7,925      7,861
    

  

Total Assets

   $ 10,128    $ 9,955
    

  

Current Liabilities

   $ 1,517    $ 1,105

Long Term Debt

     8,513      8,420

Partners’ Capital

     98      430
    

  

Total Liabilities and Partners’ Capital

   $ 10,128    $ 9,955
    

  

 

    

Twenty-Six Weeks

Ended


    

July 26,

2003


   July 31,
2004


Net Sales

   $ 8,872    $ 10,172

Cost of Goods Sold

     7,004      8,100
    

  

Gross Profit

     1,868      2,072

Income From Operations

     1,412      1,573

Net Income

     1,338      1,477

 

On August 11, 2004, Monterey Carpets gave notice to The Dixie Group, Inc. (“Dixie”) that it has elected to terminate its supply arrangement with Chroma effective August, 2005. Chroma currently dyes and finishes substantially all of Monterey Carpets’ carpet production and Dixie’s Fabrica Division’s carpet production and performs dyeing and finishing operations for other carpet mills. Under the terms of the partnership agreement, Monterey Carpets’ decision will effectively give Dixie the option to acquire Monterey Carpets’ interest in the partnership for a nominal value and assume full control of Chroma’s operations when the supply agreement terminates.

 

14. Comprehensive Income

 

Comprehensive income is as follows (in thousands):

 

    

Thirteen Weeks

Ended


  

Twenty-Six Weeks

Ended


 
     July 26,
2003


   July 31,
2004


   July 26,
2003


   July 31,
2004


 

Net Income

   $ 5,078    $ 7,951    $ 4,981    $ 7,196  

Other Comprehensive Income (Loss): Foreign Currency Translation Adjustments

     245      21      660      (31 )
    

  

  

  


Comprehensive Income

   $ 5,323    $ 7,972    $ 5,641    $ 7,165  
    

  

  

  


 

13


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

15. Commitments & Contingencies

 

During March 2004, a jury found in favor of Employers Mutual Insurance Companies (“EMC”) related to alleged violations of express oral warranty and implied warranty of fitness for particular purpose and awarded damages totaling $0.8 million. The Company has accrued the full judgment amount of $0.8 million as of January 31, 2004. During the thirteen and twenty-six weeks ended July 31, 2004, the Company incurred approximately $0.0 million and $0.5 million, respectively, of legal expenses related to this lawsuit. The Company continues to deny liability and is evaluating its options, which include a motion for a new trial. If the Company pursues those options and is unsuccessful, it will be required to pay the full judgment amount and related legal and professional fees. Subsequent to the end of the second quarter of fiscal 2004, the judgment amount was reduced from $0.8 million to $0.6 million. However, the reduction may be appealed by EMC through September 20, 2004.

 

On August 10, 2004, the Company and its parent announced its intent to close its manufacturing facility in Santa Ana, California, and transfer the production to its existing Truro, Nova Scotia, Canada, facility. The plan to close the facility was approved on August 9, 2004, and is expected to be complete by the end of the Company’s first fiscal quarter in 2005. It is anticipated that there will be one-time costs of approximately $6.4 million consisting of severance, moving, reinstallation, professional fees and other costs. In addition the Company anticipates capital expenditures of approximately $2.8 million related to the move. No costs have been incurred or accrued as of July 31, 2004.

 

16. Employee Benefit Plans

 

The Company maintains a defined benefit program for its domestic employees, which was frozen during fiscal 2002. Accordingly, no new benefits are being accrued under the plan. Participant accounts are credited with interest at the rates defined by the plan. Company contributions are based on computations by independent actuaries, although the Company may decide to make additional contributions to the plan beyond minimum funding requirements as is deemed appropriate by management. Plan assets at July 31, 2004 and January 31, 2004 were invested primarily in mutual funds and money market funds.

 

Net periodic pension cost for the thirteen weeks and twenty-six weeks ended July 31, 2004 and July 26, 2003 was comprised of the following components:

 

    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
     July 26,
2003


    July 31,
2004


    July 26,
2003


   

July 31,

2004


 

Service cost – benefits earned during the period

   $ —       $ —       $ —       $ —    

Interest cost on projected benefit obligation

     (25 )     (136 )     145       137  

Expected return on plan assets

     23       65       (130 )     (181 )

Recognized net actuarial losses

     (12 )     (88 )     73       49  
    


 


 


 


Net periodic pension cost (benefit)

   $ (14 )   $ (159 )   $ 88     $ 5  
    


 


 


 


 

Employer contributions of $0.3 million and $0.2 million were made for the thirteen weeks ended July 31, 2004 and July 26, 2003, and $0.5 million and $0.5 million were made for the twenty-six weeks ended July 31, 2004 and July 26, 2003, respectively. There is no additional minimum employer contribution required for the remainder of fiscal 2004.

 

Canadian Defined Benefit Plan

 

Substantially all Canadian employees of Crossley Carpets Ltd. (“Crossley”) who meet eligibility requirements can participate in a defined benefit plan administered by the Company. Plan benefits are generally based on years of service and employees’ compensation during their years of employment. The Company’s policy is to contribute annually the maximum amount that can be deducted for income tax purposes. Assets of the pension plan are held in a trust invested primarily in mutual funds.

 

14


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Net periodic pension cost for the thirteen weeks and twenty-six weeks ended July 31, 2004 and July 26, 2003 was comprised of the following components:

 

    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
     July 26,
2003


    July 31,
2004


    July 26,
2003


   

July 31,

2004


 

Service cost – benefits earned during the period

   $ 166     $ 198     $ 199     $ 279  

Interest cost on projected benefit obligation

     152       128       182       202  

Expected return on plan assets

     (154 )     (145 )     (185 )     (220 )

Recognized net actuarial losses

     2       1       3       1  
    


 


 


 


Net periodic pension cost

   $ 166     $ 182     $ 199     $ 262  
    


 


 


 


 

Employer contributions for fiscal 2004 are dependent upon the amounts contributed by employees and were $0.1 million and $0.2 million for the thirteen weeks and twenty-six weeks ended July 31, 2004 and July 26, 2003, respectively. Company contributions are expected to be approximately $0.3 million in fiscal 2004.

 

Postretirement Benefit Plan

 

The Company provides a fixed dollar reimbursement for life and medical coverage for certain of the Company’s retirees (over age 65 with 10 years of service or more) under the plan currently in effect. The plan is unfunded.

 

Net periodic postretirement benefit costs for the thirteen weeks and twenty-six weeks ended July 31, 2004 and July 26, 2003 was comprised of the following components:

 

    

Thirteen Weeks

Ended


  

Twenty-Six Weeks

Ended


     July 26,
2003


   July 31,
2004


   July 26,
2003


  

July 31,

2004


Service cost – benefits earned during the period

   $ 56    $ 37    $ 80    $ 83

Interest cost on projected benefit obligation

     43      28      60      62
    

  

  

  

Net periodic postretirement benefit cost

   $ 99    $ 65    $ 140    $ 145
    

  

  

  

 

17. Condensed Consolidating Financial Statements

 

The 9.75% Notes of the Company are guaranteed by the Company’s domestic subsidiaries. Effective August 18, 2004, Monterey Carpets, Inc. was released as a guarantor. The guarantee of the guarantor subsidiaries is full and unconditional and joint and several and arose in conjunction with the Company’s issuance of the 9.75% Notes on February 20, 2002 and the $109 million Senior Credit Facility, which was amended by the Company on February 20, 2002, May 1, 2004 and August 18, 2004. The guarantees’ terms match the terms of the 9.75% Notes and the Senior Credit Facility. The maximum amount of future payments the guarantors would be required to make under the guarantees as of July 31, 2004 is $214.4 million. This represents the principal amount outstanding of the Company’s Senior Credit Facility, the 9.75% Notes and accrued interest on both obligations. The condensed consolidating financial information of the Company and its subsidiaries as of July 31, 2004 and January 31, 2004, and for each of the thirteen weeks and twenty-six weeks ended July 31, 2004 and July 26, 2003 are as follows:

 

15


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Balance Sheets

July 31, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


   Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


 

ASSETS

                                       

CURRENT ASSETS:

                                       

Cash and cash equivalents

   $ 6,290     $ —      $ 3,734     $ —       $ 10,024  

Accounts receivable, net

     33,056       11,218      6,995       —         51,269  

Inventories

     22,078       12,233      9,605       —         43,916  

Deferred tax assets

     3,290       859      701       —         4,850  

Prepaid expenses and other

     783       448      1,218       —         2,449  
    


 

  


 


 


Total current assets

     65,497       24,758      22,253       —         112,508  

PROPERTY, PLANT AND EQUIPMENT, net

     32,674       19,838      11,731       —         64,243  

DEFERRED TAX ASSETS

     —         2,225      1,871       (4,096 )     —    

GOODWILL

     62,386       35,992      —         —         98,378  

OTHER INTANGIBLE ASSETS, net

     32,230       492      —         —         32,722  

INVESTMENT IN SUBSIDIARIES

     71,059       —        —         (71,059 )     —    

OTHER ASSETS

     8,468       3      91       —         8,562  
    


 

  


 


 


TOTAL ASSETS

   $ 272,314     $ 83,308    $ 35,946     $ (75,155 )   $ 316,413  
    


 

  


 


 


LIABILITIES AND STOCKHOLDER’S EQUITY

                                       

CURRENT LIABILITIES:

                                       

Accounts payable

   $ 9,483     $ 5,400    $ 4,581     $ —       $ 19,464  

Accrued expenses

     18,506       7,666      3,005       —         29,177  

Current portion of long-term debt

     241       —        1,312       —         1,553  
    


 

  


 


 


Total current liabilities

     28,230       13,066      8,898       —         50,194  

INTERCOMPANY (RECEIVABLE) PAYABLE

     (25,715 )     1,586      24,129       —         —    

OTHER LIABILITES, including post- retirement obligation

     4,222       —        84       —         4,306  

DEFERRED TAX LIABILITES

     5,711       —        —         (4,096 )     1,615  

LONG-TERM DEBT, net of current portion

     206,009       —        112       —         206,121  

MINORITY INTEREST

     —         —        —         320       320  

STOCKHOLDER’S EQUITY

                                       

Preferred stock

     —         —        133       (133 )     —    

Common stock

     —         2,056      9,061       (11,117 )     —    

Paid-in capital

     72,648       49,699      2,365       (52,064 )     72,648  

Retained earnings (deficit)

     (17,313 )     16,901      (8,410 )     (8,491 )     (17,313 )

Accumulated other comprehensive loss

     (1,478 )     —        (426 )     426       (1,478 )
    


 

  


 


 


Total stockholders’ equity

     53,857       68,656      2,723       (71,379 )     53,857  
    


 

  


 


 


TOTAL LIABILITIES AND STOCKHOLDER’S EQUITY

   $ 272,314     $ 83,308    $ 35,946     $ (75,155 )   $ 316,413  
    


 

  


 


 


 

16


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Balance Sheets

January 31, 2004

 

(In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


   Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


 

ASSETS

                                       

CURRENT ASSETS:

                                       

Cash and cash equivalents

   $ 6,667     $ 106    $ 4,268     $ —       $ 11,041  

Accounts receivable, net

     18,443       10,882      6,694       —         36,019  

Inventories

     15,586       11,124      8,753       —         35,463  

Deferred tax assets

     2,677       633      703       —         4,013  

Prepaid expenses and other

     524       105      1,138       3,194       4,961  
    


 

  


 


 


Total current assets

     43,897       22,850      21,556       3,194       91,497  

PROPERTY, PLANT AND EQUIPMENT, net

     34,232       21,607      10,223       —         66,062  

DEFERRED TAX ASSETS

     —         2,250      1,876       (4,126 )     —    

GOODWILL

     62,386       35,992      —         —         98,378  

OTHER INTANGIBLE ASSETS, net

     33,435       820      —         —         34,255  

INVESTMENT IN SUBSIDIARIES

     71,335       —        —         (71,335 )     —    

OTHER ASSETS

     8,687       177      92       —         8,956  
    


 

  


 


 


TOTAL ASSETS

   $ 253,972     $ 83,696    $ 33,747     $ (72,267 )   $ 299,148  
    


 

  


 


 


LIABILITIES AND STOCKHOLDER’S EQUITY

                                       

CURRENT LIABILITIES:

                                       

Accounts payable

   $ 8,487     $ 5,751    $ 3,484     $ —       $ 17,722  

Accrued expenses

     8,260       6,096      2,748       3,194       20,298  

Current portion of long-term debt

     80       —        1,711       —         1,791  
    


 

  


 


 


Total current liabilities

     16,827       11,847      7,943       3,194       39,811  

INTERCOMPANY (RECEIVABLE) PAYABLE

     (24,520 )     4,585      19,935       —         —    

OTHER LIABILITIES, including post-retirement obligation

     4,667       —        101       —         4,768  

DEFERRED TAX LIABILITIES

     4,136       —        9       (4,126 )     19  

LONG-TERM DEBT, net of current portion

     206,170       —        1,346       —         207,516  

MINORITY INTEREST

     —         —        —         342       342  

STOCKHOLDER’S EQUITY:

                                       

Preferred stock

     —         —        133       (133 )     —    

Common stock

     —         2,056      9,061       (11,117 )     —    

Paid-in capital

     72,648       49,699      2,365       (52,064 )     72,648  

Retained earnings (deficit)

     (24,509 )     15,509      (6,751 )     (8,758 )     (24,509 )

Accumulated other comprehensive loss

     (1,447 )     —        (395 )     395       (1,447 )
    


 

  


 


 


Total stockholders’ equity

     46,692       67,264      4,413       (71,677 )     46,692  
    


 

  


 


 


TOTAL LIABILITIES AND STOCKHOLDER’S EQUITY

   $ 253,972     $ 83,696    $ 33,747     $ (72,267 )   $ 299,148  
    


 

  


 


 


 

17


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statements of Income

For the Thirteen Weeks Ended July 31, 2004

 

(Unaudited and In Thousands)

 

     Issuer

   Guarantor
Subsidiaries


   Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


Net Sales

   $ 72,161    $ 25,139    $ 13,773     $ (11,471 )   $ 99,602
    

  

  


 


 

Cost of Goods Sold

     40,999      19,663      11,376       (11,471 )     60,567

Selling, General & Administrative Expenses

     13,060      4,508      2,562       —         20,130

Amortization

     602      163      —         —         765
    

  

  


 


 

Operating Expenses

     54,661      24,334      13,938       (11,471 )     81,462
    

  

  


 


 

Operating Income

     17,500      805      (165 )     —         18,140

Minority Interest in Income of Subsidiary

     —        —        14       —         14

Equity in Earnings of Affiliate

     —        365      —         —         365

Equity in Earnings of Subsidiaries

     490      —        —         (490 )     —  

Net Interest Expense

     5,123      —        27       —         5,150
    

  

  


 


 

Income (Loss) Before Income Taxes

     12,867      1,170      (206 )     (490 )     13,341

Income Tax Expense

     4,916      456      18       —         5,390
    

  

  


 


 

Net Income (Loss)

   $ 7,951    $ 714    $ (224 )   $ (490 )   $ 7,951
    

  

  


 


 

 

18


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statement of Income

For the Thirteen Weeks Ended July 26, 2003

 

(Unaudited and In Thousands)

 

     Issuer

   Guarantor
Subsidiaries


   Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


Net Sales

   $ 64,962    $ 23,438    $ 11,831     $ (6,300 )   $ 93,931
    

  

  


 


 

Cost of Goods Sold

     37,527      17,743      10,199       (6,300 )     59,169

Selling, General & Administrative Expenses

     13,066      4,681      1,705       —         19,452

Amortization

     874      654      —         —         1,528
    

  

  


 


 

Operating Expenses

     51,467      23,078      11,904       (6,300 )     80,149
    

  

  


 


 

Operating Income (Loss)

     13,495      360      (73 )     —         13,782

Minority Interest in Income of Subsidiary

     —        —        32       —         32

Equity in Earnings of Affiliate

     —        326      —         —         326

Equity in Earnings of Subsidiaries

     215      —        —         (215 )     —  

Net Interest Expense

     5,151      —        48       —         5,199
    

  

  


 


 

Income (Loss) Before Income Taxes

     8,559      686      (153 )     (215 )     8,877

Income Tax Expense

     3,481      282      36       —         3,799
    

  

  


 


 

Net Income (Loss)

   $ 5,078    $ 404    $ (189 )   $ (215 )   $ 5,078
    

  

  


 


 

 

19


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statement of Income

For the Twenty-Six Weeks Ended July 31, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


   Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


 

Net Sales

   $ 121,606     $ 50,992    $ 25,348     $ (20,659 )   $ 177,287  
    


 

  


 


 


Cost of Goods Sold

     72,107       39,823      20,712       (20,659 )     111,983  

Selling, General & Administrative Expenses

     25,636       9,293      6,205       —         41,134  

Amortization

     1,204       327      —         —         1,531  
    


 

  


 


 


Operating Expenses

     98,947       49,443      26,917       (20,659 )     154,648  
    


 

  


 


 


Operating Income (Loss)

     22,659       1,549      (1,569 )     —         22,639  

Minority Interest in Loss of Subsidiary

     —         —        (22 )     —         (22 )

Equity in Earnings of Affiliate

     —         776      —         —         776  

Deficit in Earnings of Subsidiaries

     (246 )     —        —         246       —    

Net Interest Expense

     10,219       —        54       —         10,273  
    


 

  


 


 


Income (Loss) Before Income Taxes

     12,194       2,325      (1,601 )     246       13,164  

Income Tax Expense

     4,998       933      37       —         5,968  
    


 

  


 


 


Net Income (Loss)

   $ 7,196     $ 1,392    $ (1,638 )   $ 246     $ 7,196  
    


 

  


 


 


 

20


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statements of Income

For the Twenty-Six Weeks Ended July 26, 2003

 

(Unaudited and In Thousands)

 

     Issuer

   Guarantor
Subsidiaries


    Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


Net Sales

   $ 108,649    $ 44,762     $ 23,037     $ (10,948 )   $ 165,500
    

  


 


 


 

Cost of Goods Sold

     64,570      34,134       19,745       (10,948 )     107,501

Selling, General & Administrative Expenses

     24,387      8,740       3,783       —         36,910

Amortization

     1,748      1,308       —         —         3,056
    

  


 


 


 

Operating Expenses

     90,705      44,182       23,528       (10,948 )     147,467
    

  


 


 


 

Operating Income (Loss)

     17,944      580       (491 )     —         18,033

Minority Interest in Income of Subsidiary

     —        —         16       —         16

Equity in Earnings of Affiliate

     —        687       —         —         687

Equity in Earnings of Subsidiaries

     676      —         —         (676 )     —  

Net Interest Expense

     10,525      —         80       —         10,605
    

  


 


 


 

Income (Loss) Before Income Taxes

     8,095      1,267       (587 )     (676 )     8,099

Income Tax Expense (Benefit)

     3,114      (66 )     70       —         3,118
    

  


 


 


 

Net Income (Loss)

   $ 4,981    $ 1,333     $ (657 )   $ (676 )   $ 4,981
    

  


 


 


 

 

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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statements of Cash Flows

For the Twenty-Six Weeks Ended July 31, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


    Non-Guarantor
Subsidiaries


   

Consolidated

Total


 

CASH FLOWS FROM OPERATING ACTIVITIES

   $ (11,588 )   $ (736 )   $ 15,584     $ 3,260  
    


 


 


 


CASH FLOWS FROM INVESTING ACTIVITIES:

                                

Equity distribution from affiliate

     —         922       —         922  

Additions to property, plant and equipment

     (932 )     (186 )     (2,293 )     (3,411 )
    


 


 


 


Net cash (used in) provided by investing activities

     (932 )     736       (2,293 )     (2,489 )
    


 


 


 


CASH FLOWS FROM FINANCING ACTIVITIES:

                                

Proceeds from revolving credit facilities

     15,280       —         —         15,280  

Repayments of revolving credit facilities

     (15,280 )                     (15,280 )

Repayments of long-term debt

     —         —         (1,573 )     (1,573 )

Financing costs

     (237 )     —         —         (237 )
    


 


 


 


Net cash used in financing activities

     (237 )     —         (1,573 )     (1,810 )
    


 


 


 


EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

     —         —         22       22  
    


 


 


 


NET CHANGE IN CASH AND CASH EQUIVALENTS

     (12,757 )     —         11,740       (1,017 )

CASH AND CASH EQUIVALENTS, beginning of period

     19,047       —         (8,006 )     11,041  
    


 


 


 


CASH AND CASH EQUIVALENTS, end of period

   $ 6,290     $ —       $ 3,734     $ 10,024  
    


 


 


 


 

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Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statement of Cash Flows

For the Twenty-Six Weeks Ended July 26, 2003

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


    Non-Guarantor
Subsidiaries


   

Consolidated

Total


 

CASH FLOWS FROM OPERATING ACTIVITIES

   $ 3,876     $ (1,758 )   $ 250     $ 2,368  
    


 


 


 


CASH FLOWS FROM INVESTING ACTIVITIES:

                                

Equity distribution from affiliate

     —         2,282       —         2,282  

Additions to property, plant and equipment

     (2,772 )     (476 )     (882 )     (4,130 )
    


 


 


 


Net cash provided by (used in) investing activities

     (2,772 )     1,806       (882 )     (1,848 )
    


 


 


 


CASH FLOWS FROM FINANCING ACTIVITIES:

                                

Proceeds from revolving credit facility

     3,500       —         —         3,500  

Repayments of revolving credit facility

     (3,500 )     —         —         (3,500 )

Repayments of long-term debt

     (10,000 )     —         (1,130 )     (11,130 )

Dividends to Tandus Group, Inc.

     (2,263 )     —         —         (2,263 )

Financing Costs

     (18 )     —         —         (18 )
    


 


 


 


Net cash used in financing activities

     (12,281 )     —         (1,130 )     (13,411 )
    


 


 


 


EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

     —         —         318       318  
    


 


 


 


NET CHANGE IN CASH AND CASH EQUIVALENTS

     (11,177 )     48       (1,444 )     (12,573 )

CASH AND CASH EQUIVALENTS, beginning of period

     19,047       —         1,860       20,907  
    


 


 


 


CASH AND CASH EQUIVALENTS, end of period

   $ 7,870     $ 48     $ 416     $ 8,334  
    


 


 


 


 

18. Subsequent Events

 

On August 10, 2004, the Company and its parent announced its intent to close its manufacturing facility in Santa Ana, California, and transfer the production to its existing Truro, Nova Scotia, Canada, facility. The plan to close the facility was approved on August 9, 2004, and is expected to be complete by the end of the Company’s first fiscal quarter in 2005. It is anticipated that there will be one-time costs of approximately $6.4 million consisting of severance, moving, reinstallation, professional fees and other costs. In addition the Company anticipates capital expenditures of approximately $2.8 million related to the move. No costs have been incurred or accrued as of July 31, 2004.

 

On August 11, 2004, Monterey gave notice to Dixie that it has elected to terminate its supply arrangement with Chroma effective August 2005. Chroma currently dyes and finishes substantially all of Monterey’s carpet production and Dixie’s Fabrica Division’s carpet production and performs dyeing and finishing operations for other carpet mills. Under the terms of the partnership agreement, Monterey’s decision will effectively give Dixie the option to acquire Monterey’s interest in the partnership for a nominal value and assume full control of Chroma’s operations when the supply agreement terminates.

 

23


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

On August 18, 2004, the Company executed Amendment No. 3 (the “Amendment”) to its Senior Credit Facility. The amendment provides for, among other things, 1) the transfer of certain of the broadloom manufacturing fixed assets located in Santa Ana, California to the Company’s facility, located in Truro, Nova Scotia, 2) the disposal of and/or transfer to Collins & Aikman Floorcoverings, Inc. of substantially all of the remaining Santa Ana, California fixed assets and transfer all or substantially all of the accounts receivable, inventory and other liquid current assets from its Monterey Carpets, Inc. legal entity to Collins & Aikman Floorcoverings, Inc., 3) the release of Monterey Carpets, Inc. as a subsidiary guarantor under the subsidiary guarantee agreement and the security agreement and any other loan documents to which it is a party, 4) the exclusion from the calculation of covenants of the costs incurred in connection with the consolidation of up to $10.0 million, and 5) the reduction of the credit spread to Libor plus 2.75 on the Term B Loan. The Amendment further authorizes the collateral agent to release any and all liens held by the collateral agent in or on the assets to be transferred from Santa Ana, California to Truro, Nova Scotia.

 

24


Table of Contents

Item 2. Management’s Discussion and Analysis of Financial Condition and Results of Operations

 

The following discussion and analysis of the financial condition and results of operations should be read in conjunction with and is qualified in its entirety by reference to our consolidated financial statements and the accompanying notes. Except for historical information, the discussions in this section contain forward-looking statements that involve risks and uncertainties. Future results could differ materially from these discussed below for many reasons. See “Forward-Looking Statements.”

 

GENERAL

 

Based on annual sales and brand recognition, Collins & Aikman Floorcoverings, Inc. (the “Company”), a Delaware corporation, is a leading manufacturer of floorcovering products for the North American specified commercial carpet market. The Company’s floorcovering products include (i) vinyl-backed six-foot roll carpet and modular carpet tile and (ii) high style tufted and woven broadloom carpet. The Company designs, manufactures and markets its C&A, Monterey and Crossley brands under the Tandus name for a wide variety of end markets, including corporate offices, education, healthcare, government facilities and retail stores. Because of the diversity of the Company’s end markets, management believes its business tends to be less sensitive to economic downturns than many of its competitors, which rely more heavily on the corporate market. The ability to provide a “package of product offerings” in various forms, coupled with flexible distribution channels, allows the Company to provide a wide array of floorcovering solutions tailored for each of its customers. The Company is headquartered in Georgia, with additional locations in California, Canada, the United Kingdom, Singapore and China.

 

The Company is a wholly owned subsidiary of Tandus Group, Inc. (“Tandus Group”). Subsequent to a recapitalization transaction on January 25, 2001, investment funds managed by Oaktree Capital Management, LLC (“Oaktree”) and Banc of America Capital Investors (“BACI”) control a majority of the outstanding capital stock of Tandus Group.

 

RESULTS OF OPERATIONS

 

The following table sets forth certain operating results as a percentage of net sales for the periods indicated:

 

    

Thirteen Weeks

Ended


   

Twenty-Six Weeks

Ended


 
     July 26,
2003


    July 31,
2004


    July 26,
2003


   

July 31,

2004


 

Net Sales

   100.0 %   100.0 %   100.0 %   100.0 %

Cost of Goods Sold

   63.0     60.8     65.0     63.2  
    

 

 

 

Gross Profit

   37.0     39.2     35.0     36.8  

Selling, General & Administrative Expenses

   20.7     20.2     22.3     23.2  

Amortization

   1.6     0.8     1.8     0.8  
    

 

 

 

Operating Income

   14.7     18.2     10.9     12.8  

Net Interest Expense

   5.5     5.2     6.4     5.8  

Net Income

   5.4     8.0     3.0     4.1  

Adjusted EBITDA

   19.4     22.2     17.2     17.0  

 

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Table of Contents

Thirteen Weeks Ended July 31, 2004 As Compared with the Thirteen Weeks Ended July 26, 2003

 

Net Sales. Net sales for the thirteen weeks ended July 31, 2004 were $99.6 million, an increase of 6.1% from the $93.9 million for the thirteen weeks ended July 26, 2003. Net sales of the Company’s Floorcovering segment were $94.9 million for the thirteen weeks ended July 31, 2004 as compared to $86.7 million for the thirteen weeks ended July 26, 2003, an increase of $8.3 million or 9.6%. The increase in the Floorcovering segment’s net sales was due to improved demand throughout the specified commercial market in the United States. Net sales of the Extrusion segment were $4.7 million for the thirteen weeks ended July 31, 2004 as compared to $7.2 million for the thirteen weeks ended July 26, 2003, a decrease of $2.5 million or 34.8%. The reduction in sales for the Extrusion segment was due to lower sales to the Extrusion segment’s two largest customers as well as increased usage by the Company’s Floorcovering segment. The reduction was partially offset by increased sales to new and existing external customers as well as increased usage by the Company’s Floorcovering segment.

 

Cost of Goods Sold. Cost of goods sold was $60.6 million for the thirteen weeks ended July 31, 2004 as compared to $59.2 million in the thirteen weeks ended July 26, 2003. As a percentage of sales, costs of goods sold were 60.8% and 63.0% for the thirteen weeks ended July 31, 2004 and July 26, 2003, respectively. The percentage decrease was primarily due to the increased absorption of fixed manufacturing costs as a result of improved sales volume, increased usage of yarn from the Company’s Extrusion facility and cost manufacturing improvements.

 

Selling, General and Administrative Expenses. Selling, general and administrative expenses increased to $20.1 million for the thirteen weeks ended July 31, 2004, an increase of 3.1% from $19.5 million in the thirteen weeks ended July 26, 2003. This increase was primarily due to increased salaries, taxes and benefits of $0.8 million, sampling and related costs of $0.6 million, commissions of $0.1 million, and currency exchange costs of $0.3 million, partially offset by lower legal and professional expenses of $0.9 million and advertising and other of $0.2 million. As a percentage of sales, these expenses decreased to 20.2% from 20.7% in the prior year.

 

Amortization. Intangible asset amortization decreased to $0.8 million for the thirteen weeks ended July 31, 2004 as compared to $1.5 million for the thirteen weeks ended July 26, 2003. The decrease was due to the Company’s non-compete with its former parent being fully amortized as of January 31, 2004, and lower amortization of the extrusion supply agreement due to the non-cash impairment charge during the fourth quarter of fiscal 2003.

 

Interest Expense. Net interest expense for the thirteen weeks ended July 31, 2004 and thirteen weeks ended July 26, 2003 was $5.2 million for both periods, which included minimal interest income.

 

Income Taxes. The Company had income tax expense of $5.4 million for the thirteen weeks ended July 31, 2004 as compared to $3.8 million for the thirteen weeks ended July 26, 2003. The increase was predominantly due to the higher profitability of the Company during the second quarter of fiscal 2004.

 

Net Income. Net income for the thirteen weeks ended July 31, 2004 increased to $8.0 million compared to $5.1 million in the thirteen weeks ended July 26, 2003. This was due to the combined result of the factors described above.

 

Adjusted EBITDA. Adjusted EBITDA represents earnings before interest, taxes, depreciation, amortization plus Chroma cash dividends and minority interest in income of subsidiary less equity in earnings of Chroma. Adjusted EBITDA for the thirteen weeks ended July 31, 2004 increased to $22.1 million from $18.2 million in the thirteen weeks ended July 26, 2003. As a percentage of sales, Adjusted EBITDA was 22.2% in the thirteen weeks ended July 31, 2004 compared to 19.4% in the thirteen weeks ended July 26, 2003. The increase was principally due to the increased sales volume. Adjusted EBITDA is presented because it is commonly used by certain investors and analysts to analyze a company’s ability to service debt. The Company utilizes Adjusted EBITDA as (a) a benchmark for its annual budget and long range plan, (b) a valuation method for potential acquisitions, and (c) a measure to determine compliance with senior credit facility debt covenants. Adjusted EBITDA is not a measure of financial performance under accounting principles generally accepted in the United States and should not be

 

26


Table of Contents

considered an alternative to operating income or net income as a measure of operating performance or to net cash provided by operating activities as a measure of liquidity. Because Adjusted EBITDA is not calculated identically by all companies, the presentation in these statements may not be comparable to those disclosed by other companies.

 

A reconciliation of net income to Adjusted EBITDA is as follows:

 

    

Thirteen Weeks

Ended


 
    

July 26,

2003


    July 31,
2004


 

Net income

   $ 5,078     $ 7,951  

Income taxes

     3,799       5,390  

Net interest expense

     5,199       5,150  

Depreciation

     2,512       2,533  

Amortization

     1,528       765  

Chroma cash dividends

     405       644  

Equity in earnings of Chroma

     (326 )     (365 )

Minority interest of income of subsidiary

     32       14  
    


 


Adjusted EBITDA

   $ 18,227     $ 22,082  
    


 


 

RESULTS OF OPERATIONS

 

Twenty-Six Weeks Ended July 31, 2004 As Compared with the Twenty-Six Weeks Ended July 26, 2003

 

Net Sales. Net sales for the twenty-six weeks ended July 31, 2004 were $177.3 million, an increase of 7.1% from the $165.5 million for the twenty-six weeks ended July 26, 2003. Net sales of the Company’s Floorcovering segment were $164.9 million for the twenty-six weeks ended July 31, 2004 as compared to $150.5 million for the twenty-six weeks ended July 26, 2003, an increase of $14.4 million or 9.6%. The increase in the Floorcovering segment’s net sales was due to improved demand throughout the specified commercial market in the United States. Net sales of the Extrusion segment were $12.4 million for the twenty-six weeks ended July 31, 2004 as compared to $15.0 million for the twenty-six weeks ended July 26, 2003, a decrease of $2.6 million or 17.3%. The reduction in sales for the Extrusion segment was due to lower sales to the Extrusion segment’s two largest customers as well as increased usage by the Company’s Floorcovering segment. The reduction was partially offset by increased sales to new and existing external customers.

 

Cost of Goods Sold. Cost of goods sold was $112.0 million for the twenty-six weeks ended July 31, 2004 as compared to $107.5 million in the twenty-six weeks ended July 26, 2003. As a percentage of sales, cost of goods sold were 63.2% and 65.0%, respectively. The percentage decrease was primarily due to the increased absorption of fixed manufacturing costs as a result of improved sales volume, increased usage of the yarn from the Company’s Extrusion facility and manufacturing cost improvements.

 

Selling, General and Administrative Expenses. Selling, general and administrative expenses for the twenty-six weeks ended July 31, 2004 were $41.1 million, an increase of 11.3% from $36.9 million in the twenty-six weeks ended July 26, 2003. The increase was primarily due to increased salaries, taxes and benefits of $1.8 million, sampling and related costs of $0.9 million, commissions of $0.5 million, advertising and other of $0.2 million and currency exchange costs of $1.1 million, partially offset by lower legal and professional expenses of $0.3 million. As a percentage of sales, these expenses increased to 23.2% from 22.3% in the prior year.

 

Amortization. Intangible asset amortization decreased to $1.5 million for the twenty-six weeks ended July 31, 2004 as compared to $3.1 million for the twenty-six weeks ended July 26, 2003. The decrease was due to the Company’s non-compete with its former parent being fully amortized as of January 31, 2004 and lower amortization of the Extrusion supply agreement due to the non-cash impairment charge during the fourth quarter of fiscal 2003.

 

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Table of Contents

Interest Expense. Net interest expense for the twenty-six weeks ended July 31, 2004 and the twenty-six weeks ended July 26, 2003 was $10.3 million and $10.6 million, respectively, which included interest income of $0.1 million and $0.1 million, respectively. The twenty-six weeks ended July 26, 2003 included a charge to interest expense of $0.2 million to reflect the write-off of a pro-rata share of deferred financing costs associated with the prepayment of term debt from cash generated by operations.

 

Income Taxes. The Company has income tax expense of $6.0 million for the twenty-six weeks ended July 31, 2004 as compared to $3.1 million for the twenty-six weeks ended July 26, 2003. The increase was predominantly due to the higher profitability of the Company during the first six months of the current fiscal year combined with tax benefits on foreign losses which carry a full valuation allowance.

 

Net Income. Net income for the twenty-six weeks ended July 31, 2004 increased to $7.2 million from $5.0 million in the twnety-six weeks ended July 26, 2003. This was due to the combined result of the factors described above.

 

Adjusted EBITDA. Adjusted EBITDA represents earnings before interest, taxes, depreciation, amortization, plus Chroma cash dividends and minority interest in income (loss) of subsidiary less equity in earnings of Chroma. Adjusted EBITDA for the twenty-six weeks ended July 31, 2004 increased to $30.2 million from $28.4 million in the twenty-six weeks ended July 26, 2003. As a percentage of sales, Adjusted EBITDA was 17.0% in the twenty-six weeks ended July 26, 2003 compared to 17.2% in the twenty-six weeks ended July 26, 2003. The increase was principally due to the increased sales volume in the twenty-six weeks ended July 31, 2004, although it was partially offset by a special dividend of $1.8 million distributed by Chroma in the twenty-six weeks ended July 26, 2003. Adjusted EBITDA is presented because it is commonly used by certain investors and analysts to analyze a company’s ability to service debt. The Company utilizes Adjusted EBITDA as (a) a benchmark for its annual budget and long range plan, (b) a valuation method for potential acquisitions, and (c) a measure to determine compliance with senior credit facility debt covenants. Adjusted EBITDA is not a measure of financial performance under accounting principles generally accepted in the United States and should not be considered an alternative to operating income or net income as a measure of operating performance or to net cash provided by operating activities as a measure of liquidity. Because Adjusted EBITDA is not calculated identically by all companies, the presentation in these statements may not be comparable to those disclosed by other companies.

 

A reconciliation of net income to Adjusted EBITDA is as follows:

 

    

Twenty-Six Weeks

Ended


 
     July 26,
2003


   

July 31,

2004


 

Net income

   $ 4,981     $ 7,196  

Income taxes

     3,118       5,968  

Net interest expense

     10,605       10,273  

Depreciation

     5,024       5,119  

Amortization

     3,056       1,531  

Chroma cash dividends

     2,282       922  

Equity in earnings of Chroma

     (687 )     (776 )

Minority interest in income (loss) of subsidiary

     16       (22 )
    


 


Adjusted EBITDA

   $ 28,395     $ 30,211  
    


 


 

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Table of Contents

LIQUIDITY AND CAPITAL RESOURCES

 

The Company’s principal uses of cash have historically been for operating expenses, working capital, capital expenditures and debt repayment. The Company has financed its cash requirements through internally generated cash flows, borrowings and the offering of the senior subordinated notes.

 

Net cash provided by operating activities in the twenty-six weeks ended July 31, 2004 was $3.3 million compared to $2.4 million in the twenty-six weeks ended July 26, 2003. The change was due to the increased profitability of $2.2 million partially offset by higher working capital requirements of $1.4 million.

 

Net cash used in investing activities in the twenty-six weeks ended July 31, 2004 was $2.5 million compared to $1.8 million in the twenty-six weeks ended July 26, 2003. The increase in cash used in investing activities in the current year was primarily due to a special dividend having been declared from Chroma Systems in the twenty-six weeks ended July 26, 2003, and no such special dividend in the twenty-six weeks ended July 31, 2004. Capital expenditures for the twenty-six weeks ended July 31, 2004 were $3.4 million compared to $4.1 million for the twenty-six weeks ended July 26, 2003. The Company anticipates capital expenditures for the remainder of the year to be approximately $6.0 to $7.0 million.

 

Net cash used in financing activities for the twenty-six weeks ended July 31, 2004 was $1.8 million compared to $13.4 million in the twenty-six weeks ended July 26, 2003. The decrease in cash used by financing activities was due primarily to lower prepayment amounts of the Senior Credit Facility and reduced dividends to the Company’s parent during the twenty-six weeks ended July 31, 2004 as compared to the twenty-six weeks ended July 26, 2003.

 

The Company has significant indebtedness which, as of July 31, 2004, consists of $175.0 million of 9.75% senior subordinated notes due 2010, $31.0 million of senior term debt, $0.5 million in purchase money and other indebtedness and $1.2 million in sinking fund bonds under Crossley. As of July 31, 2004, the Company’s $50.0 million revolving line of credit had no borrowings outstanding and $2.2 million of letters of credit outstanding leaving total availability of $47.8 million. The Company was in compliance with all covenants as of July 31, 2004.

 

The Company’s semi-annual interest payments of the 9.75% Notes are due on each February 15 and August 15 through February 15, 2010. The amount due on each date is $8.5 million.

 

During the first quarter of fiscal 2004, the Company leased a facility to be used for a carpet tile production facility in Suzhou, China. Products manufactured at this facility will be sold into mainland China and throughout southeast Asia. Funding of $3.0 million was provided during fiscal 2003 with additional $2.0 million provided on August 6, 2004. Additional funding of up to $1.0 million may be required during the remainder of the year.

 

During March 2004, a jury found in favor of Employers Mutual Insurance Companies (“EMC”) related to alleged violations of express oral warranty and implied warranty of fitness for particular purpose and awarded damages totaling $0.8 million. The Company has accrued the full judgment of $0.8 million as of January 31, 2004. During the thirteen and twenty-six weeks ended July 31, 2004, the Company incurred approximately $0.0 and $0.5 million, respectively, of legal expenses related to this lawsuit. The Company continues to deny liability and is evaluating its options, which include a motion for a new trial. If the Company pursues those options and is unsuccessful, it will be required to pay the full judgment amount and related legal and professional fees. Subsequent to the end of the second quarter of fiscal 2004, the judgment amount was reduced from $0.8 million to $0.6 million. However, the reduction may be appealed by EMC through September 20, 2004.

 

The Company’s ability to make scheduled payments of principal, interest, or to refinance its indebtedness, depends on its future performance, which, to a certain extent, is subject to general economic, financial, competitive, and other factors beyond its control. However, there can be no assurance that the Company’s business will generate sufficient cash flow from operations or that future borrowings will be available in an amount sufficient to enable the Company to service its indebtedness or to make necessary capital expenditures. We periodically evaluate potential acquisitions of businesses, which complement our existing operations. Depending on various factors, including, among others, the cash consideration required in such potential acquisitions, we may determine to finance any such transaction with existing sources of liquidity.

 

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Table of Contents

On August 18, 2004, the Company executed Amendment No. 3 to its Senior Credit Facility. The Amendment provides for, among other things, 1) the transfer of certain of the broadloom manufacturing fixed assets located in Santa Ana, California to the Company’s facility located in Truro, Nova Scotia, 2) the disposal of and/or transfer to Collins & Aikman Floorcoverings, Inc. of substantially all of the remaining Santa Ana, California fixed assets and transfer all or substantially all of the accounts receivable, inventory and other liquid current assets from its Monterey Carpets, Inc. legal entity to Collins & Aikman Floorcoverings, Inc., 3) the release of Monterey Carpets, Inc. as a subsidiary guarantor under the subsidiary guarantee agreement and the security agreement and any other loan documents to which it is a party, 4) the exclusion from the calculation of covenants of the costs incurred in connection with the consolidation of up to $10.0 million and 5) the reduction of the credit spread to Libor plus 2.75 on the Term B Loan. The Amendment further authorizes the collateral agent to release any and all liens held by the collateral agent in or on the assets to be transferred from Santa Ana, California to Truro, Nova Scotia.

 

Effective May 1, 2004, the Company amended its Senior Credit Facility to revise certain covenants. The amended principal financial covenants are as follows:

 

     Q1

   Q2

   Q3

   Q4

   Thereafter

Fixed charge coverage ratio

   1.00:1.00    1.00:1.00    1.00:1.00    1.10:1.00    1.10:1.00

Interest coverage ratio

   1.75:1.00    1.75:1.00    1.85:1.00    2.00:1.00    2.25:1.00

 

The Company’s fixed charge coverage ratio and interest coverage ratio were 1.49:1.00 and 2.29:1.00, respectively, at July 31, 2004. As is customary in debt agreements, in the event the Company is not in compliance with the covenants of the Senior Credit Facility, the Company will also be subject to the provisions of a cross-default for the 9.75% Senior Subordinated Notes. The Company was in compliance with all covenants as of July 31, 2004 and expects to remain in compliance throughout fiscal 2004, although no assurances to that effect can be given.

 

On August 10, 2004, the Company and its parent announced its intent to close its manufacturing facility in Santa Ana, California, and transfer the production to its existing Truro, Nova Scotia, Canada, facility. The plan to close the facility was approved on August 9, 2004, and is expected to be complete by the end of the Company’s first fiscal quarter in 2005. It is anticipated that there will be one-time costs of approximately $6.4 million consisting of severance, moving, reinstallation, professional fees and other costs. In addition the Company anticipates capital expenditures of approximately $2.8 million related to the move. No costs have been incurred or accrued as of July 31, 2004.

 

Management believes that cash generated by its operations and availability under its $50.0 million revolving credit line will be sufficient to fund the Company’s current commitments and planned requirements.

 

EFFECTS OF INFLATION

 

The impact of inflation on the Company’s operations has not been significant in recent years. However, there can be no assurance that a high rate of inflation in the future would not have an adverse effect on the Company’s operating results.

 

SEASONALITY

 

The Company experiences seasonal fluctuations, with generally lower sales and gross profit in the first and fourth quarters of the fiscal year and higher sales and gross profit in the second and third quarters of the fiscal year. The seasonality of sales and profitability is primarily a result of disproportionately higher education end market sales during the summer months.

 

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RELIANCE ON PRIMARY THIRD-PARTY SUPPLIER OF NYLON YARN

 

Invista, Inc. (“Invista”) currently supplies a majority of the Company’s requirements for nylon yarn, the principal raw material used in the Company’s floorcovering products. The unanticipated termination or interruption of the supply arrangement with Invista could have a material adverse effect on the Company because of the cost and delay associated with shifting this business to another supplier. Historically, the Company has not experienced significant interruptions in the supply of nylon yarn from Invista, although no assurances can be given.

 

RECENT ACCOUNTING PRONOUNCEMENTS

 

In May 2003, the FASB issued Statement of Financial Accounting Standards No. 150, “Accounting for Certain Financial Instruments with Characteristics of Both Liabilities and Equity” (“SFAS No. 150”). SFAS No. 150 modifies the accounting for certain financial instruments, that under previous guidance could be accounted for as either a liability or equity, to require liability treatment for those instruments in a company’s statement of financial position. This statement is effective for our interim periods beginning after December 15, 2003. The adoption of SFAS 150 did not have an impact on our financial position, results of operations or cash flows.

 

In December 2003, the FASB issued SFAS No. 132 (revised 2003), “Employers’ Disclosure about Pensions and Other Postretirement Benefits, an amendment of FASB Statements No. 87, 88 and 106” (“SFAS No. 132”). The revision of SFAS No. 132 provides for additional disclosures including the description of the types of plan assets, investment strategy, measurement date(s), plan obligations, cash flows and components of net periodic benefit cost recognized in interim periods. The revision of SFAS No. 132 is effective for our consolidated financial statements as of January 31, 2004 and did not have an impact on our financial position, results of operations or cash flows.

 

CRITICAL ACCOUNTING POLICIES

 

The Company’s significant accounting policies are more fully described in Note 3 to the audited consolidated financial statements included in the Company’s Form 10-K for the year neded January 31, 2004, which was filed with the Securities and Exchange Commission in May 2004. Certain of the Company’s accounting policies require the application of significant judgment by management in selecting the appropriate assumptions for calculating financial estimates. By their nature, these judgments are subject to an inherent degree of uncertainty and actual results could differ from these estimates. These judgments are based on the Company’s historical experience, terms of existing contracts, current economic trends in the industry, information provided by our customers, and information available from outside sources, as appropriate. The Company’s significant accounting policies include:

 

Revenue Recognition. Revenue is recognized when goods are shipped, which is when legal title passes to the customer. For product installations subject to customer approval, revenue is recognized upon acceptance by the customer. The Company provides certain installation services to customers utilizing independent third-party contractors. The billings and expenses for these services are included in net sales and cost of goods sold, respectively.

 

A customer claims reserve and allowance for product returns is established based upon historical claims experience as a percent of gross sales as of the balance sheet date. The allowance for customer claims is recorded upon shipment of goods and is recorded as a reduction of sales. While we believe that our customer claims reserve and allowance for product returns is adequate and that the judgment applied is appropriate based upon our historical experience for these items, actual amounts determined to be due and payable could differ and additional allowances may be required.

 

Impairment of Goodwill and Indefinite Lived Intangible Assets. In addition to the annual impairment tests required by SFAS No. 142, the Company may periodically evaluate the carrying value of its goodwill and indefinite lived intangible asset for potential impairment. Judgments regarding the existence of impairment

 

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indicators are based on legal factors, market conditions and operational performance. Future events could cause the Company to conclude that impairment indicators exist and that goodwill and indefinite lived intangible asset associated with acquired businesses is impaired. Any resulting impairment loss could have a material adverse impact on the Company’s financial condition and results of operations.

 

Accounts Receivable Allowances. The Company provides allowances for expected cash discounts, returns, claims and doubtful accounts based upon historical experience and periodic evaluation of the financial condition of the Company’s customers and collectability of the Company’s accounts receivable. If the financial condition of the Company’s customers were to deteriorate, resulting in an impairment of their ability to pay their debts, allowances recorded in the Company’s financial statements may not be adequate.

 

Inventory Reserves. Inventories are stated at the lower of cost or market. Cost is determined using the first-in, first-out, method. Reserves are established based on percentage markdowns applied to inventories aged for certain time periods and size of lot.

 

Income Taxes. The Company uses the liability method in accounting for income taxes. Deferred tax assets and liabilities are recorded for temporary differences between the tax basis of assets and liabilities and their reported amounts in the consolidated financial statements using statutory rates. The effect on deferred tax assets and liabilities of a change in tax rates is recognized in the results of operations in the period that includes the rate change.

 

FORWARD-LOOKING STATEMENTS

 

The Company may from time to time make written and oral forward-looking statements. Written forward-looking statements may appear in documents filed with the Securities and Exchange Commission, in press releases and in reports to shareholders. The Private Securities Litigation Reform Act of 1995 contains a safe harbor for forward-looking statements. The Company relies on this safe harbor in making such disclosures. All statements contained in this Quarterly Report on Form 10-Q as to future expectations and financial results including, but not limited to, statements containing the words “plans,” “believes,” “intend,” “anticipates,” “expects,” “projects,” “should,” “will” and similar expressions, should be considered forward-looking statements subject to the safe harbor. The forward-looking statements are based on management’s current beliefs and assumptions about expectations, estimates, strategies and projections for the Company. These statements are not guarantees of future performance and involve risks, uncertainties and assumptions that are difficult to predict. Therefore, actual outcomes and results may differ materially from what is expressed or forecasted in such forward-looking statements. The Company undertakes no obligation to update publicly any forward-looking statements whether as a result of new information, future events or otherwise. The risks, uncertainties and assumptions regarding forward-looking statements include, but are not limited to, product demand and market acceptance risks; product development risks, such as delays or difficulties in developing, producing and marketing new products; the impact of competitive products, pricing and advertising constraints resulting from the financial condition of the Company, including the degree to which the Company is leveraged; cycles in the construction and renovation of commercial and institutional buildings; failure to retain senior executives and other qualified personnel; unanticipated termination or interruption of the Company’s arrangement with its primary third-party supplier of nylon yarn; debt service requirements and restrictions under credit agreements and indentures; general economic conditions in the United States and in markets outside of the United States served by the Company; government regulations; risks of loss of material customers; environmental matters; and other risks described in the Company’s Securities and Exchange Commission filings.

 

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Item 3. Quantitative and Qualitative Disclosures About Market Risk

 

Market risk is the potential loss arising from adverse changes in market rates and prices, such as foreign currency exchange and interest rates. Although we are not subject to material foreign currency exchange risk, we are exposed to changes in interest rates. Other than the 9.75% Notes, substantially all of our debt is variable rate debt. Therefore, interest rate changes generally do not affect the fair market value of such debt but do impact future earnings and cash flows, assuming other factors are held constant. Conversely, for fixed rate debt, interest rate changes do not impact future cash flows and earnings, but do impact the fair market value of such debt, assuming other factors are held constant. At July 31, 2004, we had variable rate debt of $31.2 million and fixed rate debt of $176.4 million. The variable interest rate per annum applicable to borrowings under the Senior Credit Facility is equal to the Company’s choice of (a) an adjusted rate based upon LIBOR plus a Eurodollar margin or (b) an alternative base rate, as defined by the Senior Credit Facility, plus a base rate margin. The Eurodollar margin and the base rate margin adjust quarterly on a sliding scale based on our leverage ratio for the immediately preceding four fiscal quarters. The impact on our results of operations of a one-point change on the outstanding balance of our term loan as of the twenty-six weeks ended July 31, 2004 would be approximately $0.2 million annually, net of tax.

 

Item 4. Controls and Procedures

 

As of July 31, 2004, the Company carried out an evaluation, under the supervision and with the participation of the Company’s Chief Executive Officer and the Chief Financial Officer, of the design and operation of the Company’s disclosure controls and procedures pursuant to Exchange Act Rule 13a-15. Based on this evaluation, the Company’s Chief Executive Officer and Chief Financial Officer concluded that the Company’s disclosure controls and procedures are effective for gathering, analyzing and disclosing the information the Company is required to disclose in the reports it files under the Securities Exchange Act of 1934, within the time periods specified in the SEC’s rules and forms. The Chief Executive Officer and Chief Financial Officer also concluded that the Company’s disclosure controls and procedures are effective in timely alerting them to material information relating to the Company required to be included in the Company’s periodic SEC filings. In connection with the new rules, the Company is in the process of further reviewing and documenting its disclosure controls and procedures, including its internal controls and procedures for financial reporting, and may from time to time make changes designed to enhance their effectiveness and to ensure that the Company’s systems evolve with its business.

 

There have been no significant changes in the Company’s internal controls or in other factors that could significantly affect internal controls subsequent to the date of this evaluation.

 

PART II Other Information

 

Item 1. Legal Proceedings

 

During March 2004, a jury found in favor of Employers Mutual Insurance Companies (“EMC”) related to alleged violations of express oral warranty and implied warranty of fitness for particular purpose and awarded damages totaling $0.8 million. The Company has accrued the full judgment amount of $0.8 million as of January 31, 2004. During the thirteen and twenty-six weeks ended July 31, 2004, the Company incurred approximately $0.0 million and $0.5 million, respectively, of legal expenses related to this lawsuit. The Company continues to deny liability and is evaluating its options, which include a motion for a new trial. If the Company pursues those options and is unsuccessful, it will be required to pay the full judgment amount and related legal and professional fees. Subsequent to the end of the second quarter of fiscal 2004, the judgment amount was reduced from $0.8 million to $0.6 million. However, the reduction may be appealed by EMC through September 20, 2004.

 

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The Company from time to time is subject to claims and suits arising in the ordinary course of business, including workers’ compensation and product liability claims that may or may not be covered by insurance. The ultimate outcome of all legal proceedings to which the Company is a party will not, in the opinion of the Company’s management, based on the facts presently known to it, have a material adverse effect on the Company’s financial condition or results of operations.

 

The Company is subject to federal, state, and local laws and regulations concerning the environment. In the opinion of the Company’s management, based on the facts presently known to it, the ultimate outcome of any environmental matters is not expected to have a material adverse effect on the Company’s financial condition or results of operations.

 

Item 6. Exhibits and Reports on Form 8-K

 

  (a) Exhibits

 

  10.1 Amendment No. 3 to Senior Credit Facility, dated August 18, 2004 (incorporated by reference from Exhibit 10.1 to the Company’s Form 8-K filed on August 24, 2004)

 

  31.1 Certification of the Chief Executive Officer pursuant to Rule 13a-14(a) under the Securities Exchange Act of 1934, as amended

 

  31.2 Certification of the Chief Financial Officer pursuant to Rule 13a-14(a) under the Securities Exchange Act of 1934, as amended

 

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

 

  (b) Reports on Form 8-K

 

Current Report Form 8-K: Announcement of appointment of Leonard F. Ferro as the Company’s Vice President and Chief Financial Officer, dated June 9, 2004

 

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SIGNATURE

 

Pursuant to the requirement 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 on September 14, 2004.

 

COLLINS & AIKMAN FLOORCOVERINGS, INC.
(Registrant)
By:  

/s/ Leonard F. Ferro


    Leonard F. Ferro
    Chief Financial Officer and Vice President
    (duly authorized officer and principal financial and accounting officer)

 

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