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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 October 30, 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 December 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 October 30, 2004

   3
   

Consolidated Statements of Income – Thirteen Weeks and Thirty-Nine Weeks Ended October 25, 2003 and October 30, 2004

   4
   

Consolidated Statements of Stockholder’s Equity – Thirty-Nine Weeks Ended October 30, 2004

   5
   

Consolidated Statements of Cash Flows – Thirty-Nine Weeks Ended October 25, 2003 and October 30, 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

   34
   

Item 4.      Controls and Procedures

   34

Part II.

 

Other Information

    
   

Item 1.      Legal Proceedings

   35
   

Item 6.      Exhibits

   35

Signature

   36

 

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


   

October 30,

2004


 
           (Unaudited)  
ASSETS                 

CURRENT ASSETS:

                

Cash and cash equivalents

   $ 11,041     $ 17,558  

Accounts receivable, net of allowances of $918 and $843 in fiscal 2003 and 2004, respectively

     36,019       40,464  

Inventories

     35,463       45,322  

Deferred tax assets

     4,013       3,976  

Prepaid expenses and other

     4,961       2,201  
    


 


Total current assets

     91,497       109,521  

PROPERTY, PLANT AND EQUIPMENT, net

     66,062       65,418  

GOODWILL

     98,378       98,378  

OTHER INTANGIBLE ASSETS, net

     34,255       31,956  

OTHER ASSETS

     8,956       8,334  
    


 


TOTAL ASSETS

   $ 299,148     $ 313,607  
    


 


LIABILITIES AND STOCKHOLDER’S EQUITY                 

CURRENT LIABILITIES:

                

Accounts payable

   $ 17,722     $ 15,979  

Accrued expenses

     20,298       23,425  

Current portion of long-term debt

     1,791       477  
    


 


Total current liabilities

     39,811       39,881  

OTHER LIABILITIES, including post-retirement benefit obligation

     4,768       4,310  

DEFERRED TAX LIABILITIES

     19       5,607  

LONG-TERM DEBT, net of current portion

     207,516       207,280  

MINORITY INTEREST

     342       323  

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 )     (15,486 )

Accumulated other comprehensive loss:

                

Foreign currency translation adjustment

     (493 )     (2 )

Minimum pension liability adjustment, net of tax

     (954 )     (954 )
    


 


Total stockholder’s equity

     46,692       56,206  
    


 


TOTAL LIABILITIES AND STOCKHOLDER’S EQUITY

   $ 299,148     $ 313,607  
    


 


 

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

   Thirty-Nine Weeks Ended

 
     October 25,
2003


   

October 30,

2004


   October 25,
2003


  

October 30,

2004


 

NET SALES

   $ 74,139     $ 82,501    $ 239,639    $ 259,788  
    


 

  

  


COST OF GOODS SOLD

     51,851       55,014      159,352      166,997  

SELLING, GENERAL & ADMINISTRATIVE EXPENSES

     17,066       17,548      53,976      58,682  

AMORTIZATION

     1,528       768      4,584      2,299  
    


 

  

  


OPERATING EXPENSES

     70,445       73,330      217,912      227,978  
    


 

  

  


OPERATING INCOME

     3,694       9,171      21,727      31,810  

NET INTEREST EXPENSE

     5,381       4,876      15,986      15,149  

MINORITY INTEREST IN INCOME (LOSS) OF SUBSIDIARY

     10       2      26      (20 )

EQUITY IN EARNINGS OF AFFILIATE

     387       117      1,074      893  

OTHER EXPENSE

     —         133      —        133  
    


 

  

  


INCOME (LOSS) BEFORE INCOME TAXES

     (1,310 )     4,277      6,789      17,441  

INCOME TAX EXPENSE (BENEFIT)

     (1,345 )     2,450      1,773      8,418  
    


 

  

  


NET INCOME

   $ 35     $ 1,827    $ 5,016    $ 9,023  
    


 

  

  


 

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

 

4


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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

CONSOLIDATED STATEMENTS OF STOCKHOLDER’S EQUITY

FOR THE THIRTY-NINE WEEKS ENDED OCTOBER 30, 2004

(Unaudited and In Thousands, Except Share Amounts)

 

     Common Stock

             

Accumulated Other

Comprehensive

Income (Loss)


     
     Shares

   Amount

   Paid - in
Capital


   Retained Earnings
(Deficit)


    Foreign Currency
Translation Adjustment


    Minimum Pension
Liability


    Total

BALANCE, January 31, 2004

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

  

  


 


 


 

Net Income

   —        —        —        9,023       —         —         9,023

Foreign Currency Translation Adjustment

   —        —        —        —         491       —         491
    
  

  

  


 


 


 

Total Comprehensive Income

   —        —        —        9,023       491       —         9,514
    
  

  

  


 


 


 

BALANCE, October 30, 2004

   1,000    $ —      $ 72,648    $ (15,486 )   $ (2 )   $ (954 )   $ 56,206
    
  

  

  


 


 


 

 

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)

 

     Thirty-Nine Weeks Ended

 
     October 25,
2003


   

October 30,

2004


 

CASH FLOWS FROM OPERATING ACTIVITIES:

                

Net income

   $ 5,016     $ 9,023  
    


 


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

                

Depreciation and leasehold amortization

     7,689       7,688  

Amortization of other intangible assets

     4,584       2,299  

Amortization and write-off of deferred financing fees

     1,381       1,259  

Change in deferred income tax

     310       5,625  

Equity in earnings of affiliate

     (1,074 )     (893 )

Minority interest in income (loss) of subsidiary

     26       (20 )

Changes in operating assets and liabilities:

                

Accounts receivable

     1,728       (4,445 )

Inventories

     (4,527 )     (9,859 )

Accounts payable

     (3,219 )     (1,743 )

Accrued expenses

     (2,691 )     3,127  

Other, net

     (426 )     2,016  
    


 


Total adjustments

     3,781       5,054  
    


 


Net cash provided by operating activities

     8,797       14,077  
    


 


CASH FLOWS FROM INVESTING ACTIVITIES:

                

Equity distribution from affiliate

     3,023       922  

Additions to property, plant, and equipment

     (7,220 )     (6,647 )
    


 


Net cash used in investing activities

     (4,197 )     (5,725 )
    


 


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

     (21,912 )     (1,618 )

Cash dividends to Tandus Group, Inc.

     (2,263 )     —    

Financing costs

     (18 )     (380 )
    


 


Net cash used in financing activities

     (24,193 )     (1,998 )
    


 


EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

     36       163  
    


 


NET CHANGE IN CASH AND CASH EQUIVALENTS

     (19,557 )     6,517  

CASH AND CASH EQUIVALENTS, beginning of period

     20,907       11,041  
    


 


CASH AND CASH EQUIVALENTS, end of period

   $ 1,350     $ 17,558  
    


 


 

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

 

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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 U.S. generally accepted accounting principles 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 U.S. generally accepted accounting principles 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

 

Collins & Aikman Floorcoverings, Inc. (the “Company”), a Delaware corporation, is a 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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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


  

October 30,

2004


          (Unaudited)

Raw materials

   $ 16,074    $ 22,843

Work in process

     5,153      7,395

Finished goods

     14,236      15,084
    

  

     $ 35,463    $ 45,322
    

  

 

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 $11.2 million and $9.5 million for the thirty-nine weeks ended October 30, 2004 and October 25, 2003, respectively, and $5.0 million and $3.8 million for the thirteen weeks ended October 30, 2004 and October 25, 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


  

October 30,

2004


          (Unaudited)

Payroll and employee benefits

   $ 5,952    $ 10,039

Accrued taxes

     —        1,331

Customer claims

     2,206      2,825

Accrued interest

     8,145      3,835

Accrued professional fees

     2,862      3,257

Other

     1,133      2,138
    

  

     $ 20,298    $ 23,425
    

  

 

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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 October 30, 2004 are as follows:

 

     October 30, 2004

 
     Gross Carrying
Amount


  Accumulated
Amortization


 

Amortized intangible assets:

              

Non-compete

   $ 12,000   $ (12,000 )

Patent

     27,000     (18,985 )

Supply Agreement

     8,000     (7,672 )
    

 


Total

   $ 47,000   $ (38,657 )
    

 


 

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

   Thirty-Nine Weeks Ended

     October 25,
2003


   October 30,
2004


   October 25,
2003


   October 30,
2004


Aggregate amortization expense

   $ 1,528    $ 768    $ 4,584    $ 2,299
    

  

  

  

 

Estimated amortization expense:

      

Fiscal 2004

   $ 3,091

Fiscal 2005

     2,639

Fiscal 2006

     2,455

Fiscal 2007

     2,455

Fiscal 2008

     —  

 

For the period ended October 30, 2004, there were no changes to the carrying value of goodwill.

 

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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

9. Stock Based Compensation

 

As of October 30, 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 October 30, 2004 and October 25, 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

    Thirty-Nine Weeks Ended

 
     October 25,
2003


    October 30,
2004


    October 25,
2003


    October 30,
2004


 

Net income as reported

   $ 35     $ 1,827     $ 5,016     $ 9,023  

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

     (16 )     (6 )     (31 )     (24 )
    


 


 


 


Proforma net income

   $ 19     $ 1,821     $ 4,985     $ 8,999  
    


 


 


 


 

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 facility located in Truro, Nova Scotia, 2) the disposal of and/or transfer to the Company of substantially all of the remaining Santa Ana, California fixed assets and transfer of all or substantially all of the accounts receivable, inventory and other liquid current assets from Monterey Carpets, Inc. (“Monterey”), a wholly-owned subsidiary of

 

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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

the Company, to the Company, 3) the release of Monterey 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 financial covenants calculation of up to $10.0 million of costs related to the move and relocation to the Truro, Nova Scotia plant (“the Crossley transfer”) 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 forming part of the Crossley transfer.

 

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 1.73:1.00 and 2.54:1.00, respectively, at October 30, 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 October 30, 2004 and expects to remain in compliance throughout fiscal 2004, although no assurances to that effect can be given.

 

Total net interest expense was $4.9 million and $5.4 million for the thirteen weeks ended October 30, 2004 and October 25, 2003, respectively, which includes minimal interest income. Total net interest expense was $15.1 and $16.0 million for the thirty-nine weeks ended October 30, 2004 and October 25, 2003, respectively, which includes minimal interest income.

 

12. Segment Information

 

Based on the provisions of SFAS No. 131, “Disclosures about Segments of an Enterprise and Related Information” (“SFAS No. 131”) which addresses reporting of operating segment information and disclosures about products, services, geographic areas, and major customers, management believes that the Company has 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, noncash charges or expenses (other than the write-down of current assets), costs related to board-approved acquisitions and attempted acquisitions, expenses related to the facility maximization project, 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 four largest external customers accounted for 25.5%, 25.1%, 14.3% and 10.3% of sales in the thirteen weeks ended October 30, 2004. The Extrusion segment’s largest external customer accounted for 40.5% and its second largest external customer accounted for 14.1% of sales in the thirty-nine weeks ended October 30, 2004.

 

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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

   Thirty-Nine Weeks Ended

     October 25,
2003


   October 30,
2004


   October 25,
2003


   October 30,
2004


Net Sales to External Customers

                           

Floorcoverings

   $ 67,546    $ 76,835    $ 218,086    $ 241,762

Extrusion

     6,593      5,666      21,553      18,026
    

  

  

  

Total Sales to External Customers

   $ 74,139    $ 82,501    $ 239,639    $ 259,788
    

  

  

  

 

     Thirteen Weeks Ended

   Thirty-Nine Weeks Ended

     October 25,
2003


   October 30,
2004


   October 25,
2003


   October 30,
2004


Adjusted EBITDA

                           

Floorcoverings

   $ 8,183    $ 12,710    $ 33,846    $ 40,843

Extrusion

     1,236      816      3,969      2,894
    

  

  

  

Total Adjusted EBITDA

   $ 9,419    $ 13,526    $ 37,815    $ 43,737
    

  

  

  

 

     Thirteen Weeks Ended

    Thirty-Nine Weeks Ended

 
     October 25,
2003


    October 30,
2004


    October 25,
2003


   

October 30,

2004


 

Net income

   $ 35     $ 1,827     $ 5,016     $ 9,023  

Income tax expense (benefit)

     (1,345 )     2,450       1,773       8,418  

Net interest expense

     5,381       4,876       15,986       15,149  

Depreciation

     2,665       2,569       7,689       7,688  

Amortization

     1,528       768       4,584       2,299  

Chroma cash dividends

     740       —         3,023       922  

Equity in earnings in Chroma

     (387 )     (117 )     (1,074 )     (893 )

Minority interest in income (loss) of subsidiary

     10       2       26       (20 )

Other Noncash Expense

     —         133       —         133  

Expenses associated with facility maximization project

     —         1,018       —         1,018  

Costs associated with unsuccessful acquisition

     792       —         792       —    
    


 


 


 


Adjusted EBITDA

   $ 9,419     $ 13,526     $ 37,815     $ 43,737  
    


 


 


 


 

     As of January 31, 2004

   As of October 30, 2004

Consolidated Assets

             

Floorcoverings

   $ 267,090    $ 285,068

Extrusion

     32,058      28,539
    

  

Total Consolidated Assets

   $ 299,148    $ 313,607
    

  

 

12


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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

13. Investment in Equity Affiliate

 

Subsequent to October 30, 2004, the Company successfully negotiated its exit from the Chroma partnership and entered into the Chroma Transition Agreement with Dixie Group, Inc. (“Dixie”) to allow for the transition of dyeing and finishing services needed until the Santa Ana, California manufacturing facility has been closed. Prior to the execution of this Agreement, Monterey Color Systems, Inc. (“Monterey Color Systems”) had a fifty percent (50%) ownership interest in Chroma, which operates a carpet dyeing and finishing plant. Because the Company did not exercise control over Chroma, the Company accounted for its interest in Chroma under the equity method of accounting. The unaudited condensed financial information of Chroma for the thirty-nine weeks ended October 30, 2004 and October 25, 2003, and as of October 30, 2004 and January 31, 2004 are summarized below:

 

    

As of

January 31, 2004


  

As of

October 30, 2004


Current Assets

   $ 2,203    $ 2,274

Non-current Assets

     7,925      7,750
    

  

Total Assets

   $ 10,128    $ 10,024
    

  

Current Liabilities

   $ 1,517    $ 1,254

Long Term Debt

     8,513      8,371

Partners’ Capital

     98      399
    

  

Total Liabilities and Partners’ Capital

   $ 10,128    $ 10,024
    

  

 

     Thirty-Nine Weeks Ended

     October 26,
2003


  

October 30,

2004


Net Sales

   $ 13,801    $ 14,887

Cost of Goods Sold

     10,847      11,895
    

  

Gross Profit

     2,954      2,992

Income From Operations

     2,252      2,254

Net Income

     2,124      2,112

 

On August 11, 2004, Monterey gave notice to Dixie that it had elected to terminate its supply arrangement with Chroma effective August, 2005. Chroma has historically dyed and finished 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. The Chroma Transition Agreement provides for the Company’s withdrawal from the partnership and for the transition of the continued dyeing and finishing needs of Monterey, until the closing of the Santa Ana, California facility is completed. A charge of $0.2 million has been recorded as of October 30, 2004 to reflect the negotiated settlement related to Monterey’s early termination of its Dyeing and Finishing Agreement with Chroma and withdrawal from the Chroma Partnership. It is anticipated that the closure of the Santa Ana, California facility will be complete by the end of the Company’s first fiscal quarter in 2005.

 

13


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COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

14. Comprehensive Income

 

Comprehensive income is as follows (in thousands):

 

     Thirteen Weeks Ended

   Twenty-Six Weeks Ended

     October 25,
2003


   October 30,
2004


   October 25,
2003


   October 30,
2004


Net Income

   $ 35    $ 1,827    $ 5,016    $ 9,023

Other Comprehensive Income:

                           

Foreign Currency Translation Adjustments

     127      522      787      491
    

  

  

  

Comprehensive Income

   $ 162    $ 2,349    $ 5,803    $ 9,514
    

  

  

  

 

15. Commitments and 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 to EMC totaling $0.8 million. The Company accrued the full judgment amount of $0.8 million as of January 31, 2004. During the thirteen and thirty-nine weeks ended October 30, 2004, the Company incurred approximately $0.1 million and $0.6 million, respectively, of legal expenses related to this lawsuit. The Company requested a new trial. The judge granted the Company’s motion for a new trial but allowed EMC to reduce the judgment by $0.2 million to avoid a new trail. EMC agreed to the reduction of the judgment by $0.2 million. The Company has appealed the $0.2 million reduction of the judgment and EMC has counter appealed. If the Company is unsuccessful, it will be required to pay the judgment amount and related legal and professional fees. The amount accrued in the consolidated balance sheet for the judgment was reduced to $0.6 million during the thirteen weeks ended October 30, 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 “facility maximization project”). The plan to close the facility was approved by the Company’s Board of Directors 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 the costs incurred will be less than the $6.4 million previously disclosed by the Company in its Form 8-K filed on August 10, 2004. It is currently estimated that the remaining costs will be approximately $3.9 million and consist of severance, lease termination, moving, reinstallation, professional fees and other costs. As part of the facility maximization project, the Company negotiated with the Nova Scotia government the forgiveness of the remaining $1.3 million of Crossley’s sinking fund bonds debt outstanding. The forgiveness will be over the remaining five-year term of the current note and is based upon certain employee hours worked during the year and will commence in fiscal 2005. The debt will also be non-interest bearing. During the thirteen weeks ended October 30, 2004, the Company incurred approximately $1.0 million in costs associated with the facility maximization project, which consist of professional fees, severance and other related costs. Costs of Goods Sold included $0.4 million and Selling, General and Administrative Expenses included $0.6 million of these expenses in the accompanying Consolidated Statement of Income. In addition the Company anticipates capital expenditures of approximately $3.0 million related to the move.

 

The costs incurred and the anticipated expenditures remaining are as follows:

 

(Amounts in millions)


  

Anticipated
Total Expenditures
as of

August 10, 2004


  

Change in
Estimate of
Expenditures as of

October 30, 2004


   

Amounts
Incurred

as of
October 30, 2004


  

Anticipated

Remaining

Expenditures


Severance Costs

   $ 1.8    $ 0.3     $ 0.4    $ 1.7

Contractual Obligations and Professional Fees

     3.1      (1.8 )     0.1      1.2

Other Project Costs

     1.5      —         0.5      1.0
    

  


 

  

Gross Project Expenditures

   $ 6.4    $ (1.5 )   $ 1.0    $ 3.9
    

  


 

  

 

The accrued facility maximization costs at October 30, 2004 amounted to $0.6 million, which consisted of severance and other costs. These costs are included in Accrued Expenses in the accompanying Consolidated Balance Sheets.

 

14


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

On November 8, 2004, the Company executed the Chroma Transition Agreement (the “Agreement”). As part of the Agreement and California Partnership Law, the Company retains its share of the third party claims that may be asserted for the period prior to the Company’s exit from the partnership.

 

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 federally mandated rates. 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 October 30, 2004 and October 25, 2003 were invested primarily in mutual funds and money market funds.

 

Net periodic pension cost for the thirteen weeks and thirty-nine weeks ended October 30, 2004 and October 25, 2003 was comprised of the following components:

 

     Thirteen Weeks Ended

    Thirty-Nine Weeks Ended

 
     October 25,
2003


    October 30,
2004


    October 25,
2003


   

October 30,

2004


 

Service cost – benefits earned during the period

   $ —       $ —       $ —       $ —    

Interest cost on projected benefit obligation

     72       69       217       206  

Expected return on plan assets

     (66 )     (2 )     (196 )     (183 )

Recognized net actuarial losses

     36       25       109       74  
    


 


 


 


Net periodic pension cost

   $ 42     $ 92     $ 130     $ 97  
    


 


 


 


 

Employer contributions of $0.2 million and $0.3 million were made for the thirteen weeks ended October 30, 2004 and October 25, 2003, and $0.7 million and $0.8 million were made for the thirty-nine weeks ended October 30, 2004 and October 25, 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 the maximum amount annually that can be deducted for income tax purposes. Assets of the pension plan are held in a trust invested primarily in mutual funds.

 

15


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Net periodic pension cost for the thirteen weeks and thirty-nine weeks ended October 30, 2004 and October 25, 2003 was comprised of the following components:

 

     Thirteen Weeks Ended

    Thirty-Nine Weeks Ended

 
     October 25,
2003


    October 30,
2004


    October 25,
2003


   

October 30,

2004


 

Service cost – benefits earned during the period

   $ 99     $ 140     $ 298     $ 419  

Interest cost on projected benefit obligation

     91       101       273       303  

Expected return on plan assets

     (93 )     (110 )     (278 )     (330 )

Recognized net actuarial losses

     (1 )     —         2       1  
    


 


 


 


Net periodic pension cost

   $ 96     $ 131     $ 295     $ 393  
    


 


 


 


 

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 thirty-nine weeks ended October 30, 2004 and October 25, 2003, respectively. Company contributions are expected to be approximately $0.1 million during the fourth quarter of 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 pension costs for the thirteen weeks and thirty-nine weeks ended October 30, 2004 and October 25, 2003 was comprised of the following components:

 

     Thirteen Weeks Ended

   Thirty-Nine Weeks Ended

     October 25,
2003


   October 30,
2004


   October 25,
2003


  

October 30,

2004


Service cost – benefits earned during the period

   $ 44    $ 59    $ 124    $ 142

Interest cost on projected benefit obligation

     33      45      93      107
    

  

  

  

Net periodic pension cost

   $ 77    $ 104    $ 217    $ 249
    

  

  

  

 

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 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 $109.0 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 October 30, 2004 is $209.8 million. This represents the principal amount outstanding of the Company’s Senior Credit Facility, the 9.75% Notes and accrued interest on both obligations. As discussed in Note 11, on August 18, 2004, the Company executed the Amendment to its Senior Credit Facility. The condensed consolidating financial information of the Company and its subsidiaries as of October 30, 2004 reflect the changes in the guarantor subsidiaries as discussed above.

 

16


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

The condensed consolidating financial information of the Company and its subsidiaries as of October 30, 2004 and January 31, 2004, and for each of the thirteen weeks and thirty-nine weeks ended October 30, 2004 and October 25, 2003 are as follows:

 

Guarantor Financial Statements

Condensed Consolidating Balance Sheets

October 30, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


    Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


 

ASSETS

                                        

CURRENT ASSETS:

                                        

Cash and cash equivalents

   $ 14,449     $ —       $ 3,109     $ —       $ 17,558  

Accounts receivable, net

     29,775       3,357       7,332       —         40,464  

Inventories

     31,251       3,845       10,226       —         45,322  

Deferred tax assets

     3,125       86       765       —         3,976  

Prepaid expenses and other

     798       —         1,403       —         2,201  
    


 


 


 


 


Total current assets

     79,398       7,288       22,835       —         109,521  

PROPERTY, PLANT AND EQUIPMENT, net

     32,161       15,199       18,058       —         65,418  

DEFERRED TAX ASSETS

     —         —         2,341       (2,341 )     —    

GOODWILL

     62,386       5,631       30,361       —         98,378  

OTHER INTANGIBLE ASSETS, net

     31,628       328       —         —         31,956  

INVESTMENT IN SUBSIDIARIES

     71,416       —         —         (71,416 )     —    

OTHER ASSETS

     8,144       93       97       —         8,334  
    


 


 


 


 


TOTAL ASSETS

   $ 285,133     $ 28,539     $ 73,692     $ (73,757 )   $ 313,607  
    


 


 


 


 


LIABILITIES AND STOCKHOLDER’S EQUITY

                                        

CURRENT LIABILITIES:

                                        

Accounts payable

   $ 5,040     $ 3,587     $ 7,352     $ —       $ 15,979  

Accrued expenses

     12,266       227       10,932       —         23,425  

Current portion of long-term debt

     321       —         156       —         477  
    


 


 


 


 


Total current liabilities

     17,627       3,814       18,440       —         39,881  

INTERCOMPANY (RECEIVABLE) PAYABLE

     (6,695 )     25,074       (18,379 )     —         —    

OTHER LIABILITES, including post-retirement obligation

     4,234       —         76       —         4,310  

DEFERRED TAX LIABILITES

     7,832       107       9       (2,341 )     5,607  

LONG-TERM DEBT, net of current portion

     205,929       —         1,351       —         207,280  

MINORITY INTEREST

     —         —         —         323       323  

STOCKHOLDER’S EQUITY

                                        

Preferred stock

     —         —         133       (133 )     —    

Common stock

     —         —         11,117       (11,117 )     —    

Paid-in capital

     72,648       —         52,064       (52,064 )     72,648  

Retained earnings (deficit)

     (15,486 )     (456 )     8,785       (8,329 )     (15,486 )

Accumulated other comprehensive loss

     (956 )     —         96       (96 )     (956 )
    


 


 


 


 


Total stockholders’ equity

     56,206       (456 )     72,195       (71,739 )     56,206  
    


 


 


 


 


TOTAL LIABILITIES AND STOCKHOLDER’S EQUITY

   $ 285,133     $ 28,539     $ 73,692     $ (73,757 )   $ 313,607  
    


 


 


 


 


 

17


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  
    


 

  


 


 


 

18


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 October 30, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


  

Non-

Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


Net Sales

   $ 54,445     $ 7,308    $ 33,232     $ (12,484 )   $ 82,501
    


 

  


 


 

Cost of Goods Sold

     34,715       7,008      25,775       (12,484 )     55,014

Selling, General & Administrative Expenses

     10,999       —        6,549       —         17,548

Amortization

     603       165      —         —         768
    


 

  


 


 

Operating Expenses

     46,317       7,173      32,324       (12,484 )     73,330
    


 

  


 


 

Operating Income

     8,128       135      908       —         9,171

Net Interest Expense

     4,855       —        21       —         4,876

Minority Interest in Income of Subsidiary

     —         —        2       —         2

Equity in Earnings of Affiliate

     —         —        117       —         117

Equity in Earnings of Subsidiaries

     (164 )     —        —         164       —  

Other Expense

     —         133      —                 133
    


 

  


 


 

Income Before Income Taxes

     3,109       2      1,002       164       4,277

Income Tax Expense

     1,282       2      1,166       —         2,450
    


 

  


 


 

Net Income (Loss)

   $ 1,827     $ —      $ (164 )   $ 164     $ 1,827
    


 

  


 


 

 

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 Thirteen Weeks Ended October 25, 2003

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


    Non-Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


 

Net Sales

   $ 45,410     $ 23,519     $ 12,113     $ (6,903 )   $ 74,139  

Cost of Goods Sold

     29,966       17,941       10,847       (6,903 )     51,851  

Selling, General & Administrative Expenses

     10,691       5,181       1,194       —         17,066  

Amortization

     874       654       —         —         1,528  
    


 


 


 


 


Operating Expenses

     41,531       23,776       12,041       (6,903 )     70,445  
    


 


 


 


 


Operating Income (Loss)

     3,879       (257 )     72       —         3,694  

Net Interest Expense

     5,334       —         47       —         5,381  

Minority Interest in Income of Subsidiary

     —         —         10       —         10  

Equity in Earnings of Affiliate

     —         387       —         —         387  

Equity in Earnings of Subsidiaries

     799       —         —         (799 )     —    
    


 


 


 


 


Income (Loss) Before Income Taxes

     (656 )     130       15       (799 )     (1,310 )

Income Tax Expense (Benefit)

     (691 )     (691 )     37       —         (1,345 )
    


 


 


 


 


Net Income (Loss)

   $ 35     $ 821     $ (22 )   $ (799 )   $ 35  
    


 


 


 


 


 

20


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 Thirty-Nine Weeks Ended October 30, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


  

Non-

Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


 

Net Sales

   $ 176,051     $ 23,185    $ 93,695     $ (33,143 )   $ 259,788  
    


 

  


 


 


Cost of Goods Sold

     106,822       21,846      71,472       (33,143 )     166,997  

Selling, General & Administrative Expenses

     36,635       —        22,047       —         58,682  

Amortization

     1,807       492      —         —         2,299  
    


 

  


 


 


Operating Expenses

     145,264       22,338      93,519       (33,143 )     227,978  
    


 

  


 


 


Operating Income

     30,787       847      176       —         31,810  

Net Interest Expense

     15,074       —        75       —         15,149  

Minority Interest in Loss of Subsidiary

     —         —        (20 )     —         (20 )

Equity in Earnings of Affiliate

     —         —        893       —         893  

Equity in Earnings of Subsidiaries

     (410 )     —        —         410       —    

Other Expense

     —         133      —         —         133  
    


 

  


 


 


Income Before Income Taxes

     15,303       714      1,014       410       17,441  

Income Tax Expense

     6,280       290      1,848       —         8,418  
    


 

  


 


 


Net Income (Loss)

   $ 9,023     $ 424    $ (834 )   $ 410     $ 9,023  
    


 

  


 


 


 

21


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 Thirty-Nine Weeks Ended October 25, 2003

 

(Unaudited and In Thousands)

 

     Issuer

   Guarantor
Subsidiaries


   

Non-

Guarantor
Subsidiaries


    Eliminations

    Consolidated
Total


Net Sales

   $ 154,059    $ 68,281     $ 35,150     $ (17,851 )   $ 239,639
    

  


 


 


 

Cost of Goods Sold

     94,536      52,075       30,592       (17,851 )     159,352

Selling, General & Administrative Expenses

     35,078      13,921       4,977       —         53,976

Amortization

     2,622      1,962       —         —         4,584
    

  


 


 


 

Operating Expenses

     132,236      67,958       35,569       (17,851 )     217,912
    

  


 


 


 

Operating Income (Loss)

     21,823      323       (419 )     —         21,727

Net Interest Expense

     15,859      —         127       —         15,986

Minority Interest in Income of Subsidiary

     —        —         26       —         26

Equity in Earnings of Affiliate

     —        1,074       —         —         1,074

Equity in Earnings of Subsidiaries

     1,475      —         —         (1,475 )     —  
    

  


 


 


 

Income (Loss) Before Income Taxes

     7,439      1,397       (572 )     (1,475 )     6,789

Income Tax Expense (Benefit)

     2,423      (757 )     107       —         1,773
    

  


 


 


 

Net Income (Loss)

   $ 5,016    $ 2,154     $ (679 )   $ (1,475 )   $ 5,016
    

  


 


 


 

 

22


Table of Contents

COLLINS & AIKMAN FLOORCOVERINGS, INC. AND SUBSIDIARIES

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

(Unaudited)

 

Guarantor Financial Statements

Condensed Consolidating Statements of Cash Flows

For the Thirty-Nine Weeks Ended October 30, 2004

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


    Non-Guarantor
Subsidiaries


   

Consolidated

Total


 

CASH FLOWS FROM OPERATING ACTIVITIES

   $ 9,843     $ 135     $ 4,099     $ 14,077  

CASH FLOWS FROM INVESTING ACTIVITIES:

                                

Equity distribution from affiliate

     —         —         922       922  

Additions to property, plant and equipment

     (1,681 )     (135 )     (4,831 )     (6,647 )
    


 


 


 


Net cash used in investing activities

     (1,681 )     (135 )     (3,909 )     (5,725 )
    


 


 


 


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

     —         —         (1,618 )     (1,618 )

Financing costs

     (380 )     —         —         (380 )
    


 


 


 


Net cash used in financing activities

     (380 )     —         (1,618 )     (1,998 )
    


 


 


 


EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

     —         —         163       163  
    


 


 


 


NET CHANGE IN CASH AND CASH EQUIVALENTS

     7,782       —         (1,265 )     6,517  

CASH AND CASH EQUIVALENTS, beginning of period

     6,667       —         4,374       11,041  
    


 


 


 


CASH AND CASH EQUIVALENTS, end of period

   $ 14,449     $ —       $ 3,109     $ 17,558  
    


 


 


 


 

23


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 Thirty-Nine Weeks Ended October 25, 2003

 

(Unaudited and In Thousands)

 

     Issuer

    Guarantor
Subsidiaries


   

Non-

Guarantor
Subsidiaries


   

Consolidated

Total


 

CASH FLOWS FROM OPERATING ACTIVITIES

   $ 8,316     $ (1,598 )   $ 2,079     $ 8,797  
    


 


 


 


CASH FLOWS FROM INVESTING ACTIVITIES:

                                

Equity distribution from affiliate

     —         3,023       —         3,023  

Additions to property, plant and equipment

     (4,826 )     (1,365 )     (1,029 )     (7,220 )
    


 


 


 


Net cash provided by (used in) investing activities

     (4,826 )     1,658       (1,029 )     (4,197 )
    


 


 


 


CASH FLOWS FROM FINANCING ACTIVITIES:

                                

Proceeds from revolving credit facilities

     3,500       —         —         3,500  

Repayments of revolving credit facilities

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

Repayments of long-term debt

     (20,000 )     —         (1,912 )     (21,912 )

Dividends to Tandus Group, Inc.

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

Financing Costs

     (18 )     —         —         (18 )
    


 


 


 


Net cash used in financing activities

     (22,281 )     —         (1,912 )     (24,193 )
    


 


 


 


EFFECT OF EXCHANGE RATE CHANGES ON CASH AND CASH EQUIVALENTS

     —         —         36       36  
    


 


 


 


NET CHANGE IN CASH AND CASH EQUIVALENTS

     (18,791 )     60       (826 )     (19,557 )

CASH AND CASH EQUIVALENTS, beginning of period

     19,047       —         1,860       20,907  
    


 


 


 


CASH AND CASH EQUIVALENTS, end of period

   $ 256     $ 60     $ 1,034     $ 1,350  
    


 


 


 


 

18. Income Taxes

 

The Company’s effective tax rate was 48.3% and 26.1% for the thirty-nine weeks ended October 30, 2004 and October 25, 2003, respectively. The higher rate for the thirty-nine weeks ended October 30, 2004 was primarily due to the recognition of a $0.9 million valuation allowance against certain state income tax credits carried forward from prior periods that may not be utilized in future periods. These credits were produced by Monterey and management believes it is more likely than not that their use may be limited after the closure of the Santa Ana, California facility. The tax benefit for the thirty-nine weeks ended October 25, 2003 was primarily due to the initial qualification for these credits, which included a component related to prior years and was recorded during the thirteen weeks ended October 25, 2003.

 

19. Subsequent Events

 

Subsequent to October 30, 2004, the Company successfully negotiated its exit from the Chroma partnership and entered into the Chroma Transition Agreement (“Agreement”) with Dixie to allow for the transition of dyeing and finishing services needed until the Santa Ana, California manufacturing facility has been closed. It is anticipated to be complete by the end of the Company’s first fiscal quarter in 2005.

 

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

 

Collins & Aikman Floorcoverings, Inc. (the “Company”), a Delaware corporation, is a 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. 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

    Thirty-Nine Weeks Ended

 
     October 25,
2003


    October 30,
2004


    October 25,
2003


   

October 30,

2004


 

Net Sales

   100.0 %   100.0 %   100.0 %   100.0 %

Cost of Goods Sold

   70.0     66.7     66.5     64.3  
    

 

 

 

Gross Profit

   30.0     33.3     33.5     35.7  

Selling, General & Administrative Expenses

   19.2     21.3     22.5     22.6  

Amortization

   2.1     0.9     1.9     0.9  
    

 

 

 

Operating Income

   4.9     11.1     9.1     12.2  

Net Interest Expense

   7.3     5.9     6.7     5.8  

Net Income

   0.0     2.2     2.1     3.5  

Adjusted EBITDA

   12.7     16.4     15.8     16.8  

 

25


Table of Contents

Thirteen Weeks Ended October 30, 2004 As Compared with the Thirteen Weeks Ended October 25, 2003

 

Net Sales. Net sales for the thirteen weeks ended October 30, 2004 were $82.5 million, an increase of 11.3% from the $74.1 million for the thirteen weeks ended October 25, 2003. Net sales of the Company’s Floorcovering segment were $76.8 million for the thirteen weeks ended October 30, 2004 as compared to $67.5 million for the thirteen weeks ended October 25, 2003, an increase of $9.3 million or 13.8%. The increase in the Floorcovering segment’s net sales was due to improved demand throughout the specified commercial market in North America. Net sales of the Extrusion segment were $5.7 million for the thirteen weeks ended October 30, 2004 as compared to $6.6 million for the thirteen weeks ended October 25, 2003, a decrease of $0.9 million or 13.6%. The reduction in sales for the Extrusion segment was due to lower sales this quarter to the former owner than in the prior year period and significantly increased usage by the Company’s Floorcovering segment. The reduction was partially offset by increased sales to new external customers.

 

Cost of Goods Sold. Cost of goods sold was $55.0 million for the thirteen weeks ended October 30, 2004 as compared to $51.9 million in the thirteen weeks ended October 25, 2003. As a percentage of sales, costs of goods sold were 66.7% and 70.0% for the thirteen weeks ended October 30, 2004 and October 25, 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. Included in cost of goods sold for the 2004 period are expenses of $0.4 million related to the Company’s planned closure of its manufacturing facility in Santa Ana, California and transfer of production to its existing Truro, Nova Scotia facility. (See further discussion in Liquidity and Capital Resources.)

 

Selling, General and Administrative Expenses. Selling, general and administrative expenses increased to $17.5 million for the thirteen weeks ended October 30, 2004, an increase of 2.8% from $17.1 million in the thirteen weeks ended October 25, 2003. This increase was primarily due to increased salaries, taxes and benefits of $1.9 million, partially offset by lower legal and professional expenses of $1.0 million, lower advertising and other expenses of $0.1 million and lower sampling expenses of $0.4 million. As a percentage of sales, these expenses decreased to 20.1% from 23.1% in the prior year. Included in the selling, general and administrative expenses for the 2004 period is $0.6 million of expenses related to the Company’s planned closure and relocation of assets from the Santa Ana, California facility.

 

Amortization. Intangible asset amortization decreased to $0.8 million for the thirteen weeks ended October 30, 2004 as compared to $1.5 million for the thirteen weeks ended October 25, 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 was $4.9 million and $5.4 million for the thirteen weeks ended October 30, 2004 and October 25, 2003, respectively, which included minimal interest income. The reduction was principally due to lower interest rates and lower levels of debt outstanding during the 2004 period.

 

Income Taxes. The Company had income tax expense of $2.5 million for the thirteen weeks ended October 30, 2004 as compared to a tax benefit of $1.3 million for the thirteen weeks ended October 25, 2003. The Company’s effective tax rate for the thirteen weeks ended October 30, 2004 was 57.3% and was primarily due to 1) higher profitability of the Company and its subsidiaries in the United States, 2) combined net loss of its foreign subsidiaries against which no tax benefit can be recognized and, 3) the recognition of a $0.9 million valuation allowance against certain state income tax credits carried forward from prior periods that may not be utilized in future periods. These credits were produced by Monterey and management believes it is more likely than not that their use may by limited after the closure of the Santa Ana, California facility. The tax benefit for the thirteen weeks ended October 25, 2003 was primarily due to the initial qualification for these credits, which included a component related to prior years and was recorded during the thirteen weeks ended October 25, 2003.

 

26


Table of Contents

Net Income. Net income for the thirteen weeks ended October 30, 2004 increased to $1.8 million compared to $0.04 million in the thirteen weeks ended October 25, 2003. This was due to the combined result of the factors described above.

 

Adjusted EBITDA. Adjusted EBITDA represents earnings before interest, taxes, depreciation, amortization, noncash charges or expenses (other than the write-down of current assets), costs related to board-approved acquisitions and attempted acquisitions, expenses related to the facility maximization project, plus Chroma cash dividends and minority interest in income of subsidiary less equity in earnings of Chroma. Adjusted EBITDA for the thirteen weeks ended October 30, 2004 increased to $13.5 million from $9.4 million in the thirteen weeks ended October 25, 2003. As a percentage of sales, Adjusted EBITDA was 16.4% in the thirteen weeks ended October 25, 2004 compared to 12.7% in the thirteen weeks ended October 25, 2003. The increase was principally due to the increased sales volume, partially offset by the reduction of Chroma dividends due to the facility maximization project. 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 U.S. generally accepted accounting principles 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:

 

     Thirteen Weeks Ended

 
     October 25,
2003


   

October 30,

2004


 

Net income

   $ 35     $ 1,827  

Income taxes

     (1,345 )     2,450  

Net interest expense

     5,381       4,876  

Depreciation

     2,665       2,569  

Amortization

     1,528       768  

Chroma cash dividends

     740       —    

Equity in earnings of Chroma

     (387 )     (117 )

Minority interest of income of subsidiary

     10       2  

Other Noncash Expense

     —         133  

Expenses associated with facility maximization project

     —         1,018  

Costs associated with unsuccessful acquisition

     792       —    
    


 


Adjusted EBITDA

   $ 9,419     $ 13,526  
    


 


 

RESULTS OF OPERATIONS

 

Thirty-Nine Weeks Ended October 30, 2004 As Compared with the Thirty-Nine Weeks Ended October 25, 2003

 

Net Sales. Net sales for the thirty-nine weeks ended October 30, 2004 were $259.8 million, an increase of 8.4% from the $239.6 million for the thirty-nine weeks ended October 25, 2003. Net sales of the Company’s Floorcovering segment were $241.8 million for the thirty-nine weeks ended October 30, 2004 as compared to $218.1 million for the thirty-nine weeks ended October 25, 2003, an increase of $23.7 million or 10.9%. The increase in the Floorcovering segment’s net sales was due to improved demand throughout the specified commercial market in North America. Net sales of the Extrusion segment were $18.0 million for the thirty-nine weeks ended October 30, 2004 as compared to $21.6 million for the thirty-nine weeks ended October 25, 2003, a decrease of $3.6 million or 16.4%. The reduction in sales for the Extrusion segment was due to lower sales to the former owner and successor of the supply agreement and significantly increased usage by the Company’s Floorcovering segment. The reduction in sales was partially offset by increased sales to new and existing external customers.

 

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Table of Contents

Cost of Goods Sold. Cost of goods sold was $167.0 million for the thirty-nine weeks ended October 30, 2004 as compared to $159.4 million in the thirty-nine weeks ended October 25, 2003. As a percentage of sales, cost of goods sold were 64.3% and 66.5%, 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. Included in cost of goods sold for the 2004 period are expenses of $0.4 million related to the Company’s planned closure and transfer of assets from its Santa Ana, California facility. (See further discussion in Liquidity and Capital Resources.)

 

Selling, General and Administrative Expenses. Selling, general and administrative expenses for the thirty-nine weeks ended October 30, 2004 were $58.7 million, an increase of 8.7% from $54.0 million in the thirty-nine weeks ended October 25, 2003. The increase was primarily due to increased salaries, taxes and benefits of $3.7 million, sampling and related costs of $0.4 million, commissions of $0.5 million, advertising and other costs of $0.5 million and foreign currency expense of $1.2 million, partially offset by lower legal and professional expenses of $1.3 million. As a percentage of sales, these expenses were 22.5% for the thirty-nine weeks ended October 30, 2004 and 22.5% for the thirty-nine weeks ended October 25, 2003. Included in the selling, general and administrative expenses for the 2004 period is $0.6 million of expenses related to the Company’s planned closure and relocation of assets from the Santa Ana, California facility.

 

Amortization. Intangible asset amortization decreased to $2.3 million for the thirty-nine weeks ended October 30, 2004 as compared to $4.6 million for the thirty-nine weeks ended October 25, 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 thirty-nine weeks ended October 30, 2004 and the thirty-nine weeks ended October 25, 2003 was $15.1 million and $16.0 million, respectively, which included interest income of $0.1 million in both periods. The thirty-nine weeks ended October 25, 2003 included a charge to interest expense of $0.4 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. The reduction was principally due to lower interest rates and lower levels of debt outstanding during the 2004 period.

 

Income Taxes. The Company has income tax expense of $8.4 million for the thirty-nine weeks ended October 30, 2004 as compared to $1.8 million for the thirty-nine weeks ended October 25, 2003. The Company’s effective tax rate for the thirty-nine weeks ended October 30, 2004 was 48.3%, and was primarily due to 1) higher profitability of the Company and its subsidiaries in the United States, 2) combined net loss of its foreign subsidiaries against which no tax benefit can be recognized and, 3) the recognition of a $0.9 million valuation allowance against certain state income tax credits carried forward from prior periods that may not be utilized in future periods. These credits were produced by Monterey and management believes it is more likely than not that their use may be limited after the closure of the Santa Ana, California facility. The Company’s effective tax rate for the thirty-nine weeks ended October 25, 2003 was 41.5%. The lower effective tax rate in fiscal 2003 was primarily due to the initial qualification for the credits, which included a component related to prior years and was recorded during the thirteen weeks ended October 25, 2003.

 

Net Income. Net income for the thirty-nine weeks ended October 30, 2004 increased to $9.0 million from $5.0 million in the thirty-nine weeks ended October 25, 2003. This was due to the combined result of the factors described above.

 

Adjusted EBITDA. Adjusted EBITDA represents earnings before interest, taxes, depreciation, amortization, noncash charges or expenses (other than the write-down of current assets), costs related to board-approved acquisitions and attempted acquisitions, expenses related to the facility maximization project, plus Chroma cash dividends and minority interest in income

 

28


Table of Contents

(loss) of subsidiary less equity in earnings of Chroma. Adjusted EBITDA for the thirty-nine weeks ended October 30, 2004 increased to $43.7 million from $37.8 million in the thirty-nine weeks ended October 25, 2003. As a percentage of sales, Adjusted EBITDA was 16.8% in the thirty-nine weeks ended October 30, 2004 compared to 15.8% in the thirty-nine weeks ended October 25, 2003. The increase was principally due to the increased sales volume in the thirty-nine weeks ended October 30, 2004, although it was partially offset by a special dividend of $1.8 million distributed by Chroma in the thirty-nine weeks ended October 25, 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:

 

     Thirty-Nine Weeks Ended

 
     October 25,
2003


   

October 30,

2004


 

Net income

   $ 5,016     $ 9,023  

Income taxes

     1,773       8,418  

Net interest expense

     15,986       15,149  

Depreciation

     7,689       7,688  

Amortization

     4,584       2,299  

Chroma cash dividends

     3,023       922  

Equity in earnings of Chroma

     (1,074 )     (893 )

Minority interest in income (loss) of subsidiary

     26       (22 )

Other Noncash Expense

     —         133  

Expenses associated with facility maximization project

     —         1,018  

Costs associated with unsuccessful acquisition

     792       —    
    


 


Adjusted EBITDA

   $ 37,815     $ 43,737  
    


 


 

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 thirty-nine weeks ended October 30, 2004 was $14.1 million compared to $8.8 million in the thirty-nine weeks ended October 25, 2003. The change was primarily due to the increased profitability of $4.0 million.

 

Net cash used in investing activities in the thirty-nine weeks ended October 30, 2004 was $5.7 million compared to $4.2 million in the thirty-nine weeks ended October 25, 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 thirty-nine weeks ended October 25, 2003, and no such special dividend in the thirty-nine weeks ended October 30, 2004. Capital expenditures for the thirty-nine weeks ended October 30, 2004 were $6.6 million compared to $7.2 million for the thirty-nine weeks ended October 25, 2003. The Company anticipates capital expenditures for the remainder of the year to be approximately $3.0 to $4.0 million.

 

Net cash used in financing activities for the thirty-nine weeks ended October 30, 2004 was $2.0 million compared to $24.2 million in the thirty-nine weeks ended October 25, 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 thirty-nine weeks ended October 30, 2004 as compared to the thirty-nine weeks ended October 25, 2003.

 

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The Company has significant indebtedness which, as of October 30, 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 $1.3 million in sinking fund bonds under Crossley. As of October 30, 2004, the Company’s $50.0 million revolving line of credit had no borrowings outstanding and $3.0 million of letters of credit outstanding leaving total availability of $47.0 million.

 

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. 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. The Company periodically evaluates potential acquisitions of businesses that would complement its existing operations. Depending on various factors, including, among others, the cash consideration required in such potential acquisitions, the Company may determine to finance any such transaction with existing sources of liquidity.

 

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. The Company expects production to begin at this facility during the first quarter of fiscal 2005.

 

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 to EMC totaling $0.8 million. The Company accrued the full judgment amount of $0.8 million as of January 31, 2004. During the thirteen and thirty-nine weeks ended October 30, 2004, the Company incurred approximately $0.1 million and $0.6 million, respectively, of legal expenses related to this lawsuit. The Company requested a new trial. The judge granted the Company’s motion for a new trial but allowed EMC to reduce the judgment by $0.2 million to avoid a new trial. EMC agreed to the reduction of the judgment by $0.2 million. The Company has appealed the $0.2 million reduction of the judgment and EMC has counter appealed. The amount accrued in the consolidated balance sheet for the judgment was reduced to $0.6 million during the thirteen weeks ended October 30, 2004.

 

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 its facility located in Truro, Nova Scotia, 2) the disposal of and/or transfer to the Company 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 Monterey Carpets, Inc. (“Monterey”), a wholly-owned subsidiary of the Company, to the Company, 3) the release of Monterey 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 financial covenants calculation of up to $10.0 million of costs related to the move and relocation to the Truro, Nova Scotia plant (the Crossley transfer”), 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 forming part of the Crossley transfer.

 

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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 1.73:1.00 and 2.54:1.00, respectively, at October 30, 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 October 30, 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 “facility maximization project”). The plan to close the facility was approved by the Company’s Board of Directors 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 the costs incurred will be less than the $6.4 million previously disclosed by the Company in its Form 8-K filed on August 10, 2004. It is currently estimated that the remaining costs will be approximately $3.9 million and consist of severance, lease termination, moving, reinstallation, professional fees and other costs. As part of the facility maximization project, the Company negotiated with the Nova Scotia government the forgiveness of the remaining $1.3 million of Crossley’s sinking fund bonds debt outstanding. The forgiveness will be over the remaining five-year term of the current note and is based upon certain employee hours worked during the year and will commence in fiscal 2005. The debt will also be non-interest bearing. During the thirteen weeks ended October 30, 2004, the Company incurred approximately $1.0 million in costs associated with the facility maximization project, which consist of professional fees, severance and other related costs. Costs of Goods Sold included $0.4 million and Selling, General and Administrative Expenses included $0.6 million of these expenses in the accompanying Consolidated Statements of Income. In addition the Company anticipates capital expenditures of approximately $3.0 million related to the move. The costs incurred and the anticipated expenditures remaining are as follows:

 

(Amounts in millions)


  

Anticipated
Total Expenditures
as of

August 10, 2004


  

Change in
Estimate of
Expenditures as of

October 30, 2004


   

Amounts
Incurred

as of
October 30, 2004


  

Anticipated

Remaining

Expenditures


Severance Costs

   $ 1.8    $ 0.3     $ 0.4    $ 1.7

Contractual Obligations and Professional Fees

     3.1      (1.8 )     0.1      1.2

Other Project Costs

     1.5      —         0.5      1.0
    

  


 

  

Gross Project Expenditures

   $ 6.4    $ (1.5 )   $ 1.0    $ 3.9
    

  


 

  

 

The accrued facility maximization costs at October 30, 2004 amounted to $0.6 million, which consisted of severance and other costs. These costs are included in Accrued Expenses in the accompanying Consolidated Balance Sheets.

 

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.

 

As discussed in Note 13, subsequent to the end of the quarter, the Company terminated its partnership interest in Chroma. The Company will receive no future cash dividends from Chroma.

 

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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.

 

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 ended 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.

 

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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 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 assets associated with acquired businesses are 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 sells floorcovering products to a wide variety of manufacturers and retailers located primarily throughout the United States and generally does not require collateral. Allowances are provided for expected cash discounts, return, claims and doubtful accounts based upon historical experience and periodic evaluations of the financial condition of the Company’s customers and collectability of the Company’s accounts receivable. These allowances are maintained at a level which management believes is sufficient to cover potential credit losses. Accounts receivable balances are aged according to invoice and applicable terms, and are written off as uncollectible only after all reasonable collection efforts have been made.

 

Inventories. Inventories are stated at the lower of cost or market. Cost is determined using the first-in, first-out, method. Reserves for potentially excess or obsolete inventory 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;

 

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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.

 

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 October 30, 2004, we had variable rate debt of $31.3 million and fixed rate debt of $176.5 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 thirty-nine weeks ended October 30, 2004 would be approximately $0.2 million annually, net of tax.

 

Item 4. Controls and Procedures

 

As of October 30, 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.

 

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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 to EMC totaling $0.8 million. The Company accrued the full judgment amount of $0.8 million as of January 31, 2004. During the thirteen and thirty-nine weeks ended October 30, 2004, the Company incurred approximately $0.1 million and $0.6 million, respectively, of legal expenses related to this lawsuit. The Company requested a new trial. The judge granted the Company’s motion for a new trial but allowed EMC to reduce the judgment by $0.2 million to avoid a new trail. EMC agreed to the reduction of the judgment by $0.2 million. The Company has appealed the $0.2 million reduction of the judgment and EMC has counter appealed. If the Company is unsuccessful, it will be required to pay the judgment amount and related legal and professional fees. The amount accrued in the consolidated balance sheet for the judgment was reduced to $0.6 million during the thirteen weeks ended October 30, 2004.

 

On November 8, 2004, the Company executed the Chroma Transition Agreement (the “Agreement”). As part of the Agreement and California Partnership Law, the Company retains its share of the third party claims that may be asserted for the period prior to the Company’s exit from the partnership.

 

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

 

Exhibits
10.1    Chroma Transition Agreement, dated November 8, 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

 

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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 December 10, 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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