UNITED STATES
SECURITIES AND EXCHANGE COMMISSION
Washington, D. C. 20549
FORM 10-K
(Mark One)
ý
ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE SECURITIES EXCHANGE ACT OF 1934
For the fiscal year ended December 31, 2005
or
o
TRANSITION REPORT PURSUANT TO SECTION 13 OR 15(D) OF THE SECURITIES EXCHANGE ACT OF 1934
Commission file number 1-9576
OWENS-ILLINOIS, INC.
(Exact name of registrant as specified in its charter)
Delaware
22-2781933
(State or other jurisdiction of
(IRS Employer
incorporation or organization)
Identification No.)
One SeaGate, Toledo, Ohio
43666
(Address of principal executive offices)
(Zip Code)
Registrants telephone number, including area code: (419) 247-5000
Securities registered pursuant to Section 12(b) of the Act:
Name of each exchange on
Title of each class
which registered
Common Stock, $.01 par value
New York Stock Exchange
Convertible Preferred Stock, $.01 par value, $50 liquidation preference
Securities registered pursuant to Section 12(g) of the Act: None
Indicate by check mark if the registrant is a well-known seasoned issuer, as defined in Rule 405 of the Securities Act.
Yes ý
No o
Indicate by check mark if the registrant is not required to file reports pursuant to Section 13 or 15(d) of the Act.
Yes o
No ý
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.
Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrants knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K.ý
Indicate by check mark whether the registrant is a large accelerated filer, an accelerated filer, or a non-accelerated filer. See definition of accelerated filer and large accelerated filer in Rule 12b-2 of the Exchange Act. (Check one):
Large accelerated filer ý
Accelerated filer o
Non-accelerated filer o
Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act).
The aggregate market value (based on the consolidated tape closing price on June 30, 2005) of the voting and non-voting stock beneficially held by non-affiliates of Owens-Illinois, Inc. was approximately $2,378,430,000. For the sole purpose of making this calculation, the term non-affiliate has been interpreted to exclude directors and executive officers of the Company. Such interpretation is not intended to be, and should not be construed to be, an admission by Owens-Illinois, Inc. or such directors or executive officers of the Company that such directors and executive officers of the Company are affiliates of Owens-Illinois, Inc., as that term is defined under the Securities Act of 1934.
The number of shares of common stock, $.01 par value of Owens-Illinois, Inc. outstanding as of January 31, 2006 was 152,961,486.
DOCUMENTS INCORPORATED BY REFERENCE
Portions of Owens-Illinois, Inc. Proxy Statement for The Annual Meeting of Share Owners To Be Held Wednesday, May 3, 2006 (Proxy Statement) are incorporated by reference into Part III hereof.
TABLE OF GUARANTORS
Primary
Standard
State/Country of
Industrial
I.R.S
Incorporation
Classification
Employee
Exact Name of Registrant
Code
Identification
As Specified In Its Charter
Organization
Number
Owens-Illinois Group, Inc
6719
34-1559348
Owens-Brockway Packaging, Inc
34-1559346
The address, including zip code, and telephone number, of each additional registrants principal executive office is One Seagate, Toledo, Ohio 43666; (419) 247-5000. These companies are listed as guarantors of the debt securities of the registrant. The consolidating condensed financial statements of the Company depicting separately its guarantor and non-guarantor subsidiaries are presented in the notes to the consolidated financial statements. All of the equity securities of each of the guarantors set forth in the table above are owned, either directly or indirectly, by Owens-Illinois, Inc.
TABLE OF CONTENTS
PART I
ITEM 1.
BUSINESS
ITEM 1A.
RISK FACTORS
ITEM 1B.
UNRESOLVED STAFF COMMENTS18
ITEM 2.
PROPERTIES
ITEM 3.
LEGAL PROCEEDINGS
ITEM 4.
SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS
PART II
ITEM 5.
MARKET FOR REGISTRANTS COMMON EQUITY, RELATED SHARE
OWNER MATTERS AND ISSUER PURCHASES OF EQUITY SECURITIES
ITEM 6.
SELECTED FINANCIAL DATA
ITEM 7.
MANAGMENTS DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS
ITEM 7A.
QUALITATIVE AND QUANTITATIVE DISCLOSURES ABOUT MARKET RISK
ITEM 8.
FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA
ITEM 9.
CHANGES IN AND DISAGREEMENTS WITH ACCOUNTANTS ON ACCOUNTING AND FINANCIAL DISCLOSURE
ITEM 9A.
CONTROLS AND PROCEDURES
ITEM 9B.
OTHER INFORMATION
PART III
ITEM 10.
DIRECTORS AND EXECUTIVE OFFICERS OF THE REGISTRANT
ITEM 11.
EXECUTIVE COMPENSATION CERTAIN 125
ITEM 12.
SECURITY OWENERSHIP OF CERTAIN BENEFICIAL OWNERS AND
MANAGEMENT AND RELATED SHARE OWNER MATTERS
ITEM 13.
CERTAIN RELATIONSHIPS AND RELATED TRANSACTIONS
ITEM 14.
PRINCIPAL ACCOUNTANT FEES AND SERVICES
PART IV
ITEM 15.
EXHIBITS AND FINANCIAL STATEMENT SCHEDULES
SIGNATURES
EXHIBITS
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General Development of Business
Owens-Illinois, Inc. (the Company), through its subsidiaries, is the successor to a business established in 1903. The Company is one of the worlds leading manufacturers of packaging products based on sales revenue and is the largest manufacturer of glass containers in the world, with leading positions in Europe, North America, Asia Pacific and South America. The Company is also a leading manufacturer of healthcare packaging including plastic prescription containers and medical devices, and plastic closure systems including tamper-evident caps and child-resistant closures, with operations in the United States, Mexico, Puerto Rico, Brazil, Hungary and Singapore.
Strategy and Competitive Strengths
The Company is pursuing a strategy aimed at leveraging its global capabilities, broadening its market base and focusing on modern management technologies and fundamentals including incentive compensation linked to cash flows and fact-based, data-driven decision making.
The Companys current priorities include the following:
Achieve successful European integration
Implement global procurement initiatives
Build modest growth momentum
Improve liquidity and reduce leverage
Improve system cost and capital capabilities
Increase prices near term to offset inflationary pressures
The Companys current core competitive strengths are:
Global leadership in manufacturing glass containers
Technological leadership and worldwide licensee networkglass and plastic closures
Long-standing relationships with industry-leading consumer products companies
Low-cost production of glass containers
Leading healthcare packaging businesses
New leadership team with turnaround and transformation agenda
Experienced and motivated management team and work force
Consistent with its vision to become the worlds leading packaging company, the Company has acquired 17 glass container businesses in 22 countries since 1990, including businesses in Europe, North America, Asia Pacific and South America. These acquisitions include the purchase of BSN Glasspack, S.A., on June 21, 2004 for a total consideration of approximately $1.3 billion (the BSN Acquisition). In the
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BSN Acquisition, the Company acquired 19 manufacturing plants in France, Germany, the Netherlands and Spain. Through these acquisitions, the Company has enhanced its global presence in order to better serve the needs of its multi-national customers. Through global leveraging, we have also achieved purchasing and cost reduction synergies.
The Company has 84 glass manufacturing plants in 20 countries and 22 plastics packaging facilities, 13 of which are in the United States.
Technology Leader
The Company believes it is a technological leader in the worldwide glass container and plastics packaging segments of the rigid packaging market in which it competes. During the five years ended December 31, 2005, on a continuing operations basis, the Company invested more than $1.7 billion in capital expenditures (excluding acquisitions) and more than $281 million in research, development and engineering to, among other things, improve labor and machine productivity, increase capacity in growing markets and commercialize technology into new products.
Worldwide Corporate Headquarters
The principal executive office of the Company is located at One SeaGate, Toledo, Ohio 43666; the telephone number is (419) 247-5000. The Companys website is www.o-i.com. The Companys annual report and SEC filings can be obtained from this site at no cost. The Companys Corporate Governance Guidelines, Code of Business Conduct and Ethics and the charters of the Compensation, Nominating/Corporate Governance, Audit Committee are available on the Investor Relations section of the Companys website. Copies of these documents are available in print to share owners upon request, addressed to the Corporate Secretary at the address above.
Financial Information about Product Segments
Information as to sales, earnings from continuing operations before interest income, interest expense, provision for income taxes and minority share owners interests in earnings of subsidiaries and excluding amounts related to certain items that management considers not representative of ongoing operations (Segment Operating Profit), and total assets by product segment is included in Note 20 to the Consolidated Financial Statements.
Narrative Description of Business
The Company has two product segments: (1) Glass Containers and (2) Plastics Packaging. Below is a description of these segments and information to the extent material to understanding the Companys business taken as a whole.
Products and Services, Customers, Markets and Competitive Conditions, and Methods of Distribution
GLASS CONTAINERS PRODUCT SEGMENT
The Company is the largest manufacturer of glass containers in the world. The Company is the leading glass container manufacturer in 19 of the 22 countries where it competes in the glass container segment of the rigid packaging market, including the U.S., and the sole manufacturer of glass containers in 8 of these countries. On a continuing operations basis, worldwide glass container sales represented 89%, 88%, and 84%, of the Companys consolidated net sales for the years ended December 31, 2005, 2004, and 2003, respectively.
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Products and Services
The Company produces glass containers for beer and ready-to-drink low alcohol refreshers, spirits, wine, food, tea, juice and pharmaceuticals. The Company also produces glass containers for soft drinks and other non-alcoholic beverages, principally outside the U.S. The Company manufactures these products in a wide range of sizes, shapes and colors. The Company is active in new product development and glass container innovation.
Customers
In most of the countries where the Company competes, it has the leading position in the glass container segment of the rigid packaging market based on sales revenue. The largest customers include many of the leading manufacturers and marketers of glass packaged products in the world. In the U.S., the majority of customers for glass containers are brewers, wine vintners, distillers and food producers. The Company also produces glass containers for soft drinks, principally outside the U.S. The largest U.S. glass container customers include (in alphabetical order) Anheuser-Busch, Diageo, H.J. Heinz, Molson/Coors, Novartis, Pepsico, SABMiller, and Saxco-Demptos, Inc. The largest glass container customers outside the U.S. include (in alphabetical order) Diageo, Fosters, Heineken, InBev, Scottish & Newcastle, Lion Nathan, Molson/Coors and SABMiller. The Company is the major glass container supplier to some of these customers.
The Company sells most of its glass container products directly to customers under annual or multi-year supply agreements. The Company also sells some of its products through distributors. Glass containers are typically scheduled for production in order to maintain reasonable inventories in relation to customers forecasts of their quarterly requirements.
Markets and Competitive Conditions
The principal markets for glass container products made by the Company are in Europe, North America, Asia Pacific, and South America. The Company believes it is the low-cost producer in the glass container segment of the rigid packaging market in most of the countries in which it competes. Much of this cost advantage is due to proprietary equipment and process technology used by the Company. The Companys machine development activities and systematic upgrading of production equipment in the 1990s and early 2000s have given it low-cost leadership in the glass container segment in most of the countries in which it competes, a key strength to competing successfully in the rigid packaging market.
The Company has the leading share of the glass container segment of the U.S. rigid packaging market based on sales revenue by domestic producers in the U.S. The principal glass container competitors in the U.S. are Saint-Gobain Containers, Inc., a wholly-owned subsidiary of Compagnie de Saint-Gobain, and Anchor Glass Container Corporation. In addition, imports from Mexico and other countries increasingly compete in U.S. glass container segments. Additionally, a few major consumer packaged goods companies also self-manufacture glass containers.
In supplying glass containers outside of the U.S., the Company competes directly with Compagnie de Saint-Gobain in Europe and Brazil, Ardagh plc in the U.K., Vetropak in the Czech Republic and Amcor Limited in Australia. In other locations in Europe, the Company competes indirectly with a variety of glass container firms including Compagnie de Saint-Gobain, Vetropak and Rexam plc. Except as mentioned above, the Company does not compete with any large, multi-national glass container manufacturers in South America or the Asia Pacific region.
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In addition to competing with other large, well-established manufacturers in the glass container segment, the Company competes with manufacturers of other forms of rigid packaging, principally aluminum cans and plastic containers, on the basis of quality, price and service. The principal competitors producing metal containers are Amcor, Crown Cork & Seal Company, Inc., Rexam plc, Ball Corporation and Silgan Holdings Inc. The principal competitors producing plastic containers are Consolidated Container Holdings, LLC, Graham Packaging Company, Plastipak Packaging, Inc. and Silgan Holdings Inc. The Company also competes with manufacturers of non-rigid packaging alternatives, including flexible pouches and aseptic cartons.
The Companys unit shipments of glass containers in countries outside of the U.S. have grown substantially from levels of the early 1990s. The Company has added to its international operations by acquiring glass container companies, many of which have leading positions in growing or established markets, increasing capacity at select foreign subsidiaries, and maintaining the global network of glass container companies that license its technology. In many developing countries, the Companys international glass operations have benefited in the last ten years from increased consumer spending power, a trend toward the privatization of industry, a favorable climate for foreign investment, lowering of trade barriers and global expansion programs by multi-national consumer companies.
North America. In addition to the glass container operations in the U.S., the Companys subsidiary in Canada is the sole manufacturer of glass containers in that country.
South America. The Company is the sole manufacturer of glass containers in Colombia, Ecuador and Peru. In both Brazil and Venezuela, the Company is the leading manufacturer of glass containers. In South America, there is a large infrastructure for returnable/refillable glass containers. However, with improving economic conditions in South America after the recessions of the late 1990s, unit sales of non-returnable glass containers have grown in Venezuela, Colombia and Brazil.
Europe. The Companys European glass container business, headquartered in Switzerland, has consolidated manufacturing operations in 11 countries and is the largest in Europe. The Companys subsidiary in France is a leading producer of wine and champagne bottles and is the sole supplier of glass containers to Scottish & Newcastle, Frances leading brewer. In Italy, the Companys wholly-owned subsidiary is the leading manufacturer of glass containers and operates 13 glass container plants. In Germany, the Companys key customers include Scottish & Newcastle and Nestle Europe. In the Netherlands, the Company is one of the leading suppliers of glass containers to Heineken. The Companys subsidiary in the U.K. is a leading manufacturer of glass containers for the U.K. spirits business. In Spain, the Company serves the market for olives in the Sevilla area and the market for wine bottles in the Barcelona and southern France area. In Poland, the Company is the leading glass container manufacturer and currently operates two plants. The Companys subsidiary in the Czech Republic is the leading glass container manufacturer in that country and also ships a portion of its beer bottle production to Germany. In Hungary, the Company is the sole glass container manufacturer and serves the Hungarian food industry. In Finland and the Baltic country of Estonia, the Company is the only manufacturer of glass containers. The Company coordinates production activities between Finland and Estonia in order to efficiently serve the Finnish, Baltic and Russian markets. In recent years, Western European brewers have been establishing beer production facilities in Central Europe and the Russian Republic. Because these new beer plants use high-speed filling lines, they require high quality glass containers in order to operate properly. The Company believes it is well positioned to meet this growing demand. In October 2005 the Company entered a joint venture with the Ost Group, one of Russias largest spirits producers, by purchasing a minority interest in Ost Tara, which is a glass manufacturing facility near Moscow.
Asia Pacific. The Company has glass operations in four countries in the Asia Pacific region: Australia, New Zealand, Indonesia and China. In the Asia Pacific region, the Company is the leading manufacturer
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of glass containers in most of the countries in which it competes. In Australia, the Companys subsidiary operates four glass container plants, including a plant focused on serving the needs of the growing Australian wine industry. In New Zealand, the Company is the sole glass container manufacturer. In Indonesia, the Company supplies the Indonesian market and exports glass containers for food and pharmaceutical products to Australian customers. In China, the glass container segments of the packaging market are regional and highly fragmented with a number of local competitors. The Company has three modern glass container plants in China manufacturing high-quality beer bottles to serve Fosters as well as Anheuser-Busch, which is now producing Budweiser® in and for the Chinese market. In December 2005, the Company acquired the business and assets of Tianjin New World Glass Containers Co. Ltd., of the Peoples Republic of China, for approximately $9 million USD. The acquisition will be operated as a joint venture in which the Company holds a 95 % equity interest. The business produces containers for the beer and wine industries in northeast China.
The Company continues to focus on serving the needs of leading multi-national consumer companies as they pursue international growth opportunities. The Company believes that it is often the glass container partner of choice for such multi-national consumer companies due to its leadership in glass technology and its status as a high quality producer in most of the markets it serves.
Manufacturing
The Company believes it is the low-cost producer in the glass container segment of the North American rigid packaging market, as well as the low-cost producer in most of the international glass segments in which it competes. Much of this cost advantage is due to the Companys proprietary equipment and process technology. The Company believes its proprietary high volume glass forming machines, developed and refined by its engineering group, are significantly more efficient and productive than those used by competitors. The Companys machine development activities and systematic upgrading of production equipment has given it low-cost leadership in the glass container segment in most of the countries in which it competes, a key strength to competing successfully in the rigid packaging market.
Since the early 1990s, the Company has more than doubled its overall glass container labor and machine productivity in the U.S., as measured by output produced per man-hour. By applying its technology and worldwide best practices during this period, the Company decreased the number of production employees required per glass-forming machine line in the U.S. by over 35%, and increased the daily output of glass-forming machines by approximately 40%. The Company has achieved similar productivity improvements in its operations around the world. The Company also operates several machine and mold shops that manufacture high-productivity glass-forming machines, molds and related equipment.
Methods of Distribution
Due to the significance of transportation costs and the importance of timely delivery, glass container manufacturing facilities are generally located close to customers. In the U.S., most of the Companys glass container products are shipped by common carrier to customers within a 250-mile radius of a given production site. In addition, the Companys glass container operations outside the U.S. export some products to customers beyond their national boundaries, which may include transportation by rail and ocean delivery in combination with common carriers.
Suppliers and Raw Materials
The primary raw materials used in the Companys glass container operations are sand, soda ash, limestone and recycled glass. Each of these materials, as well as the other raw materials used to
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manufacture glass containers, has historically been available in adequate supply from multiple sources. For certain raw materials, however, there may be temporary shortages due to weather or other factors, including disruptions in supply caused by raw material transportation or production delays.
Energy
The Companys glass container operations require a continuous supply of significant amounts of energy, principally natural gas, fuel oil, and electrical power. Adequate supplies of energy are generally available to the Company at all of its manufacturing locations. Energy costs typically account for 15-20% of the Companys total manufacturing costs, depending on the factory location and its particular energy requirements. The percentage of total cost related to energy can vary significantly because of volatility in market prices, particularly for natural gas in particularly volatile markets such as North America. In order to limit the effects of fluctuations in market prices for natural gas and fuel oil, the Company uses commodity futures contracts related to its forecasted requirements, principally in North America and Europe. The objective of these futures contracts is to reduce the potential volatility in cash flows due to changing market prices. The Company continually evaluates the energy markets with respect to its forecasted energy requirements in order to optimize its use of commodity futures contracts. If energy costs increase substantially in the future, the Company could experience a corresponding increase in operating costs, which may not be fully recoverable through increased selling prices.
Glass Recycling
The Company is an important contributor to the recycling effort in the U.S. and abroad and continues to melt substantial recycled glass tonnage in its glass furnaces. If sufficient high-quality recycled glass were available on a consistent basis, the Company has the technology to operate using 100% recycled glass. Using recycled glass in the manufacturing process reduces energy costs and prolongs the operating life of the glass melting furnaces.
The Company is a leading manufacturer in North America of plastic packaging including healthcare containers, prescription containers, and closures. The Company also has plastics packaging operations in South America, Europe, Singapore, and Australia. On a continuing operations basis, plastics packaging sales represented 11%, 12% and 16% of the Companys consolidated net sales for the years ended December 31, 2005, 2004 and 2003, respectively.
Manufacturing and Products
The exact type of manufacturing process the Company uses is dependent on the plastic product type and package requirements. Injection blow-molding and injection molding are plastics manufacturing processes where plastic resin in the form of pellets or powder is melted and then injected or otherwise forced under pressure into a mold. The mold is then cooled and the product is removed from the mold.
The Companys healthcare container unit manufactures injection blow molded plastic containers for pharmaceutical manufacturers and over-the-counter products. These products are sold primarily to pharmaceutical manufacturers and over-the-counter producers.
The prescription products unit manufactures injection-molded plastic prescription containers. These products are sold primarily to drug wholesalers and major drug chains. Containers for prescriptions include vials, ovals, closures, ointment jars, dropper bottles and automation friendly prescription containers.
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Injection-molding is used in the manufacture of plastic closures, deodorant canisters, ink cartridges and vials. The Company develops and produces injection-molded plastic closures and closure systems, which typically incorporate functional features such as tamper evidence and child resistance or dispensing. Other products include injection-molded containers for deodorant and toothpaste.
Compression-molding, an alternative to injection-molding which has advantages in high volume applications, is used in manufacturing plastic closures for carbonated soft drink and other beverage closures that require tamper evidence.
The Companys largest customers for plastic healthcare containers include (in alphabetical order) Alcon, Bausch & Lomb, Bristol Myers Squib, Hospira, McNeil, and Pfizer. The Companys largest customers for prescription containers include (in alphabetical order) Albertsons, Kroger, McKesson, Medco Health Solutions, Rite-Aid and Walgreen. The Companys largest customers for plastic closures include (in alphabetical order) Coca-Cola Enterprises, Cott Beverages, Nestle USA., Pepsico and Proctor & Gamble.
The Company sells most plastic healthcare containers, prescription containers and closures directly to customers under annual or multi-year supply agreements. These supply agreements typically allow a pass-through of resin price increases and decreases, except for the prescription containers business. The Company also sells some of its products through distributors.
Major markets for the Companys plastics packaging include consumer products and healthcare products.
The Company competes with other manufacturers in the plastics packaging segment on the basis of quality, price, service and product design. The principal competitors producing plastics packaging are Amcor, Consolidated Container Holdings, LLC, Berry Plastics, Plastipak Packaging, Inc., and Silgan Holdings Inc. The Company emphasizes proprietary technology and products, new package development and packaging innovation. The plastic closures segment is divided into various categories in which several suppliers compete for business on the basis of quality, price, service and product design. The principal competitors producing plastic closures are Alcoa, Aptar, Berry Plastics and Rexam.
In addition to competing with other established manufacturers in the plastics packaging segment, the Company competes with manufacturers of other forms of rigid packaging, principally aluminum cans and glass containers, on the basis of quality, price, and service. The principal competitors producing metal containers are Crown Holdings, Inc., Rexam plc, Ball Corporation and Silgan Holdings Inc. The principal competitors producing glass containers in the U.S. are Saint-Gobain Containers, Inc., a wholly-owned subsidiary of Compagnie de Saint-Gobain, and Anchor Glass Container Corporation. The Company also competes with manufacturers of non-rigid packaging alternatives, including flexibles for food and beverages and blister packs, in serving the packaging needs of healthcare customers.
In the U.S., most of the Companys plastic containers, plastic closures and plastic prescription containers are shipped by common carrier. In addition, the Companys plastics packaging operations outside the U.S. export some products to customers beyond their national boundaries, which may include transportation by rail and ocean delivery in combination with common carriers.
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The Company manufactures plastic healthcare containers, closures and prescription containers using HDPE, polypropylene, PET and various other plastic resins. The Company also purchases large quantities of batch colorants, corrugated materials and labels. In general, these raw materials are available in adequate supply from multiple sources. However, for certain raw materials, there may be temporary shortages due to market conditions and other factors.
Worldwide suppliers of plastic resins used in the production of plastics packaging include Chevron Phillips, ExxonMobil, and Total Petrochemicals. Historically, prices for plastic resins have been subject to dramatic fluctuations. However, resin cost pass-through provisions are typical in the Companys supply contracts with its plastics packaging customers.
With the exception of PolyOne, Ampacet and Clariant, each of which does business worldwide, most suppliers of batch colorants are regional in scope. Historically, prices for these raw materials have been subject to dramatic fluctuations. However, cost recovery for batch colorants is included in resin pass-through provisions which are typical of the Companys supply contracts with its plastics packaging customers.
Domestic suppliers of corrugated materials include Georgia-Pacific, International Paper, Smurfit-Stone Container, Temple-Inland, and Weyerhauser. Historically, prices for corrugated materials have not been subject to dramatic fluctuations, except for temporary spikes or troughs from time to time.
Recycling
Recycling content legislation, which has been enacted in several states, requires that a certain specified minimum percentage of recycled plastic be included in certain new plastics packaging. The Company has met such legislated standards in part due to its material process technology. In addition, its plastics packaging manufacturing plants also recycle virtually all of the internal scrap generated in the production process.
The Company has agreements to license its proprietary glass container technology and provide technical assistance to 22 companies in 20 countries. In plastics packaging, the Company has such agreements with 12 companies in 9 countries. These agreements cover areas ranging from manufacturing and engineering assistance to support in functions such as marketing, sales and administration. The worldwide licensee network provides a stream of revenue to support the Companys development activities and gives it the opportunity to participate in the rigid packaging market in countries where it does not already have a direct presence. In addition, the Companys technical agreements enable it to apply best practices developed by its worldwide licensee network. In the years 2005, 2004 and 2003, the Company earned $16.9 million, $21.1 million and $17.5 million, respectively, in royalties and net technical assistance revenue on a continuing operations basis.
The Company believes it is a technological leader in the worldwide glass container segment of the rigid packaging market. Research, development, and engineering constitute important parts of the Companys
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technical activities. On a continuing operations basis, research, development, and engineering expenditures were $65.4 million, $59.0 million, and $64.6 million for 2005, 2004, and 2003, respectively. The Companys research, development and engineering activities include new products, manufacturing process control, automatic inspection and further automation of manufacturing activities.
The Companys worldwide operations, in common with those of the industry generally, are subject to extensive laws, ordinances, regulations and other legal requirements relating to environmental protection, including legal requirements governing investigation and clean-up of contaminated properties as well as water discharges, air emissions, waste management and workplace health and safety. Capital expenditures for property, plant and equipment for environmental control activities were not material during 2005.
In the U.S., Canada, Europe and elsewhere, a number of government authorities have adopted or are considering legal requirements that would mandate certain rates of recycling, the use of recycled materials, or limitations on or preferences for certain types of packaging. The Company believes that governments worldwide will continue to develop and enact legal requirements seeking to, or having the effect of, guiding customer and end-consumer packaging choices.
In North America, sales of beverage containers are affected by governmental regulation of packaging, including deposit return laws. As of January 1, 2006, there were 11 U.S. states with bottle deposit laws in effect, requiring consumer deposits of between 4 and 15 cents, USD, depending on the size of the container. In Canada, there are 8 provinces with consumer deposits between 5 and 20 cents Canadian, depending on the size of the container. In Europe a number of countries have some form of consumer deposit law in effect, including Austria, Belgium, Denmark, Finland, Germany, the Netherlands, Norway, Sweden and Switzerland. The structure and enforcement of such laws and regulations can impact the sales of beverage containers in a given jurisdiction. Such laws and regulations also impact the availability of post-consumer recycled glass for the Company to use in container production.
A number of U.S. states and Canadian provinces have recently considered or are now considering laws and regulations to encourage curbside, deposit return, and on-premise recycling. Although there is no clear trend in the direction of these state and provincial laws and regulations, the Company believes that U.S. states and Canadian provinces, as well as municipalities within those jurisdictions, will continue to adopt recycling laws which will affect supplies of post-consumer glass cullet. As a large user of post-consumer cullet for bottle to bottle production, O-I has an interest in laws and regulations impacting supplies of such material in its markets.
The European Union Emissions Trading Scheme (EUETS) commenced January 1, 2005. The EU has committed to Kyoto Protocol emissions reduction targets and the EUETS is intended to facilitate such reduction. The Companys manufacturing installations which operate in EU countries will need to restrict the volume of their CO2 emissions to the level of their individually allocated Emissions Allowances as set by country regulators. If the actual level of emissions for any installation exceeds its allocated allowance, additional allowances can be bought on the market to cover deficits, while if the actual level of emissions for such installation is less than its allocation, the excess allowances can be sold on the same market. The Company is now engaged in independent verification of its 2005 year end position, comparing actual emissions against allowances, and has until the end of April 2006 to balance its position. The Company will comply with this scheme while continuing to monitor its operations in relation to environmental impacts and considering investments in environmentally friendly and emissions reduction projects. No material effect is anticipated as a result of the EUETS.
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The Company is unable to predict what environmental legal requirements may be adopted in the future. The Company has made significant expenditures for environmental improvements at certain of its factories over the last several years; however, these expenditures did not have a material adverse affect on the Companys results of operations. The compliance costs associated with environmental legal requirements may continue to result in future additional costs to operations.
The Company has a large number of patents which relate to a wide variety of products and processes, has a substantial number of patent applications pending, and is licensed under several patents of others. While in the aggregate the Companys patents are of material importance to its businesses, the Company does not consider that any patent or group of patents relating to a particular product or process is of material importance when judged from the standpoint of any segment or its businesses as a whole.
The Company has a number of intellectual property rights, comprised of both patented and proprietary technology, that make the Companys glass forming machines more efficient and productive than those used by our competitors. In addition, the efficiency of the Companys glass forming machines is enhanced by the Companys overall approach to cost efficient manufacturing technology, which extends from batch house to warehouse. This technology is proprietary to the Company through a combination of issued patents, pending applications, copyrights, trade secret and proprietary know-how.
Upstream of the glass forming machines, there is technology to deliver molten glass to the forming machine at high rates of flow and fully conditioned to be homogeneous in consistency, viscosity and temperature for efficient forming into glass containers. The Company has proprietary know-how in (a) the batch house, where raw materials are stored, measured and mixed, (b) the furnace control system and furnace combustion, and (c) the forehearth and feeding system to deliver such homogeneous glass to the forming machines.
In the Companys glass container manufacturing processes, computer control and electro-mechanical mechanisms are commonly used for a wide variety of applications in the forming machines and auxiliary processes. Various patents held by the Company are directed to the electro-mechanical mechanisms and related technologies used to control sections of the machines. Additional U.S. patents held by the Company and various pending applications are directed to the technology used by the Company for the systems that control the operation of the forming machines and many of the component mechanisms that are embodied in the machine systems.
Downstream of the glass forming machines, there is patented and unpatented technology for ware handling, annealing, coating and inspection, which further enhance the overall efficiency of the manufacturing process.
While the above patents and intellectual property rights are representative of the technology used in the Companys glass manufacturing operations, there are numerous other pending patent applications, trade secrets and other proprietary know-how and technology, as supplemented by administrative and operational best practices, which contribute to the Companys competitive advantage. As noted above, however, the Company does not consider that any patent or group of patents relating to a particular product or process is of material importance when judged from the standpoint of any segment or its businesses as a whole.
12
Sales of particular glass container and plastics packaging products such as beer, food and beverage containers and closures for beverages are seasonal. Shipments in the U.S. and Europe are typically greater in the second and third quarters of the year, while shipments in South America and the Asia Pacific region are typically greater in the first and fourth quarters of the year.
Employees
The Companys worldwide operations employed approximately 28,200 persons as of December 31, 2005. Approximately 66% of North American employees are hourly workers covered by collective bargaining agreements. The principal collective bargaining agreement, which at December 31, 2005, covered approximately 72% of the Companys union-affiliated employees in North America. will expire on March 31, 2008. In addition, a large number of the Companys employees are employed in countries in which employment laws provide greater bargaining or other rights to employees than the laws of the U.S. Such employment rights require the Company to work collaboratively with the legal representatives of the employees to effect any changes to labor arrangements. The Company considers its employee relations to be good and does not anticipate any material work stoppages in the near term.
Executive Officers of the Registrant
Name and Age
Position
Steven R. McCracken (52)
Chairman and Chief Executive Officer since April 2004. He previously served as President of Invista, the global fibers and related intermediates business subsidiary of E. I. DuPont de Nemours and Company (DuPont) 2003-2004, Vice President of DuPont Group 2000-2003; Vice President and General Manager of DuPont Lycra ® 1997-2000.
Edward C. White (58)
Chief Financial Officer since 2005; Senior Vice President and Director of Sales and Marketing for O-I Europe 2004-2005; Senior Vice President since 2003; Senior Vice President of Finance and Administration 2003-2004; Controller 1999-2004; Vice President 2002-2003; Vice President and Director of Finance, Planning, and Administration - International Operations 1997-1999.
John Bachey (57)
Vice President since 1997; Vice President of Glass Container Sales and Marketing since 2000; General Manager, European and Latin American Plastics Operations 1999-2000; General Manager, Europe and Latin America, Continental PET Technologies 1998-1999.
James W. Baehren (55)
Chief Administrative Officer since 2004; Senior Vice President and General Counsel since 2003;
13
Corporate Secretary since 1998; Vice President and Director of Finance 2001-2003; Associate General Counsel 1996-2001.
Joseph V. Conda (64)
President of Healthcare Packaging since 2004; Vice President since 1998; Vice President and General Manager of Prescription Products 2000-2004; Vice President of Glass Container Sales and Marketing 1997-2000.
L. Richard Crawford (45)
President, Latin America Glass since 2005; Vice President, Director of Operations and Technology for O-I Europe 2004-2005; Vice President of Global Glass Technology 2002-2004; Vice President, Manufacturing Manager of Domestic Glass Container 2000-2002; Vice President of Domestic Glass Container and Area Manufacturing Manager, West Coast 1997-2000.
Jeffrey A. Denker (58)
Vice President since 2005; Treasurer since 1998; Assistant Treasurer 1988-1998; Director of International Finance 1987-1998.
Gerard D. Doyle (51)
Vice President and Chief Information Officer since 2004; CIO, ACI Packaging, O-I subsidiary in Australia 1996-2004.
Robert E. Lachmiller (52)
Vice President since 2003; Vice President, Global Operations and Technology since 2004; Vice President and Manufacturing Manager of Glass Container North America 2002-2004; Area Manufacturing Manager of Glass Container North America 1997-2002.
Matthew G. Longthorne (39)
President, North America Glass since 2005; Vice President and Corporate Controller 2004-2005; Glass Containers Vice President 2000-2004; Director of Finance and Administration, Glass Container North America 1999-2004.
Stephen P. Malia (51)
Senior Vice President, Chief Human Resources Officer since 2004; Senior Vice President, Human Resources, IMC Global Inc. 2000-2004.
Michael D. McDaniel (57)
Vice President since 1992; Vice President, President of Closure and Specialty Products since 2001; Vice President and General Manager of Continental PET Technologies 1998-2001; Vice President and General Manager of Closure and Specialty Products 1991-1998.
14
Philip McWeeny (66)
Vice President and General Counsel- Corporate and Assistant Secretary since 1988.
Gilberto Restrepo (65)
Senior Vice President since 2003; President of O-I Europe since 2004; General Manager of Latin American Glass Container Operations 2000-2004; Vice President of International Operations and General Manager, Western Region Latin America 1997-2000; President of Cristaleria Peldar, S.A. since 1982.
Gregory W.J. Ridder (46)
President, OI Asia Pacific since 2006; Chief Financial Officer, OI Asia Pacific 1999-2005; Group Business Development Manager 1995-1999.
Raymond C. Schlaff (50)
Vice President, Chief Procurement Officer since 2004; Vice President, Global Supply Chain, Tyco Plastics and Adhesives business of Tyco International Ltd. 2003-2004; Group Vice President, Managing Director, Nalco Europe, a division of Ondeo Nalco Company 2002- 2003; Vice President, Global Supply Chain, Ondeo Nalco Company 2001-2002; Vice President, Global Procurement, Ondeo Nalco Company 2000- 2001.
Financial Information about Foreign and Domestic Operations
Information as to net sales, Segment Operating Profit, and assets of the Companys product and geographic segments is included in Note 20 to the Consolidated Financial Statements.
Asbestos-Related Contingent Liability The Company has made, and will continue to make, substantial payments to satisfy claims of persons alleging exposure to asbestos-containing products and may need to record additional charges in the future for estimated asbestos-related costs. These substantial payments have affected and may continue to affect the Companys cost of borrowing and the ability to pursue acquisitions.
The Company is one of a number of defendants in a substantial number of lawsuits filed in numerous state and federal courts by persons alleging bodily injury (including death) as a result of exposure to dust from asbestos fibers. From 1948 to 1958, one of the Companys former business units commercially produced and sold approximately $40 million of a high-temperature, calcium-silicate based pipe and block insulation material containing asbestos. The Company exited the pipe and block insulation business in April 1958. The traditional asbestos personal injury lawsuits and claims relating to such production and sale of asbestos material typically allege various theories of liability, including negligence, gross negligence and strict liability and seek compensatory and in some cases, punitive damages in various amounts (herein referred to as asbestos claims).
15
The Company believes that its ultimate asbestos-related liability (i.e., its indemnity payments or other claim disposition costs plus related legal fees) cannot be estimated with certainty. Beginning with the initial liability of $975 million established in 1993, the Company has accrued a total of approximately $2.99 billion through 2005, before insurance recoveries, for its asbestos-related liability. The Companys ability to reasonably estimate its liability has been significantly affected by the volatility of asbestos-related litigation in the United States, the expanding list of non-traditional defendants that have been sued in this, the large number of claims asserted or filed by parties who claim prior exposure to asbestos materials but have no present physical impairment as a result of such exposure, and the growing number of co-defendants that have filed for bankruptcy.
The Company conducted a comprehensive review of its asbestos-related liabilities and costs in connection with finalizing and reporting its results of operations for the year ended December 31, 2005 and concluded that an increase in its reserve for future asbestos-related costs in the amount of $135.0 million was required.
The ultimate amount of distributions which may be required to be made by the Company to fund the Companys asbestos-related payments cannot be estimated with certainty. The Companys reported results of operations for 2005 were materially affected by the $135.0 million fourth quarter charge and asbestos-related payments continue to be substantial. Any future additional charge may likewise materially affect the Companys results of operations for the period in which it is recorded. Also, the continued use of significant amounts of cash for asbestos-related costs has affected and may continue to affect the Companys cost of borrowing and its ability to pursue global or domestic acquisitions.
Substantial Leverage The Companys substantial indebtedness could adversely affect the Companys financial health.
The Company has a significant amount of debt. As of December 31, 2005, the Company had $5.3 billion of total debt outstanding. The Companys substantial indebtedness could result in the following consequences:
Increase vulnerability to general adverse economic and industry conditions;
Increase vulnerability to interest rate increases for the portion of the unhedged and fixed rate borrowing swapped into variable rates;
Require the Company to dedicate a substantial portion of cash flow from operations to payments on indebtedness, thereby reducing the availability of cash flow to fund working capital, capital expenditures, acquisitions, development efforts and other general corporate purposes;
Limit flexibility in planning for, or reacting to the Companys competitors that have less debt; and
Limit, along with the financial and other restrictive covenants in the documents governing our indebtedness, among other things, the ability to borrow additional funds.
Ability to Service DebtTo service its indebtedness, the Company will require a significant amount of cash. The Companys ability to generate cash depends on many factors beyond its control.
The Companys ability to make payments on and to refinance its indebtedness and to fund working capital, capital expenditures, acquisitions, development efforts and other general corporate purposes depends on its ability to generate cash in the future. The Company has no assurance that it will generate sufficient cash flow from operations, or that future borrowings will be available under the secured credit agreement, in an amount sufficient to enable the Company to pay its indebtedness, or to fund other liquidity needs. If short term interest rates increase, the Companys debt service cost will increase because some of its debt is subject to short term variable interest rates. At December 31, 2005, the Companys
16
debt subject to variable interest rates, including fixed rate debt swapped to variable rate, represented approximately 45% of total debt.
The Company may need to refinance all or a portion of its indebtedness on or before maturity. If the Company is unable to generate sufficient cash flow and is unable to refinance or extend outstanding borrowings on commercially reasonable terms or at all, it may have to take one or more of the following actions:
reduce or delay capital expenditures planned for replacements, improvements and expansions;
sell assets;
restructure debt; and/or
obtain additional debt or equity financing.
The Company can provide no assurance that it could effect or implement any of these alternatives on satisfactory terms, if at all.
Debt RestrictionsThe Company may not be able to finance future needs or adapt its business plans to changes because of restrictions contained in the secured credit agreement and the indentures and instruments governing other indebtedness.
The secured credit agreement, the indentures governing secured and unsecured notes and debentures, and certain of the agreements governing other indebtedness contain affirmative and negative covenants that limit the ability of the Company to take certain actions. For example, some of these indentures restrict, among other things, the ability of the issuer and its restricted subsidiaries to borrow money, pay dividends on, or redeem or repurchase its stock, make investments, create liens, enter into certain transactions with affiliates and sell certain assets or merge with or into other companies. These restrictions could adversely affect the Companys ability to operate its businesses and may limit its ability to take advantage of potential business opportunities as they arise.
Failure to comply with these or other covenants and restrictions contained in the secured credit agreement, the indentures or agreements governing other indebtedness could result in a default under those agreements, and the debt under those agreements, together with accrued interest, could then be declared immediately due and payable. If a default occurs under the secured credit agreement, the lenders could cause all of the outstanding debt obligations under such secured credit agreement to become due and payable, which would result in a default under a number of other outstanding debt securities and could lead to an acceleration of obligations related to these debt securities. A default under the secured credit agreement, indentures or agreements governing other indebtedness could also lead to an acceleration of debt under other debt instruments that contain cross acceleration or cross-default provisions.
International Operations The Company is subject to risks associated with operating in foreign countries.
The Company operates manufacturing and other facilities throughout the world. Net sales from international operations totaled approximately $4.7 billion, representing approximately 67% of the Companys net sales for the year ended December 31, 2005. As a result of its international operations, the Company is subject to risks associated with operating in foreign countries, including:
Political, social and economic instability;
War, civil disturbance or acts of terrorism;
Taking of property by nationalization or expropriation without fair compensation;
Changes in government policies and regulations;
17
Devaluations and fluctuations in currency exchange rates;
Imposition of limitations on conversions of foreign currencies into dollars or remittance of dividends and other payments by foreign subsidiaries;
Imposition or increase of withholding and other taxes on remittances and other payments by foreign subsidiaries;
Hyperinflation in certain foreign countries; and
Impositions or increase of investment and other restrictions or requirements by foreign governments.
The risks associated with operating in foreign countries may have a material adverse effect on operations.
Competition The Company faces intense competition from other glass container producers, as well as from makers of alternative forms of packaging. Competitive pressures could adversely affect the Companys financial health.
The Company is subject to significant competition from other glass container producers, as well as from makers of alternative forms of packaging, such as aluminum cans and plastic containers. The Company competes with each rigid packaging competitor on the basis of price, quality, service and the marketing attributes of the container and the closure. Advantages or disadvantages in any of these competitive factors may be sufficient to cause the customer to consider changing suppliers and/or using an alternative form of packaging.
In addition to competing with other large, well-established manufacturers in the glass container segment, the Company competes with manufacturers of other forms of rigid packaging, principally aluminum cans and plastic containers, on the basis of quality, price and service. The Company also competes with manufacturers of non-rigid packaging alternatives, including flexible pouches and aseptic cartons, in serving the packaging needs of juice customers.
Pressures from competitors and producers of alternative forms of packaging have resulted in excess capacity in certain countries in the past and have led to significant pricing pressures in the rigid packaging market.
High Energy Costs Higher energy costs worldwide and interrupted power supplies may have a material adverse effect on operations.
Electrical power and natural gas are vital to the Companys operations as it relies on a continuous power supply to conduct its business. In 2004 and 2005, higher energy costs worldwide negatively impacted the Companys glass container segment operating profit by $22.8 million and $75.7 million, respectively. If energy costs substantially increase in the future, the Company could experience a significant increase in operating costs, which may have a material adverse effect on operations.
Integration Risks The Company may not be able to effectively integrate BSN or additional businesses it acquires in the future.
In addition to the BSN Acquisition, the Company is considering strategic transactions, including acquisitions that will complement, strengthen and enhance growth in its worldwide glass and plastics packaging operations. The Company is evaluating a number of these transactions on a preliminary basis but it is not certain that any of these transactions will advance beyond the preliminary stages or be completed. The BSN Acquisition and strategic transactions, including any future acquisitions, are subject to various risks and uncertainties, including:
18
The inability to integrate effectively the operations, products, technologies and personnel of the acquired companies (some of which are located in diverse geographic regions) and achieve expected synergies;
The potential disruption of existing business and diversion of managements attention from day-to-day operations;
The inability to maintain uniform standards, controls, procedures and policies;
The need or obligation to divest portions of the acquired companies; and
The potential impairment of relationships with customers.
In addition, the Company cannot make assurances that the integration and consolidation of newly acquired businesses, including BSN, will achieve any anticipated cost savings and operating synergies.
Customer Consolidation The continuing consolidation of the Companys customer base may intensify pricing pressures and have a material adverse effect on operations.
Since the early 1990s, many of the Companys largest customers have acquired companies with similar or complementary product lines. This consolidation has increased the concentration of the Companys business with its largest customers. In many cases, such consolidation has been accompanied by pressure from customers for lower prices, reflecting the increase in the total volume of products purchased or the elimination of a price differential between the acquiring customer and the company acquired. Increased pricing pressures from the Companys customers may have a material adverse effect on operations.
Seasonality and Raw Materials Profitability could be affected by varied seasonal demands and the availability of raw materials.
Due principally to the seasonal nature of the brewing, iced tea and other beverage industries, in which demand is stronger during the summer months, sales of the Companys products have varied and are expected to vary by quarter. Shipments in the U.S. and Europe are typically greater in the second and third quarters of the year, while shipments in South America and the Asia Pacific region are typically greater in the first and fourth quarters of the year. Unseasonably cool weather during peak demand periods can reduce demand for certain beverages packaged in the Companys containers.
The raw materials that the Company uses have historically been available in adequate supply from multiple sources. For certain raw materials, however, there may be temporary shortages due to weather or other factors, including disruptions in supply caused by raw material transportation or production delays. These shortages, as well as material increases in the cost of any of the principal raw materials that the Company uses, may have a material adverse effect on operations.
Environmental Risks The Company is subject to various environmental legal requirements and may be subject to new legal requirements in the future. These requirements may have a material adverse effect on operations.
The Companys operations and properties, both in the U.S. and abroad, are subject to extensive laws, ordinances, regulations and other legal requirements relating to environmental protection, including legal requirements governing investigation and clean-up of contaminated properties as well as water discharges, air emissions, waste management and workplace health and safety. Such legal requirements frequently change and vary among jurisdictions. The Companys operations and properties, both in the U.S. and abroad, must comply with these legal requirements. These requirements may have a material adverse effect on operations.
19
The Company has incurred, and expects to incur, costs for its operations to comply with environmental legal requirements, and these costs could increase in the future. Many environmental legal requirements provide for substantial fines, orders (including orders to cease operations), and criminal sanctions for violations. These legal requirements may apply to conditions at properties that the Company presently or formerly owned or operated, as well as at other properties for which the Company may be responsible, including those at which wastes attributable to the Company were disposed. A significant order or judgment against the Company, the loss of a significant permit or license or the imposition of a significant fine may have a material adverse effect on operations.
A number of governmental authorities both in the U.S. and abroad have enacted, or are considering, legal requirements that would mandate certain rates of recycling, the use of recycled materials and/or limitations on certain kinds of packaging materials such as plastics. In addition, some companies with packaging needs have responded to such developments and/or perceived environmental concerns of consumers by using containers made in whole or in part of recycled materials. Such developments may reduce the demand for some of the Companys products and/or increase the Companys costs, which may have a material adverse effect on operations.
Labor Relations Some of the Companys employees are unionized or represented by workers councils.
The Company is party to a number of collective bargaining agreements with labor unions which at December 31, 2005, covered approximately 66% of the Companys employees in North America. The agreement covering substantially all of the Companys union-affiliated employees in its U.S. glass container operations expires in 2008. Upon the expiration of any collective bargaining agreement, if the Company is unable to negotiate acceptable contracts with labor unions, it could result in strikes by the affected workers and increased operating costs as a result of higher wages or benefits paid to union members. In addition, a large number of the Companys employees are employed in countries in which employment laws provide greater bargaining or other rights to employees than the laws of the U.S. Such employment rights require us to work collaboratively with the legal representatives of the employees to effect any changes to labor arrangements. For example, most of the Companys employees in Europe are represented by workers councils that must approve any changes in conditions of employment, including salaries and benefits and staff changes, and may impede efforts to restructure the Companys workforce. Although the Company believes that it has a good working relationship with its employees, if the Companys employees were to engage in a strike or other work stoppage, the Company could experience a significant disruption of operations and/or higher ongoing labor costs, which may have a material adverse effect on operations.
Accounting The Companys financial results are based upon estimates and assumptions that may differ from actual results.
In preparing the Companys consolidated financial statements in accordance with U.S. generally accepted accounting principles, several estimates and assumptions are made that affect the accounting for and recognition of assets, liabilities, revenues and expenses. These estimates and assumptions must be made because certain information that is used in the preparation of the Companys financial statements is dependent on future events, cannot be calculated with a high degree of precision from data available or is not capable of being readily calculated based on generally accepted methodologies. In some cases, these estimates are particularly difficult to determine and the Company must exercise significant judgment. The Company believes that accounting for pension benefit plans, contingencies and litigation, goodwill, and deferred tax assets involves the more significant judgments and estimates used in the preparation of its consolidated financial statements. Actual results for all estimates could differ materially from the
20
estimates and assumptions that the Company uses, which could have a material adverse effect on the Companys financial condition and results of operations.
Accounting Standards The adoption of new accounting standards or interpretations could adversely impact the Companys financial results.
The Companys implementation of and compliance with changes in accounting rules and interpretations could adversely affect its operating results or cause unanticipated fluctuations in its results in future periods. The accounting rules and regulations that the Company must comply with are complex and continually changing. Recent actions and public comments from the SEC have focused on the integrity of financial reporting generally. The Financial Accounting Standards Board, or FASB, has recently introduced several new or proposed accounting standards, or is developing new proposed standards, which would represent a significant change from current industry practices. For example, in December 2004, the FASB issued Statement No. 123 (revised 2004), Share-Based Payment, which requires publicly traded companies to expense stock options, among other equity instruments, in the reporting period beginning January 1, 2006. FAS No. 123R requires each such company to recognize the grant-date fair-value of stock options and other equity-based compensation issued to employees in the companys income statement over the vesting period of the award rather than as a disclosure in the footnotes to the financial statements. FAS No. 123R will reduce the Companys reported financial results and could decrease the Companys stock price. In addition, many companies accounting policies are being subject to heightened scrutiny by regulators and the public. While the Company believes that its financial statements have been prepared in accordance with U.S. generally accepted accounting principles, the Company cannot predict the impact of future changes to accounting principles or its accounting policies on its financial statements going forward.
Funded Status of Pension Plans Recognition of a minimum pension liability may cause a significant reduction in net worth.
Statement of Financial Accounting Standards No. 87, Accounting for Pensions, requires balance sheet recognition of a minimum liability if the fair value of plan assets is less than the accumulated benefit obligation (ABO) at the end of the year. The fair values of the Companys U.S. pension plan assets exceeded the ABO at December 31, 2005; therefore, no recognition of a minimum liability was required with respect to these plans. If the ABO of any of the Companys principal pension plans in the U.S., the Netherlands and Australia exceeds the fair value of its assets at the next measurement date, the Company will be required to write off the related prepaid pension asset and record a liability equal to the excess of the ABO over the fair value of the assets of such plan. The non-cash charge would result in a decrease in the Accumulated Other Comprehensive Income component of share owners equity that would significantly reduce net worth. Even if the fair values of the U.S. plans assets are less than ABO at December 31, 2006, the Company believes it will not be required to make cash contributions to the U.S. plans for at least several years. The covenants under the Companys Third Amended and Restated Secured Credit Agreement would not be affected by a reduction in the Companys net worth if a significant non-cash charge was taken to write off the prepaid pension assets.
Deferred Tax Assets Recognition of minimum pension liabilities may require a deferred tax valuation allowance.
In the U.S., the Company has recorded significant deferred tax assets, the largest of which relate to net operating losses, capital losses, tax credits and the accrued liability for asbestos-related costs that are not deductible until paid. The deferred tax assets are partially offset by deferred tax liabilities, the most significant of which relate to the prepaid pension asset and accelerated depreciation. The Company has recorded a valuation allowance for the portion of U.S. deferred tax assets not offset by deferred tax liabilities. Should the Company be required to write off the prepaid pension assets related to the U.S.
21
pension plans, the related deferred tax liability would also be written off, leaving deferred tax assets amounting to approximately $262 million without a valuation allowance. It is currently likely that an additional valuation allowance would be required in that case since it is currently more likely than not that the deferred tax asset would not be realized.
Goodwill A significant write down of goodwill would have a material adverse effect on the Companys reported results of operations and net worth.
As required by FAS No. 142, Goodwill and Other Intangibles, the Company evaluates goodwill annually (or more frequently if impairment indicators arise) for impairment using the required business valuation methods. These methods include the use of a weighted average cost of capital to calculate the present value of the expected future cash flows of the Companys reporting units. Future changes in the cost of capital, expected cash flows, or other factors may cause the Companys goodwill to be impaired, resulting in a non-cash charge against results of operations to write down goodwill for the amount of the impairment. If a significant write down is required, the charge would have a material adverse effect on the Companys reported results of operations and net worth.
None.
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ITEM 2 . PROPERTIES
The principal manufacturing facilities and other material important physical properties of the continuing operations of the Company at December 31, 2005 are listed below and grouped by product segment. All properties shown are owned in fee except where otherwise noted.
Glass Containers
North American Operations
United States
Glass Container Plants
Atlanta, GA
Oakland, CA
Auburn, NY
Portland, OR
Brockway, PA
Streator, IL
Charlotte, MI
Toano, VA
Clarion, PA
Tracy, CA
Crenshaw, PA
Waco, TX
Danville, VA
Windsor, CO
Lapel, IN
Winston-Salem, NC
Los Angeles, CA
Zanesville, OH
Muskogee, OK
Machine Shops
Godfrey, IL
Canada
Brampton, Ontario
Scoudouc, New Brunswick
Lavington, British Columbia
Toronto, Ontario
Montreal, Quebec
Asia Pacific Operations
Australia
Adelaide
Melbourne
Brisbane
Sydney
Mold Shop
China
Guangzhou
Tianjin
Shanghai
Wuhan
Indonesia
Glass Container Plant
Jakarta
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New Zealand
Auckland
European Operations
Czech Republic
Sokolov
Teplice
Estonia
Jarvakandi
Finland
Karhula
France
Beziers
Vayres
Gironcourt
Veauche
Labegude
VMC Reims
Puy-Guillaume
Wingles
Reims BSN
Germany
Achern
Holzminden
Bernsdorf
Stoevesandt
Hungary
Oroshaza
Italy
Asti
Pordenone
Bari (2 plants)
Terni
Bologna
Trento (2 plants)
Latina
Treviso
Trapani
Varese
Napoli
Glass Recycling Plant
Alessandria
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Netherlands
Leerdam
Schiedam
Maastricht
Poland
Antoninek
Jaroslaw
Spain
Alcala
Barcelona
United Kingdom
Alloa
Harlow
Sand Plant
Devilla
Machine Shop
Birmingham
South American Operations
Brazil
Rio de Janeiro
Sao Paulo
(glass container and tableware)
Manaus
Silica Sand Plant
Descalvado
Colombia
Envigado
Zipaquira (glass container and flat glass)
Soacha
Tableware Plant
Buga
Cali
Zipaquira
25
Ecuador
Guayaquil
Peru
Callao
Venezuela
Valencia
Valera
Plastics Packaging
Berlin, OH (1)
Hamlet, NC
Bowling Green, OH
Hattiesburg, MS
Brookville, PA
Nashua, NH
Constantine, MI
Rocky Mount, NC
Erie, PA
Rossville, GA (2)
Franklin, IN
Washington, NJ (2)
Greenville, SC
Puerto Rico
Las Piedras
Perth
Singapore
Singapore (2)
Gyor (2)
Corporate Facilities
World Headquarters Building
Toledo, OH (2)
Levis Development Park
Perrysburg, OH
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(1) This facility is financed in whole or in part under tax-exempt financing agreements.
(2) This facility is leased in whole or in part.
The Company believes that its facilities are well maintained and currently adequate for its planned production requirements over the next three to five years.
For further information on legal proceedings, see Note 19 to the Consolidated Financial Statements and the section entitled Environmental and Other Governmental Regulation in Item 1.
No matter was submitted to a vote of security holders during the last quarter of the fiscal year ended December 31, 2005.
The price range for the Companys common stock on the New York Stock Exchange, as reported by National Association of Securities Dealers, was as follows:
2005
2004
High
Low
First Quarter
$
26.68
20.25
14.13
10.80
Second Quarter
27.19
22.62
17.40
13.26
Third Quarter
27.50
20.05
17.10
13.92
Fourth Quarter
22.35
17.56
23.89
15.41
The number of share owners of record on January 31, 2006 was 1,320. Approximately 94% of the outstanding shares were registered in the name of Depository Trust Company, or CEDE, which held such shares on behalf of a number of brokerage firms, banks, and other financial institutions. The shares attributed to these financial institutions, in turn, represented the interests of more than 25,000 unidentified beneficial owners. No dividends have been declared or paid since the Companys initial public offering in December 1991 and the Company does not anticipate paying any dividends in the near future. For restrictions on payment of dividends on common stock, see Managements Discussion and Analysis of Financial Condition and Results of Operations Capital Resources and Liquidity Current and Long Term Debt and Note 6 to the Consolidated Financial Statements.
27
The selected consolidated financial data presented below relates to each of the five years in the period ended December 31, 2005. The financial data for each of the five years in the period ended December 31, 2005 was derived from the audited consolidated financial statements of the Company. For more information, see the Consolidated Financial Statements included elsewhere in this document.
Years ended December 31,
Consolidated operating results (a):
2003
2002
2001
(Dollar amounts in millions)
Net sales
7,079.0
6,128.4
4,975.6
4,621.2
4,343.7
Other revenue (b)
110.7
135.0
90.2
110.0
599.2
7,189.7
6,263.4
5,065.8
4,731.2
4,942.9
Costs and expenses:
Manufacturing, shipping and delivery (c)
5,719.5
4,918.4
3,967.9
3,572.9
3,359.3
Research, engineering, selling, administrative and other (d)
1,222.1
659.8
1,106.1
848.6
572.4
Earnings (loss) before interest expense and items below
248.1
685.2
(8.2
)
309.7
1,011.2
Interest expense (e)
466.7
474.9
429.8
372.2
360.3
Earnings (loss) from continuing operations before items below
(218.6
210.3
(438.0
(62.5
650.9
Provision (credit) for income taxes (f)
367.1
5.9
(133.7
(49.8
266.4
Minority share owners interests in earnings of subsidiaries
35.9
32.9
25.8
25.5
19.5
Earnings (loss) from continuing operations before cumulative effect of accounting change
(621.6
171.5
(330.1
(38.2
365.0
Net earnings (loss) of discontinued operations (g)
63.0
64.0
(660.7
38.0
(8.4
Cumulative effect of accounting change (h)
(460.0
Net earnings (loss)
(558.6
235.5
(990.8
(460.2
356.6
28
(Dollar amounts in millions, except per share data)
Basic earnings (loss) per share of common stock:
(4.26
1.01
(2.39
(0.41
2.36
Net earnings (loss) of discontinued operations
0.41
0.44
(4.50
0.26
(0.06
Cumulative effect of accounting change
(3.14
(3.85
1.45
(6.89
(3.29
2.30
Weighted average shares outstanding (in thousands)
150,910
147,963
146,914
146,616
145,456
Diluted earnings (loss) per share of common stock:
1.00
0.43
1.43
Diluted average shares (in thousands)
149,680
145,661
The Companys convertible preferred stock was not included in the computation of 2004 and 2001 diluted earnings per share since the result would have been antidilutive. Options to purchase 5,067,104 and 7,776,942 weighted average shares of common stock which were outstanding during 2004 and 2001, respectively, were not included in the computation of diluted earnings per share because the options exercise price was greater than the average market price of the common shares. For the years ended December 31, 2005, 2003 and 2002, diluted earnings per share of common stock are equal to basic earnings per share of common stock due to the net losses.
29
Other data:
The following are included in net earnings:
Depreciation
480.2
436.0
391.9
353.4
335.9
Amortization of goodwill
55.9
Amortization of intangibles
27.8
23.8
21.4
21.5
21.8
Amortization of deferred finance fees (included in interest expense)
16.0
15.0
14.4
16.1
524.0
474.8
427.7
391.0
428.6
Balance sheet data (at end of period):
Working capital
460
494
758
590
756
Total assets
9,522
10,737
9,531
9,869
10,107
Total debt
5,297
5,360
5,426
5,346
5,401
Share owners equity
724
1,544
1,003
1,671
2,152
(a) Amounts for the year ended December 31, 2004 include the results of BSN from the date of acquisition on June 21, 2004.
(b) Other revenue in 2005 includes $28.1 million (pretax and after tax) from the sale of the Companys glass container facility in Corsico, Italy.
Other revenue in 2004 includes: (1) a gain of $20.6 million ($14.5 million after tax) for the sale of certain real property, and (2) a gain of $31.0 million ($13.1 million after tax) for a restructuring in the Italian Specialty Glass business.
Other revenue in 2001 includes: (1) a gain of $457.3 million ($284.4 million after tax) related to the sale of the Harbor Capital Advisors business and (2) gains totaling $13.1 million ($12.0 million after tax) related to the sale of the label business and the sale of a minerals business in Australia.
(c) Amount for 2005 includes a gain of $3.8 million ($2.3 million after tax) from the mark to market effect of natural gas hedge contracts.
Amount for 2004 includes a gain of $4.9 million ($3.2 million after tax) from the mark to market effect of natural gas hedge contracts.
(d) Amount for 2005 includes a charge of $135.0 million ($86.0 million after tax) to increase the reserve for estimated future asbestos-related costs and a charge of $494.0 million (pretax and after tax) to write down goodwill in the Asia-Pacific Glass unit.
Amount for 2004 includes charges totaling $159.0 million ($90.3 million after tax) for the following: (1) $152.6 million ($84.9 million after tax) to increase the reserve for estimated future asbestos-related costs; and (2) $6.4 million ($5.4 million after tax) for restructuring a life insurance program in order to comply with recent statutory and tax regulation changes.
30
Amount for 2003 includes charges totaling $694.2 million ($490.5 million after tax) for the following: (1) $450.0 million ($292.5 million after tax) to increase the reserve for estimated future asbestos-related costs; (2) $50.0 million ($50.0 million after tax) write-down of an equity investment in a soda ash mining operation; (3) $43.0 million ($30.1 million after tax) for the write-down of Plastics Packaging assets in the Asia Pacific region; (4) $37.4 million ($37.4 million after tax) for the loss on the sale of long-term notes receivable; (5) $37.4 million ($23.4 million after tax) for the estimated loss on the sale of certain closures assets; (6) $28.5 million ($17.8 million after tax) for the permanent closure of the Hayward, California glass container factory; (7) $23.9 million ($17.4 million after tax) for the shutdown of the Perth, Australia glass container factory; (8) $20.1 million ($19.5 million after tax) for the shutdown of the Milton, Ontario glass container factory; and (9) $3.9 million ($2.4 million after tax) for an additional loss on the sale of certain closures assets.
Amount for 2002 includes an adjustment of $475.0 million ($308.8 million after tax) to the reserve for estimated future asbestos-related costs.
Amount for 2001 includes charges totaling $133.7 million ($109.2 million after tax and minority share owners interests) for the following: (1) charges of $66.1 million ($55.3 million after tax and minority share owners interests) related to restructuring and impairment charges at certain of the Companys international glass operations, principally Venezuela and Puerto Rico, as well as certain other domestic and international operations; (2) a charge of $31.0 million (pretax and after tax) related to the loss on the sale of the Companys facilities in India; (3) charges of $28.7 million ($18.0 million after tax) related to special employee benefit programs; and (4) a charge of $7.9 million ($4.9 million after tax) related to restructuring manufacturing capacity in the medical devices business.
(e) Amount for 2004 includes charges of $28.0 million ($18.3 million after tax) for note repurchase premiums.
Amount for 2003 includes a charge of $13.2 million ($8.2 million after tax) for note repurchase premiums.
Amount for 2001 includes a net interest charge of $4.0 million ($2.8 million after tax) related to interest on the resolution of the transfer of pension assets and liabilities for a previous acquisition and divestiture.
Includes additional interest charges for the write off of unamortized deferred financing fees related to the early extinguishment of debt as follows: $2.8 million ($1.8 million after tax) for 2004; $1.3 million ($0.9 million after tax) for 2003; $9.1 million ($5.7 million after tax) for 2002; and $4.7 million ($2.9 million after tax) for 2001.
(f) Amount for 2005 includes a charge of $306.6 million to record a valuation allowance related to accumulated deferred tax assets in the U.S. and a benefit of $5.3 million for the reversal of an accrual for potential tax liabilities related to a previous divestiture. The accrual is no longer required based on the Companys reassessment of potential liabilities.
Amount for 2004 includes a benefit of $33.1 million for a tax consolidation in the Australian glass business.
Amount for 2001 includes a $6.0 million charge to adjust tax liabilities in Italy as a result of recent legislation.
31
(g) Amount for 2005 consists principally of a third quarter benefit from the reversal of an accrual for potential tax liabilities related to a previous divestiture. The accrual is no longer required based on the Companys reassessment of the potential liabilities.
Amounts related to the Companys plastic blow-molded container business have been reclassified to discontinued operations for 2001-2004 as a result of the sale of that business in 2004.
(h) On January 1, 2002, the Company adopted Financial Accounting Standards No. 142, Goodwill and Other Intangible Assets (FAS No. 142). As required by FAS No. 142, the Company changed its method of accounting for goodwill and discontinued amortization of goodwill effective January 1, 2002. Also as required by FAS No. 142, the transitional goodwill impairment loss of $460.0 million is recognized as the cumulative effect of a change in method of accounting.
Executive Overview Year ended December 2005 and 2004
Net sales of the Glass Containers segment were $900.8 million higher than the prior year principally resulting from the BSN Acquisition and favorable foreign currency exchange rates.
Net sales of the Plastics Packaging segment were $49.8 million higher than the prior year. Higher sales from improved pricing, increased sales volume and pass-through of higher resin costs were partially offset by the absence of sales from plastic container assets in the Asia Pacific region that were divested in the second quarter of 2004.
Segment Operating Profit of the Glass Containers segment was $31.2 million higher than the prior year. The BSN Acquisition accounted for most of the increase. The benefits of stronger foreign currencies and higher selling prices were partially offset by inflationary cost increases.
Segment Operating Profit of the Plastics Products segment was $12.2 million higher than the prior year. Increases from improved pricing, sales volume, product mix and a gain from the sale of a plant related to the partial exit from the Australian plastics business more than offset increased costs.
Interest expense was $8.2 million lower than the prior year. The decrease resulted from lower debt levels in the third and fourth quarters of 2005 and the non-recurrence of repurchase premiums partially offset by higher variable interest rates and higher debt from the BSN Acquisition.
Loss from continuing operations in 2005 was $621.6 million, or $4.26 per share (diluted), down from earnings of $171.5 million, or $1.00 per share (diluted), from continuing operations in 2004. Earnings in both periods included items that management considers not representative of continuing operations. These items decreased net earnings in 2005 by $850.9 million, or $5.62 per share, and decreased net earnings in 2004 by $46.5 million, or $0.31 per share.
Cash payments for asbestos-related costs were $171.1 million, down 10.0% from the prior year.
The Companys total debt at December 31, 2005 was $5.30 billion or $63.4 million lower than the prior year balance. Exclusive of the $191.8 million increase in both debt and accounts receivable required by a change in the Companys European accounts receivable securitization program, total debt decreased by $255.2 million to its lowest level since 1998.
32
Results of Operations - Comparison of 2005 with 2004
Net Sales
The Companys net sales by segment for 2005 and 2004 are presented in the following table. The Plastics Packaging amounts for 2004 reflect only the continuing operations. For further information, see Segment Information included in Note 20 to the Condensed Consolidated Financial Statements.
(dollars in millions)
6,266.9
5,366.1
812.1
762.3
Segment and consolidated net sales
Consolidated net sales for 2005 increased $950.6 million, or 15.5%, to $7,079.0 million from $6,128.4 million in 2004.
Net sales of the Glass Containers segment increased $900.8 million, or 16.8%, over 2004. Contributing to the increase were the additional sales from the BSN Acquisition. Increased shipments of beverage containers throughout the Americas more than offset reduced shipments of food containers in North America. Improved pricing also had a favorable effect on net sales. Favorable currency exchange rates accounted for about 5% of the increase. Partially offsetting these increases was the absence of sales from the Castellar factory sold in January 2005.
The change in net sales for the Glass Containers segment can be summarized as follows (dollars in millions):
Net sales - 2004
Net effect of the BSN Acquisition, volume,
price, and mix
883.3
Effects of changing foreign currency rates
46.2
Divestiture of Castellar factory
(28.7
Total net effect on sales
900.8
Net sales - 2005
Net sales of the Plastics Packaging segment increased $49.8 million, or 6.5%, from 2004. The higher sales reflected improved pricing and sales volume in several product lines, the pass-through effect of higher resin costs, and favorable currency translation rates. Partially offsetting these increases was the absence of sales from plastic container assets in the Asia Pacific region that were divested in the second quarter of 2004.
The change in net sales for the Plastics Packaging segment can be summarized as follows (dollars in millions):
33
Effect of increased resin cost pass-throughs
44.8
Net effect of volume, price and mix
34.4
3.5
Divestiture
(32.9
49.8
Segment Operating Profit
Operating Profit for product segments includes an allocation of some corporate expenses based on both a percentage of sales and direct billings based on the costs of specific services provided. For the Companys U.S. pension plans, net periodic pension cost (credit) has been allocated to product segments. The Plastics Packaging amounts for 2004 reflect only the continuing operations. For further information, see Segment Information included in Note 20 to the Consolidated Financial Statements.
790.8
759.6
127.2
115.0
Eliminations and other retained items
(89.4
(102.2
Segment Operating Profit of the Glass Containers segment for 2005 increased $31.2 million, or 4.1%, to $790.8 million, compared with Segment Operating Profit of $759.6 million in 2004. Factors contributing to the increase were: (1) the additional operating profit from the BSN Acquisition; (2) increased unit shipments of beverage containers principally in the Americas; (3) favorable exchange rates; (4) generally improved selling prices; and (5) the non-recurrence of the acquisition step-up of BSN finished goods inventory. Factors that partially offset the increase were: (1) inflationary cost increases including energy, raw material costs, and transportation; (2) temporarily idled production capacity to reduce inventory; (3) costs of the European integration and new European headquarters; (4) the absence of equity earnings from Consol Limited (divested in the fourth quarter of 2004); (5) the absence of operating profit from the Corsico and Castellar factories; and (6) reduced food container shipments in North America.
The change in Segment Operating Profit for the Glass Containers segment can be summarized as follows:
34
Segment Operating Profit - 2004
Net effect of BSN acquisition and volume, price, and mix
184.0
Non-recurrence of BSN inventory step-up
31.1
14.5
Higher energy costs
(75.7
Other inflationary cost increases
(57.7
Temporarily idled production capacity to reduce inventory
(20.5
Effects of European integration and new European headquarter costs
(18.0
Divestiture of Corsico and Castellar factories and Consol investment
(13.6
Increased delivery and warehousing costs
(4.7
Other
Total net effect on Segment Operating Profit
31.2
Segment Operating Profit -2005
Segment Operating Profit of the Plastics Packaging segment for 2005 increased $12.2 million, or 10.6%, to $127.2 million compared with Segment Operating Profit of $115.0 million in 2004. The 2005 amount includes a $6 million fourth quarter gain from the sale of one plant related to the partial exit from the Australian plastics business and a reduction of the accrued exit costs. Also contributing to the increase were the effects of improved pricing, product mix, and sales volume which more than offset the effect of increases in manufacturing, shipping and delivery costs, and the absence of profits from the plastic container assets in the Asia Pacific region that were divested in the second quarter of 2004.
The change in Segment Operating Profit for the Plastics Packaging segment can be summarized as follows (dollars in millions):
14.8
Partial exit of Australian plastics business
6.0
Non-recurrence plant shut down costs
3.7
(4.1
Increased delivery, warehousing and other inflationary cost increases
(4.2
(1.9
(2.1
12.2
Segment Operating Profit - 2005
Eliminations and other retained items for 2005 were favorable by $12.8 million compared to 2004. The 2005 year reflects a favorable adjustment of approximately $10.0 million to the Companys accruals for self-insured risks, partially offset by higher retained costs for the divested blow molded plastic container business and adjustments made to certain accruals. The 2004 year included self-insured property and casualty losses that did not recur in 2005.
Interest Expense
Interest expense decreased to $466.7 million in 2005 from $474.9 million in 2004. The 2004 amount included $30.8 million for repurchase premiums and write-offs of unamortized finance fees. Exclusive of
35
that amount, interest expense increased $22.6 million in 2005 due to higher interest rates on the Companys variable rate debt and additional interest as a result of higher debt related to the BSN Acquisition. Partially offsetting this increase was lower interest as a result of lower average debt balances in the third and fourth quarters of 2005 and lower interest rates on fixed rate debt in the fourth quarter of 2005 compared to the fourth quarter of 2004.
Provision for Income Taxes
Excluding the effects of separately taxed items in both periods, listed in the table below, the Companys effective tax rate for 2005 was 29.9% compared with 26.9% in 2004. The higher 2005 effective rate is principally due to a change in the mix of earnings toward higher tax international jurisdictions, the recent tax legislation in Ohio and recognition of other discrete changes in deferred taxes during 2005.
Minority Share Owners Interest in Earnings of Subsidiaries
Minority share owners interest in earnings of subsidiaries for 2005 was $35.9 million compared to $32.9 million for 2004.
Earnings from Continuing Operations
For 2005, the Company recorded a loss from continuing operations of $621.6 million compared to earnings from continuing operations of $171.5 million for the year ended December 31, 2004. The after tax effects of the items excluded from Segment Operating Profit, the tax charge to increase the valuation allowance, the tax benefit of reversing an accrual for potential tax liabilities, the additional interest charges and the tax benefit on the Australian tax consolidation, increased or decreased earnings in 2005 and 2004 as set forth in the following table (dollars in millions).
Net EarningsIncrease (Decrease)
Description
Gain on the sale of the Corsico, Italy glass container facility
28.1
A tax benefit from the reversal of an accrual for potential tax liabilities
5.3
Gain on the sale of certain real property
Gain on a restructuring in the Italian Specialty Glass business
13.1
Gain from the mark to market effect of natural gas hedge contracts
2.3
3.2
A benefit for a tax consolidation in the Australian glass business
33.1
Impairment of goodwill in the Asia-Pacific Glass unit
(494.0
Increase in the deferred tax valuation allowance
(306.6
Increase in the reserve for future asbestos related costs
(86.0
(84.9
Note repurchase premiums and write-off of finance fees
(20.1
Life insurance restructuring charge
(5.4
Total
(850.9
(46.5
Executive Overview Year ended December 2004 and 2003
Net sales of the Glass Containers segment increased $1,183.2 million as a result of the BSN Acquisition, world wide unit shipment volume growth of approximately 2%, generally higher selling prices, a
36
favorable product mix, and stronger foreign exchange rates in the major regions that the Company does business.
Net sales of the continuing Plastics Packaging segment decreased $30.4 million as a result of lower sales following the divestiture of certain closure assets in the fourth quarter of 2003, the divestiture of a portion of the Asia Pacific plastics business in the second quarter of 2004, and lower shipments of prescription vials in 2004 as compared to 2003 due to the strong flu season in the prior year. These negative effects were partially offset by higher unit shipments of closures.
Segment Operating Profit of the Glass Containers segment increased by $100.8 million over 2003 as a result of the same principal factors that increased sales. In addition, improved productivity also improved Segment Operating Profit over the prior year, but was partially offset by inflation in the Companys manufacturing and overhead costs.
Segment operating Profit of the Plastics Packaging segment increased by $16.3 million as a result of favorable product sales mix, improved productivity, and the non-recurrence of a third quarter 2003 write-off of miscellaneous assets that were no longer being used.
Interest expense for continuing operations increased by $45.1 million as a result of the BSN Acquisition and from tender offer premiums and the write-off of deferred finance fees related to the refinancing of the BSN Senior Subordinated notes and the early retirement of certain outstanding public obligations of the Company.
Net earnings from continuing operations increased by $501.6 million over 2003 as a result of the items listed above in Segment Operating Profit as well as a smaller charge in 2004 to increase the Companys asbestos reserve ($84.9 million after tax in 2004 versus $292.5 million after tax in 2003). During 2004 and 2003, the Company recorded several items that management considers not representative of ongoing operations. The net after tax effect of these items was an increase in earnings of $38.4 million for 2004 and a decrease in earnings of $207.1 million for 2003.
The Company completed the BSN Acquisition on June 21, 2004 for a total purchase price of approximately $1.3 billion.
The Company completed the sale of its blow-molded plastic container operations on October 7, 2004 with total sales proceeds of approximately $1.2 billion.
Asbestos related cash payments of $190.1 million were lower than the prior year by 4.5%.
The Companys total debt at December 31, 2004 was $5.36 billion or $65.1 million lower than the prior year balance.
Cash provided by continuing operating activities improved by $239.7 million over the prior year, principally as a result of higher earnings and the Companys focus on working capital reductions and capital efficiency.
37
Results of Operations - Comparison of 2004 with 2003
The Companys net sales by segment for 2004 and 2003 are presented in the following table. The Plastics Packaging amounts reflect the continuing operations and therefore, the results of the discontinued operations have been reclassified from the 2004 and 2003 amounts. For further information, see Segment Information included in Note 20 to the Consolidated Financial Statements.
4,182.9
792.7
Consolidated net sales for 2004 increased $1,152.8 million, or 23.2%, to $6,128.4 million from $4,975.6 million for 2003.
Net sales of the Glass Containers segment increased $1,183.2 million, or 28.3%, over 2003.
In Europe, the Companys largest region, sales increased $939.5 million from 2003. Net sales from the newly acquired BSN business made up $768.6 million of the regions increase. Stronger currency rates against the U.S. dollar for the European currencies also contributed to the sales growth. Unit volumes for the previously owned European businesses were up 2.8% overall with strong growth in the food, beverage and spirit markets.
In North America, sales for 2004 were $47.2 million higher than sales in 2003. The higher sales resulted principally from increased selling prices and improved product sales mix as unit shipments declined by about 2% overall. The decrease in unit shipments was more than accounted for by the previously disclosed loss of a beverage container customer. Shipments of beer and malt beverage containers increased by approximately 4.8% over 2003, primarily due to the increase in business from a significant malt beverage customer. Shipments of containers for wine and spirits were also higher for 2004; however, shipments of containers for tea, juice and other beverages were lower.
In the Asia Pacific region, sales increased $117.7 million from 2003 principally due to unit volumes that were up 2.9% overall resulting from strong growth in beer, wine and low alcohol refreshers partially offset by lower shipments of food containers.
In South America, sales increased $78.8 million principally as a result of glass container shipments increasing by more than 5% led by strong growth in the beer and beverage markets. Unit growth was significantly affected by lower exports to North America as a result of the loss of a previously disclosed beverage customer. Excluding the loss of those shipments, overall volume growth in South America was approximately 15%.
38
2003 Net sales Glass Containers segment
Additional sales from BSN businesses
768.6
The effects of sales volume, price and mix
257.5
The effects of changing foreign currency rates on net sales
172.1
(15.0
1,183.2
2004 Net sales Glass Containers segment
Net sales of the Plastics Packaging segment decreased $30.4 million, or 3.8%, from 2003. The lower sales primarily reflect the absence of sales from the closure assets divested in the fourth quarter of 2003 and the Asia Pacific plastic operations that were divested in the second quarter of 2004. In addition, sales of containers for prescription packaging were adversely affected due to a milder flu season in December 2004 compared to December 2003. Increased resin prices passed through to customers and stronger currencies in Europe, Brazil and the Asia Pacific region partially offset these reductions.
2003 Net sales Plastics Packaging segment
Divested businesses
(95.7
Effects of higher resin cost pass-throughs
24.1
21.0
9.7
10.5
(30.4
2004 Net sales Plastics Packaging segment
The Companys Segment Operating Profit results (dollars in millions) for 2004 and 2003 are presented in the following table. The Plastics Packaging Segment Operating Profit amounts reflect the continuing operations, and therefore, the results of the discontinued operations have been reclassified from the 2004 and 2003 amounts. In addition, certain Glass Container amounts from prior years have been reclassified to conform to current year presentation. For further information, see Segment Information included in Note 20 to the Consolidated Financial Statements.
658.8
98.7
(91.9
39
Segment Operating Profit of the Glass Containers segment for 2004 increased $100.8 million, or 15.3%, to $759.6 million, compared with Segment Operating Profit of $658.8 million for 2003.
In Europe, Segment Operating Profit for 2004 increased $60.4 million over 2003. The newly acquired BSN business contributed $27.6 million of the increase. Stronger currency rates against the U.S. dollar for the European currencies also contributed to the growth in Segment Operating Profit. In addition, higher unit shipments over 2003 in combination with improved pricing and improved productivity also contributed to the growth. These increases were partially offset by higher energy costs. The Segment Operating Profit contribution from BSN for 2004 includes a reduction in gross profit of $31.1 million related to the impact of the acquisition step-up of BSN finished goods inventory as required by FAS No. 141.
In North America, Segment Operating Profit for 2004 increased $5.7 million over 2003. The benefits of higher selling prices and a more favorable product sales mix were the principal reasons for the increase. These increases were partially offset by a number of unfavorable effects, including: (1) lower production to control inventories consistent with the Companys working capital goals; (2) increased freight expense reflecting higher diesel fuel costs; and (3) a reduction in pension income. Also contributing to this decline was a 2% decline in unit shipments that was the result of the previously disclosed loss of a beverage customer. This decline in shipments of beverage containers was partially offset by increased shipments of containers for beer, wine, and liquor.
In the Asia Pacific region, Segment Operating Profit for 2004 increased $11.8 million over 2003. The effects of overall improved pricing as well as increased unit shipments were partially offset by higher energy costs. The increased unit shipments primarily relate to higher shipments in Australia for containers for wine and beer and increased shipments in New Zealand.
In South America, Segment Operating Profit for 2004 increased $22.9 million over 2003. The increase is primarily attributed to increased unit shipments during the year. Unit shipments were higher in Venezuela where shipments increased 30% over prior year and in Ecuador where shipments increased 34% over prior year. In addition to higher unit shipments, the increase is also attributed to a better product sales mix in Brazil as the sales mix moved away from lower margin exports.
The change in Segment Operating Profit for the Glass Containers segment can be summarized as follows (dollars in millions):
2003 Segment Operating Profit - Glass Containers
107.3
Additional Segment Operating Profit from BSN businesses
27.6
The effect of changing foreign currency rates on Segment Operating Profit
27.0
Improved productivity and other manufacturing costs
Lower pension income
(25.2
(22.8
Increased warehouse and other manufacturing costs
(18.8
2.0
100.8
2004 Segment Operating Profit - Glass Containers
40
Segment Operating Profit of the Plastics Packaging segment for 2004 increased $16.3 million, or 16.5%, to $115.0 million compared to Segment Operating Profit of $98.7 million for 2003. The increase is primarily attributable to improved productivity and higher unit shipments. Also contributing to this increase was the non-recurrence of the third quarter of 2003 write-off of miscellaneous assets that were no longer being utilized. These increases were partially offset by higher delivery, warehouse, shipping and other manufacturing costs, as well as lower pension income.
2003 Segment Operating Profit Plastics Packaging
The effects of price,mix, sales volume and production volume
7.4
The effect of improved productivity
7.0
The non-recurrence of a write-off of miscellaneous assets
4.0
Increased delivery, warehouse, shipping and other manufacturing costs
(3.6
(0.7
2.2
16.3
2004 Segment Operating Profit Plastics Packaging
Eliminations and other retained items for 2004 were $10.3 million higher than for 2003. A reduction in pension income, higher legal and professional services costs in 2004 resulting in part from compliance with the Sarbanes-Oxley Act of 2002 and higher retention of property and casualty losses were the primary reasons for the increase. These increases were partially offset by lower spending on information systems costs as compared to prior year.
Interest expense increased to $474.9 million in 2004 from $429.8 million in 2003. Interest expense for 2004 included charges of $28.0 million for note repurchase premiums and $2.8 million for the write-off of unamortized finance fees related to debt that was repaid prior to its maturity. Interest expense for 2003 included charges of $13.2 million for note repurchase premiums and related write-off of unamortized finance fees and $1.3 million for the write-off of unamortized finance fees related to the reduction of available credit under the Companys previous bank credit agreement. Exclusive of these items in both years, interest expense for 2004 was $28.8 million higher than in 2003. The higher interest in 2004 reflects additional interest as a result of higher debt related to the BSN acquisition. Partially offsetting this increase were lower interest expense that was principally the result of savings from the December 2003 repricing of the Secured Credit Agreement and approximately $21 million in interest savings as a result of the Companys fixed-to-floating interest rate swap on a portion of its fixed-rate debt.
The Companys effective tax rate from continuing operations for 2004 was 2.8%. Excluding the effects of items excluded from Segment Operating Profit discussed above, the additional interest charges for
41
early retirement of debt and a tax benefit on an Australian tax consolidation, the Companys effective tax rate from continuing operations for 2004 was 26.9%. The Companys effective tax rate from continuing operations for 2003 was 30.5%. Excluding the effects of items excluded from Segment Operating Profit discussed above and the additional interest charges for early retirement of debt, the Companys effective tax rate from continuing operations for 2003 was 27.9%. The lower effective tax rate in 2004 is principally due to a favorable change in the global mix of earnings.
Minority share owners interest in earnings of subsidiaries for 2004 was $32.9 million compared to $25.8 million for 2003. The increase in 2004 is primarily due to higher earnings for the Companys subsidiaries in Venezuela, Colombia, and Italy.
For 2004, the Company recorded earnings from continuing operations of $171.5 million compared to a loss from continuing operations of $330.1 million for the year ended December 31, 2003. The aftertax effects of the items excluded from Segment Operating Profit, the additional interest charges discussed above and the tax benefit on the Australian tax consolidation, increased or decreased earnings in 2004 and 2003 as set forth in the following table (dollars in millions).
Gain from the mark to market effect of certain commodity futures contracts
(292.5
(9.1
Write-down of equity investment
(50.0
Write-down of Plastics Packaging assets in the Asia Pacific region
(30.1
Loss on the sale of long-term notes receivable
(37.4
Loss on the sale of certain closures assets
(25.8
Shutdown of the Milton, Ontario glass container factory
(19.5
Shutdown of the Hayward, California glass container factory
(17.8
Shutdown of the Perth, Australia glass container factory
(17.4
(499.6
Acquisition of BSN Glasspack, S.A.
On June 21, 2004, the Company completed the acquisition of BSN Glasspack, S.A. (BSN) from Glasspack Participations (the BSN Acquisition). Total consideration for the BSN Acquisition was approximately $1.3 billion, including the assumption of approximately $650 million of debt, a portion of which was refinanced in connection with the BSN Acquisition. BSN was the second largest glass container manufacturer in Europe with manufacturing facilities in France, Spain, Germany and the
42
Netherlands. The BSN Acquisition was financed with borrowings under the Companys Second Amended and Restated Secured Credit Agreement. In order to secure the European Commissions approval, the Company committed to divest the Barcelona, Spain, and Corsico, Italy glass plants. The Company completed the sale of these plants in January 2005 and received cash proceeds of approximately 138.2 million.
The BSN Acquisition was part of the Companys overall strategy to improve its presence in the European market in order to better serve the needs of its customers throughout the European region and to take advantage of synergies including purchasing leverage and cost reductions. This integration strategy should lead to significant improvement in earnings from the European operations by the end of 2006.
During the second quarter of 2005, the Company concluded its evaluation of acquired capacity and announced the permanent closing of its Düsseldorf, Germany glass container factory, and the shutdown of a furnace at its Reims, France glass container facility, both in 2005. These actions were part of the previously announced European integration strategy to optimally align the manufacturing capacities with the market and improve operational efficiencies. As a result, the Company recorded an accrual of 47.1 million through an adjustment to goodwill.
These second quarter actions will result in the elimination of approximately 400 jobs and a corresponding reduction in the Companys workforce. The Company expects to reduce fixed cash costs by approximately 35 million per year by closing the Düsseldorf factory, shutting down the furnace at Reims and moving most of the production to other locations. The Company anticipates that it will pay out approximately 110.9 million in cash related to severance, benefits, plant clean-up, and other plant closing costs related to restructuring accruals. In addition, the Company expects to pay approximately 65 million for other European reorganization and integration activities, approximately 60% of which will be expensed. Approximately 50% of these payments were made by the end of 2005 and the Company expects that most of the balance will be paid in 2006.
The restructuring accrual recorded in the second quarter of 2005 was in addition to the initial estimated accrual of 63.8 recorded in 2004. Selected information related to the restructuring accrual is as follows, with activity translated from Euros into dollars at the December 31, 2005 exchange rate (dollars in millions):
Total restructuring accrual (110.9 million)
134.1
Net cash paid, principally severance and related benefits
(41.0
Other, principally translation
(12.2
Remaining European restructuring accrual as of December 31, 2005
80.9
The total purchase cost of approximately $1.3 billion was allocated to the tangible and identifiable intangible assets and liabilities based upon their respective fair values. The following table summarizes the fair values of the assets acquired and liabilities assumed on June 21, 2004, translated from Euros into dollars at the exchange rate on that date (dollars in millions):
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June 21,2004
Inventories
294.3
Accounts receivable
197.7
Other current assets (excluding cash acquired)
31.8
Total current assets
523.8
Goodwill
716.6
Other long-term assets
85.4
Net property, plant and equipment
762.1
Assets acquired
2,087.9
Accounts payable and other current liabilities
(425.4
Other long-term liabilities
(387.5
Aggregate purchase costs
1,275.0
The assets above include $48.1 million of intangible assets related to customer relationships, which will be amortized over the next 13 years. The liabilities above include $133.6 million (110.9 million) for the restructuring actions discussed above, the majority of which relates to employee termination costs and related fringe benefits.
Discontinued Operations
On October 7, 2004, the Company announced that it had completed the sale of its blow-molded plastic container operations in North America, South America and Europe, to Graham Packaging Company.
Cash proceeds of approximately $1.2 billion were used to repay term loans under the Companys bank credit facility, which was amended to permit the sale. The sale agreement included a post-closing purchase price adjustment based on changes in certain working capital components and certain other assets and liabilities of the business. This adjustment was finalized in April 2005, and Graham was paid approximately $39 million. The adjustment did not impact results of operations.
Included in the sale were 24 plastics manufacturing plants in the U.S., two in Mexico, three in Europe and two in South America, serving consumer products companies in the food, beverage, household, chemical and personal care industries. The blow-molded plastic container operations were part of the consumer products business unit of the plastics packaging segment.
As required by FAS No. 144, the Company has presented the results of operations for the blow-molded plastic container business in the Consolidated Results of Operations for 2004 and 2003 as a discontinued operation. Interest expense was allocated to discontinued operations based on debt that was required to be repaid from the proceeds.
The following summarizes the revenues and expenses of the discontinued operations as reported in the condensed consolidated results of operations for the period indicated:
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Year ended December 31,
Revenues:
875.3
1,083.4
Other revenue
7.7
9.0
883.0
1,092.4
Manufacturing, shipping and delivery
754.6
949.3
Research, development and engineering
20.2
Selling and administrative
23.7
33.8
Interest
45.1
60.8
22.9
681.0
862.3
1,745.1
Earnings (loss) before items below
20.7
(652.7
Provision for income taxes
27.1
8.0
Gain on sale of discontinued operations
70.4
Net earnings (loss) from discontinued operations
The sale of the blow-molded plastic business resulted in a substantial capital loss, primarily related to previous goodwill write downs that were not deductible when recorded. The 2004 gain on the sale of discontinued operations of $70.4 million includes a credit for income taxes of $39.7 million, representing the tax benefit from offsetting a portion of the loss against otherwise taxable capital gains.
Discontinued operations of $63.0 million for 2005 includes $61.8 million for a benefit from the reversal of an accrual for potential tax liabilities related to a previous divestiture. The accrual is no longer required based on the Companys reassessment of the potential liabilities due to several factors, including statute expiration in September 2005. The balance of $1.2 million relates to an adjustment of the 2004 gain on the sale of the blow-molded plastic container operations principally from finalizing certain tax allocations.
Asbestos-Related Costs
The fourth quarter 2005 charge for asbestos-related costs was $135.0 million ($86.0 million after tax), compared to the fourth quarter 2004 charge of $152.6 million ($84.9 million after tax). These charges resulted from the Companys comprehensive annual review of asbestos-related liabilities and costs. In each case, the Company concluded that an increase in the accrued liability was required to provide for estimated indemnity payments and legal fees arising from asbestos personal injury lawsuits and claims pending and expected to be filed during the several years following the completion of the comprehensive review. See Critical Accounting Estimates for further information.
Asbestos-related cash payments for 2005 were $171.1 million, a reduction of $19.0 million, or 10.0%, from 2004. During 2005, the Company disposed of approximately 12,000 claims. Certain dispositions in 2005 and prior years have included deferred amounts payable over periods ranging up to seven years.
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Deferred amounts payable at December 31, 2005 were approximately $91 million virtually unchanged from the amount at December 31, 2004. The Company anticipates that cash flows from operations and other sources will be sufficient to meet all asbestos-related obligations on a short-term and long-term basis.
As of December 31, 2005, the number of asbestos-related claims pending against the Company was approximately 32,000, down from approximately 35,000 pending claims at December 31, 2004. A former business unit of the Company produced specialized high-temperature insulation material containing asbestos from 1948 until 1958, when the business was sold. In line with its limited involvement with an asbestos-containing product and its exit from that business over 45 years ago, the Company will continue to work aggressively to minimize the number of incoming cases and will continue to limit payments to only those impaired claimants who were exposed to the Companys products and whose claims have merit under applicable state law. See Note 19 to the Consolidated Financial Statements for further information.
2005 Non-operational Items
Impairment of Goodwill
During the fourth quarter of 2005, the Company completed its annual impairment testing using business enterprise values and determined that impairment existed in the goodwill of its Asia Pacific Glass business unit. Lower projected cash flows as a result of competitive pricing pressures in the Companys Australian glass operations caused the decline in the business enterprise value. Following a review of the valuation of the units identifiable assets, the Company recorded an impairment charge of $494.0 million to reduce the reported value of its goodwill.
Deferred Tax Valuation Allowance
The Company recorded a non-cash charge of $306.6 million in the fourth quarter of 2005 to increase the valuation allowance against its accumulated net deferred tax assets in the United States. The Company had recorded net deferred tax assets related principally to asbestos charges and net operating losses in recent years. The amount of valuation allowance required under the provisions of FAS No. 109 is dependent upon projected near-term U.S. profitability including the effects of tax planning. During the fourth quarter of 2005, the Company determined that an additional valuation allowance was necessary because of the near-term effects on U.S. profitability of continued asbestos-related payments, significant interest expense, rising energy costs and other cost increases.
2004 Non-operational Items
Plastics Packaging Assets
In August of 2003, the Company initiated a review of its Plastics Packaging assets in the Asia Pacific region. The review was completed during the fourth quarter of 2003. The Company used a combination of estimated divestment cash flows, which included bid prices from potential purchasers, and partial liquidation values for certain assets to determine the net realizable values of the assets. The Company compared the estimated net realizable values to the book values of the assets and determined that asset impairment existed. As a result, the Company recorded a charge of $43.0 million ($30.1 million after tax) to write-down the assets to realizable values. Certain of the plastics businesses in the Asia Pacific region operate in highly competitive markets leading to reduced profit margins. In addition, the Companys PET container business has lost a significant amount of business in the past few years. The reduced business and overall excess capacity in the industry has caused a reduction in the overall value of the business.
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During 2004, the Company completed the sale of a portion of this business and is continuing to evaluate prospective buyers for the remaining businesses. The Company does not expect to record any further material losses related to this business.
Capital Resources and Liquidity
Current and Long-Term Debt
The Companys total debt at December 31, 2005 was $5.30 billion, compared to $5.36 billion at December 31, 2004.
On October 7, 2004, in connection with the sale of the Companys blow-molded plastic container operations, the Companys subsidiary borrowers entered into the Third Amended and Restated Secured Credit Agreement (the Agreement). The proceeds from the sale were used to repay C and D term loans and a portion of the B1 term loan outstanding under the previous credit agreement. On January 19, 2005, the Company completed the required divestiture of two European glass container factories and received proceeds of approximately $180 million. The proceeds were largely used to repay debt during the first quarter.
At December 31, 2005, the Agreement included a $600.0 million revolving credit facility and a $223.9 million A1 term loan, each of which has a final maturity date of April 1, 2007. It also included a $220.8 million B1 term loan, a $185.6 million C1 term loan, and a 46.3 million C2 term loan, each of which has a final maturity date of April 1, 2008. The Agreement also permits the Company, at its option, to refinance certain of its outstanding notes and debentures prior to their scheduled maturity. At December 31, 2005, the Companys subsidiary borrowers had unused credit of $511.0 million available under the Agreement.
The weighted average interest rate on borrowings outstanding under the Agreement at December 31, 2005 was 5.96%. Including the effects of cross-currency swap agreements related to borrowings under the Agreement by the Companys Australian subsidiary, as discussed in Note 9, the weighted average interest rate was 6.76%.
The Agreement contains covenants and provisions that, among other things, restrict the ability of the Company and its subsidiaries to dispose of assets, incur additional indebtedness, prepay other indebtedness or amend certain debt instruments, pay dividends, create liens on assets, enter into contingent obligations, enter into sale and leaseback transactions, make investments, loans or advances, make acquisitions, engage in mergers or consolidations, change the business conducted, or engage in certain transactions with affiliates and otherwise restrict certain corporate activities. In addition, the Agreement contains financial covenants that require the Company to maintain specified financial ratios and meet specified tests based upon financial statements of the Company and its subsidiaries on a consolidated basis, including minimum fixed charge coverage ratios, maximum leverage ratios and specified capital expenditure tests.
During December 2004, a subsidiary of the Company issued Senior Notes totaling $400.0 million and Senior Notes totaling 225.0 million. The notes bear interest at 6.75%, and are due December 1, 2014. Both series of notes are guaranteed by substantially all of the Companys domestic subsidiaries. The indentures for both series of notes have substantially the same restrictions as the previously issued 7.75%, 8.875% and 8.75% Senior Secured Notes and 8.25% Senior Notes. The issuing subsidiary used the net proceeds from the notes of approximately $680.0 million in addition to borrowings under the Agreement to purchase in a tender offer $237.6 million of the $350.0 million 7.15% Senior Notes due 2005, 159.6
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million of the 160.0 million 9.25% BSN notes due 2009 and 127.3 million of the 140.0 million 10.25% BSN notes due 2009. As part of the issuance of these notes and the related tender offer, the Company recorded in the fourth quarter of 2004 additional interest charges of $28.3 million for note repurchase premiums and the related write-off of unamortized finance fees.
The Senior Secured Notes and Senior Notes that were issued during the past four years were part of the Companys plan to improve financial flexibility by issuing long-term fixed rate debt, as well as refinance existing fixed rate debt that was nearing maturity. While this strategy extended the maturity of the Companys debt, long-term fixed rate debt increases the cost of borrowing compared to shorter term, variable rate debt. The Company does not intend to continue to refinance variable rate debt with new fixed rate issuances, but will continue to issue long-term fixed rate debt in order to repay existing fixed rate debt that is nearing maturity.
During the fourth quarter of 2005, the Company expanded the capacity of its European accounts receivable securitization program from 200 million to 320 million to include operations in Italy and the United Kingdom. The accounts receivable securitization program provides lower costs of financing than traditional bank debt. The terms of this expansion resulted in a changing from off-balance sheet to on-balance sheet accounting for the program. The net impact was an increase, at December 31, 2005, in reported accounts receivable and consolidated debt of $191.8 million.
Cash Flows
For 2005, cash provided by continuing operating activities was $503.8 million compared with $544.7 million for 2004. The working capital reduction in 2004 occurred largely in BSN operations following its acquisition in June 2004 when inventories were at seasonally high levels. Higher payments of accrued liabilities and accounts payable, including approximately $41.0 million for European restructuring activities, also required more cash in 2005 than in 2004. In addition, cash flows in 2004 benefited from the initial effects of the Companys program to improve working capital management.
For the year ended December 31, 2005, the Company paid $450.9 million in cash interest compared with $548.8 million for 2004. The 2004 amount included $47.2 million for repurchase premiums. Exclusive of that amount, cash paid for interest decreased $50.7 million from 2004. The decrease in cash interest paid is primarily due to lower overall interest rates from the June 2005 repricing of the Agreement, lower rates on fixed rate debt, lower average debt balances and the effects of cross currency swaps in Australia.
Asbestos-related payments for 2005 decreased $19.0 million, or 10.0%, to $171.1 million, compared with $190.1 million for 2004. The Company expects that its total asbestos-related payments in 2006 will be moderately lower than 2005. Based on the Companys expectations regarding future payments for lawsuits and claims and also based on the Companys expected operating cash flow, the Company believes that the payment of any deferred amounts of previously settled or otherwise determined lawsuits and claims, and the resolution of presently pending and anticipated future lawsuits and claims associated with asbestos, will not have a material adverse effect upon the Companys liquidity on a short-term or long-term basis.
Capital spending for property, plant and equipment from continuing operating activities was $404.1 million compared to $436.7 million in the prior year. The 2005 amount included spending in the acquired BSN operations for the full year compared to the 2004 amount which included only the period from June 21 through December 31, 2004. The Company continues to focus on reducing capital spending and improving its return on invested capital by improving capital efficiency.
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Cash flows from financing activities included payments by foreign operations to settle swaps of borrowings denominated in currencies other than the local functional currency. In particular, during the second quarter of 2005 certain swaps that hedged U.S. dollar borrowings in Australia required payments at maturity of approximately $65 million. These payments offset the Australian dollar gains recorded over the 2-year duration of the swaps during which the Australian dollar strengthened significantly against the U.S. dollar.
The Company anticipates that cash flow from its operations and from utilization of credit available under the Agreement will be sufficient to fund its operating and seasonal working capital needs, debt service and other obligations on a short-term and long-term basis.
Contractual Obligations and Off-Balance Sheet Arrangements
The following information summarizes the Companys significant contractual cash obligations at December 31, 2005 (dollars in millions).
Payments due by period
Contractual cash obligations:
Less thanone year
1-2 years
3-5 years
More than 5years
Long-term debt
5,263.6
251.7
1,325.2
1,254.8
2,431.9
Capital lease obligations
7.1
0.3
2.1
2.6
Operating leases
226.3
73.3
89.1
40.9
23.0
Contractual purchase obligation
10.7
2,253.7
402.7
746.1
513.3
591.6
Pension benefit plan contributions
48.9
Postretirement benefit plan benefit payments
214.4
42.6
42.7
107.6
Total contractual cash obligations
8,024.7
809.1
2,205.1
1,853.8
3,156.7
Amount of commitment expiration per period
Other commercial commitments:
1-3 years
More than 5 years
Standby letters of credit
89.0
Guarantees
Total commercial commitments
98.0
Critical Accounting Estimates
The Companys analysis and discussion of its financial condition and results of operations are based upon its consolidated financial statements that have been prepared in accordance with accounting principles generally accepted in the United States (U.S. GAAP). The preparation of financial statements in conformity with U.S. GAAP requires management to make estimates and assumptions that affect the reported amounts of assets, liabilities, revenues and expenses, and the disclosure of contingent assets and liabilities. The Company evaluates these estimates and assumptions on an ongoing basis, including but not limited to those related to pension benefit plans, contingencies and litigation, goodwill, and deferred tax assets. Estimates and assumptions are based on historical and other factors believed to be reasonable under the circumstances. The results of these estimates may form the basis of the carrying value of
49
certain assets and liabilities and may not be readily apparent from other sources. Actual results, under conditions and circumstances different from those assumed, may differ from estimates. The impact and any associated risks related to estimates and assumptions are discussed within Managements Discussion and Analysis of Financial Condition and Results of Operations, as well as in the Notes to the Consolidated Financial Statements, if applicable, where estimates and assumptions affect the Companys reported and expected financial results.
The Company believes that accounting for pension benefit plans, contingencies and litigation, goodwill, and deferred tax assets involves the more significant judgments and estimates used in the preparation of its consolidated financial statements.
Pension Benefit Plans
The determination of pension obligations and the related pension expense or credits to operations involves significant estimates. The most significant estimates are the discount rate used to calculate the actuarial present value of benefit obligations and the expected long-term rate of return on assets used in calculating the pension charges or credits for the year. The Company uses discount rates based on yields of highly rated fixed income debt securities at the end of the year. At December 31, 2005, the weighted average discount rate for all plans was 5.3%. The Company uses an expected long-term rate of return on assets that is based on both past performance of the various plans assets and estimated future performance of the assets. Due to the nature of the plans assets and the volatility of debt and equity markets, results may vary significantly from year to year. For example, actual returns in the Companys two largest plans were negative in each of the years 2000-2002. The returns exceeded 20% in 2003, 18% in 2004 and 10% in 2005. The Company refers to average historical returns over longer periods (up to 10 years) in determining its expected rates of return because short-term fluctuations in market values do not reflect the rates of return the Company expects to achieve based upon its long-term investing strategy. For 2005, the Companys estimated weighted average expected long-term rate of return on pension assets was 8.4% compared to 8.7% for the year ended December 31, 2004. The Company recorded pension expense from continuing operations totaling approximately $4.0 million and $8.7 million for 2005 and 2004, respectively, from its principal defined benefit pension plans. The reduction in net pension expense resulted from changes in the U.S. salary plan, partially offset by lower discount rates, lower return rates and higher amortization. Depending on currency translation rates, the Company expects to record approximately $30.0 million of pension expense for the full year of 2006, compared with expense of $4.0 million for 2005.
Future effects on reported results of operations depend on economic conditions and investment performance. For example, a one-half percentage point change in the actuarial assumption regarding the expected return on assets would result in a change of approximately $18 million in pretax pension expense for the full year 2006. In addition, changes in external factors, including the fair values of plan assets and the discount rates used to calculate plan liabilities, could result in possible future balance sheet recognition of additional minimum pension liabilities.
If the Accumulated Benefit Obligation (ABO) of any of the Companys principal pension plans in the U.S. and Australia exceeds the fair value of its assets at the next measurement date of December 31, 2006, the Company will be required to write off the related prepaid pension asset and record a liability equal to the excess of the ABO over the fair value of the asset of such plan at the next measurement date of December 31, 2006. The non-cash charge would result in a decrease in the Accumulated Other Comprehensive Income component of share owners equity that would significantly reduce net worth. Amounts related to the Companys U.S. and Australian plans as of December 31, 2005 were as follows (millions of dollars):
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U.S. SalaryPlans
U.S. HourlyPlans
AustralianPlans
Fair value of assets
832.4
1,730.4
107.4
2,670.2
Accumulated benefit obligations
766.2
1,441.2
79.3
2,286.7
Excess
66.2
289.2
383.5
Prepaid pension asset
327.2
643.8
17.1
988.1
The Company is unable to predict discount rates or asset values at the next measurement date of December 31, 2006. However, if asset values and discount rates decline from their December 31, 2005 levels, the ABO of the U.S. salary plan may exceed the plans assets at the measurement date. In that event, the plans prepaid asset would be written off resulting in a pre-tax charge to other comprehensive income in the range of $330 million to $340 million.
Even if the fair values of the U.S. plans assets are less than ABO at December 31, 2006, the Company believes it will not be required to make cash contributions to the U.S. plans for at least several years. The covenants under the Companys Third Amended and Restated Secured Credit Agreement would not be affected by a reduction in the Companys net worth if a significant non-cash charge was taken to write off the prepaid pension assets.
Contingencies and Litigation
The Company believes that its ultimate asbestos-related liability (i.e., its indemnity payments or other claim disposition costs plus related legal fees) cannot be estimated with certainty. The Companys ability to reasonably estimate its liability has been significantly affected by the volatility of asbestos-related litigation in the United States, the expanding list of non-traditional defendants that have been sued in this litigation, the continued use of litigation screenings to generate new lawsuits, the large number of claims asserted or filed by parties who claim prior exposure to asbestos materials but have no present physical impairment as a result of such exposure, and the growing number of co-defendants that have filed for bankruptcy. The Company believes that the bankruptcies of additional co-defendants have resulted in an acceleration of the presentation and disposition of a number of claims, which would otherwise have been presented and disposed of over the next several years. The Company continues to monitor trends which may affect its ultimate liability and continues to analyze the developments and variables affecting or likely to affect the resolution of pending and future asbestos claims against the Company.
The Company conducts a comprehensive review of its asbestos-related liabilities and costs annually in connection with finalizing and reporting its annual results of operations, unless significant changes in trends or new developments warrant an earlier review. If the results of an annual comprehensive review indicate that the existing amount of the accrued liability is insufficient to cover its estimated future asbestos-related costs, then the Company will record an appropriate charge to increase the accrued liability. The Company believes that an estimation of the reasonably probable amount of the contingent liability for claims not yet asserted against the Company is not possible beyond a period of several years. Therefore, while the results of future annual comprehensive reviews cannot be determined, the Company expects the addition of one year to the estimation period will result in an annual charge.
In the fourth quarter of 2005, the Company recorded a charge of $135.0 million ($86.0 million after tax) to increase its accrued liability for asbestos-related costs. This amount was reduced from the 2004 charge of $152.6 million. The factors and developments that particularly affected the determination of this increase in the accrual included the following: (i) the 10% decline in yearly cash outlays; (ii) the slight decline in serious disease filings against the Company and the significant decline in the non-malignancy
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filings; (iii) the Companys successful litigation record during the year; and (iv) legislative developments in several states.
The Companys estimates are based on a number of factors as described further in Note 19 to the Consolidated Financial Statements.
As required by FAS No. 142, Goodwill and Other Intangibles, the Company evaluates goodwill annually (or more frequently if impairment indicators arise) for impairment. The Company conducts its evaluation as of October 1 of each year. Goodwill impairment testing is performed using the business enterprise value (BEV) of each reporting unit which is calculated as of a measurement date by determining the present value of debt-free, after-tax projected future cash flows, discounted at the weighted average cost of capital of a hypothetical third party buyer. This BEV is then compared to the book value of each reporting unit as of the measurement date to assess whether an impairment of goodwill may exist.
During the fourth quarter of 2005, the Company completed its annual testing and determined that impairment existed in the goodwill of its Asia Pacific Glass business unit. Following a review of the units identifiable assets, the Company recorded an impairment charge of $494.0 million to reduce the reported value of its goodwill.
If the Companys projected future cash flows were substantially lower, or if the assumed weighted average cost of capital were substantially higher, the testing performed as of October 1, 2005, may have indicated an impairment of one or more of the Companys other reporting units and, as a result, the related goodwill would also have been impaired. However, based on the Companys testing as of that date, modest changes in the projected future cash flows or cost of capital would not have created impairment in any other reporting unit.
The Company will monitor conditions throughout 2006 that might significantly affect the projections and variables used in the impairment test to determine if a review prior to October 1 may be appropriate. If the results of impairment testing confirm that a write down of goodwill is necessary, then the Company will record a charge in the fourth quarter of 2006, or earlier if appropriate. In the event the Company would be required to record a significant write down of goodwill, the charge would have a material adverse effect on reported results of operations and net worth.
Deferred Tax Assets
FAS No. 109, Accounting for Income Taxes, requires that a valuation allowance be recorded when it is more likely than not that some portion or all of the deferred tax assets will not be realized. This assessment is largely dependent upon projected near-term profitability including the effects of tax planning. Deferred tax assets and liabilities are determined separately for each tax jurisdiction in which the Company conducts its operations or otherwise incurs taxable income or losses. In the United States, the Company has recorded significant deferred tax assets, the largest of which relate to net operating losses, capital losses, tax credits and the accrued liability for asbestos-related costs that are not deductible until paid. The deferred tax assets are partially offset by deferred tax liabilities, the most significant of which relate to the prepaid pension asset and accelerated depreciation. The Company has recorded a valuation allowance for the portion of U.S. deferred tax assets not offset by deferred tax liabilities. Should the Company be required to write off the prepaid pension assets related to the U.S. pension plans (as described above under Pension Benefit Plans), the related deferred tax liability would also be written off, leaving deferred tax assets amounting to approximately $262 million without a valuation allowance.
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It is currently likely that an additional valuation allowance would be required in that case since it is currently more likely than not that the deferred tax asset would not be realized.
Market risks relating to the Companys operations result primarily from fluctuations in foreign currency exchange rates, changes in interest rates, and changes in commodity prices, principally energy. The Company uses certain derivative instruments to mitigate a portion of the risk associated with changing foreign currency exchange rates and fluctuating energy prices. In addition, the Company uses interest rate swap agreements to manage a portion of fixed and floating rate debt and to reduce interest expense. These instruments carry varying degrees of counterparty credit risk. To mitigate this risk, the Company has established limits on the exposure with individual counterparties and the Company regularly monitors these exposures. Substantially all of these exposures are with counterparties that are rated single-A or above.
Foreign Currency Exchange Rate Risk
Earnings of operations outside the United States
A substantial portion of the Companys operations are conducted by subsidiaries outside the U.S. The primary international markets served by the Companys subsidiaries are in Canada, Australia, South America (principally Colombia, Brazil and Venezuela), and Europe (principally Italy, France, the Netherlands, Germany, the United Kingdom, and Poland). In general, revenues earned and costs incurred by the Companys major international operations are denominated in their respective local currencies. Consequently, the Companys reported financial results could be affected by factors such as changes in foreign currency exchange rates or highly inflationary economic conditions in the international markets in which the Companys subsidiaries operate. When the U.S. dollar strengthens against foreign currencies, the reported dollar value of local currency earnings generally decreases; when the U.S. dollar weakens against foreign currencies, the reported U.S. dollar value of local currency earnings generally increases. The Company does not have any significant foreign subsidiaries that are denominated in the U.S. dollar, however, if economic conditions in Venezuela continue to decline, the Company may be required to adopt the U.S. dollar as the functional currency for its subsidiaries in that country. The Company does not hedge the foreign currency exchange rate risk related to earnings of operations outside the United States.
Borrowings not denominated in the functional currency
Because the Companys subsidiaries operate within their local economic environment, the Company believes it is appropriate to finance those operations with borrowings denominated in the local currency to the extent practicable where debt financing is desirable or necessary. Considerations which influence the amount of such borrowings include long- and short-term business plans, tax implications, and the availability of borrowings with acceptable interest rates and terms. In those countries where the local currency is the designated functional currency, this strategy mitigates the risk of reported losses or gains in the event the foreign currency strengthens or weakens against the U.S. dollar. In those countries where the U.S. dollar is the designated functional currency, however, local currency borrowings expose the Company to reported losses or gains in the event the foreign currency strengthens or weakens against the U.S. dollar.
Available excess funds of a subsidiary may be redeployed through intercompany loans to other subsidiaries for debt repayment, capital investment, or other cash requirements. Generally, each
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intercompany loan is denominated in the lenders local currency giving rise to foreign currency exchange rate risk for the borrower. To mitigate this risk, the borrower generally enters into a forward exchange contract which effectively swaps the intercompany loan and related interest to its local currency.
Similarly, certain of the Companys international subsidiaries have external borrowings denominated in currencies other than the designated functional currency, giving rise to foreign currency exchange rate risk for the borrower. To mitigate this risk, certain subsidiaries have entered into currency swaps or forward exchange contracts for the principal amount of their borrowings and, in some cases, the related interest.
Significant transactions related to foreign currency exchange rate risk arising from borrowings not denominated in the functional currency are as follows:
At the end of 2005, the Companys subsidiary in Australia had an agreement that swaps a total of U.S. $175.0 million of borrowings into 251.8 million Australian dollars. This derivative instrument swaps the principal from U.S. dollars to Australian dollars and also swaps the interest rate from a U.S.-based rate to an Australian-based rate. This agreement has a maturity date of March 2006.
In connection with debt refinancing in late December 2004, the Companys subsidiary in France borrowed approximately 91 million from Owens-Brockway Glass Container (OBGC), a U.S. subsidiary of the Company, at a fixed interest rate through 2009. In order to hedge the changes in the cash flows of the foreign currency interest and principal repayments, OBGC entered into a swap that converts the Euro coupon interest payments into a predetermined U.S. dollar coupon interest payment and also converts the final principal payment in December 2009 from 91.0 million to approximately $120.7 million U.S. dollars.
The Companys subsidiaries in Australia, Canada and several European countries have also entered into short term forward exchange contracts which effectively swap additional intercompany and external borrowings by each subsidiary into its local currency. These contracts swap the principal amount of borrowings and in some cases they swap the related interest.
Purchases and sales not denominated in the functional currency
Through the use of forward exchange contracts, the Company fixes some or all of the future amount payable/receivable on significant purchases and sales denominated in currencies other than the functional currency of the subsidiary entering into the underlying transaction. These instruments typically have terms of one year or less. Significant transactions related to foreign currency exchange rate risk arising from purchases and sales not denominated in the functional currency are as follows:
The Company entered into a foreign currency exchange contract to swap 37.5 million into $47.3 million U.S. dollars related to anticipated 2006 western European fuel oil purchases, a portion of which is denominated in U.S. dollars. The swap mitigates foreign currency exchange rate risk relating to approximately 93% of the anticipated 2006 fuel oil purchases in western Europe.
The Company believes the near term exposure to foreign currency exchange rate risk of its foreign currency risk sensitive instruments was not material at December 31, 2005 and 2004.
54
Interest Rate Risk
The Companys interest expense is most sensitive to changes in the general level of U.S. interest rates applicable to its U.S. dollar indebtedness.
In the fourth quarter of 2003 and the first quarter of 2004, the Company entered into a series of interest rate swap agreements with a total notional amount of $1.25 billion that mature from 2007 through 2013. The swaps were executed in order to: (i) convert a portion of the senior notes and senior debentures fixed-rate debt into floating-rate debt; (ii) maintain a capital structure containing appropriate amounts of fixed and floating-rate debt; and (iii) reduce net interest payments and expense in the near-term.
Under the swaps, the Company receives fixed rate interest amounts (equal to interest on the corresponding hedged note) and pays interest at a six-month U.S. LIBOR rate (set in arrears) plus a margin spread (see table below). The interest rate differential on each swap is recognized as an adjustment of interest expense during each six-month period over the term of the agreement.
The following table provides information about the Companys interest rate sensitivity related to its significant debt obligations and interest rate swaps at December 31, 2005. For debt obligations, the table presents principal cash flows and related weighted-average interest rates by expected maturity date. For interest rate swaps, the table presents notional amounts and weighted-average interest rates by contract maturity date. Notional amounts are used to calculate the contractual cash flows to be exchanged under the swap contracts.
2006
2007
2008
2009
2010
There-after
FairValue at12/31/2005
Long-term debt at variable rate:
Principal by expected maturity
231.8
304.5
461.3
997.6
Avg. principal outstanding
945.5
597.9
115.3
Approx. avg. margin over Eurodollar rate
2.29
%
2.02
2.75
Long-term debt at fixed rate:
300.0
250.0
1,000.0
2,442.0
4,242.0
4,359.1
4,079.5
3,806.6
2,757.8
2,556.6
Avg. interest rate
8.05
8.07
7.83
7.82
Interest rate swaps (pay variable/receive fixed):
Notional by expected maturity
450.0
1,250.0
(34.0
Avg. notional outstanding
1,087.5
814.6
700.0
564.6
Avg. pay rate margin over U.S. LIBOR
3.75
3.64
3.52
3.60
3.70
Avg. fixed receive rate
7.88
7.85
7.89
7.98
8.10
8.25
The Company believes the near term exposure to interest rate risk of its debt obligations and interest rate swaps has not changed materially since December 31, 2004.
55
Commodity Price Risk
The Company has exposure to commodity price risk, principally related to energy. The Company believes it can mitigate a portion of this risk by passing commodity cost changes through to customers. In addition, the Company enters into commodity futures contracts related to forecasted natural gas and fuel oil requirements, the objectives of which are to limit the effects of fluctuations in the future market price paid for natural gas and fuel oil and the related volatility in cash flows. The Company continually evaluates the natural gas and fuel oil market with respect to its forecasted usage requirements over the next twelve to eighteen months and periodically enters into commodity futures contracts in order to hedge a portion of its usage requirements over that period. Significant transactions related to commodity price risk are as follows:
At December 31, 2005, the Company had entered into commodity futures contracts for approximately 62% (approximately 14,780,000 MM BTUs) of its expected North American natural gas usage for full year of 2006 and approximately 15% (approximately 3,600,000 MM BTUs) for the full year of 2007.
At December 31, 2005, the Company had also entered into commodity futures contracts for substantially all of its expected western European fuel oil usage (approximately 43,500 metric tons) for the first quarter of 2006.
The Company believes the near term exposure to commodity price risk of its commodity futures contracts was not material at December 31, 2005 and 2004.
Forward Looking Statements
This document contains forward looking statements within the meaning of Section 21E of the Securities Exchange Act of 1934 and Section 27A of the Securities Act of 1933. Forward-looking statements reflect the Companys current expectations and projections about future events at the time, and thus involve uncertainty and risk. It is possible the Companys future financial performance may differ from expectations due to a variety of factors including, but not limited to the following: (1) foreign currency fluctuations relative to the U.S. dollar, (2) changes in capital availability or cost, including interest rate fluctuations, (3) the general political, economic and competitive conditions in markets and countries where the Company has its operations, including disruptions in the supply chain, competitive pricing pressures, inflation or deflation, and changes in tax rates and laws, (4) consumer preferences for alternative forms of packaging, (5) fluctuations in raw material and labor costs, (6) availability of raw materials, (7) costs and availability of energy, (8) transportation costs, (9) consolidation among competitors and customers, (10) the ability of the Company to integrate operations of acquired businesses and achieve expected synergies, (11) unanticipated expenditures with respect to environmental, safety and health laws, (12) the performance by customers of their obligations under purchase agreements, and (13) the timing and occurrence of events which are beyond the control of the Company, including events related to asbestos-related claims. It is not possible to foresee or identify all such factors. Any forward looking statements in this document are based on certain assumptions and analyses made by the Company in light of its experience and perception of historical trends, current conditions, expected future developments, and other factors it believes are appropriate in the circumstances. Forward-looking statements are not a guarantee of future performance and actual results or developments may differ materially from expectations. While the Company continually reviews trends and uncertainties affecting the Companys results of operations and financial condition, the Company does not assume any obligation to update or supplement any particular forward looking statements contained in this document.
56
Report of Independent Registered Public Accounting Firm
Consolidated Balance Sheets at December 31, 2005 and 2004
For the years ended December 31, 2005, 2004, and 2003:
Consolidated Results of Operations
Consolidated Share Owners Equity
Consolidated Cash Flows
Notes to Consolidated Financial Statements
Selected Quarterly Financial Data
57
REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM
The Board of Directors and Share Owners of
Owens-Illinois, Inc.
We have audited the accompanying consolidated balance sheets of Owens-Illinois, Inc. as of December 31, 2005 and 2004, and the related consolidated statements of results of operations, share owners equity, and cash flows for each of the three years in the period ended December 31, 2005. Our audits also included the financial statement schedule listed in the Index included in Item 15. These financial statements and schedule are the responsibility of the Companys management. Our responsibility is to express an opinion on these financial statements and schedule based on our audits.
We conducted our audits in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion.
In our opinion, the financial statements referred to above present fairly, in all material respects, the consolidated financial position of Owens-Illinois, Inc. at December 31, 2005 and 2004, and the consolidated results of its operations and its cash flows for each of the three years in the period ended December 31, 2005, in conformity with U.S. generally accepted accounting principles. Also, in our opinion, the related financial statement schedule, when considered in relation to the basic financial statements taken as a whole, presents fairly in all material respects the information set forth therein.
We also have audited, in accordance with the standards of the Public Company Accounting Oversight Board (United States), the effectiveness of Owens-Illinois, Inc.s internal control over financial reporting as of December 31, 2005, based on criteria established in Internal Control-Integrated Framework issued by the Committee of Sponsoring Organization of the Treadway Commission and our report dated March 15, 2006 expressed an unqualified opinion thereon.
Ernst & Young LLP
Toledo, Ohio
March 15, 2006
58
CONSOLIDATED RESULTS OF OPERATIONS Owens-Illinois, Inc.
Dollars in millions, except per share amountsYears ended December 31,
Royalties and net technical assistance
16.9
21.1
17.5
Equity earnings
22.6
16.6
15.3
20.4
54.6
70.8
25.2
Manufacturing, shipping, and delivery
Research and development
29.8
25.4
29.9
Engineering
35.6
33.6
34.7
488.1
402.3
320.9
668.6
198.5
720.6
7,408.3
6,053.1
5,503.8
Provision (benefit) for income taxes
Earnings (loss) from continuing operations
59
CONSOLIDATED BALANCE SHEETS Owens-Illinois, Inc.
Dollars in millionsDecember 31,
Assets
Current assets:
Cash, including time deposits of $117.0($175.9 in 2004)
246.6
277.9
Short-term investments
51.9
Receivables, less allowances of $47.4($50.3 in 2004) for losses and discounts
1,006.2
821.3
940.4
1,117.7
Prepaid expenses
37.2
156.3
2,282.3
2,400.8
Other assets:
Equity investments
114.9
117.1
Repair parts inventories
170.3
192.2
Prepaid pension
962.5
Deposits, receivables, and other assets
444.5
557.3
2,369.2
3,009.1
Total other assets
4,087.0
4,838.2
Property, plant, and equipment:
Land, at cost
240.0
165.2
Buildings and equipment, at cost:
Buildings and building equipment
1,045.3
945.0
Factory machinery and equipment
4,620.4
4,821.2
Transportation, office, and miscellaneous equipment
123.6
139.2
Construction in progress
116.7
185.7
6,146.0
6,256.3
Less accumulated depreciation
2,993.5
2,758.6
Net property, plant, and equipment
3,152.5
3,497.7
9,521.8
10,736.7
60
Dollars in millions, except per share amountsDecember 31,
Liabilities and Share Owners Equity
Current liabilities:
Short-term loans
26.3
18.2
Accounts payable
843.0
857.8
Salaries and wages
153.0
178.4
U.S. and foreign income taxes
32.6
53.8
Current portion of asbestos-related liabilities
158.0
170.0
Other accrued liabilities
357.0
454.0
Long-term debt due within one year
252.0
174.3
Total current liabilities
1,821.9
1,906.5
5,018.7
5,167.9
Deferred taxes
186.0
183.3
Nonpension postretirement benefits
277.1
285.6
Other liabilities
740.6
Asbestos-related liabilities
572.1
596.2
Commitments and contingencies
Minority share owners interests
181.5
169.6
Share owners equity:
Convertible preferred stock, par value $.01 per share, liquidation preference $50 per share, 9,050,000 shares authorized, issued and outstanding
452.5
Common stock, par value $.01 per share, 250,000,000 shares authorized, 165,216,558 shares issued and outstanding, less 12,305,308 treasury shares at December 31, 2005 (163,502,417 issued and outstanding less 12,586,053 treasury shares at December 31, 2004)
1.7
1.6
Capital in excess of par value
2,297.0
2,261.1
Treasury stock, at cost
(236.0
(241.3
Retained deficit
(1,555.4
(975.3
Accumulated other comprehensive income (loss)
(235.9
45.7
Total share owners equity
723.9
1,544.3
Total liabilities and share owners equity
See accompanying Notes to the Consolidated Financial Statements.
61
CONSOLIDATED SHARE OWNERS EQUITY Owens-Illinois, Inc.
Dollars in millionsYears ended December 31,
Convertible preferred stock
Balance at beginning of year
Balance at end of year
Common stock
Issuance of common stock
0.1
2,229.3
2,224.9
4.4
Treasury stock
(247.6
Reissuance of common stock
6.3
62
(1,189.3
(177.0
Cash dividends on convertible preferred stock $2.375 per share
(21.5
(243.1
(583.6
Foreign currency translation adjustments
(288.9
317.4
361.0
Change in minimum pension liability, net of tax
(7.2
(27.5
(19.3
Change in fair value of certain derivative instruments, net of tax
(1.1
(1.2
1,003.4
Total comprehensive income (loss)
(840.2
524.3
(650.3
63
CONSOLIDATED CASH FLOWS Owens-Illinois, Inc.
Operating activities:
Non-cash charges (credits):
Amortization of deferred costs
Amortization of deferred finance fees
Deferred tax credit
(75.0
(93.3
(182.7
Impairment of goodwill
494.0
Deferred tax valuation allowance
306.6
Future asbestos-related costs
152.6
Gains on asset sales
(28.1
(51.6
Mark to market effect of natural gas hedge contracts
(3.8
(4.9
50.0
Restructuring costs and writeoffs of certain assets
115.5
Loss on sale of long-term notes receivable
37.4
Loss on sale of certain closures assets
41.3
24.0
(59.8
(43.7
Change in non-current operating assets
(29.0
(9.8
(7.5
Asbestos-related payments
(171.1
(190.1
(199.0
Reduction of non-current liabilities
(69.5
(25.6
(13.4
Change in components of working capital
18.3
180.9
(40.5
Cash provided by continuing operating activities
503.8
544.7
305.0
Cash provided by discontinued operating activities
65.2
48.1
Total cash provided by operating activities
609.9
353.1
Investing activities:
Additions to property, plant and equipment - continuing
(404.1
(436.7
(344.4
Additions to property, plant and equipment - discontinued
(25.1
(87.1
Acquisitions, net of cash acquired
(11.6
(630.3
Proceeds from sale of long-term notes receivable
163.0
Net cash proceeds from divestitures and other
167.0
1,430.9
66.7
Cash provided by (utilized in) investing activities
(248.7
338.8
(201.8
Financing activities:
Additions to long-term debt
555.1
2,125.1
2,154.5
Repayments of long-term debt
(740.3
(2,885.4
(2,063.4
Increase (decrease) in short-term loans
11.6
(23.2
(28.0
Net payments for debt-related hedging activity
(98.0
(25.9
(123.1
Payment of finance fees and debt retirement costs
(1.0
(34.4
(44.5
Convertible preferred stock dividends
27.4
3.6
Cash utilized in financing activities
(273.1
(837.9
(122.4
Effect of exchange rate fluctuations on cash
(13.3
8.1
Increase (decrease) in cash
(31.3
114.5
37.0
Cash at beginning of year
163.4
126.4
Cash at end of year
64
NOTES TO CONSOLIDATED FINANCIAL STATEMENTS
Tabular data dollars in millions, except share and per share amounts
1. Significant Accounting Policies
Basis of Consolidated Statements The consolidated financial statements of Owens-Illinois, Inc. (Company) include the accounts of its subsidiaries. Newly acquired subsidiaries have been included in the consolidated financial statements from dates of acquisition. Results of operations for the blow-molded plastic container business divested in 2004 have been presented as a discontinued operation.
The Company uses the equity method of accounting for investments in which it has a significant ownership interest, generally 20% to 50%. Other investments are accounted for at cost.
Nature of Operations The Company is a leading manufacturer of glass container and plastics packaging products operating in two product segments. The Companys principal product lines in the Glass Containers product segment are glass containers for the food and beverage industries. Sales of the Glass Containers product segment were 89% of the Companys 2005 consolidated sales. The Company has glass container operations located in 22 countries, while the plastics packaging products operations are located in 5 countries. The principal markets and operations for the Companys glass products are in North America, Europe, South America, and Australia. The Companys principal product lines in the Plastics Packaging product segment include healthcare containers, closures and prescription containers. Major markets for the Companys plastics packaging products include the United States health care market.
Use of Estimates The preparation of financial statements in conformity with accounting principles generally accepted in the United States requires management of the Company to make estimates and assumptions that affect certain amounts reported in the financial statements and accompanying notes. Actual results may differ from those estimates, at which time the Company would revise its estimates accordingly. For further information on certain of the Companys significant estimates relative to contingent liabilities, see Note 19.
Cash The Company defines cash as cash and time deposits with maturities of three months or less when purchased. Outstanding checks in excess of funds on deposit are included in accounts payable.
Fair Values of Financial Instruments The carrying amounts reported for cash, short-term investments and short-term loans approximate fair value. In addition, carrying amounts approximate fair value for certain long-term debt obligations subject to frequently redetermined interest rates. Fair values for the Companys significant fixed rate debt obligations are generally based on published market quotations.
Derivative Instruments The Company uses interest rate swaps, currency swaps, and commodity futures contracts to manage risks generally associated with foreign exchange rate, interest rate and commodity market volatility. Derivative financial instruments are included on the balance sheet at fair value. Whenever possible, derivative instruments are designated and effective as hedges, in accordance with accounting principles generally accepted in the United States. If the underlying hedged transaction ceases to exist, all changes in fair value of the related derivatives that have not been settled are recognized in current earnings. The Company does not enter into derivative financial instruments for trading purposes and is not a party to leveraged derivatives. In accordance with FAS No. 104, cash flows from fair value hedges of debt and short-term forward exchange contracts are classified as a financing activity. Cash flows of currency swaps, interest rate swaps, and commodity futures contracts are classified as operating activities. See Note 9 for additional information related to derivative instruments.
65
Inventory Valuation The Company values most U.S. inventories at the lower of last-in, first-out (LIFO) cost or market. Other inventories are valued at the lower of standard costs (which approximate average costs) or market.
Goodwill Goodwill represents the excess of cost over fair value of assets of businesses acquired. Goodwill is evaluated annually, as of October 1, for impairment or more frequently if an impairment indicator exists.
Intangible Assets and Other Long-Lived Assets Intangible assets are amortized over the expected useful life of the asset. The Company evaluates the recoverability of intangible assets and other long-lived assets based on undiscounted projected cash flows, excluding interest and taxes, when factors indicate that impairment may exist. If impairment exists, the asset is written down to fair value.
Property, Plant, and Equipment Property, plant and equipment (PP&E) is carried at cost and includes expenditures for new facilities and equipment and those costs which substantially increase the useful lives or capacity of existing PP&E. In general, depreciation is computed using the straight-line method. Factory machinery and equipment is depreciated over periods ranging from 5 to 25 years and buildings and building equipment over periods ranging from 10 to 50 years. Maintenance and repairs are expensed as incurred. Costs assigned to PP&E of acquired businesses are based on estimated fair values at the date of acquisition.
Revenue Recognition The Company recognizes sales, net of estimated discounts and allowances, when the title to the products and risk of loss are transferred to customers. Provisions for rebates to customers are provided in the same period that the related sales are recorded.
Shipping and Handling Costs Shipping and handling costs are included with manufacturing, shipping, and delivery costs in the Consolidated Statements of Operations.
Income Taxes on Undistributed Earnings In general, the Company plans to continue to reinvest the undistributed earnings of foreign subsidiaries and foreign corporate joint ventures accounted for by the equity method. Accordingly, taxes are provided only on that amount of undistributed earnings in excess of planned reinvestments.
Foreign Currency Translation The assets and liabilities of most subsidiaries and associates are translated at current exchange rates and any related translation adjustments are recorded directly in share owners equity.
Accounts Receivable Receivables are stated at amounts estimated by management to be the net realizable value. The Company charges off accounts receivable when it becomes apparent based upon age or customer circumstances that amounts will not be collected.
Allowance for Doubtful Accounts The allowance for doubtful accounts is established through charges to the provision for bad debts. The Company evaluates the adequacy of the allowance for doubtful accounts on a periodic basis. The evaluation includes historical trends in collections and write-offs, managements judgment of the probability of collecting accounts and managements evaluation of business risk.
New Accounting Standards In December 2004, the Financial Accounting Standards Board issued FAS No. 123R, Share-Based Payment, which requires that the cost resulting from all share-based payment transactions be recognized in the financial statements. The statement requires a public entity to measure the cost of employee services received in exchange for an award of equity instruments based on the grant-date
66
fair value of the award. That cost will be recognized over the required service period (usually the vesting period). No compensation cost is recognized for equity instruments for which employees do not render the required service. FAS No. 123R is effective for the Company beginning January 1, 2006.
Under FAS No. 123Rs provisions, there are two transition alternatives: the modified-prospective method and the modified-retrospective method. Under the modified-prospective method, the Company would be required to recognize compensation cost in the financial statements beginning on January 1, 2006. Under the modified-retrospective method, the Company would be required to restate the financial statements of prior periods by recognizing the same amount of compensation cost as previously reported in the pro forma footnote disclosures under FAS No. 123. Management expects to adopt the provisions of FAS No. 123R using the modified-prospective method. The pre-tax expense expected to be recorded in 2006 related to options outstanding at December 31, 2005 is $4.5 million.
In May 2005, the Financial Accounting Standards Board issued FAS No. 154, Accounting Changes and Error Corrections, which changes the requirements for accounting for and reporting a change in accounting principle. The statement requires changes in accounting principle to be applied retrospectively to prior periods financial statements. The statement also redefines restatement as being the correction of an error. FAS No. 154 is effective for the Company beginning after January 1, 2006. The Company will apply FAS No. 154 as required.
Stock Options The Company has five equity compensation plans, which are described more fully in Note 13. The Company has adopted the disclosure-only provisions for stock options (intrinsic value method) of FAS No. 123, Accounting for Stock-Based Compensation. All options have been granted at prices equal to the market price of the Companys common stock on the date granted. Accordingly, the Company recognized no compensation expense related to stock options.
If the Company had elected to recognize compensation cost based on the fair value of the options granted at grant date as allowed by FAS No. 123, pro forma net earnings (loss) and earnings (loss) per share would have been as follows:
Net earnings (loss):
As reported
Total stock-based employee compensation expense determined under fair value based method, net of related tax effects
(7.0
(6.8
(5.6
Additional valuation allowance on deferred tax assets
(4.3
Pro forma
(569.9
228.7
(996.4
Basic earnings (loss) per share:
(3.92
1.40
(6.93
Diluted earnings (loss) per share:
1.38
The fair value of each option grant is estimated on the date of grant using the Black-Scholes option pricing model with the following assumptions:
67
Expected life of options
4.75 years
5 years
Expected stock price volatility
73.9
72.7
Risk-free interest rate
4.2
2.7
3.1
Expected dividend yield
0.0
2. Earnings Per Share The following table sets forth the computation of basic and diluted earnings per share:
Numerator:
Numerator for basic earnings (loss) per share income (loss) available to common share owners
(643.1
150.0
(351.6
Denominator:
Denominator for basic earnings (loss) per share weighted average shares outstanding
150,909,812
147,963,416
146,913,819
Effect of dilutive securities: Stock options and other
1,716,175
Denominator for diluted earnings (loss) per share adjusted weighted average shares and assumed exchanges of preferred stock for common stock
149,679,591
Earnings from continuing operations
See Note 12 for additional information on Convertible Preferred Stock.
The convertible preferred stock was not included in the computation of 2004 diluted earnings per share since the result would have been antidilutive. Options to purchase 5,067,104 weighted average shares of common stock which were outstanding during 2004 were not included in the computation of diluted earnings per share because the options exercise prices were greater than the average market price of the common shares. For the years ended December 31, 2005 and 2003, diluted earnings per share of common stock were equal to basic earnings per share of common stock due to the net losses.
68
3. Changes in Components of Working Capital Related to Operations Changes in the components of working capital related to operations (net of the effects related to acquisitions and divestitures) were as follows:
Decrease (increase) in current assets:
(23.7
(0.6
Receivables
(24.5
61.5
13.7
73.0
106.7
(4.0
36.4
Increase (decrease) in current liabilities:
47.8
75.3
Accrued liabilities
(18.4
(107.7
(77.1
9.9
(15.1
(24.4
(36.5
145.0
(95.0
Continuing operations
Discontinued operations
(35.9
(54.5
4. Inventories Major classes of inventory are as follows:
Finished goods
779.6
929.9
Work in process
6.4
Raw materials
91.1
100.1
Operating supplies
81.3
If the inventories which are valued on the LIFO method had been valued at standard costs, which approximate current costs, consolidated inventories would be higher than reported by $40.6 million and $28.7 million at December 31, 2005 and 2004, respectively.
Inventories which are valued at the lower of standard costs (which approximate average costs) or market at December 31, 2005 and 2004 were approximately $780.3 million and $922.4 million, respectively.
69
5. Equity Investments Summarized information pertaining to the Companys equity associates follows:
At end of year:
Equity in undistributed earnings:
Foreign
18.9
Domestic
17.6
45.2
36.5
For the year:
Equity in earnings:
$9.0
$17.8
$17.2
13.6
10.0
$22.6
$27.8
$27.1
Dividends received
$11.0
$12.8
$31.1
70
6. Long-Term Debt The following table summarizes the long-term debt of the Company at December 31, 2005 and 2004:
Secured Credit Agreement:
Revolving Credit Facility:
Revolving Loans
30.1
Term Loans:
A1 Term Loan
223.9
315.0
B1 Term Loan
220.8
226.8
C1 Term Loan
185.6
190.6
C2 Term Loan (46.3 million at Dec. 31, 2005)
54.9
64.7
Accounts receivable securitization:
European program
Asia Pacific program
80.6
Senior Secured Notes:
8.875%, due 2009
7.75%, due 2011
8.75%, due 2012
625.0
Senior Notes:
7.15%, due 2005
112.4
8.10%, due 2007
294.8
298.2
7.35%, due 2008
244.0
248.4
8.25%, due 2013
433.3
440.0
6.75%, due 2014
400.0
6.75%, due 2014 (225 million at Dec. 31, 2005)
267.0
306.4
Senior Debentures:
7.50%, due 2010
243.9
249.6
7.80%, due 2018
Senior Subordinated Notes:
10.25%, due 2009
17.4
9.25%, due 2009 (0.4 million at Dec. 31, 2005)
0.5
0.6
64.6
117.0
5,270.7
5,342.2
Less amounts due within one year
At December 31, 2005, the Agreement included a $600.0 million revolving credit facility and a $223.9 million A1 term loan, each of which has a final maturity date of April 1, 2007. It also included a $220.8
71
million B1 term loan, a $185.6 million C1 term loan, and a 46.3 million C2 term loan, each of which has a final maturity date of April 1, 2008. The Agreement also permits the Company, at its option, to refinance certain of its outstanding notes and debentures prior to their scheduled maturity. At December 31, 2005, the Companys subsidiary borrowers had unused credit of $511.0 million available under the Agreement.
The interest rate on borrowings under the Revolving Credit Facility is, at the Companys option, the Base Rate or a reserve adjusted Eurodollar rate. The interest rate on borrowings under the Revolving Credit Facility also includes a margin linked to the Companys Consolidated Leverage Ratio, as defined in the Agreement. The margin is limited to ranges of 2.25% to 2.75% for Eurodollar loans and 1.25% to 1.75% for Base Rate loans. The interest rate on Overdraft Account loans is the Base Rate. The weighted average interest rate on borrowings outstanding under the Agreement at December 31, 2005 was 5.96%. Including the effects of cross-currency swap agreements related to borrowings under the Agreement by the Companys Australian subsidiary, as discussed in Note 9, the weighted average interest rate at December 31, 2005 was 6.76%. While no compensating balances are required by the Agreement, the Borrowers must pay a facility fee on the Revolving Credit Facility commitments of .50%.
Borrowings under the Agreement are secured by substantially all of the assets of the Companys domestic subsidiaries and certain foreign subsidiaries, which have a book value of approximately $3.9 billion. Borrowings are also secured by a pledge of intercompany debt and equity in most of the Companys domestic subsidiaries and stock of certain foreign subsidiaries. All borrowings under the agreement are guaranteed by substantially all domestic subsidiaries of the Company for the term of the Agreement.
During December 2004, a subsidiary of the Company issued Senior Notes totaling $400.0 million and Senior Notes totaling 225.0 million. The notes bear interest at 6.75%, and are due December 1, 2014. Both series of notes are guaranteed by substantially all of the Companys domestic subsidiaries. The indentures for both series of notes have substantially the same restrictions as the previously issued 7.75%, 8.875% and 8.75% Senior Secured Notes and 8.25% Senior Notes. The issuing subsidiary used the net proceeds from the notes of approximately $680.0 million in addition to borrowings under the Agreement to purchase in a tender offer $237.6 million of the $350.0 million 7.15% Senior Notes due 2005, 159.6 million of the 160.0 million 9.25% BSN notes due 2009 and 127.3 million of the 140.0 million 10.25% BSN notes due 2009. As part of the issuance of these notes and the related tender offer, the Company recorded in the fourth quarter of 2004 additional interest charges of $28.3 million for note repurchase premiums and the related write-off of unamortized finance fees.
During the fourth quarter of 2005, the Company expanded the capacity of its European accounts receivable securitization program from 200 million to 320 million to include operations in Italy and the United Kingdom. The accounts receivable securitization program provides lower costs of financing than traditional bank debt. The terms of this expansion resulted in a changing from off-balance sheet to on-balance
72
sheet accounting for the program. The net impact was an increase, at December 31, 2005, in reported accounts receivable and consolidated debt of $191.8 million.
The interest rate on the accounts receivable securitization program is a variable rate and also includes a margin of 1.35% for the European program and 0.85% for the Asia Pacific program. The weighted average interest rates on borrowings on the European program were 5.0% for the UK and Italy, and 3.9% for France at December 31, 2005. The weighted average interest rates on borrowings on the Asia pacific program were 6.5% for the Australian program, and 8.5% for New Zealand program at December 31, 2005. These programs have maturity dates ranging from October of 2006 through September of 2008.
Annual maturities for all of the Companys long-term debt through 2010 are as follows: 2006, $252.0 million; 2007, $532.7 million; 2008, $794.6 million; 2009, $1,007.2 million; and 2010, $249.7 million.
Interest paid in cash, including note repurchase premiums in 2004 and 2003, aggregated $450.9 million for 2005, $548.8 million for 2004, and $458.8 million for 2003.
Fair values at December 31, 2005, of the Companys significant fixed rate debt obligations were as follows:
Principal Amount
Indicated
Fair Value
Hedge Value
(millions of
Market
dollars)
Price
104.25
1,042.5
104.00
468.0
107.50
671.9
102.00
306.0
100.75
251.9
102.75
462.4
96.00
384.0
6.75%, due 2014 (225 million)
272.3
100.50
251.3
99.50
248.8
9.25%, due 2009 (0.4 million)
100.00
7. Operating Leases Rent expense attributable to all warehouse, office buildings and equipment operating leases was $81.9 million in 2005, $89.8 million in 2004, and $85.0 million in 2003. Minimum future rentals under operating leases are as follows: 2006, $73.3 million; 2007, $52.7 million; 2008, $36.4 million; 2009, $23.6 million; and 2010, $17.3 million; and 2011 and thereafter, $23.0 million.
8. Foreign Currency Translation Aggregate foreign currency exchange gains (losses) included in other costs and expenses were $2.8 million in 2005, $(9.5) million in 2004, and $2.2 million in 2003.
9. Derivative Instruments At December 31, 2005, the Company has the following derivative instruments related to its various hedging programs:
73
Hedges of Debt
At the end of 2005, the Companys subsidiary in Australia had an agreement that swaps a total of U.S. $175.0 million of borrowings into 251.8 million Australian dollars. This derivative instrument swaps the principal from U.S. dollars to Australian dollars and also swaps the interest rate from a U.S.-based rate to an Australian-based rate. This agreement has a maturity date of March 2006.
The Companys subsidiaries in Australia, Canada and several European countries have also entered into short term forward exchange contracts which effectively swap additional intercompany and external borrowings by each subsidiary into its local currency. These contracts swap the principal amount of borrowings and in some cases they swap the related interest.
The Company recognizes the above derivatives on the balance sheet at fair value. Accordingly, the changes in the value of the swaps are recognized in current earnings and are expected to substantially offset any exchange rate gains or losses on the related U.S. dollar borrowings. For the year ended December 31, 2005, the amount not offset was immaterial.
Foreign Currency Exchange Contracts Designated as Cash Flow Hedges
In connection with debt refinancing in late December 2004, the Companys subsidiary in France borrowed approximately 91 million from Owens-Brockway Glass Container (OBGC), a U.S. subsidiary of the Company, at a fixed interest rate through 2009. In order to hedge the changes in the cash flows of the foreign currency interest and principal repayments, OBGC entered into a swap that converts the Euro coupon interest payments into a predetermined U.S. dollar coupon interest payment and also converts the final principal payment in December 2009 from 91.0 million to approximately $120.7 million U.S. dollars.
The Company accounts for the above cross-currency swap on the balance sheet at fair value. The effective portion of changes in the fair value of a derivative that is designated as, and meets the required criteria for, a cash flow hedge is recorded in accumulated other comprehensive income (OCI) and reclassified into earnings in the same period or periods during which the underlying hedged item affects earnings. Any material portion of the change in the fair value of a derivative designated as a cash flow hedge that is deemed to be ineffective is recognized in current earnings.
The above cross-currency swap is accounted for as a cash flow hedge at December 31, 2005. At December 31, 2005, an unrecognized gain of $10.5 million was included in OCI related to this cross-currency swap. The ineffectiveness related to this hedge for year ended December 31, 2005 was not material.
The Company has also entered into a foreign currency exchange contract in Europe to swap 37.5 million into $47.3 million U.S. dollars related to anticipated fuel oil purchases for 2006. A portion of European fuel oil purchases fluctuates based on U.S. dollars. The swap mitigates foreign currency exchange rate risk relating to approximately 93% of the anticipated 2006 fuel oil purchases in western Europe. Changes in the fair value of this contract are recognized in current earnings.
Interest Rate Swaps Designated as Fair Value Hedges
In the fourth quarter of 2003 and the first quarter of 2004, the Company entered into a series of interest rate swap agreements with a total notional amount of $1.25 billion that mature from 2007 through 2013. The swaps were executed in order to: (i) convert a portion of the senior notes and senior debentures fixed-rate
74
debt into floating-rate debt; (ii) maintain a capital structure containing appropriate amounts of fixed and floating-rate debt; and (iii) reduce net interest payments and expense in the near-term.
The Companys fixed-to-variable interest rate swaps are accounted for as fair value hedges. Because the relevant terms of the swap agreements match the corresponding terms of the notes, there is no hedge ineffectiveness. Accordingly, the Company recorded the net of the fair market values of the swaps as a long-term liability along with a corresponding net decrease in the carrying value of the hedged debt.
The following selected information relates to fair value swaps at December 31, 2005 (based on a projected U.S. LIBOR rate of 4.8618%):
Asset
Amount
Receive
Average
(Liability)
Hedged
Rate
Spread
Recorded
Senior Notes due 2007
4.5
(5.2
Senior Notes due 2008
7.35
(6.0
Senior Debentures due 2010
7.50
(6.1
Senior Notes due 2013
(16.7
Commodity Hedges
The Company enters into commodity futures contracts related to forecasted natural gas and fuel oil requirements, the objectives of which are to limit the effects of fluctuations in the future market price paid for natural gas and fuel oil and the related volatility in cash flows. The Company continually evaluates the natural gas and fuel oil market with respect to its forecasted usage requirements over the next twelve to eighteen months and periodically enters into commodity futures contracts in order to hedge a portion of its usage requirements over that period. At December 31, 2005, the Company had entered into commodity futures contracts for approximately 62% (approximately 14,780,000 MM BTUs) of its expected North American natural gas usage for full year of 2006 and approximately 15% (approximately 3,600,000 MM BTUs) for the full year of 2007. At December 31, 2005, the Company had also entered into commodity futures contracts for substantially all of its expected western European fuel oil usage (approximately 43,500 metric tons) for the first quarter of 2006.
The Company accounts for the above futures contracts on the balance sheet at fair value. The effective portion of changes in the fair value of a derivative that is designated as, and meets the required criteria for, a cash flow hedge is recorded in OCI and reclassified into earnings in the same period or periods during which the underlying hedged item affects earnings. Any material portion of the change in the fair value of a derivative designated as a cash flow hedge that is deemed to be ineffective is recognized in current earnings.
With the exception of the European fuel oil contracts, the above futures contracts are accounted for as cash flow hedges at December 31, 2005.
75
At December 31, 2005, an unrecognized gain of $26.2 million ($17.0 million after tax), related to the domestic commodity futures contracts, was included in OCI. The ineffectiveness related to these natural gas hedges for 2005 was not material. Changes in the fair value of the western European commodity futures contracts are recognized in current earnings.
Other Hedges
The Companys subsidiaries may enter into short-term forward exchange agreements to purchase foreign currencies at set rates in the future. These foreign currency forward exchange agreements are used to limit exposure to fluctuations in foreign currency exchange rates for all significant planned purchases of fixed assets or commodities that are denominated in currencies other than the subsidiaries functional currency. Subsidiaries may also use forward exchange agreements to offset the foreign currency risk for receivables and payables not denominated in, or indexed to, their functional currencies. The Company records these short-term forward exchange agreements on the balance sheet at fair value and changes in the fair value are recognized in current earnings.
Balance Sheet Classification
The Company records the fair values of derivative financial instruments on the balance sheet as follows: (1) receivables if the instrument has a positive fair value and maturity within one year, (2) deposits, receivables, and other assets if the instrument has a positive fair value and maturity after one year, (3) other accrued liabilities if the instrument has a negative fair value and maturity within one year, and (4) other liabilities if the instrument has a negative fair value and maturity after one year.
10. Accumulated Other Comprehensive Income (Loss) The components of comprehensive income (loss) are: (a) net earnings (loss); (b) change in fair value of certain derivative instruments; (c) adjustment of minimum pension liabilities; and, (d) foreign currency translation adjustments. The net effect of exchange rate fluctuations generally reflects changes in the relative strength of the U.S. dollar against major foreign currencies between the beginning and end of the year.
The following table lists the beginning balance, yearly activity and ending balance of each component of accumulated other comprehensive income (loss):
76
Net Effect ofExchangeRateFluctuations
DeferredTax EffectforTranslation
Change inMinimumPensionLiability(net oftax)
Change inCertainDerivativeInstruments(net of tax)
TotalAccumulatedComprehensiveIncome (Loss)
Balance on January 1, 2003
(520.3
26.0
(91.5
2003 Change
365.6
(4.6
340.5
Balance on December 31, 2003
(154.7
(110.8
1.0
2004 Change
326.1
(8.7
288.8
Balance on December 31, 2004
171.4
12.7
(138.3
(0.1
2005 Change
(281.6
Balance on December 31, 2005
(117.5
(145.5
The 2004 change in exchange rate fluctuations includes $52.4 million related to the sales of the blow-molded plastics business and the 20% investment in Consol Glass.
The change in minimum pension liability for 2005, 2004, and 2003 was net of tax of $0.1 million, $8.1 million and $1.4 million, respectively. The change in minimum pension liability for 2005 included $(14.8) million ($19.5 million pretax) of translation effect on the minimum pension liability recorded in prior years. The change in minimum pension liability for 2004 included $9.0 million ($12.6 million pretax) of translation effect on the minimum pension liability recorded in prior years. The change in minimum pension liability for 2003 included $10.1 million ($14.7 million pretax) of translation effect on the minimum pension liability recorded in 2002.
The change in certain derivative instruments for 2005, 2004 and 2003 was net of tax of $9.2 million, $0.5 million, and $0.7 million, respectively.
11. Income Taxes Deferred income taxes reflect: (1) the net tax effects of temporary differences between the carrying amounts of assets and liabilities for financial reporting purposes and the amounts used for income tax purposes and (2) carryovers and credits for income tax purposes. Significant components of the Companys deferred tax assets and liabilities at December 31, 2005 and 2004 are as follows:
77
Deferred tax assets:
Accrued postretirement benefits
89.3
93.4
255.1
268.2
Tax loss and credit carryovers
639.2
471.0
Capital loss carryovers
391.3
405.2
Alternative minimum tax credits
21.2
21.7
203.1
189.8
31.3
Total deferred tax assets
1,630.5
1,480.5
Deferred tax liabilities:
Property, plant and equipment
273.9
Prepaid pension costs
293.5
277.3
Insurance for asbestos-related costs
0.4
1.2
Inventory
29.3
33.4
89.9
51.8
Total deferred tax liabilities
664.8
637.6
Valuation allowance
(1,043.9
(731.2
Net deferred taxes
(78.2
111.7
Deferred taxes are included in the Consolidated Balance Sheets at December 31, 2005 and 2004 as follows:
125.2
101.9
169.8
(186.0
(183.3
The provision (benefit) for income taxes consists of the following:
78
Current:
U.S. Federal
State
3.0
133.9
101.6
55.3
135.5
104.6
56.9
Deferred:
167.7
(82.6
(174.7
9.1
(12.4
(1.8
164.4
(111.3
(182.6
Total:
(4.5
121.5
81.1
53.5
299.9
(6.7
(125.7
Total for continuing operations
Total for discontinued operations
(67.2
(12.6
79
The provision (benefit) for income taxes was calculated based on the following components of earnings (loss) before income taxes:
(187.7
(203.8
(617.4
(30.9
414.1
179.4
(670.4
6.2
17.7
51.4
Income taxes paid in cash were as follows:
1.9
1.4
112.9
98.8
51.1
125.1
100.7
52.5
A reconciliation of the provision (benefit) for income taxes based on the statutory U.S. Federal tax rate of 35% to the provision for income taxes is as follows:
Pretax earnings (loss) from continuing operations at statutory U.S. Federal tax rate
(76.5
73.6
(153.3
Increase (decrease) in provision for income taxes due to:
Goodwill impairment
172.9
517.5
State taxes, net of federal benefit
4.9
(11.2
(3.1
Rate differences on international earnings
(28.2
(25.0
(16.0
Ardagh note
11.1
Australian tax consolidation
(2.8
(33.1
Adjustment for non-U.S. tax law changes
(7.1
(7.6
Other items
(2.7
At December 31, 2005, the Company has unused net operating losses, capital losses, and research tax credits expiring from 2007 to 2026.
80
The Company also has unused alternative minimum tax credits which do not expire and which will be available to offset future U.S. Federal income tax.
At December 31, 2005, the Companys equity in the undistributed earnings of foreign subsidiaries for which income taxes had not been provided approximated $1,385.4 million. It is not practicable to estimate the U.S. and foreign tax which would be payable should these earnings be distributed.
During the fourth quarter of 2005, the Company recorded an additional valuation allowance of $306.6 million because of the near-term effects on U. S. profitability of continued asbestos-related payments, significant interest expense, rising energy costs and other cost increases. These changes in circumstances would have increased the beginning-of-year valuation allowance by approximately $170 million.
The October 2004 sale of the blow-molded plastic business resulted in a substantial capital loss, only a small portion of which was utilized to offset otherwise taxable capital gains. Because of the significant amount and limited life of the remaining unused capital loss, a full valuation allowance of approximately $361 million was established in 2004 to offset the tax benefit.
Valuation allowances approximating $140 million (including approximately $85 million related to the 2004 acquisition of BSN Glasspack, S.A.) were established in allocation of the costs of acquisitions. Any future reductions of these components will result in reductions of goodwill.
During 2005, the Company recorded a benefit of $61.8 million from discontinued operations resulting from the reversal of an accrual for potential tax liabilities related to a previous divestiture. The accrual was no longer required based on the Companys reassessment of the potential liabilities due to several factors, including statute expiration in September 2005.
12. Convertible Preferred Stock Annual cumulative dividends of $2.375 per share are payable in cash quarterly. The convertible preferred stock is convertible at the option of the holder at any time, unless previously redeemed, into shares of common stock of the Company at an initial conversion rate of 0.9491 shares of common stock for each share of convertible preferred stock, subject to adjustment based on certain events. The convertible preferred stock may be redeemed only in shares of common stock of the Company at the option of the Company at predetermined redemption prices plus accrued and unpaid dividends, if any, to the redemption date.
Holders of the convertible preferred stock have no voting rights, except as required by applicable law and except that among other things, whenever accrued and unpaid dividends on the convertible preferred stock are equal to or exceed the equivalent of six quarterly dividends payable on the convertible preferred stock such holders will be entitled to elect two directors to the Companys board of directors until the dividend arrearage has been paid or amounts have been set apart for such payment. In addition, certain changes that would be materially adverse to the rights of holders of the convertible preferred stock cannot be made without the vote of holders of two-thirds of the outstanding convertible preferred stock. The convertible preferred stock is senior to the common stock with respect to dividends and liquidation events.
13. Stock Options and Other Stock Based Compensation The Company has five equity compensation plans under which it has granted stock options, restricted shares, and restricted share units: (1) the Stock Option Plan for Key Employees of Owens-Illinois, Inc.; (2) the Stock Option Plan for Directors of Owens-Illinois, Inc.; (3) the 1997 Equity Participation Plan of Owens-Illinois, Inc.; (4) the 2004 Equity Incentive Plan for Directors of Owens-Illinois, Inc.; and (5) the 2005 Equity Incentive Plan of Owens-Illinois, Inc.
81
For options granted prior to March 31, 2005, under the Key Employees Plan and the 1997 Equity Plan, no options may be exercised in whole or in part during the first year after the date granted. In general, subject to accelerated exercisability provisions related to the performance of the Companys common stock or change of control, 50% of the options become exercisable on the fifth anniversary of the date of the option grant, with the remaining 50% becoming exercisable on the sixth anniversary date of the option grant. In general, options expire following termination of employment or the day after the tenth anniversary date of the option grant.
For options granted after March 30, 2005, under the 1997 Equity Plan and the 2005 Equity Incentive Plan, no options may be exercised in whole or in part during the first year after the date granted. In general, subject change of control, options become exercisable 25% per year beginning on the first anniversary. In general, options expire following termination of employment or the seventh anniversary of the option grant.
All options have been granted at prices equal to the market price of the Companys common stock on the date granted. Accordingly, under the disclosure-only provisions of FAS 123, the Company recognized no compensation expense related to the stock option plans. The fair value of each option grant is estimated on the date of grant using the Black-Scholes option pricing model with the assumptions described in the accounting policies note on stock options.
Stock option activity is as follows:
82
Weighted
Number of
Exercise
Fair
Shares
Value
Options outstanding at January 1, 2003
9,847,855
20.15
Granted
930,800
9.98
6.15
Exercised
(182,955
6.85
Canceled
(198,284
20.66
Options outstanding at December 31, 2003
10,397,416
19.46
1,162,000
13.41
8.30
(2,239,874
10.26
(858,042
20.77
Options outstanding at December 31, 2004
8,461,500
20.94
788,752
24.21
15.00
(1,605,677
12.78
(744,749
31.70
Options outstanding at December 31, 2005
6,899,826
22.05
Options exercisable at:
December 31, 2005
5,728,828
22.29
December 31, 2004
6,141,175
22.74
December 31, 2003
5,030,410
19.51
Shares available for option grant at:
7,332,497
4,632,810
5,083,627
83
The following table summarizes significant option groups outstanding at December 31, 2005, and related weighted average price and life information:
Options Outstanding
Options Exercisable
Range of
Remaining
Options
Contractual Life
Prices
Outstanding
(in years)
Exercisable
5.69 to
$ 16.98
3,059,614
11.72
2,696,218
11.45
18.53 to
$ 31.63
2,679,312
4.6
26.23
1,871,710
27.17
34.88 to
$ 41.50
1,160,900
2.4
39.62
During 2005, the Company awarded 238,136 performance vested units under the 1997 Equity Plan and the 2005 Equity Incentive Plan. As soon as practicable after 2007, holders of each unit will receive a number of shares ranging from .5 shares to 1.5 shares, depending upon the attainment of established performance goals. Failure to meet minimum goals will result in forfeiture of the shares. Granted but unvested shares are forfeited upon termination of employment. The Company expensed approximately $1.3 million related to these units in 2005.
During 2005, 2004 and 2003 the Company awarded shares of restricted stock to certain key employees under the 1997 Equity Plan and the 2005 Equity Incentive Plan and, in 2005 and 2004, to non-management directors under the 2004 Equity Incentive Plan for Directors. Shares granted to employees prior to March 31, 2005, generally vest upon retirement. Shares granted to employees after March 30, 2005, vest 25% per year beginning on the first anniversary. Granted but unvested shares are forfeited upon termination of employment, unless certain retirement criteria are met. Shares granted to directors vest on the later of the three-year anniversary of the grant date or the end of the directors term on the board.
The fair value of the shares is equal to the market price of the shares on the date of the grant. The fair value of the restricted shares is amortized ratably over the vesting period. The following table summarizes total restricted shares issued and the total expense recognized for each of the years ended December 31:
Year ended
December 31,
Expense
117,064
24.34
5.5
487,622
13.73
3.9
303,000
9.93
84
14. Pension Benefit Plans Net expense (credits) to results of operations for all of the Companys pension plans and certain deferred compensation arrangements amounted to $15.4 million in 2005, $27.0 million in 2004, and $(17.8) million in 2003.
The Company has defined benefit pension plans covering substantially all employees located in the United States, the United Kingdom, the Netherlands, Canada, Australia, Germany and France. Benefits generally are based on compensation for salaried employees and on length of service for hourly employees. The Companys policy is to fund pension plans such that sufficient assets will be available to meet future benefit requirements. The Companys defined benefit pension plans use a December 31 measurement date. The following tables relate to the Companys principal defined benefit pension plans.
The changes in the pension benefit obligations for the year were as follows:
Obligations at beginning of year
3,754.5
3,090.0
Change in benefit obligations:
Service cost
51.7
Interest cost
199.7
197.0
Actuarial loss, including effect of changing discount rates
179.5
190.4
Acquisitions
448.8
Divestitures
(35.2
Participant contributions
9.4
Benefit payments
(250.3
(281.2
Plan amendments
2.8
(44.6
Foreign currency translation
(123.7
119.3
5.4
Net increase in benefit obligations
69.1
664.5
Obligations at end of year
3,823.6
The changes in the fair value of the pension plans assets for the year were as follows:
85
Fair value at beginning of year
3,510.1
2,869.9
Change in fair value:
Actual gain on plan assets
403.9
482.4
285.1
Employer contributions
43.7
63.8
(85.4
82.4
Net increase in fair value of assets
121.3
640.2
Fair value at end of year
3,631.4
86
The funded status of the pension plans at year end was as follows:
Plan assets at fair value
Projected benefit obligations
Plan assets less than projected benefit obligations
(192.2
(244.4
Net unrecognized items:
Actuarial loss
1,073.7
1,080.0
Prior service cost
6.9
(5.5
1,080.6
1,074.5
Net amount recognized
888.4
830.1
The net amount recognized is included in the Consolidated Balance Sheets at December 31, 2005 and 2004 as follows:
Accrued pension, included with other liabilities
(163.2
(205.5
Minimum pension liability, included with other liabilities
(143.7
(134.7
Intangible asset, included with deposits and other assets
Accumulated other comprehensive income
197.8
195.6
The accumulated benefit obligation for all defined benefit pension plans was $3,495.4 million and $3,470.2 million at December 31, 2005 and 2004, respectively.
87
The components of the net pension expense (credit) for the year were as follows:
48.8
179.1
Expected asset return
(296.6
(289.5
(275.1
Amortization:
(0.3
6.8
Loss
49.5
38.3
Net amortization
49.2
44.3
17.3
Net expense (credit)
8.7
(29.9
The following selected information is for plans with projected benefit obligations in excess of the fair value of plan assets at year end:
1,353.2
1,317.3
Fair value of plan assets
961.2
906.8
The following information is for plans with accumulated benefit obligations in excess of the fair value of plan assets at year end:
876.3
1,197.9
621.5
The weighted average assumptions used to determine benefit obligations were as follows:
Discount rate
5.30
5.52
Rate of compensation increase
4.54
4.40
88
The weighted average assumptions used to determine net periodic pension costs were as follows:
6.10
6.52
4.71
4.72
Expected long-term rate of return on assets
8.35
8.71
Future benefits are assumed to increase in a manner consistent with past experience of the plans, which, to the extent benefits are based on compensation, includes assumed salary increases as presented above. Amortization included in net pension expense (credits) is based on the average remaining service of employees.
As of December 31, 2005, the Company recorded an additional minimum pension liability for the pension plan in the United Kingdom in addition to the minimum liabilities recorded in 2002, 2003 and 2004. Pursuant to this requirement, the Company decreased the minimum pension liability by $4.6 million, reduced the intangible asset by $1.4 million, and decreased accumulated other comprehensive loss by $3.2 million.
As of December 31, 2005, the Company adjusted the minimum pension liability for the pension plan in Canada from the minimum liabilities recorded in 2002, 2003 and 2004. Pursuant to this requirement, the Company increased the minimum pension liability by $13.2 million, reduced the intangible asset by $0.1 million, and increased accumulated other comprehensive loss by $13.3 million.
As of December 31, 2005, the Company recorded an additional minimum pension liability for the pension plan in Germany. Pursuant to this requirement, the Company recorded a minimum pension liability of $11.9 million and increased accumulated other comprehensive loss by $11.9 million.
For 2005, the Companys weighted average expected long-term rate of return on assets was 8.10%. In developing this assumption, the Company evaluated input from its third party pension plan asset managers, including their review of asset class return expectations and long-term inflation assumptions. The Company also considered its historical 10-year average return (through December 31, 2004), which was in line with the expected long-term rate of return assumption for 2005.
The weighted average actual asset allocations and weighted average target allocation ranges by asset category for the Companys pension plan assets were as follows:
Target
Actual Allocation
Allocation
Asset Category
Ranges
Equity securites
56 - 66%
Debt securities
26 - 36%
Real estate
2 - 12%
0 - 2%
100
89
It is the Companys policy to invest pension plan assets in a diversified portfolio consisting of an array of asset classes within the above target asset allocation ranges. The investment risk of the assets is limited by appropriate diversification both within and between asset classes. The assets for both the U.S. and non-U.S. plans are primarily invested in a broad mix of domestic and international equities, domestic and international bonds, and real estate, subject to the target asset allocation ranges. The assets are managed with a view to ensuring that sufficient liquidity will be available to meet expected cash flow requirements.
The Company expects to contribute $48.9 million to its defined benefit pension plans in 2006.
The following estimated future benefit payments, which reflect expected future service, as appropriate, are expected to be paid in the years indicated:
Year(s)
232.3
228.2
230.3
233.5
2011 - 2015
1,195.9
The Company also sponsors several defined contribution plans for all salaried and hourly U.S. employees. Participation is voluntary and participants contributions are based on their compensation. The Company matches contributions of participants, up to various limits, in substantially all plans. Company contributions to these plans amounted to $7.7 million in 2005, $7.1 million in 2004, and $6.8 million in 2003.
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15. Postretirement Benefits Other Than Pensions The Company provides certain retiree health care and life insurance benefits covering substantially all U.S. salaried and certain hourly employees, substantially all employees in Canada and in the Netherlands. Employees are generally eligible for benefits upon retirement and completion of a specified number of years of creditable service. The Company uses a December 31 measurement date to measure its Postretirement Benefit Obligations.
The changes in the postretirement benefit obligations for the year were as follows:
340.9
380.8
4.3
18.5
Actuarial gain (loss), including the effect of changing discount rates
(1.6
(63.7
(32.6
(33.8
Net change in benefit obligations
(11.8
(39.9
329.1
The funded status of the postretirement benefit plans at year end was as follows:
Projected postretirement benefit obligations
Prior service credit
(92.9
(100.5
(52.0
(55.3
Nonpension accumulated postretirement benefit obligations
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The components of the net postretirement benefit cost for the year were as follows:
23.3
(13.0
4.7
(9.3
Net postretirement benefit cost
24.2
23.2
21.3
The weighted average discount rate used to determine the accumulated postretirement benefit obligation was 5.45% and 5.67% at December 31, 2005 and 2004, respectively.
The weighted average discount rate used to determine net postretirement benefit cost was 5.67%, 6.21%, and 6.72% at December 31, 2005, 2004, and 2003, respectively.
The weighted average assumed health care cost trend rates at December 31 were as follows:
Health care cost trend rate assumed for next year
8.31
9.19
Rate to which the cost trend rate is assumed to decline(ultimate trend rate)
5.64
5.66
Year that the rate reaches the ultimate trend rate
Assumed health care cost trend rates affect the amounts reported for the postretirement benefit plans. A one-percentage-point change in assumed health care cost trend rates would have the following effects:
1-Percentage-
Point Increase
Point Decrease
Effect on total of service and interest cost
Effect on accumulated postretirement benefit obligations
(19.2
Amortization included in net postretirement benefit cost is based on the average remaining service of employees.
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Benefits provided by the Company for certain hourly retirees are determined by collective bargaining. Most other domestic hourly retirees receive health and life insurance benefits from a multi-employer trust established by collective bargaining. Payments to the trust as required by the bargaining agreements are based upon specified amounts per hour worked and were $6.6 million in 2005, $7.6 million in 2004, and $8.7 million in 2003. Postretirement health and life benefits for retirees of foreign subsidiaries are generally provided through the national health care programs of the countries in which the subsidiaries are located.
16. Other Revenue Other revenue in 2005 includes $28.1 million (pre-tax and after tax) for the sale of the Companys Corsico, Italy glass container facility.
Other revenue in 2004 includes a gain of $20.6 million ($14.5 million after tax) for the sale of certain real property and a gain of $31.0 million ($13.1 million after tax) for a restructuring in the Italian Specialty Glass business.
17. Other Costs and Expenses Other costs and expenses for the year ended December 31, 2005 included the following:
During the fourth quarter of 2005 the Company recorded a pretax charge of $135.0 million ($86.0 million after tax) to increase the reserve for estimated future asbestos-related costs as a result of the findings from the annual review of asbestos-related liabilities.
During the fourth quarter of 2005 the Company recorded a charge of $494.0 million to write down a portion of the goodwill in its Asia Pacific Glass business unit. See Note 21 for more information.
Manufacturing costs for the first quarter of 2005 included a favorable adjustment of approximately $10.0 million to the Companys accruals for self insured risks.
Manufacturing costs for the second quarter of 2005 included a favorable adjustment for depreciation and amortization in connection with finalizing the fair values of the BSN Glasspack assets acquired in June 2004. The difference between the estimated amounts recorded in 2004 and the final amounts related to 2004 accounted for a benefit of approximately $6.5 million.
Other costs and expenses for the year ended December 31, 2004 included a pretax charge of $152.6 million ($84.9 million after tax) to increase the reserve for estimated future asbestos-related costs as a result of the findings from the annual review of asbestos-related liabilities.
Other costs and expenses for the year ended December 31, 2003 included pretax charges of $694.2 million ($490.5 after tax) related to the following:
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On July 11, 2003, the Company received payments totaling 100 million British pounds sterling (US$163.0 million) in connection with the sale to Ardagh Glass Limited of certain long-term notes receivable. The notes were received from Ardagh in 1999 by the Companys wholly-owned subsidiary, United Glass Limited, in connection with its sale of Rockware, a United Kingdom glass container manufacturer obtained in the 1998 acquisition of the worldwide glass and plastics packaging businesses of BTR plc. The notes were due in 2006 and interest had previously been paid in kind through periodic increases in outstanding principal balances. The proceeds from the sale of the notes were used to reduce outstanding borrowings under the Agreement. The notes were sold at a discount of approximately 22.6 million British pounds sterling which resulted in a loss of US$37.4 million (US$37.4 million after tax).
During the fourth quarter of 2003, the Company completed the sale of its assets related to the production of plastic trigger sprayers and finger pumps. Included in the sale were manufacturing facilities in Bridgeport, Connecticut and El Paso, Texas, in addition to related production assets at the Erie, Pennsylvania plant. As a result of the sale, the Company recorded a loss of $41.3 million ($25.8 million after tax) in the third and fourth quarters of 2003. The net cash proceeds from the sale of approximately $44 million, including liquidation of related working capital, were used to reduce debt.
The Companys decision to sell the long-term notes receivable and its assets related to the production of plastic trigger sprayers and finger pumps is consistent with its objectives to improve liquidity and to focus on its core businesses.
In August of 2003, the Company initiated a review of its Plastics Packaging assets in the Asia Pacific region. The review was completed during the fourth quarter of 2003. The Company used a combination of estimated divestment cash flows, which included bid prices from potential purchasers, and partial liquidation values for certain assets to determine the net realizable values of the assets. The Company compared the estimated net realizable values to the book values of the asset and determined that an asset impairment existed. As a result, the Company recorded a charge of $43.0 million ($30.1 million after tax) to write-down the assets to realizable values. Certain of the plastics businesses in the Asia Pacific region operate in highly competitive markets leading to reduced profit margins. In addition, the Companys PET container business has lost a significant amount of business in the past few years. The reduced business and overall excess capacity in the industry has caused a reduction in the overall value of the business.
During the fourth quarter of 2003, the Company determined that the value of its 25% investment in a North American soda ash mining operation was impaired and not likely to recover. Increasing global competition and recent development of foreign sources of soda ash have created significant excess capacity in that industry. The resulting competitive environment caused management of the soda ash mining operation to significantly lower its projections of earnings and cash flows. Following an evaluation of future estimated earnings and cash flows, the Company determined that its carrying value should be written down to estimated fair value and recorded a $50 million charge in the fourth quarter which substantially reduced the carrying value of this equity method investment.
During the fourth quarter of 2003, the Company completed its annual review of asbestos-related liabilities and as a result recorded a charge of $450.0 million ($292.5 million after tax) to increase the reserve for future asbestos-related liabilities.
In August 2003, the Company announced the permanent closing of its Hayward, California glass container factory. Production at the factory was suspended in June 2003 following a major leak in its
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only glass furnace. As a result, the Company recorded a capacity curtailment charge of $28.5 million ($17.8 million after tax) in the third quarter of 2003. The closing of this factory resulted in the elimination of approximately 170 jobs and a corresponding reduction in the Companys workforce. Substantially all of the closing costs were paid out by the end of 2005.
In November 2003, the Company announced the permanent closing of its Milton, Ontario glass container factory. This closing was part of an effort to bring capacity and inventory levels in line with anticipated demand. As a result, the Company recorded a capacity curtailment charge of $20.1 million ($19.5 million after tax) in the fourth quarter of 2003. The closing of this factory in November 2003 resulted in the elimination of approximately 150 jobs and a corresponding reduction in the Companys workforce. Substantially all of the closing costs were paid out by the end of 2005.
In December 2003, the Company announced the permanent closing of its Perth, Australia glass container factory. This closing was part of an effort to reduce overall capacity in Australia and bring inventory levels in line with anticipated demand. The Perth plants western location and small size contributed to the plant being a higher cost facility that was no longer economically feasible to operate. As a result, the Company recorded a capacity curtailment charge of $23.9 million ($17.4 million after tax) in other costs and expenses in the results of operations for 2003.
The closing of this factory in December 2003 resulted in the elimination of approximately 107 jobs and a corresponding reduction in the Companys workforce. The closing costs were paid out by the end of 2005.
Selected information related to glass container factory closings is as follows:
Hayward
Milton
Plant closing charges
28.5
20.1
48.6
Write-down of assets to net realizable value
(6.4
(18.6
Net cash paid
(1.7
(5.8
Remaining accruals related to plant closing charges as of December 31, 2003
12.0
(4.4
2.5
Remaining accruals related to plant closing charges as of December 31, 2004
4.8
16.8
(0.9
(0.5
Remaining accruals related to plant closing charges as of December 31, 2005
3.4
14.1
18. Additional Interest Charges from Early Extinguishment of Debt During 2005, the Company recorded additional interest charges of $1.4 million ($1.0 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys bank credit
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agreement. During 2004, the Company recorded additional interest charges of $28.3 million ($18.5 million after tax) for note repurchase premiums and related write-off of unamortized finance fees and $7.1 million ($2.5 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys bank credit agreement. During 2003, the Company recorded additional interest charges of $13.2 million ($8.2 million after tax) for note repurchase premiums and related write-off of unamortized finance fees and $3.6 million ($2.5 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys previous bank credit agreement.
19. Contingencies The Company is one of a number of defendants in a substantial number of lawsuits filed in numerous state and federal courts by persons alleging bodily injury (including death) as a result of exposure to dust from asbestos fibers. From 1948 to 1958, one of the Companys former business units commercially produced and sold approximately $40 million of a high-temperature, calcium-silicate based pipe and block insulation material containing asbestos. The Company exited the pipe and block insulation business in April 1958. The traditional asbestos personal injury lawsuits and claims relating to such production and sale of asbestos material typically allege various theories of liability, including negligence, gross negligence and strict liability and seek compensatory and in some cases, punitive damages in various amounts (herein referred to as asbestos claims).
The following table shows the approximate number of plaintiffs and claimants involved in asbestos claims pending at the beginning of, disposed of and filed during, and pending at the end of, each of the years listed (eliminating duplicate filings):
Pending at beginning of year
35,000
29,000
24,000
Disposed
12,000
9,000
21,000
Filed
15,000
26,000
Pending at end of year
32,000
Based on an analysis of the claims and lawsuits pending as of December 31, 2005, approximately 89% of plaintiffs and claimants either do not specify the monetary damages sought, or in the case of court filings, claim an amount sufficient to invoke the jurisdictional minimum of the trial court. Approximately 10% of plaintiffs specifically plead damages of $15 million or less, and 1% of plaintiffs specifically plead damages greater than $15 million but less than $100 million. Fewer than 1% of plaintiffs specifically plead damages $100 million or greater but less than $123 million.
As indicated by the foregoing summary, current pleading practice permits considerable variation in the assertion of monetary damages. This variability, together with the actual experience discussed further below of litigating or resolving through settlement hundreds of thousands of asbestos claims and lawsuits over an extended period, demonstrates that the monetary relief which may be specified in a lawsuit or claim bears little relevance to its merits or disposition value. Rather, the amount potentially recoverable for a specific claimant is determined by other factors such as the claimants severity of disease, product identification evidence against specific defendants, the defenses available to those defendants, the specific jurisdiction in which the claim is made, the claimants history of smoking or exposure to other possible disease-causative factors, and the various other matters discussed further below.
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In addition to the pending claims set forth above, the Company has claims-handling agreements in place with many plaintiffs counsel throughout the country. These agreements require evaluation and negotiation regarding whether particular claimants qualify under the criteria established by such agreements. The criteria for such claims include verification of a compensable illness and a reasonable probability of exposure to a product manufactured by the Companys former business unit during its manufacturing period ending in 1958. Some plaintiffs counsel have historically withheld claims under these agreements for later presentation while focusing their attention on active litigation in the tort system. The Company believes that as of December 31, 2005 there are approximately 22,000 claims against other defendants and which are likely to be asserted some time in the future against the Company. These claims are not included in the totals set forth above. The Company further believes that the bankruptcies of additional co-defendants, as discussed below, resulted in an acceleration of the presentation and disposition of a number of these previously withheld preexisting claims under such agreements, which claims would otherwise have been presented and disposed of over the next several years. This acceleration resulted in a significant increase in the dispositions and cash payments during the period 2001-2002; however, the resolution of the accumulated yet previously unpresented cases continues to affect the annual dispositions and cash payments.
The Company is also a defendant in other asbestos-related lawsuits or claims involving maritime workers, medical monitoring claimants, co-defendants and property damage claimants. Based upon its past experience, the Company believes that these categories of lawsuits and claims will not involve any material liability and they are not included in the above description of pending matters or in the following description of disposed matters.
Since receiving its first asbestos claim, the Company as of December 31, 2005, has disposed of the asbestos claims of approximately 325,000 plaintiffs and claimants at an average indemnity payment per claim of approximately $6,400. Certain of these dispositions have included deferred amounts payable over a number of years. Deferred amounts payable totaled approximately $91 million at December 31, 2005 ($91 million at December 31, 2004) and are included in the foregoing average indemnity payment per claim. The Companys indemnity payments for these claims have varied on a per claim basis, and are expected to continue to vary considerably over time. As discussed above, a part of the Companys objective is to achieve, where possible, resolution of asbestos claims pursuant to claims-handling agreements. Under such agreements, qualification by meeting certain illness and exposure criteria has tended to reduce the number of claims presented to the Company that would ultimately be dismissed or rejected due to the absence of impairment or product exposure evidence. The Company expects that as a result, although aggregate spending may be lower, there may be an increase in the per claim average indemnity payment involved in such resolution.
The Company believes that its ultimate asbestos-related liability (i.e., its indemnity payments or other claim disposition costs plus related legal fees) cannot be estimated with certainty. Beginning with the initial liability of $975 million established in 1993, the Company has accrued a total of approximately $2.99 billion through 2005, before insurance recoveries, for its asbestos-related liability. The Companys ability to reasonably estimate its liability has been significantly affected by the volatility of asbestos-related litigation in the United States, the expanding list of non-traditional defendants that have been sued in this litigation and found liable for substantial damage awards, the continued use of litigation screenings to generate new lawsuits, the large number of claims asserted or filed by parties who claim prior exposure to asbestos materials but have no present physical impairment as a result of such exposure, and the growing number of co-defendants that have filed for bankruptcy.
The Company has continued to monitor trends which may affect its ultimate liability and has continued to analyze the developments and variables affecting or likely to affect the resolution of pending and future asbestos claims against the Company. The Company expects that the total asbestos-related cash
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payments will be moderately lower in 2006 compared to 2005 and will continue to decline thereafter as the preexisting but presently unasserted claims withheld under the claims handling agreements are presented to the Company and as the number of potential future claimants continues to decrease. The material components of the Companys accrued liability are based on amounts estimated by the Company in connection with its annual comprehensive review and consist of the following: (i) the reasonably probable contingent liability for asbestos claims already asserted against the Company, (ii) the contingent liability for preexisting but unasserted asbestos claims for prior periods arising under its administrative claims-handling agreements with various plaintiffs counsel, (iii) the contingent liability for asbestos claims not yet asserted against the Company, but which the Company believes it is reasonably probable will be asserted in the next several years, to the degree that an estimation as to future claims is possible, and (iv) the legal defense costs likely to be incurred in connection with the foregoing types of claims.
The significant assumptions underlying the material components of the Companys accrual are:
a) the extent to which settlements are limited to claimants who were exposed to the Companys asbestos-containing insulation prior to its exit from that business in 1958;
b) the extent to which claims are resolved under the Companys administrative claims agreements or on terms comparable to those set forth in those agreements;
c) the extent of decrease or increase in the inventory of pending serious disease cases;
d) the extent to which the Company is able to successfully defend itself at trial;
e) the extent of actions by courts and legislatures to eliminate, reduce or permit the diversion of financial resources for unimpaired claimants and so-called forum shopping;
f) the extent to which additional defendants with substantial resources and assets are required to participate significantly in the resolution of future asbestos lawsuits and claims;
g) the number and timing of co-defendant bankruptcies; and
h) the extent to which the resolution of co-defendant bankruptcies divert resources to unimpaired claimants.
Other litigation is pending against the Company, in many cases involving ordinary and routine claims incidental to the business of the Company and in others presenting allegations that are nonroutine and involve compensatory, punitive or treble damage claims as well as other types of relief. In accordance with FAS No. 5, Accounting for Contingencies, the Company records a liability for such matters when it is both probable that the liability has been incurred and the amount of the liability can be reasonably
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estimated. Recorded amounts are reviewed and adjusted to reflect changes in the factors upon which the estimates are based including additional information, negotiations, settlements, and other events.
The ultimate legal and financial liability of the Company with respect to the lawsuits and proceedings referred to above, in addition to other pending litigation, cannot be estimated with certainty. The Companys reported results of operations for 2005 were materially affected by the $135.0 million fourth quarter charge and asbestos-related payments continue to be substantial. Any future additional charge would likewise materially affect the Companys results of operations for the period in which it is recorded. Also, the continued use of significant amounts of cash for asbestos-related costs has affected and will continue to affect the Companys cost of borrowing and its ability to pursue global or domestic acquisitions. However, the Company believes that its operating cash flows and other sources of liquidity will be sufficient to pay its obligations for asbestos-related costs and to fund its working capital and capital expenditure requirements on a short-term and long-term basis.
20. Segment Information The Company operates in the rigid packaging industry. The Company has two reportable product segments within the rigid packaging industry: (1) Glass Containers and (2) Plastics Packaging. The Glass Containers segment includes operations in Europe, the Americas, and the Asia Pacific region. Following the sale of a substantial portion of the Companys blow-molded plastic container operations which was completed on October 7, 2004, the Plastics Packaging segment consists of healthcare packaging, and closures and specialty products.
The Companys measure of profit for its reportable segments is Segment Operating Profit, which consists of consolidated earnings from continuing operations before interest income, interest expense, provision for income taxes and minority share owners interests in earnings of subsidiaries and excludes amounts related to certain items that management considers not representative of ongoing operations. The Companys management uses Segment Operating Profit, in combination with selected cash flow information, to evaluate performance and to allocate resources.
Segment Operating Profit for product segments includes an allocation of some corporate expenses based on both a percentage of sales and direct billings based on the costs of specific services provided. For the Companys U.S. pension plans, net periodic pension cost (credit) has been allocated to product segments. The information below is presented on a continuing operations basis, and therefore, the prior period amounts have been restated to remove the discontinued operations. See Note 22 for more information.
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Financial information regarding the Companys product segments is as follows:
Eliminations and
Glass
Plastics
Product
Retained
Consolidated
Containers
Packaging
Segments
Costs
Totals
Net sales:
Segment Operating Profit:
918.0
828.6
874.6
772.4
757.5
665.6
Items excluded from Segment Operating Profit:
2005:
Mark to market effect of certain commodity futures contracts
3.8
Charge for asbestos-related costs
(135.0
2004:
20.6
Italian Specialty Glass gain
31.0
(152.6
Restructuring of a life insurance program
2003:
Charge for asbestos- related costs
(450.0
Capacity curtailment charges
(72.5
(43.0
(41.3
Loss on the sale of notes receivable
Eliminations
and
Depreciation and amortization expense:
465.3
514.8
9.2
407.5
55.4
462.9
11.9
351.3
62.9
414.2
13.5
Total assets (1):
7,575.7
754.0
8,329.7
1,192.1
8,579.4
789.3
9,368.7
1,368.0
6,277.2
895.8
7,173.0
2,358.3
9,531.3
Capital expenditures (2):
Continuing
366.2
397.3
404.1
405.7
30.4
436.1
436.7
Discontinued
25.1
296.8
50.2
347.0
(2.6
344.4
87.1
(1) Assets of discontinued operations for 2003 are included in eliminations and other retained.
(2) Excludes property, plant and equipment acquired through acquisitions.
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Financial information regarding the Companys geographic segments is as follows:
North
Asia
South
Geographic
America
Europe
Pacific
2,701.4
2,840.0
844.7
692.9
2,551.6
2,138.8
870.9
567.1
2,492.9
1,197.0
798.8
486.9
345.0
279.4
136.3
157.3
365.1
242.3
142.1
379.2
164.5
118.9
94.9
(48.6
(23.9
102
The Companys net property, plant and equipment by geographic segment are as follows (includes assets of discontinued operations in 2003):
United
States
1,025.5
2,127.0
2,509.6
1,614.9
1,772.1
3,387.0
The Companys net sales by geographic segment are as follows:
2,330.7
4,748.3
2,194.5
3,933.9
2,156.8
2,818.8
Operations in individual countries outside the United States that accounted for more than 10% of consolidated net sales from continuing operations were in Italy (2004 10.7%, and 2003 11.7%), France (2005 13.8%), and Australia (2004 10.6%, and 2003 12.0%).
Reconciliations to consolidated totals are as follows:
Net sales for reportable segments
Interest income
Reconciliation of Segment Operating Profit to earnings (loss) before income taxes, and minority share owners interest in earnings of subsidiaries:
Segment Operating Profit for reportable segments
Items excluded from Segment Operating Profit
(462.1
56.5
(244.2
Eliminations and other retained items, excluding certain items below
Items excluded from eliminations and other retained items
(159.0
Interest expense
(466.7
(474.9
(429.8
103
21. Goodwill The changes in the carrying amount of goodwill for the years ended December 31, 2003, 2004 and 2005 are as follows:
Balance as of January 1, 2003
1,652.6
1,038.6
2,691.2
Write-down of goodwill - discontinued operations
(670.0
Translation effects
285.5
Other changes, principally adjustments to acquisition-related deferred tax assets
(27.0
(26.5
Balance as of December 31, 2003
1,911.1
369.1
2,280.2
Goodwill acquired during the year
696.0
165.6
Sale of discontinued operations
(151.1
Other changes
18.4
Balance as of December 31, 2004
2,791.1
218.0
(160.9
Write-down of goodwill
Other changes, principally adjustments to finalize acquisition purchase price
Balance as of December 31, 2005
2,151.2
During the fourth quarter of 2003, the Company completed its annual impairment testing and determined that impairment existed in the goodwill of its consumer products reporting unit. The consumer products unit operates in a highly competitive and fragmented industry. During the course of 2003, a number of the product lines within this reporting unit experienced price reductions, principally as a result of the Companys strategy to preserve and expand market share. The reduced pricing, along with continued capital expenditures, caused the Company to lower its earnings and cash flow projections for the consumer products reporting unit for several years following the measurement date (October 1, 2003) resulting in an estimated fair value for the unit that was lower than its book value. Following a review of the valuation of the units identifiable assets, the Company recorded an impairment charge of $670.0 million to reduce the reported value of its goodwill.
During the fourth quarter of 2004, the Company completed its annual impairment testing and determined that no impairment existed.
During the fourth quarter of 2005, the Company completed its annual impairment testing and determined that impairment existed in the goodwill of its Asia Pacific Glass business unit. Lower projected cash flows, principally as a result of competitive pricing pressures in the Companys Australian glass operations, caused the decline in the business enterprise value. Following a review of the valuation of the units identifiable assets, the Company recorded an impairment charge of $494.0 million to reduce the reported value of its goodwill.
22. Discontinued Operations On October 7, 2004, the Company announced that it had completed the sale of its blow-molded plastic container operations in North America, South America and Europe, to Graham Packaging Company.
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23. Acquisition of BSN Glasspack, S.A. On June 21, 2004, the Company completed the acquisition of BSN Glasspack, S.A. (BSN) from Glasspack Participations (the BSN Acquisition). Total consideration for the BSN Acquisition was approximately $1.3 billion, including the assumption of approximately $650 million of debt, a portion of which was refinanced in connection with the BSN Acquisition. BSN was the second largest glass container manufacturer in Europe with manufacturing facilities in France, Spain, Germany and the Netherlands. The BSN Acquisition was financed with borrowings under the Companys Second Amended and Restated Secured Credit Agreement. In order to secure the European Commissions approval, the Company committed to divest the Barcelona, Spain, and Corsico, Italy glass plants. The Company completed the sale of these plants in January 2005 and received cash proceeds of approximately 138.2 million.
The restructuring accrual recorded in the second quarter of 2005 was in addition to the initial estimated accrual of 63.8 recorded in 2004. Selected information related to the restructuring accrual is as follows, with activity translated from Euros into dollars at the December 31, 2005 exchange rate:
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The total purchase cost of approximately $1.3 billion was allocated to the tangible and identifiable intangible assets and liabilities based upon their respective fair values. The following table summarizes the fair values of the assets acquired and liabilities assumed on June 21, 2004, translated from Euros into dollars at the exchange rate on that date:
June 21,
24. Pro Forma Information - Acquisition of BSN Glasspack, S.A. Had the Acquisition described in Note 23 and the related financing described in Note 6 occurred at the beginning of each respective period, pro forma consolidated net sales, net earnings, and net earnings per share of common stock would have been as follows:
Year ended December 31, 2004
As
BSN
Financing
Pro Forma
Reported
Adjustments
As Adjusted
752.5
6,880.9
182.7
Diluted earnings from continuing operations per share of common stock
1.08
107
Year ended December 31, 2003
AsReported
BSNAdjustments
FinancingAdjustments
Pro FormaAs Adjusted
1,417.5
6,393.1
Loss from continuing operations
28.9
(18.5
(319.7
Diluted loss from continuing operations per share of common stock
(2.32
The 2004 earnings included the step-up effect of the finished goods inventory acquired in the Acquisition that reduced gross profit by approximately $31.1 million. The 2004 and 2003 earnings include estimated amortization related to the $48.1 million of intangible assets recorded for customer relationships. At average exchange rates for each respective year, the pro forma amortization of the intangible asset was $4.0 million (net of tax) for 2004 and $3.6 million (net of tax) for 2003.
25. Accounts Receivable Securitization Program As part of the acquisition of BSN, the Company acquired a trade accounts receivable securitization program through a BSN subsidiary, BSN Glasspack Services. The program was entered into by BSN in order to provide lower interest costs on a portion of its financing. In November 2000, BSN created a securitization program for its trade receivables through a sub-fund (the fund) created in accordance with French Law.
According to the program, subject to eligibility criteria, certain, but not all, receivables held by the BSN Glasspack Services are sold to the fund on a weekly basis. The purchase price for the receivables is determined as a function of the book value and the term of each receivable and a Euribor three-month rate increased by a 1.51% margin. A portion of the purchase price for the receivables is deferred and paid by the fund to BSN Glasspack Services only when receivables are collected or at the end of the program. This deferred portion varies based on the status and updated collection history of BSN Glasspack Services receivable portfolio.
The fund assumes all collection risk on the receivables and the transferred receivables have been isolated from BSN Glasspack Services and are no longer controlled by BSN Glasspack Services. For the period from January 1, 2005 through December 13, 2005, the Company received $1.2 billion from the sale of receivables to the fund and paid interest of approximately $6.9 million.
Prior to December 2005, the transfer of the receivables to the fund was deemed to be a sale for U.S. GAAP purposes. Effective December 13, 2005, the Company expanded the capacity of its European accounts receivable securitization program from 200 million to 320 million to include operations in Italy and the United Kingdom. The terms of this expansion resulted in a changing from off-balance sheet to on-balance sheet accounting for the program. The net impact was an increase, at December 31, 2005, in reported accounts receivable and consolidated debt of $191.8 million.
BSN Glasspack Services continues to service, administer and collect the receivables on behalf of the fund. This service rendered to the fund is invoiced to the fund at a normal market rate.
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26. Financial Information for Subsidiary Guarantors and Non-Guarantors The following presents condensed consolidating financial information for the Company, segregating: (1) Owens-Illinois, Inc., the issuer of four series of senior notes and debentures (the Parent); (2) the two subsidiaries which have guaranteed the senior notes and debentures on a subordinated basis (the Guarantor Subsidiaries); and (3) all other subsidiaries (the Non-Guarantor Subsidiaries). The Guarantor Subsidiaries are 100% owned direct and indirect subsidiaries of the Company and their guarantees are full, unconditional and joint and several. They have no operations and function only as intermediate holding companies.
Wholly-owned subsidiaries are presented on the equity basis of accounting. Certain reclassifications have been made to conform all of the financial information to the financial presentation on a consolidated basis. The principal eliminations relate to investments in subsidiaries and inter-company balances and transactions.
109
Parent
GuarantorSubsidiaries
Non-GuarantorSubsidiaries
Balance Sheet
Other current assets
335.7
Investments in and advances to subsidiaries
2,247.7
1,197.7
(3,445.4
Other non-current assets
1,716.6
1,717.8
2,248.9
4,085.8
Property, plant and equipment, net
9,520.6
Current liabilities :
Accounts payable and accrued liabilities
1,385.6
Current portion of asbestos liability
Short-term loans and long-term debt due within one year
278.3
1,663.9
1,046.7
5,022.0
(1,050.0
Other non-current liabilities and minority interests
(251.8
1,637.0
1,385.2
Capital structure
(2,395.4
110
59.5
461.8
2,341.3
3,202.5
2,044.2
(5,246.7
206.8
1,702.0
(79.7
1,829.1
3,409.3
4,711.1
(5,326.4
3,468.8
10,550.1
1,544.0
192.5
(112.4
282.4
1,736.5
1,045.9
5,172.0
1,601.5
1,521.8
2,040.1
(4,084.3
111
Year ended December 31, 2005
Results of Operations
External interest income
Intercompany interest income
85.0
(170.0
Equity earnings from subsidiaries
(535.6
1,071.2
Other equity earnings
71.5
Total revenue
(450.6
901.2
Research, engineering, selling, administrative, and other
1,087.1
External interest expense
381.7
Intercompany interest expense
Total costs and expense
220.0
7,273.3
(670.6
(83.6
(49.0
416.1
Net earnings of discontinued operations
(126.0
(472.6
945.2
112
113.7
(227.4
256.4
(512.8
91.9
370.1
(740.2
507.2
361.2
266.3
5,900.5
Earnings from continuing operations before items below
103.8
362.9
(67.7
(128.0
Net earnings
320.4
(640.8
113
120.3
(240.6
(37.6
75.2
82.7
(165.4
656.1
309.5
570.3
5,053.8
Loss from continuing operations before items below
(487.6
Benefit for income taxes
(157.5
Net loss of discontinued operations
1,321.4
Net loss
(698.3
1,396.6
114
Cash provided by (used in) operating activities
(168.9
672.7
Cash provided by investing activities
Cash provided by (used in) financing activities
168.9
(442.0
Effect of exchange rate change on cash
Net change in cash
Cash at beginning of period
Cash at end of period
115
(173.6
783.5
173.6
(1,011.5
116
(192.4
545.5
Cash used in investing activities
192.4
(314.8
117
Selected Quarterly Financial Data (unaudited) The following tables present selected financial data by quarter for the years ended December 31, 2005 and 2004:
FirstQuarter
SecondQuarter
ThirdQuarter
FourthQuarter
YeartoDate
1,663.3
1,852.7
1,807.5
1,755.5
Gross profit
374.8
377.8
334.0
272.9
1,359.5
Earnings (loss) from continuing operations (a)
117.5
86.2
56.6
(881.9
Net earnings of discontinued operations (b)
119.6
Earnings (loss) per share of common stock (c):
Basic:
0.75
0.54
0.34
(5.86
Diluted:
0.73
0.53
Net (loss) earnings
(a) Amount for the first quarter includes a gain of $28.4 million ($17.0 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of this gain is an increase in earnings per share of $0.11.
Amount for the first quarter includes a gain of $28.1 million (pretax and after tax) from the sale of the Companys glass container facility in Corsico, Italy. The effect of this gain is an increase in earnings per share of $0.18.
Amount for the second quarter includes a loss of $7.0 million ($4.0 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of this loss is a decrease in earnings per share of $0.03.
Amount for the third quarter includes a loss of $8.2 million ($4.9 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of this loss is a decrease in earnings per share of $0.03.
118
Amount for the third quarter includes a benefit of $5.3 million from the reversal of an accrual for potential tax liabilities related to a previous divestiture. The accrual is no longer required based on the Companys reassessment of the potential liabilities. The effect of this benefit is an increase in earnings per share of $0.03.
Amount for the fourth quarter includes charges totaling $945.0 ($585.8 million after tax) for the following: (1) $494.0 million (pretax and after tax) to write down goodwill in the Asia-Pacific Glass unit; (2) $306.6 million to record a valuation allowance related to accumulated deferred tax assets in the U.S.; (3) $135.0 million ($86.0 million after tax) to increase the reserve for estimated future asbestos-related costs; and (4) $9.4 million ($5.8 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of these charges is a reduction in earnings per share of $5.89.
(b) Amount for the third quarter consists principally of a benefit from the reversal of an accrual for potential tax liabilities related to a previous divestiture. The accrual is no longer required based on the Companys reassessment of the potential liabilities.
(c) Earnings per share are computed independently for each period presented. As such, the sums of the amounts calculated separately for each quarter do not equal the year-to-date amount.
119
1,267.6
1,417.3
1,725.7
257.4
284.0
339.1
329.5
1,210.0
Earnings (loss) from continuing operations (d)
47.2
83.9
73.1
(32.7
7.6
(1.3
3.3
54.4
54.8
82.6
76.4
Earnings (loss) per share of common stock (e):
0.28
0.46
(0.26
0.05
(0.01
0.02
0.36
0.33
0.52
0.48
0.10
0.45
(0.25
0.47
0.11
(d) Amount for the first quarter includes a gain of $8.9 million ($5.8 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of this adjustment is an increase in earnings per share of $0.04.
Amount for the second quarter includes a gain of $20.6 million ($14.5 million after tax) for the sale of certain real property. The after-tax effect of this gain is an increase in earnings per share of $0.10.
Amount for the second quarter includes a gain of $0.9 million ($0.6 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of this adjustment resulted in no increase in earnings.
Amount for the third quarter includes a gain of $11.3 million ($7.4 million after tax) from the mark to market effect of natural gas hedge contracts. The after-tax effect of this adjustment is an increase in earnings per share of $0.05.
Amount for the fourth quarter includes a gain of $31.0 million ($13.1 million after tax) for the sale of certain real property. The after-tax effect of this gain is an increase in earnings per share of $0.09.
120
Amount for fourth quarter includes charges totaling $206.0 million ($121.0 million after tax) for the following:(1) $152.6 million ($84.9 million after tax) to increase the reserve for estimated future asbestos-related costs; (2) $28.0 million ($18.3 million after tax) for note repurchase premiums; (3) $16.2 million ($10.6 million after tax) from the mark to market effect of natural gas hedge contracts; (4) $6.4 million ($5.4 million after tax) for restructuring a life insurance program in order to comply with recent statutory and tax regulation changes; and (5) $2.8 million ($1.8 million after tax) for write-off of finance fees related to debt that was repaid prior to its maturity. The after tax effect of these charges is a reduction in earnings per share of $0.80.
Amount for the fourth quarter includes a benefit of $33.1 million for a tax consolidation in the Australian glass business. The after-tax effect of this benefit is an increase in earnings per share of $0.22.
(e) Earnings per share are computed independently for each period presented. As such, the sums of the amounts calculated separately for each quarter do not equal the year-to-date amount.
The Company maintains disclosure controls and procedures that are designed to ensure that information required to be disclosed in the Companys Exchange Act reports is recorded, processed, summarized and reported within the time periods specified in the Securities and Exchange Commissions rules and forms and that such information is accumulated and communicated to the Companys management, including its Chief Executive Officer and Chief Financial Officer, as appropriate, to allow timely decisions regarding required disclosure. In designing and evaluating the disclosure controls and procedures, management recognizes that any controls and procedures, no matter how well designed and operated, can provide only reasonable assurance of achieving the desired control objectives, and management is required to apply its judgment in evaluating the cost-benefit relationship of possible controls and procedures. Also, the Company has investments in certain unconsolidated entities. As the Company does not control or manage these entities, its disclosure controls and procedures with respect to such entities are necessarily substantially more limited than those maintained with respect to its consolidated subsidiaries.
As required by Rule 13a-15(b) of the Exchange Act, the Company carried out an evaluation, under the supervision and with the participation of management, including its Chief Executive Officer and Chief Financial Officer, of the effectiveness of the design and operation of the Companys disclosure controls and procedures as of the end of the period covered by this report. Based on the foregoing, the Companys Chief Executive Officer and Chief Financial Officer concluded that the Companys disclosure controls and procedures were effective at the reasonable assurance level as of December 31, 2005.
There has been no change in the Companys internal controls over financial reporting during the Companys most recent fiscal quarter that has materially affected, or is reasonably likely to materially affect, the Companys internal controls over financial reporting.
121
Managements Report on Internal Control over Financial Reporting
The management of Owens-Illinois Inc., is responsible for establishing and maintaining adequate internal control over financial reporting. The Companys internal control over financial reporting is designed to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with generally accepted accounting principles in the United States. However, all internal control systems, no matter how well designed, have inherent limitations. Therefore, even those systems determined to be effective can provide only reasonable assurance with respect to financial statement preparation and reporting.
Management assessed the effectiveness of the Companys internal control over financial reporting as of December 31, 2005. In making this assessment management used the criteria for effective internal control over financial reporting as described in Internal Control Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission (the COSO framework).
Based on this assessment, using the criteria above, management concluded that the Companys system of internal control over financial reporting was effective as of December 31, 2005.
The Companys independent registered public accounting firm, Ernst & Young LLP, that audited the Companys consolidated financial statements, has issued an attestation report on managements assessment of the Companys internal control over financial reporting which is included below.
122
We have audited managements assessment, included in the accompanying Managements Report on Internal Control over Financial Reporting, that Owens-Illinois, Inc. maintained effective internal control over financial reporting as of December 31, 2005, based on criteria established in Internal ControlIntegrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission (the COSO criteria). Owens-Illinois, Inc.s management is responsible for maintaining effective internal control over financial reporting and for its assessment of the effectiveness of internal control over financial reporting. Our responsibility is to express an opinion on managements assessment and an opinion on the effectiveness of the companys internal control over financial reporting based on our audit.
We conducted our audit in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether effective internal control over financial reporting was maintained in all material respects. Our audit included obtaining an understanding of internal control over financial reporting, evaluating managements assessment, testing and evaluating the design and operating effectiveness of internal control, and performing such other procedures as we considered necessary in the circumstances. We believe that our audit provides a reasonable basis for our opinion.
A companys internal control over financial reporting is a process designed to provide reasonable assurance regarding the reliability of financial reporting and the preparation of financial statements for external purposes in accordance with generally accepted accounting principles. A companys internal control over financial reporting includes those policies and procedures that (1) pertain to the maintenance of records that, in reasonable detail, accurately and fairly reflect the transactions and dispositions of the assets of the company; (2) provide reasonable assurance that transactions are recorded as necessary to permit preparation of financial statements in accordance with generally accepted accounting principles, and that receipts and expenditures of the company are being made only in accordance with authorizations of management and directors of the company; and (3) provide reasonable assurance regarding prevention or timely detection of unauthorized acquisition, use, or disposition of the companys assets that could have a material effect on the financial statements.
Because of its inherent limitations, internal control over financial reporting may not prevent or detect misstatements. Also, projections of any evaluation of effectiveness to future periods are subject to the risk that controls may become inadequate because of changes in conditions, or that the degree of compliance with the policies or procedures may deteriorate.
In our opinion, managements assessment that Owens-Illinois Inc. maintained effective internal control over financial reporting as of December 31, 2005, is fairly stated, in all material respects, based on the COSO criteria. Also, in our opinion, Owens-Illinois, Inc. maintained, in all material respects, effective internal control over financial reporting as of December 31, 2005, based on the COSO criteria.
We also have audited, in accordance with the standards of the Public Company Accounting Oversight Board (United States), the consolidated balance sheets of Owens-Illinois, Inc. as of December 31, 2005
123
and 2004, and the related consolidated statements of results of operations, share owners equity, and cash flows for each of the three years in the period ended December 31, 2005 and our report dated March 15, 2006 expressed an unqualified opinion thereon.
124
Information with respect to non-officer directors is included in the Proxy Statement in the section entitled Election of Directors and such information is incorporated herein by reference.
Information with respect to executive officers is included herein on pages 13 - 15.
Code of Business Conduct and Ethics
The Companys Code of Business Conduct and Ethics, which will be applicable to all directors, officers and employees of the Company, including the principal executive officer, the principal financial officer and the principal accounting officer, is available on the Investor Relations section of the Companys website (www.o-i.com). A copy of the Code is also available in print to share owners upon request, addressed to the Corporate Secretary at Owens-Illinois, Inc., One SeaGate, Toledo, Ohio 43666. The Company intends to post amendments to or waivers from its Code of Business Conduct and Ethics (to the extent applicable to the Companys directors, executive officers or principal financial officers) at this location on its website.
The section entitled Director and Executive Compensation and Other Information, exclusive of the subsections entitled Board Compensation Committee Report on Executive Compensation and Performance Graph, which is included in the Proxy Statement is incorporated herein by reference.
The section entitled Security Ownership of Certain Beneficial Owners and Management which is included in the Proxy Statement is incorporated herein by reference.
125
Equity Compensation Plan Information
(a)
(b)
(c)
Plan Category
Number of securitiesto be issued uponexercise ofoutstanding options,warrants and rights (1)
Weighted-averageexercise price ofoutstanding options,warrants and rights
Number of securitiesremaining available forfuture issuance underequity compensationplans (excluding securitiesreflected in column (a))
Equity compensation plans approved by security holders
Equity compensation plans not approved by security holders
(1) Represents options to purchase shares of the Companys common stock. There are no outstanding warrants or rights.
ITEM 14. PRINCIPAL ACCOUNTANT FEES AND SERVICES
Information with respect to principal accountant fees and services is included in the Proxy Statement in the section entitled Independent Registered Public Accounting Firm and such information is incorporated herein by reference.
126
FINANCIAL STATEMENTS AND FINANCIAL STATEMENT SCHEDULES
Index of Financial Statements and Financial Statement Schedules Covered by Report of Independent Auditors.
(i) Registrant
For the years ended December 31, 2005, 2004, and 2003
Notes to the Consolidated Financial Statements
Exhibit Index
Financial Statement Schedule
Schedule Page
II - Valuation and Qualifying Accounts (Consolidated)
All other schedules have been omitted since the required information is not present or not present in amounts sufficient to require submission of the schedule.
(ii) Separate Financial Statements of Affiliates Whose Securities Are Pledged As Collateral
127
EXHIBIT INDEX
S-K Item 601 No.
Document
Restated Certificate of Incorporation of Owens-Illinois, Inc. (filed as Exhibit 3.1 to Owens-Illinois, Inc.s Form S-2, File No. 33-43224, and incorporated herein by reference).
Bylaws of Owens-Illinois, Inc., as amended (filed as Exhibit 3.2 to Owens-Illinois, Inc.s Form S-2, File No. 33-43224, and incorporated herein by reference).
4.1
Indenture dated as of May 15, 1997, between Owens-Illinois, Inc. and The Bank of New York, as Trustee (filed as Exhibit 4.1 to Owens-Illinois, Inc.s Form 8-K dated May 16, 1997, File No. 1-9576, and incorporated herein by reference).
Officers Certificate, dated May 16, 1997, establishing the terms of the 8.10% Senior Notes due 2007; including the Form of 8.10% Senior Note due 2007 (filed as Exhibits 4.3 and 4.5, respectively, to Owens-Illinois, Inc.s Form 8-K dated May 16, 1997, File No. 1-9576, and incorporated herein by reference).
Supplemental Indenture, dated as of June 26, 2001 among Owens-Illinois, Inc., Owens-Illinois Group, Inc., Owens-Brockway Packaging, Inc. and The Bank of New York, as Trustee (May 15, 1997 Indenture) (filed as Exhibit 4.2 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended September 30, 2001, File No. 1-9576, and incorporated herein by reference).
Second Supplemental Indenture, dated as of May 27, 2003, among Owens-Illinois, Inc., Owens-Illinois Group, Inc., Owens-Brockway Packaging, Inc. and The Bank of New York, as Trustee (May 15, 1997 Indenture) (filed as Exhibit 4.12 to Owens-Brockway Glass Container Inc. registration statement on Form S-4 dated June 24, 2003, File No. 333-106399, and incorporated herein by reference).
Indenture dated as of May 20, 1998, between Owens-Illinois, Inc. and The Bank of New York, as Trustee (filed as Exhibit 4.1 to Owens-Illinois, Inc.s Form 8-K dated May 20, 1998, File No. 1-9576, and incorporated herein by reference).
Officers Certificate, dated May 20, 1998, establishing the terms of the 7.35% Senior Notes due 2008; including the Form of 7.35% Senior Note due 2008 (filed Exhibits 4.3 and 4.7, respectively, to Owens-Illinois, Inc.s Form 8-K dated May 20, 1998, File No. 1-9576, and incorporated herein by reference).
Officers Certificate, dated May 20, 1998, establishing the terms of the 7.50% Senior Notes due 2010; including the Form of 7.50% Senior Note due 2010 (filed as Exhibits 4.4 and 4.8, respectively, to Owens-Illinois, Inc.s Form 8-K dated May 20, 1998, File No. 1-9576, and incorporated herein by reference).
Officers Certificate, dated May 20, 1998, establishing the terms of the 7.80% Senior Notes due 2018; including the Form of 7.80% Senior Note due 2018 (filed as Exhibits 4.5 and 4.9, respectively, to Owens-Illinois, Inc.s Form 8-K filed May 20, 1998, File No. 1-9576, and incorporated herein by reference).
Supplemental Indenture, dated as of June 26, 2001 among Owens-Illinois, Inc., Owens-Illinois Group, Inc., Owens-Brockway Packaging, Inc. and The Bank of New York, as Trustee (May 20, 1998 Indenture) (filed as Exhibit 4.1 to Owens-Illinois Inc.s Form 10-Q for the quarter ended September 30, 2001, File No. 1-9576, and incorporated herein by reference).
128
4.10
Second Supplemental Indenture, dated as of December 1, 2004 among Owens-Illinois, Inc., Owens-Illinois Group, Inc., Owens-Brockway Packaging, Inc. and The Bank of New York, as Trustee (filed as Exhibit 4.1 to Owens-Illinois Inc.s Form 8-K dated December 1, 2004, File No. 1-9576, and incorporated herein by reference).
4.11
Certificate of Designations, Preferences and Relative, Participating, Optional and Other Special Rights of Preferred Stock and Qualifications, Limitations and Restrictions thereof of Convertible Preferred Stock of Owens-Illinois, Inc., dated May 15, 1998 (filed as Exhibit 4.10 to Owens-Illinois Inc.s Form 8-K dated May 20, 1998, File No. 1-9576, and incorporated herein by reference).
4.12
Third Amended and Restated Secured Credit Agreement, dated as of October 7, 2004, by and among the Borrowers named therein, Owens-Illinois General, Inc., as Borrowers Agent, Deutsche Bank Trust Company Americas, as Administrative Agent, and the other Agents, Arrangers and Lenders named therein (filed as Exhibit 4.2 to Owens-Illinois Inc.s Form 8-K dated October 7, 2004, File No. 1-9576, and incorporated herein by reference).
4.13
First Amendment to Third Amended and Restated Secured Credit Agreement, dated as of June 13, 2005, by and among the Borrowers named therein, Owens-Illinois General, Inc., as Borrowers Agent, Deutsche Bank Trust Company Americas, as Administrative Agent, and the other Agents, Arrangers and Lenders named therein (filed as Exhibit 4.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 2005, File No. 1-9576, and incorporated herein by reference).
4.14
Amended and Restated Intercreditor Agreement, dated as of June 13, 2003, by and among Deutsche Bank Trust Company Americas, as administrative agent for the lenders party to the Credit Agreement (as defined therein) and Deutsche Bank Trust Company Americas, as Collateral Agent (as defined therein) and any other parties thereto (filed as Exhibit 4.20 to Owens-Brockway Glass Container Inc. registration statement on Form S-4 dated June 24, 2003, File No. 333-106399, and incorporated herein by reference).
4.15
First Amendment to Amended and Restated Intercreditor Agreement, dated as of March 15, 2004, by and among Deutsche Bank Trust Company Americas, as administrative agent for the lenders party to the Credit Agreement (as defined therein) and Deutsche Bank Trust Company Americas, as Collateral Agent (as defined therein) and any other parties thereto (filed as Exhibit 4.2 to Owens-Illinois Group, Inc.s Form 10-Q for the quarter ended March 31, 2004, File No. 33-13061, and incorporated herein by reference).
4.16
Amended and Restated Pledge Agreement, dated as of June 13, 2003, between Owens-Illinois Group, Inc., Owens-Brockway Packaging, Inc., and Deutsche Bank Trust Company Americas, as Collateral Agent (as defined therein) and any other parties thereto (filed as Exhibit 4.21 to Owens-Brockway Glass Container Inc. registration statement on Form S-4 dated June 24, 2003, File No. 333-106399, and incorporated herein by reference).
4.17
First Amendment to Amended and Restated Pledge Agreement, dated as of March 15, 2004, between Owens-Illinois Group, Inc., Owens-Brockway Packaging, Inc., and Deutsche Bank Trust Company Americas, as Collateral Agent (as defined therein) and any other parties thereto (filed as Exhibit 4.3 to Owens-Illinois Group, Inc.s Form 10-Q for the quarter ended March 31, 2004, File No. 33-13061, and incorporated herein by reference).
129
4.18
Amended and Restated Security Agreement, dated as of June 13, 2003, between Owens-Illinois Group, Inc., each of the direct and indirect subsidiaries of Owens-Illinois Group, Inc. signatory thereto and Deutsche Bank Trust Company Americas, as Collateral Agent (as defined therein) (filed as Exhibit 4.22 to Owens-Brockway Glass Container Inc. registration statement on Form S-4 dated June 24, 2003, File No. 333-106399, and incorporated herein by reference).
4.19
First Amendment to Amended and Restated Security Agreement, dated as of March 15, 2004, between Owens-Illinois Group, Inc., each of the direct and indirect subsidiaries of Owens-Illinois Group, Inc. signatory thereto and Deutsche Bank Trust Company Americas, as Collateral Agent (as defined therein) (filed as Exhibit 4.4 to Owens-Illinois Group, Inc.s Form 10-Q for the quarter ended March 31, 2004, File No. 33-13061, and incorporated herein by reference).
4.20
Indenture, dated as of January 24, 2002, among Owens-Brockway Glass Container, Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.1 to Owens-Illinois Group, Inc.s Form S-4, File No. 333-85690, and incorporated herein by reference).
4.21
First Supplemental Indenture, dated as of January 24, 2002, among Owens-Brockway Glass Container, Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.2 to Owens-Illinois Group, Inc.s Form S-4, File No. 333-85690, and incorporated herein by reference).
4.22
Second Supplemental Indenture, dated as of August 5, 2002, among Owens-Brockway Glass Container, Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.1 to Owens-Illinois Group Inc.s Form 10-Q for the quarter ended September 30, 2002, File No. 33-13061, and incorporated herein by reference).
4.23
Third Supplemental Indenture, dated as of November 13, 2002, among Owens-Brockway Glass Container Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.4 to Owens-Illinois Group, Inc.s Form S-4, File No. 333-103263, and incorporated herein by reference).
4.24
Additional Supplemental Indenture, dated as of December 18, 2002, among Owens-Brockway Glass Container Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.5 to Owens-Illinois Group, Inc.s Form S-4, File No. 333-103263, and incorporated herein by reference).
4.25
Fourth Supplemental Indenture, dated as of May 6, 2003, among Owens-Brockway Glass Container Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.2 to Owens-Illinois Group, Inc.s Quarterly Report on Form 10-Q for the quarter ended March 31, 2003, File No. 33-13061, and incorporated herein by reference).
4.26
Indenture, dated as of May 6, 2003, among Owens-Brockway Glass Container Inc., the Guarantors (as defined therein) and U.S. Bank National Association, as Trustee (filed as Exhibit 4.3 to Owens-Illinois Group, Inc.s Quarterly Report on Form 10-Q for the quarter ended March 31, 2003, File No. 33-13061, and incorporated herein by reference).
4.27
Indenture, dated as of December 1, 2004, by and among Owens-Brockway Glass Container Inc., the guarantors party thereto and Law Debenture Trust Company of New York, as trustee (filed as Exhibit 4.26 to Owens-Illinois Group, Inc.s Form S-4, File No. 333-123960, and incorporated herein by reference).
130
10.1*
Amended and Restated Owens-Illinois Supplemental Retirement Benefit Plan (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 1998, File No. 1-9576, and incorporated herein by reference).
10.2*
First Amendment to Amended and Restated Owens-Illinois Supplemental Retirement Benefit Plan (filed as Exhibit 10.3 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 2000, File No. 1-9576, and incorporated herein by reference).
10.3*
Second Amendment to Amended and Restated Owens-Illinois Supplemental Retirement Benefit Plan (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended March 31, 2002, File No. 1-9576, and incorporated herein by reference).
10.4*
Third Amendment to Amended and Restated Owens-Illinois Supplemental Retirement Benefit Plan (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended March 31, 2003, File No. 1-9576, and incorporated herein by reference).
10.5*
Form of Employment Agreement between Owens-Illinois, Inc. and various Employees (filed as Exhibit 10(m) to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1987, File No. 1-9576, and incorporated herein by reference).
10.6*
Second Amended and Restated Stock Option Plan for Key Employees of Owens-Illinois, Inc. (filed as Exhibit 10.20 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1994, File No. 1-9576, and incorporated herein by reference).
10.7*
First Amendment to Second Amended and Restated Stock Option Plan for Key Employees of Owens-Illinois, Inc. (filed as Exhibit 10.13 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1995, File No. 1-9576, and incorporated herein by reference).
10.8*
Second Amendment to Second Amended and Restated Stock Option Plan for Key Employees of Owens-Illinois, Inc. (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 1997, File No. 1-9576, and incorporated herein by reference).
10.9*
Third Amendment to Second Amended and Restated Stock Option Plan for Key Employees of Owens-Illinois, Inc. (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended September 30, 2000, File No. 1-9576, and incorporated herein by reference.)
10.10*
Form of Non-Qualified Stock Option Agreement for use under the Second Amended and Restated Stock Option Plan for Key Employees of Owens-Illinois, Inc. (filed as Exhibit 10.21 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1994, File No. 1-9576, and incorporated herein by reference).
10.11*
Amended and Restated Owens-Illinois, Inc. Performance Award Plan (filed as Exhibit 10.16 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1993, File No. 1-9576, and incorporated herein by reference).
10.12*
First Amendment to Amended and Restated Owens-Illinois, Inc. Performance Award Plan (filed as Exhibit 10.4 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 1997, File No. 1-9576, and incorporated herein by reference).
10.13*
Owens-Illinois, Inc. Directors Deferred Compensation Plan (filed as Exhibit 10.26 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1995, File No. 1-9576, and incorporated herein by reference).
10.14*
First Amendment to Owens-Illinois, Inc. Directors Deferred Compensation Plan (filed as Exhibit 10.27 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 1995, File No. 1-9576, and incorporated herein by reference).
131
10.15*
Second Amendment to Owens-Illinois, Inc. Directors Deferred Compensation Plan (filed as Exhibit 10.2 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended March 31, 1997, File No. 1-9576, and incorporated herein by reference).
10.16*
Amended and Restated 1997 Equity Participation Plan of Owens-Illinois, Inc. (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 1999, File No. 1-9576, and incorporated herein by reference).
10.17*
First Amendment to Amended and Restated 1997 Equity Participation Plan of Owens-Illinois, Inc. (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 2002, File No. 1-9576, and incorporated herein by reference).
10.18*
Owens-Illinois, Inc. Executive Deferred Savings Plan (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended September 30, 2001, File No. 1-9576, and incorporated herein by reference).
10.19*
Employment agreement between Owens-Illinois, Inc. and Steven R. McCracken dated March 31, 2004 (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended March 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.20*
Amendment dated March 10, 2005 to the employment agreement between Owens-Illinois, Inc. and Steven R. McCracken dated March 31, 2004 (filed as Exhibit 10.27 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.21*
Restricted StockAgreement under the Amended and Restated 1997 Equity Participation Plan of Owens-Illinois, Inc. between Owens-Illinois, Inc. and Steven R. McCracken dated March 31, 2004 (filed as Exhibit 10.2 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended March 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.22*
Non-Qualified Stock Option Agreement under the Amended and Restated 1997 Equity Participation Plan of Owens-Illinois, Inc. between Owens-Illinois, Inc. and Steven R. McCracken dated March 31, 2004 (filed as Exhibit 10.3 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended March 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.23*
2004 Equity Incentive Plan for Directors of Owens-Illinois, Inc. (filed as Exhibit 10.1 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 2004, File No. 1-9576, and incorporated herein by reference).
10.24*
Owens-Illinois, Inc. Incentive Bonus Plan (filed as Exhibit 10.2 to Owens-Illinois, Inc.s Form 10-Q for the quarter ended June 30, 2004, File No. 1-9576, and incorporated herein by reference).
10.25*
Owens-Illinois 2004 Executive Life Insurance Plan (filed as Exhibit 10.32 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.26*
Owens-Illinois 2004 Executive Life Insurance Plan for Non-U.S. Employees (filed as Exhibit 10.33 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.27*
Second Amended and Restated Owens-Illinois, Inc. Senior Management Incentive Plan (filed as Exhibit 10.34 to Owens-Illinois, Inc.s Form 10-K for the year ended December 31, 2004, File No. 1-9576, and incorporated herein by reference).
10.28*
Owens-Illinois, Inc. 2005 Incentive Award Plan (filed herewith).
10.29*
Form of Non-Qualified Stock Option Agreement for use under the Owens-Illinois, Inc. 2005 Incentive Award Plan. (filed herewith).
132
10.30*
Form of Restricted Stock Agreement for use under the Owens-Illinois, Inc. 2005 Incentive Award Plan. (filed herewith).
10.31*
Form of Phantom Stock Agreement for use under the Owens-Illinois, Inc. 2005 Incentive Award Plan. (filed herewith).
10.32*
Form of Restricted Stock Unit Agreement for use under the Owens-Illinois, Inc. 2005 Incentive Award Plan. (filed herewith).
Computation of Ratio of Earnings to Fixed Charges and Earnings to Combined Fixed Charges and Preferred Stock Dividends (filed herewith).
Subsidiaries of Owens-Illinois, Inc. (filed herewith).
Consent of Independent Registered Public Accounting Firm (filed herewith).
Owens-Illinois, Inc. Power of Attorney (filed herewith).
Certification of Principal Executive Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 (filed herewith).
Certification of Principal Financial Officer pursuant to Section 302 of the Sarbanes-Oxley Act of 2002 (filed herewith).
32.1
Certification of Principal Executive Officer pursuant to 18 U.S.C Section 1350 (filed herewith).
32.2
Certification of Principal Financial Officer pursuant to 18 U.S.C Section 1350 (filed herewith).
* Indicates a management contract or compensatory plan or arrangement required to be filed as an exhibit to this form pursuant to Item 15(c).
SEPARATE FINANCIAL STATEMENTS OF AFFILIATES WHOSE SECURITIES ARE PLEDGED AS COLLATERAL.
1) Financial statements of Owens-Brockway Packaging, Inc. and subsidiaries including consolidated balance sheets as of December 31, 2005 and 2004, and the related statements of operations, net parent investment, and cash flows for the years ended December 31, 2005, 2004 and 2003.
2) Financial statements of Owens-Brockway Glass Container Inc. and subsidiaries including consolidated balance sheets as of December 31, 2005 and 2004, and the related statements of operations, net parent investment, and cash flows for the years ended December 31, 2005, 2004 and 2003.
3) Financial statements of OI Plastic Products FTS, Inc. and subsidiaries including consolidated balance sheets as of December 31, 2005 and 2004, and the related statements of operations, net parent investment, and cash flows for the years ended December 31, 2005, 2004 and 2003.
133
The Board of Directors and Share Owner of
Owens-Brockway Packaging, Inc.
We have audited the accompanying consolidated balance sheets of Owens-Brockway Packaging, Inc. as of December 31, 2005 and 2004, and the related consolidated statements of results of operations, net Parent investment, and cash flows for each of the three years in the period ended December 31, 2005. These financial statements are the responsibility of the Companys management. Our responsibility is to express an opinion on these financial statements based on our audits.
We conducted our audits in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. We were not engaged to perform an audit of the Companys internal control over financial reporting. Our audits included consideration of internal control over financial reporting as a basis for designing audit procedures that are appropriate in the circumstances, but not for the purpose of expressing an opinion on the effectiveness of the Companys internal control over financial reporting. Accordingly, we express no such opinion. An audit also includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements, assessing the accounting principles used and significant estimates made by management, and evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion.
In our opinion, the financial statements referred to above present fairly, in all material respects, the consolidated financial position of Owens-Brockway Packaging, Inc. at December 31, 2005 and 2004, and the consolidated results of its operations and its cash flows for each of the three years in the period ended December 31, 2005, in conformity with U.S. generally accepted accounting principles.
134
CONSOLIDATED RESULTS OF OPERATIONS Owens-Brockway Packaging, Inc.
Dollars in millions
6,356.4
5,522.3
4,409.0
131.6
86.5
6,460.2
5,653.9
4,495.5
5,169.2
4,455.3
3,549.6
15.2
15.7
36.1
34.1
35.5
361.9
267.2
Net intercompany interest
28.7
30.6
Other interest expense
379.5
403.7
352.9
525.4
219.3
6,516.1
5,224.2
4,401.4
(55.9
429.7
94.1
130.6
109.1
48.2
33.0
(222.4
287.6
135
CONSOLIDATED BALANCE SHEETS Owens-Brockway Packaging, Inc.
Cash, including time deposits of $104.0 ($149.0 in 2004)
251.6
Receivables including amount from related parties of $0.8 ($0.1 in 2004), less allowances of $25.7 ($29.0 in 2004) for losses and discounts
939.9
761.0
889.2
1,051.7
2,104.3
2,127.2
102.2
106.9
162.7
185.2
397.2
384.4
2,159.7
2,799.6
2,838.9
3,494.6
229.5
155.0
905.6
804.2
4,070.2
4,273.5
98.2
103.3
5,392.6
5,503.7
2,576.3
2,352.5
2,816.3
3,151.2
7,759.5
8,773.0
136
Liabilities and Net Parent Investment
Accounts payable including amount to related parties of $2.2 ($0.5 in 2004)
765.6
774.7
141.1
107.8
253.3
286.7
61.8
1,546.1
1,348.3
External long-term debt
3,958.6
4,111.0
232.9
209.6
741.3
845.5
182.0
170.1
Net Parent investment:
Investment by and advances from Parent
1,313.9
2,020.6
Accumulated other comprehensive loss
(215.3
67.9
Total net Parent investment
1,098.6
2,088.5
Total liabilities and net Parent investment
137
CONSOLIDATED NET PARENT INVESTMENT Owens-Brockway Packaging, Inc.
Investment by and advances to Parent
997.0
2,154.0
Net intercompany transactions
(484.3
736.0
(1,177.1
(198.3
(541.0
(290.5
363.2
798.7
Total comprehensive income
(505.6
553.8
362.8
See accompanying Notes to the Consolidated Financial Statements
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CONSOLIDATED CASH FLOWS Owens-Brockway Packaging, Inc.
431.3
341.3
35.4
35.2
34.2
Deferred tax provision (credit)
11.4
(3.0
165.5
(70.0
(53.9
(14.6
12.9
(17.5
Change in non-current liabilities
(58.7
(10.1
181.6
(41.2
Cash provided by operating activities
759.0
781.0
474.7
Additions to property, plant and equipment
(366.2
(407.6
(312.2
Proceeds from sale on long-term notes receivable
205.7
257.8
Cash utilized in investing activities
(172.1
(780.1
(128.8
537.5
2,114.6
2,154.4
(617.1
(2,611.1
(1,133.2
11.5
Net change in intercompany debt
(414.2
675.8
(1,127.2
(123.2
Payment of finance fees
(43.8
Cash provided by (utilized in) financing activities
(581.3
95.8
(301.0
7.9
(7.7
101.0
52.8
150.6
97.8
See Accompanying Notes to Consolidated Financial Statements.
139
Tabular data dollars in millions
Basis of Consolidated Statements The consolidated financial statements of Owens-Brockway Packaging, Inc. (Company) include the accounts of its subsidiaries. Newly acquired subsidiaries have been included in the consolidated financial statements from dates of acquisition.
Relationship with Owens-Illinois Group, Inc. and Owens-Illinois, Inc.The Company is a wholly-owned subsidiary of Owens-Illinois Group, Inc. (OI Group) and an indirect subsidiary of Owens-Illinois, Inc. (OI Inc.). Although OI Inc. does not conduct any operations, it has substantial obligations related to outstanding indebtedness, dividends for preferred stock and asbestos-related payments. OI Inc. relies primarily on distributions from its direct and indirect subsidiaries to meet these obligations.
For federal and certain state income tax purposes, the taxable income of the Company is included in the consolidated tax returns of OI Inc. and income taxes are allocated to the Company on a basis consistent with separate returns.
Nature of Operations The Company is a leading manufacturer of glass container products. The Companys principal product lines in the Glass Containers product segment are glass containers for the food and beverage industries. The Company has glass container operations located in 22 countries. The principal markets and operations for the Companys glass products are in North America, Europe, South America, and Australia. One customer accounted for 11.5% of the Companys sales in 2003.
Use of Estimates The preparation of financial statements in conformity with accounting principles generally accepted in the United States requires management of the Company to make estimates and assumptions that affect certain amounts reported in the financial statements and accompanying notes. Actual results may differ from those estimates, at which time the Company would revise its estimates accordingly.
140
Foreign Currency Translation The assets and liabilities of most subsidiaries and associates are translated at current exchange rates and any related translation adjustments are recorded directly in net Parent investment.
New Accounting Standards In May 2005, the Financial Accounting Standards Board issued FAS No. 154, Accounting Changes and Error Corrections, which changes the requirements for accounting for and reporting a change in accounting principle. The statement requires changes in accounting principle to
141
be applied retrospectively to prior periods financial statements. The statement also redefines restatement as being the correction of an error. FAS No. 154 is effective for the Company beginning after January 1, 2006. The Company will apply FAS No. 154 as required.
Participation in OI Inc. Stock Option Plans The Company participates in the equity compensation plans of OI Inc. under which employees of the Company may be granted options to purchase common shares of OI Inc. or may be granted restricted common shares of OI Inc.
For options granted prior to March 31, 2005, no options may be exercised in whole or in part during the first year after the date granted. In general, subject to accelerated exercisability provisions related to the performance of OI Inc.s common stock or change of control, 50% of the options become exercisable on the fifth anniversary of the date of the option grant, with the remaining 50% becoming exercisable on the sixth anniversary date of the option grant. In general, options expire following termination of employment or the day after the tenth anniversary date of the option grant.
For options granted after March 30, 2005, no options may be exercised in whole or in part during the first year after the date granted. In general, subject change of control, options become exercisable 25% per year beginning on the first anniversary. In general, options expire following termination of employment or the seventh anniversary of the option grant.
All options have been granted at prices equal to the market price of OI Inc.s common stock on the date granted. Accordingly, under the disclosure-only provisions of FAS 123, the Company recognized no compensation expense related to the stock option plans. The fair value of each option grant is estimated on the date of grant using the Black-Scholes option pricing model with the assumptions described in the accounting policies note on stock options.
During 2005, OI Inc. awarded 238,136 performance vested units under its equity compensation plans. As soon as practicable after 2007, holders of each unit will receive a number of shares ranging from .5 shares to 1.5 shares, depending upon the attainment of established performance goals. Failure to meet minimum goals will result in forfeiture of the shares. Granted but unvested shares are forfeited upon termination of employment.
During 2005, 2004 and 2003 OI Inc. awarded shares of restricted stock to certain key employees under its equity compensation plans Shares granted to employees prior to March 31, 2005, generally vest upon retirement. Shares granted to employees after March 30, 2005, vest 25% per year beginning on the first anniversary. Granted but unvested shares are forfeited upon termination of employment, unless certain retirement criteria are met.
A substantial number of the options, restricted shares and restricted share units have been granted to key employees of another subsidiary of OI Inc., some of whose compensation costs are included in an allocation of costs to all operating subsidiaries of OI Inc., including the Company. It is not practicable to determine an amount of additional compensation allocable to the Company for the restricted shares or for the options, had OI Inc. elected to recognize compensation cost based on the fair value of the options granted at grant date as allowed by FAS No. 123.
2. Changes in Components of Working Capital Related to Operations Changes in the components of working capital related to operations (net of the effects related to acquisitions and divestitures) were as follows:
142
(18.2
75.7
42.9
58.1
83.8
(29.1
32.4
(64.2
(6.2
66.8
(45.5
3. Inventories Major classes of inventory are as follows:
748.5
890.6
74.9
77.5
62.3
77.2
If the inventories which are valued on the LIFO method had been valued at standard costs, which approximate current costs, consolidated inventories would be higher than reported by $20.9 million and $15.1 million, at December 31, 2005 and 2004, respectively.
Inventories which are valued at the lower of standard costs (which approximate average costs), or market at December 31, 2005 and 2004 were approximately $775.6 million and $917.4 million, respectively.
4. Equity Investments. Summarized information pertaining to the Companys equity associates follows:
143
37.1
30.5
15.1
10.9
26.1
25.0
11.0
12.8
144
5. External Long-Term Debt The following table summarizes the external long-term debt of the Company at December 31, 2005 and 2004:
Term Loans
C2 Term Loan (46.3 million at December 31, 2005)
436.6
444.1
6.75%, due 2014 (225 million at December 31, 2005)
9.25%, due 2009 (0.4 million at December 31, 2005)
33.9
102.1
4,210.6
4,172.8
145
Borrowings under the Agreement are secured by substantially all the assets of the Company, its domestic subsidiaries and certain foreign subsidiaries, which have a book value of approximately $3.4 billion. Borrowings are also secured by a pledge of intercompany debt and equity in most of the Companys domestic subsidiaries and certain stock of certain foreign subsidiaries. All borrowings under the agreement are guaranteed by the Company and substantially all of its domestic subsidiaries and certain foreign subsidiaries for the term of the Agreement.
During December 2004, a subsidiary of the Company issued Senior Notes totaling $400.0 million and Senior Notes totaling 225.0 million. The notes bear interest at 6.75%, and are due December 1, 2014. Both series of notes are guaranteed by OI Group and substantially all of its domestic subsidiaries. The indentures for both series of notes have substantially the same restrictions as the previously issued 7.75%, 8.875% and 8.75% Senior Secured Notes and 8.25% Senior Notes. The issuing subsidiary used the net proceeds from the notes of approximately $680.0 million in addition to borrowings under the Agreement to purchase in a tender offer $237.6 million of the $350.0 million of OI Inc.s 7.15% Senior Notes due 2005, 159.6 million of the 160.0 million 9.25% BSN notes due 2009 and 127.3 million of the 140.0 million 10.25% BSN notes due 2009. As part of the issuance of these notes and the related tender offer, the Company recorded in the fourth quarter of 2004 additional interest charges of $22.8 million for note repurchase premiums and the related write-off of unamortized finance fees.
The interest rate on the accounts receivable securitization program is a variable rate and also includes a margin of 1.35% for the European program and 0.85% for the Asia Pacific program. The weighted
146
average interest rates on borrowings on the European program were 5.0% for the UK and Italy, and 3.9% for France at December 31, 2005. The weighted average interest rates on borrowings on the Asia pacific program were 6.5% for the Australian program, and 8.5% for New Zealand program at December 31, 2005. These programs have maturity dates ranging from October of 2006 through September of 2008.
Annual maturities for all of the Companys long-term debt through 2010 are as follows: 2006, $252.0 million; 2007, $231.4 million; 2008, $543.7 million; and 2009, $1004.8 million. There are no amounts due in 2010.
Interest paid in cash, including note repurchase premiums, aggregated $365.2 million for 2005, $434.7 million for 2004, and $324.8 million for 2003.
IndicatedMarketPrice
(millions ofdollars)
201.00
6. Guarantees of Debt OI Group and the Company guarantee OI Inc.s senior notes and debentures on a subordinated basis. The fair value of the OI Inc. debt being guaranteed was $1,058.0 at December 31, 2005.
7. Operating Leases Rent expense attributable to all warehouse, office buildings, and equipment operating leases was $66.5 million in 2005, $66.3 million in 2004, and $68.8 million in 2003. Minimum future rentals under operating leases are as follows: 2006, $57.5 million; 2007, $47.9 million; 2008, $32.3 million; 2009, $23.4 million; and 2010, $17.2 million; and 2011 and thereafter, $22.9 million.
8. Foreign Currency Translation Aggregate foreign currency exchange gains (losses) included in other costs and expenses were $2.8 million in 2005, $(1.4) million in 2004, and $2.2 million in 2003.
At the end of 2005, the Companys subsidiary in Australia had an agreement that swaps a total of U.S. $175.0 million of borrowings into 251.8 million Australian dollars. This derivative instrument swaps the
147
principal from U.S. dollars to Australian dollars and also swaps the interest rate from a U.S.-based rate to an Australian-based rate. This agreement has a maturity date of March 2006.
In the fourth quarter of 2003 and the first quarter of 2004, the Company entered into a series of interest rate swap agreements with a total notional amount of $1.05 billion that mature from 2007 through 2013. The swaps were executed in order to: (i) convert a portion of the senior notes and senior debentures fixed-rate debt into floating-rate debt; (ii) maintain a capital structure containing appropriate amounts of fixed and floating-rate debt; and (iii) reduce net interest payments and expense in the near-term.
The Companys fixed-to-variable interest rate swaps are accounted for as fair value hedges. Because the relevant terms of the swap agreements match the corresponding terms of the notes, there is no hedge
148
ineffectiveness. Accordingly, the Company recorded the net of the fair market values of the swaps as a long-term liability along with a corresponding net decrease in the carrying value of the hedged debt.
AmountHedged
AverageReceiveRate
AverageSpread
Asset(Liability)Recorded
OI Inc. public notes swapped by the company through intercompany loans:
Notes issued by OBGC:
1,050.0
(30.7
149
Deferred TaxEffect forTranslation
Change inMinimumPension Liability,Net of Tax
Change inCertainDerivativeInstruments,Net of Tax
(477.7
367.7
342.7
(110.0
303.5
266.2
193.5
(283.2
(97.0
150
Tax loss carryovers
259.2
251.0
30.3
30.7
19.8
18.1
Other, principally accrued liabilities
212.7
203.3
522.0
503.1
204.2
224.8
75.6
53.1
307.4
310.3
(349.7
(320.8
Net deferred tax liabilities
(135.1
36.2
45.4
(232.9
(209.6
151
The provision for income taxes consists of the following:
0.2
133.4
97.5
50.9
133.7
97.7
51.2
(12.8
(20.2
(1.4
8.3
13.3
(1.5
120.6
77.3
The provision for income taxes was calculated based on the following components of earnings (loss) before income taxes:
(20.7
25.3
(88.2
404.4
182.3
96.0
45.5
152
A reconciliation of the provision for income taxes based on the statutory U.S. Federal tax rate of 35% to the provision for income taxes is as follows:
Pretax earnings at statutory U.S. Federal tax rate
(19.6
150.4
(22.5
(24.6
Loss on Ardagh note sale
11.2
1.5
The Company is included in OI Inc.s consolidated tax returns. OI Inc. has net operating losses, capital losses, alternative minimum tax credits, and research and development credits available to offset future U.S. Federal income tax.
At December 31, 2005, the Companys equity in the undistributed earnings of foreign subsidiaries for which income taxes had not been provided approximated $1,383.4 million. It is not practicable to estimate the U.S. and foreign tax which would be payable should these earnings be distributed.
12. Related Party Transactions Charges for administrative services are allocated to the Company by OI Inc. based on an annual utilization level. Such services include compensation and benefits administration, payroll processing, use of certain general accounting systems, auditing, income tax planning and compliance, and treasury services. Management believes that such transactions are on terms no less favorable to the Company than those that could be obtained from unaffiliated third parties. The following information summarizes the Companys significant related party transactions:
153
Sales to affiliated companies
0.7
0.8
Expenses:
Administrative services
19.9
15.6
Corporate management fee
23.4
18.0
Total expenses
43.3
34.3
The above expenses are recorded in the statement of operations as follows:
Cost of sales
Selling, general, and adminstrative expenses
25.6
18.6
Intercompany interest is charged to the Company from OI Inc. based on intercompany debt balances. An interest rate is calculated monthly based on OI Incs total consolidated monthly external debt balance and the related interest expense, including finance fee amortization and commitment fees. The calculated rate (8.5% at December 31, 2005) is applied monthly to the intercompany debt balance to determine intercompany interest expense.
13. Pension Benefit Plans The Company participates in OI Inc.s defined benefit pension plans for substantially all employees located in the United States. Benefits generally are based on compensation for salaried employees and on length of service for hourly employees. OI Inc.s policy is to fund pension plans such that sufficient assets will be available to meet future benefit requirements. Independent actuaries determine pension costs for each subsidiary of OI Inc. included in the plans; however, accumulated benefit obligation information and plan assets pertaining to each subsidiary have not been separately determined. As such, the accumulated benefit obligation and the plan assets related to the pension plans for domestic employees have been retained by another subsidiary of OI Inc. Net credits to results of operations for the Companys allocated portion of the domestic pension costs amounted to $21.5 million in 2005, $20.8 million in 2004, and $40.1 million in 2003.
OI Inc. also sponsors several defined contribution plans for all salaried and hourly U.S. employees of the Company. Participation is voluntary and participants contributions are based on their compensation. OI Inc. matches contributions of participants, up to various limits, in substantially all plans. OI Inc. charges the Company for its share of the match. The Companys share of the contributions to these plans amounted to $5.2 million in 2005, $4.9 million in 2004, and $4.3 million in 2003.
The Companys subsidiaries in the United Kingdom, the Netherlands, Canada, Australia, Germany and France also have pension plans covering substantially all employees. The following tables relate to the Companys principal defined benefit pension plans in the United Kingdom, the Netherlands, Canada, Australia, Germany and France (the International Pension Plans).
The International Pension Plans use a December 31 measurement date.
154
The changes in the International Pension Plans benefit obligations for the year were as follows:
791.5
20.3
68.4
57.0
Actuarial loss, including the effect of changing in discount rates
118.7
57.2
(65.4
(71.8
(12.7
625.8
1,447.7
The changes in the fair value of the International Pension Plans assets for the year were as follows:
1,008.5
577.3
162.1
72.8
39.4
55.0
60.1
431.2
1,068.6
155
The funded status of the International Pension Plans at year end was as follows:
(379.1
(408.8
282.5
289.4
14.0
296.5
294.9
(113.9
The accumulated benefit obligation for all defined benefit pension plans was $1,288.1 million and $1,286.3 million at December 31, 2005 and 2004, respectively.
156
The components of the International Pension Plans net pension expense were as follows:
14.6
39.2
(46.7
10.4
9.5
Net expense
26.8
24.3
8.8
The following information is for plans with projected benefit obligations in excess of the fair value of plan assets at year end:
4.57
5.15
3.78
3.41
157
5.68
5.76
3.86
3.79
7.15
7.56
Future benefits are assumed to increase in a manner consistent with past experience of the plans, which, to the extent benefits are based on compensation, includes assumed salary increases as presented above. Amortization included in net pension expense is based on the average remaining service of employees.
For 2005, the Companys weighted average expected long-term rate of return on assets was 7.15%. In developing this assumption, the Company evaluated input from its third party pension plan asset managers, including their review of asset class return expectations and long-term inflation assumptions. The Company also considered its historical 10-year average return (through December 31, 2004), which was in line with the expected long-term rate of return assumption for 2005.
It is the Companys policy to invest pension plan assets in a diversified portfolio consisting of an array of asset classes within the above target asset allocation ranges. The investment risk of the assets is limited
158
by appropriate diversification both within and between asset classes. The assets are primarily invested in a broad mix of domestic and international equities, domestic and international bonds, and real estate, subject to the target asset allocation ranges. The assets are managed with a view to ensuring that sufficient liquidity will be available to meet expected cash flow requirements.
The Company expects to contribute $47.1 million to its defined benefit pension plans in 2006.
64.1
63.1
64.3
66.5
67.4
14. Postretirement Benefits Other Than Pensions OI Inc. provides certain retiree health care and life insurance benefits covering substantially all U.S. salaried and certain hourly employees and substantially all employees in Canada and the Netherlands. Employees are generally eligible for benefits upon retirement and completion of a specified number of years of creditable service. Independent actuaries determine postretirement benefit costs for each subsidiary of OI Inc.; however, accumulated postretirement benefit obligation information pertaining to each subsidiary has not been separately determined. As such, the accumulated postretirement benefit obligation has been retained by another subsidiary of OI Inc.
The Companys net periodic postretirement benefit cost, as allocated by OI Inc., for domestic employees was $14.5 million, $25.9 million, and $26.7 million at December 31, 2005, 2004, and 2003, respectively.
The Companys subsidiaries in Canada and the Netherlands also have postretirement benefit plans covering substantially all employees. The following tables relate to the Companys postretirement benefit plan in Canada and the Netherlands (the International Postretirement Benefit Plans).
159
The changes in the International Postretirement Benefit Plans obligations were as follows:
87.4
Actuarial loss, including the effect of changing discount rates
9.3
1.8
20.9
(2.5
(2.0
12.6
100.0
The funded status of the International Postretirement Benefit Plans at year end was as follows:
(15.9
(5.7
84.1
81.7
The Companys nonpension postretirement benefit obligations are included with other long term liabilities on the balance sheet.
The components of International Postretirement Benefit Plans net postretirement benefit cost were as follows:
(0.2
The weighted average discount rate used to determine the accumulated postretirement benefit obligation was 4.8% and 5.4% at December 31, 2005 and 2004, respectively.
The weighted average discount rate used to determine net postretirement benefit cost was 5.4% at December 31, 2005, 6.0% at December 31, 2004, and 6.5% at December 31, 2003.
160
6.74
6.84
Rate to which the cost trend rate is assumed to decline (ultimate trend rate)
4.81
4.67
Assumed health care cost trend rates affect on the amounts reported for the postretirement benefit plans. A one-percentage-point change in assumed health care cost trend rates would have the following effects:
12.1
24.6
Benefits provided by OI Inc. for certain hourly retirees of the Company are determined by collective bargaining. Most other domestic hourly retirees receive health and life insurance benefits from a multi-employer trust established by collective bargaining. Payments to the trust as required by the bargaining agreements are based upon specified amounts per hour worked and were $5.7 million in 2005, $5.7 million in 2004, and $6.0 million in 2003. Postretirement health and life benefits for retirees of foreign subsidiaries are generally provided through the national health care programs of the countries in which the subsidiaries are located.
15. Other Revenue Other revenue in 2005 includes $28.1 million (pre-tax and after tax) for the sale of the Companys Corsico, Italy glass container facility.
161
16. Other Costs and Expenses Other costs and expenses for the year ended December 31, 2005 included the following:
During the fourth quarter of 2005 the Company recorded a charge of $494.0 million to write down a portion of the goodwill in its Asia Pacific Glass business unit. See Note 23 for more information.
Other costs and expenses for the year ended December 31, 2003 included pretax charges of $202.9 million ($172.2 after tax) related to the following:
In August 2003, the Company announced the permanent closing of its Hayward, California glass container factory. Production at the factory was suspended in June 2003 following a major leak in its only glass furnace. As a result, the Company recorded a capacity curtailment charge of $28.5 million ($17.8 million after tax) in the third quarter of 2003. The closing of this factory resulted in the
162
elimination of approximately 170 jobs and a corresponding reduction in the Companys workforce. Substantially all of the closing costs were paid out by the end of 2005.
17. Contingencies Other litigation is pending against the Company, in many cases involving ordinary and routine claims incidental to the business of the Company and in others presenting allegations that are nonroutine and involve compensatory, punitive or treble damage claims as well as other types of relief. In
163
accordance with FAS No. 5, Accounting for Contingencies, the Company records a liability for such matters when it is both probable that the liability has been incurred and the amount of the liability can be reasonably estimated. Recorded amounts are reviewed and adjusted to reflect changes in the factors upon which the estimates are based including additional information, negotiations, settlements, and other events. The ultimate legal and financial liability of the Company in respect to this pending litigation cannot be estimated with certainty. However, the Company believes, based on its examination and review of such matters and experience to date, that such ultimate liability will not have a material adverse effect on its results of operations or financial condition.
18. Geographic Information The Company operates in the rigid packaging industry. The Company has one primary reportable product segment within the rigid packaging industry: Glass Containers. The Glass Containers segment includes operations in North America, Europe, the Asia Pacific region, and South America.
The Company currently evaluates performance and allocates resources based on earnings before interest income, interest expense, provision for income taxes, and minority share owners interests in earnings of subsidiaries (Operating Profit) excluding amounts related to certain items that management considers not representative of ongoing operations and, (Segment Operating Profit). Net sales as shown in the geographic segment information are based on the location of the Companys affiliate which recorded the sales.
164
1,986.6
685.1
1,926.1
2,164.1
561.2
1,876.7
1,245.3
488.2
227.7
279.7
156.9
800.6
253.5
244.1
124.0
763.7
276.4
170.2
96.2
661.7
Gain on the sale of the Corsico,
Italy glass container facility
Mark to market effect of certain
commodity futures contracts
Gain on sale of certain real property
Capacity curtailment charge
Write-down of Plastics
Packaging assets in the
Asia Pacific region
One customer accounted for 11.5% of the Companys sales in 2003.
Operations in individual countries outside the United States that accounted for more than 10% of consolidated net sales were in Italy (2005 10.2%, 2004 11.9%, and 2003 13.2%), France (2005 15.4%) and Australia (2004 11.7%, and 2003 13.6%).
165
The Companys net property, plant, and equipment by location are as follows:
694.7
2,121.6
648.4
2,502.8
589.7
1,720.5
2,310.2
1,621.1
4,735.3
1,574.8
3,947.5
1,546.4
2,862.6
16.4
17.9
13.8
18.8
53.2
24.8
Reconciliation of Segment Operating Profit to earnings before income taxes, minority share owners interests in earnings of subsidiaries:
(202.9
(408.2
(404.3
(383.5
19. Additional Interest Charges from Early Extinguishment of Debt During 2005, the Company recorded additional interest charges of $1.4 million ($1.0 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys bank credit agreement. During 2004, the Company recorded additional interest charges of $22.8 million ($14.9 million after tax) for note repurchase premiums and $7.1 million ($4.7 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys bank credit agreement. During 2003, the Company recorded additional interest charges of $12.6 million ($7.9 million
166
after tax) for note repurchase premiums and related write-off of unamortized finance fees and $3.6 million ($2.5 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys previous bank credit agreement.
167
20. Acquisition of BSN Glasspack, S.A. On June 21, 2004, the Company completed the acquisition of BSN Glasspack, S.A. (BSN) from Glasspack Participations (the BSN Acquisition). Total consideration for the BSN Acquisition was approximately $1.3 billion, including the assumption of approximately $650 million of debt, a portion of which was refinanced in connection with the BSN Acquisition. BSN was the second largest glass container manufacturer in Europe with manufacturing facilities in France, Spain, Germany and the Netherlands. The BSN Acquisition was financed with borrowings under the Companys Second Amended and Restated Secured Credit Agreement. In order to secure the European Commissions approval, the Company committed to divest the Barcelona, Spain, and Corsico, Italy glass plants. The Company completed the sale of these plants in January 2005 and received cash proceeds of approximately 138.2 million.
168
21. Pro Forma Information - Acquisition of BSN Glasspack, S.A. Had the Acquisition described in Note 20 and the related financing described in Note 5 occurred at the beginning of each respective period, pro forma consolidated net sales and net earnings, and would have been as follows:
6,274.8
298.8
5,826.5
169
22. Accounts Receivable Securitization Program As part of the acquisition of BSN, the Company acquired a trade accounts receivable securitization program through a BSN subsidiary, BSN Glasspack Services. The program was entered into by BSN in order to provide lower interest costs on a portion of its financing. In November 2000, BSN created a securitization program for its trade receivables through a sub-fund (the fund) created in accordance with French Law.
170
23. Goodwill The changes in the carrying amount of goodwill for the years ended December 31, 2003, 2004 and 2005 are as follows:
1,661.1
1,919.6
During the fourth quarter of 2005, the Company completed its annual impairment testing and determined that impairment existed in the goodwill of its Asia Pacific Glass business unit. Lower projected cash flows principally as a result of competitive pricing pressures in the Companys Australian glass operations caused the decline in the business enterprise value. Following a review of the valuation of the units identifiable assets, the Company recorded an impairment charge of $494.0 million to reduce the reported value of its goodwill.
171
Owens-Brockway Glass Container Inc.
We have audited the accompanying consolidated balance sheets of Owens-Brockway Glass Container Inc. as of December 31, 2005 and 2004, and the related consolidated statements of results of operations, net Parent investment, and cash flows for each of the three years in the period ended December 31, 2005. These financial statements are the responsibility of the Companys management. Our responsibility is to express an opinion on these financial statements based on our audits.
In our opinion, the financial statements referred to above present fairly, in all material respects, the consolidated financial position of Owens-Brockway Glass Container Inc. at December 31, 2005 and 2004, and the consolidated results of its operations and its cash flows for each of the three years in the period ended December 31, 2005, in conformity with U.S. generally accepted accounting principles.
172
CONSOLIDATED RESULTS OF OPERATIONS Owens-Brockway Glass Container Inc.
173
CONSOLIDATED BALANCE SHEETS Owens-Brockway Glass Container Inc.
174
175
CONSOLIDATED NET PARENT INVESTMENT Owens-Brockway Glass Container Inc.
176
CONSOLIDATED CASH FLOWS Owens-Brockway Glass Container Inc.
177
Basis of Consolidated Statements The consolidated financial statements of Owens-Brockway Glass Container Inc. (Company) include the accounts of its subsidiaries. Newly acquired subsidiaries have been included in the consolidated financial statements from dates of acquisition.
Relationship with Owens-Brockway Packaging, Inc., Owens-Illinois Group, Inc. and Owens-Illinois, Inc.The Company is a wholly-owned subsidiary of Owens-Brockway Packaging, Inc. (OB Packaging), and an indirect subsidiary of Owens-Illinois Group, Inc. (OI Group) and Owens-Illinois, Inc. (OI Inc.). Although OI Inc. does not conduct any operations, it has substantial obligations related to outstanding indebtedness, dividends for preferred stock and asbestos-related payments. OI Inc. relies primarily on distributions from its direct and indirect subsidiaries to meet these obligations.
Derivative Instruments The Company uses interest rate swaps, currency swaps, and commodity futures contracts to manage risks generally associated with foreign exchange rate, interest rate and commodity market volatility. Derivative financial instruments are included on the balance sheet at fair value. Whenever possible, derivative instruments are designated and effective as hedges, in accordance with accounting principles generally accepted in the United States. If the underlying hedged transaction ceases to exist, all changes in fair value of the related derivatives that have not been settled are recognized in current earnings. The Company does not enter into derivative financial instruments for trading purposes and is not a party to leveraged derivatives. In accordance with FAS No. 104, cash flows from fair value hedges of debt and short-term forward exchange contracts are classified as a financing activity. Cash flows of currency swaps, interest rate swaps, and commodity futures contracts are classified as operating activities. See Note 8 for additional information related to derivative instruments.
178
New Accounting Standards In May 2005, the Financial Accounting Standards Board issued FAS No. 154, Accounting Changes and Error Corrections, which changes the requirements for accounting for and reporting a change in accounting principle. The statement requires changes in accounting principle to be applied retrospectively to prior periods financial statements. The statement also redefines
179
restatement as being the correction of an error. FAS No. 154 is effective for the Company beginning after January 1, 2006. The Company will apply FAS No. 154 as required.
180
181
182
183
184
6. Operating Leases Rent expense attributable to all warehouse, office buildings, and equipment operating leases was $66.5 million in 2005, $66.3 million in 2004, and $68.8 million in 2003. Minimum future rentals under operating leases are as follows: 2006, $57.5 million; 2007, $47.9 million; 2008, $32.3 million; 2009, $23.4 million; and 2010, $17.2 million; and 2011 and thereafter, $22.9 million.
7. Foreign Currency Translation Aggregate foreign currency exchange gains (losses) included in other costs and expenses were $2.8 million in 2005, $(1.4) million in 2004, and $2.2 million in 2003.
185
8. Derivative Instruments At December 31, 2005, the Company has the following derivative instruments related to its various hedging programs:
186
The Company accounts for the above futures contracts on the balance sheet at fair value. The effective portion of changes in the fair value of a derivative that is designated as, and meets the required criteria for, a cash flow hedge is recorded in OCI and reclassified into earnings in the same period or periods
187
during which the underlying hedged item affects earnings. Any material portion of the change in the fair value of a derivative designated as a cash flow hedge that is deemed to be ineffective is recognized in current earnings.
9. Accumulated Other Comprehensive Income (Loss) The components of comprehensive income (loss) are: (a) net earnings (loss); (b) change in fair value of certain derivative instruments; (c) adjustment of minimum pension liabilities; and, (d) foreign currency translation adjustments. The net effect of exchange rate fluctuations generally reflects changes in the relative strength of the U.S. dollar against major foreign currencies between the beginning and end of the year.
188
Change inMinimumPensionLiability,Net of Tax
10. Income Taxes Deferred income taxes reflect: (1) the net tax effects of temporary differences between the carrying amounts of assets and liabilities for financial reporting purposes and the amounts used for income tax purposes and (2) carryovers and credits for income tax purposes. Significant components of the Companys deferred tax assets and liabilities at December 31, 2005 and 2004 are as follows:
189
190
191
192
11. Related Party Transactions Charges for administrative services are allocated to the Company by OI Inc. based on an annual utilization level. Such services include compensation and benefits administration, payroll processing, use of certain general accounting systems, auditing, income tax planning and compliance, and treasury services. Management believes that such transactions are on terms no less favorable to the Company than those that could be obtained from unaffiliated third parties. The following information summarizes the Companys significant related party transactions:
12. Pension Benefit Plans The Company participates in OI Inc.s defined benefit pension plans for substantially all employees located in the United States. Benefits generally are based on compensation for salaried employees and on length of service for hourly employees. OI Inc.s policy is to fund pension plans such that sufficient assets will be available to meet future benefit requirements. Independent actuaries determine pension costs for each subsidiary of OI Inc. included in the plans; however, accumulated benefit obligation information and plan assets pertaining to each subsidiary have not been separately determined. As such, the accumulated benefit obligation and the plan assets related to the pension plans for domestic employees have been retained by another subsidiary of OI Inc. Net credits to results of operations for the Companys allocated portion of the domestic pension costs amounted to $21.5 million in 2005, $20.8 million in 2004, and $40.1 million in 2003.
193
194
195
196
56 - 66 %
26 - 36 %
2 - 12 %
0 - 2 %
197
13. Postretirement Benefits Other Than Pensions OI Inc. provides certain retiree health care and life insurance benefits covering substantially all U.S. salaried and certain hourly employees and substantially all employees in Canada and the Netherlands. Employees are generally eligible for benefits upon retirement and completion of a specified number of years of creditable service. Independent actuaries determine postretirement benefit costs for each subsidiary of OI Inc.; however, accumulated postretirement benefit obligation information pertaining to each subsidiary has not been separately determined. As such, the accumulated postretirement benefit obligation has been retained by another subsidiary of OI Inc.
198
199
14. Other Revenue Other revenue in 2005 includes $28.1 million (pre-tax and after tax) for the sale of the Companys Corsico, Italy glass container facility.
200
15. Other Costs and Expenses Other costs and expenses for the year ended December 31, 2005 included the following:
In August 2003, the Company announced the permanent closing of its Hayward, California glass container factory. Production at the factory was suspended in June 2003 following a major leak in its only glass furnace. As a result, the Company recorded a capacity curtailment charge of $28.5 million
201
($17.8 million after tax) in the third quarter of 2003. The closing of this factory resulted in the elimination of approximately 170 jobs and a corresponding reduction in the Companys workforce. Substantially all of the closing costs were paid out by the end of 2005.
202
16. Contingencies Other litigation is pending against the Company, in many cases involving ordinary and routine claims incidental to the business of the Company and in others presenting allegations that are nonroutine and involve compensatory, punitive or treble damage claims as well as other types of relief. In accordance with FAS No. 5, Accounting for Contingencies, the Company records a liability for such matters when it is both probable that the liability has been incurred and the amount of the liability can be reasonably estimated. Recorded amounts are reviewed and adjusted to reflect changes in the factors upon which the estimates are based including additional information, negotiations, settlements, and other events. The ultimate legal and financial liability of the Company in respect to this pending litigation cannot be estimated with certainty. However, the Company believes, based on its examination and review of such matters and experience to date, that such ultimate liability will not have a material adverse effect on its results of operations or financial condition.
17. Geographic Information The Company operates in the rigid packaging industry. The Company has one primary reportable product segment within the rigid packaging industry: Glass Containers. The Glass Containers segment includes operations in North America, Europe, the Asia Pacific region, and South America.
203
204
18. Additional Interest Charges from Early Extinguishment of Debt During 2005, the Company recorded additional interest charges of $1.4 million ($1.0 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys bank credit agreement. During 2004, the Company recorded additional interest charges of $22.8 million ($14.9 million after tax) for note repurchase premiums and $7.1 million ($4.7 million after tax) for the write-off of unamortized finance fees related to the reduction of available credit under the Companys bank credit agreement. During 2003, the Company recorded additional interest charges of $12.6 million ($7.9 million
205
19. Acquisition of BSN Glasspack, S.A. On June 21, 2004, the Company completed the acquisition of BSN Glasspack, S.A. (BSN) from Glasspack Participations (the BSN Acquisition). Total consideration for the BSN Acquisition was approximately $1.3 billion, including the assumption of approximately $650 million of debt, a portion of which was refinanced in connection with the BSN Acquisition. BSN was the second largest glass container manufacturer in Europe with manufacturing facilities in France, Spain, Germany and the Netherlands. The BSN Acquisition was financed with borrowings under the Companys Second Amended and Restated Secured Credit Agreement. In order to secure the European Commissions approval, the Company committed to divest the Barcelona, Spain, and Corsico, Italy glass plants. The Company completed the sale of these plants in January 2005 and received cash proceeds of approximately 138.2 million.
206
20. Pro Forma Information - Acquisition of BSN Glasspack, S.A. Had the Acquisition described in Note 19 and the related financing described in Note 5 occurred at the beginning of each respective period, pro forma consolidated net sales and net earnings, and would have been as follows:
207
21. Accounts Receivable Securitization Program As part of the acquisition of BSN, the Company acquired a trade accounts receivable securitization program through a BSN subsidiary, BSN Glasspack Services. The program was entered into by BSN in order to provide lower interest costs on a portion of its financing. In November 2000, BSN created a securitization program for its trade receivables through a sub-fund (the fund) created in accordance with French Law.
22. Goodwill The changes in the carrying amount of goodwill for the years ended December 31, 2003, 2004 and 2005 are as follows:
208
209
OI Plastic Products FTS Inc.
We have audited the accompanying consolidated balance sheets of OI Plastic Products FTS Inc. as of December 31, 2005 and 2004, and the related consolidated statements of results of operations, net Parent investment, and cash flows for each of the three years in the period ended December 31, 2005. These financial statements are the responsibility of the Companys management. Our responsibility is to express an opinion on these financial statements based on our audits.
In our opinion, the financial statements referred to above present fairly, in all material respects, the consolidated financial position of OI Plastic Products FTS Inc. at December 31, 2005 and 2004, and the consolidated results of its operations and its cash flows for each of the three years in the period ended December 31, 2005, in conformity with U.S. generally accepted accounting principles.
210
CONSOLIDATED RESULTS OF OPERATIONS OI Plastic Products FTS Inc.
723.1
631.5
632.0
725.0
631.7
634.0
562.5
478.7
484.6
11.3
(0.4
31.9
34.5
37.5
(47.2
10.2
15.4
45.9
562.3
536.9
594.6
94.8
56.8
22.0
105.9
61.2
66.4
(658.5
107.1
127.6
(641.1
See accompanying Notes to Consolidated Financial Statements.
211
CONSOLIDATED BALANCE SHEETS OI Plastic Products FTS Inc.
Cash
Receivables including $0.5 ($0.6 in 2004) from related parties, less allowances of $21.8 ($20.7 in 2004) for losses and discounts
57.7
49.9
12.5
124.7
127.7
209.5
239.2
239.3
5.8
86.1
539.7
532.3
7.3
20.8
648.3
347.4
324.8
311.4
323.5
675.3
690.5
212
Accounts payable including $9.6 ($4.7 in 2004) to related parties
9.8
66.9
88.3
123.7
Net Parent investment
556.8
527.8
(20.6
(22.2
536.2
505.6
213
CONSOLIDATED NET PARENT INVESTMENT OI Plastic Products FTS Inc.
1,658.0
1,675.7
(78.1
(1,257.8
623.4
(44.9
(42.5
22.7
(2.4
1,613.1
Total comprehensive (loss) income
108.7
150.3
(643.5
See accompanying Notes to Consolidated Financial Statements
214
CONSOLIDATED CASH FLOWS OI Plastic Products FTS Inc.
Net earnings from continuing operations
44.1
47.9
5.1
Deferred tax provision
31.5
(54.7
6.7
207.8
78.2
44.9
Cash provided by total operating activities
222.7
123.1
(31.1
(37.3
(84.6
(38.7
1,172.3
46.3
(69.8
1,116.6
(75.6
(126.8
(1,357.6
623.7
(10.8
(666.6
(137.5
(1,347.4
(42.9
(8.8
215
Basis of Consolidated Statements The consolidated financial statements of OI Plastic Products FTS Inc. (Company) include the accounts of its subsidiaries. Newly acquired subsidiaries have been included in the consolidated financial statements from dates of acquisition. Results of operations for the divested blow-molded plastic container business which was sold in 2004 have been presented as a discontinued operation for 2004 and 2003.
Relationship with Owens-Illinois, Inc. and Owens-Illinois, Group Inc. The Company is a wholly-owned subsidiary of Owens-Illinois Group, Inc. (OI Group) and an indirect subsidiary of Owens-Illinois, Inc. (OI Inc.). Although OI Inc. does not conduct any operations, it has substantial obligations related to outstanding indebtedness, dividends for preferred stock and asbestos-related payments. OI Inc. relies primarily on distributions from its direct and indirect subsidiaries to meet these obligations.
For federal and certain state income tax purposes, the taxable income of the Company is included in the consolidated tax returns of OI Inc. and income taxes are allocated to the Company on a basis consistent with separate returns. Current income taxes are recorded by the Company on a basis consistent with separate returns.
Nature of Operations The Company is a manufacturer of plastics packaging products. The Companys principal product lines include healthcare containers, closures and prescription containers. The Companys principal operations are in North America, however, the Company does have minor operations in Europe and South America. Major markets include the United States healthcare market. One customer accounted for 10.4% and 15.7% of the Companys sales in 2005 and 2003 respectively.
Fair Values of Financial Instruments The carrying amounts reported for cash, short-term investments and short-term loans approximate fair value. In addition, carrying amounts approximate fair value for certain long-term debt obligations subject to frequently redetermined interest rates. The Company is not a party to any material derivative financial instruments.
216
Foreign Currency Translation The assets and liabilities of most affiliates and associates are translated at current exchange rates and any related translation adjustments are recorded directly in net Parent investment.
New Accounting Standards In May 2005, the Financial Accounting Standards Board issued FAS No. 154, Accounting Changes and Error Corrections, which changes the requirements for accounting for and reporting a change in accounting principle. The statement requires changes in accounting principle to be applied retrospectively to prior periods financial statements. The statement also redefines restatement as being the correction of an error. FAS No. 154 is effective for the Company beginning after January 1, 2006. The Company will apply FAS No. 154 as required.
217
218
(7.9
2.9
14.9
5.2
(45.1
64.2
(3.7
(14.7
(60.1
(40.2
(54.9
38.8
If the inventories which are valued on the LIFO method had been valued at standard costs, which approximate current costs, consolidated inventories would be higher than reported by $19.7 million and $13.6 million at December 31, 2005 and 2004, respectively.
Inventories which are valued at the lower of standard costs (which approximate average costs), or market at December 31, 2005 and 2004 were approximately $4.0 million and $4.3 million, respectively.
4. Supplemental Cash Flow Information Interest paid in cash aggregated $0.7 million for 2005, $0.3 million for 2004, and $14.2 million for 2003.
5. Guarantees of Debt Under the Third Amended and Restated Secured Credit Agreement, the Company has guaranteed certain of OI Groups domestic and foreign subsidiaries which amounted to $685.2 million at December 31, 2005. This guarantee expires with the Agreement on April 1, 2007.
The Company also has guaranteed $1.0 billion of 8.875%, $625.0 million of 8.75%, and $450.0 million of 7.75% Senior Secured Notes, and $450.0 million of 8.25%, $400.0 million of 6.75%, and 225.0 million of 6.75% Senior notes issued by an affiliate of the Company. These guarantees expire in 2009 for the $1.0 billion of 8.875% Senior Secured Notes, 2012 for the $625.0 million of 8.75% Senior Secured Notes, 2011 for the $450.0 million of 7.75% Senior Secured Notes, 2013 for the $450.0 million of 8.25% Senior Notes, and 2009 for the $400.0 million of 6.75% Senior Notes and 225 million of 6.75% Senior Notes. The assets of the Company and most of its domestic subsidiaries are pledged as security for the Senior Secured Notes.
The Company will be obligated under the above guarantees in the event that OI Groups domestic or foreign subsidiaries cannot make the required interest or principal payments under the above obligations.
219
6. Operating Leases Rent expense attributable to all warehouse, office buildings, and equipment operating leases was $3.5 million in 2005, $3.4 million in 2004, and $4.1 million in 2003. Minimum future rentals under operating leases are as follows: 2006, $1.3 million; 2007, $0.6 million; 2008, $0.3 million; 2009, $0.1 million; and 2010, $0.1 million.
7. Foreign Currency Translation Aggregate foreign currency exchange gains (losses) included in other costs and expenses were $(0.6) million in 2004 and $(0.1) million in 2003. Amounts for 2005 were not significant.
8. Income Taxes Deferred income taxes reflect: (1) the net tax effects of temporary differences between the carrying amounts of assets and liabilities for financial reporting purposes and the amounts used for income tax purposes and (2) carryovers and credits for income tax purposes. Significant components of the Companys deferred tax assets and liabilities at December 31, 2005 and 2004 are as follows:
7.8
7.5
22.5
47.6
48.5
56.4
57.6
(40.4
8.9
10.6
220
1.3
8.4
49.6
8.2
0.9
26.9
158.4
87.0
41.4
(653.6
221
33.2
Effective tax rate
31.6
55.6
The Company is included with OI Inc.s consolidated tax returns. OI Inc. has net operating losses, capital losses, alternative minimum tax credits, and research and development credits available to offset future U.S. Federal income tax.
At December 31, 2005, the Companys equity in the undistributed earnings of foreign subsidiaries for which income taxes had not been provided approximated $2.0 million. It is not practicable to estimate the U.S. and foreign tax which would be payable should these earnings be distributed.
222
9. Related Party Transactions Charges for administrative services are allocated to the Company by OI Inc. based on an annual utilization level. Such services include compensation and benefits administration, payroll processing, use of certain general accounting systems, auditing, income tax planning and compliance, and treasury services. Management believes that such transactions are on terms no less favorable to the Company than those that could be obtained from unaffiliated third parties. The following information summarizes the Companys significant related party transactions:
8.5
10.1
6.1
10. Pension Benefit Plans The Company participates in OI Inc.s defined benefit pension plans for substantially all employees located in the United States. Benefits generally are based on compensation for salaried employees and on length of service for hourly employees. OI Inc.s policy is to fund pension plans such that sufficient assets will be available to meet future benefit requirements. Independent actuaries determine pension costs for each subsidiary of OI Inc. included in the plans; however, accumulated benefit obligation information and plan assets pertaining to each subsidiary have not been separately determined. As such, the accumulated benefit obligation and the plan assets related to the pension plans for domestic employees have been retained by another subsidiary of OI Inc. Net credits to results of operations for the Companys allocated portion of the domestic pension costs amounted to $2.9 million in 2005, $0.2 million in 2004, and $0.8 million in 2003.
OI Inc. also sponsors several defined contribution plans for all salaried and hourly U.S. employees of the Company. Participation is voluntary and participants contributions are based on their compensation. OI Inc. matches contributions of participants, up to various limits, in substantially all plans. OI Inc. charges the Company for its share of the match. The Companys share of the contributions to these plans amounted to $1.7 million in 2005, $1.4 million in 2004, and $1.8 million in 2003.
11. Postretirement Benefits Other Than Pensions OI Inc. provides certain retiree health care and life insurance benefits covering substantially all U.S. salaried and certain hourly employees. Employees are
223
generally eligible for benefits upon retirement and completion of a specified number of years of creditable service. Independent actuaries determine postretirement benefit costs for each subsidiary of OI Inc.; however, accumulated postretirement benefit obligation information pertaining to each subsidiary has not been separately determined. As such, the accumulated postretirement benefit obligation has been retained by another subsidiary of OI Inc.
The Companys net periodic postretirement benefit cost, as allocated by OI Inc., was $3.3 million, $4.3 million, and $1.9 million at December 31, 2005, 2004, and 2003, respectively.
12. Other Costs and Expenses Other costs and expenses for the year ended December 31, 2003 included pretax charges of $41.3 million ($25.8 after tax) related to the following:
The Companys decision to sell its assets related to the production of plastic trigger sprayers and finger pumps is consistent with its objectives to improve liquidity and to focus on its core businesses.
13. Contingencies Litigation is pending against the Company, in many cases involving ordinary and routine claims incidental to the business of the Company and in others presenting allegations that are non-routine and involve compensatory, punitive or treble damage claims as well as other types of relief. In accordance with FAS No. 5, Accounting for Contingencies, the Company records a liability for such matters when it is both probable that the liability has been incurred and the amount of the liability can be reasonably estimated. Recorded amounts are reviewed and adjusted to reflect changes in the factors upon which the estimates are based including additional information, negotiations, settlements, and other events. The ultimate legal and financial liability of the Company in respect to this pending litigation cannot be estimated with certainty. However, the Company believes, based on its examination and review of such matters and experience to date, that such ultimate liability will not have a material adverse effect on its results of operations or financial condition.
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14. Goodwill The changes in the carrying amount of goodwill for the years ended December 31, 2003, 2004 and 2005 are as follows:
1,030.0
360.6
During the fourth quarter of 2003, the Company completed its annual impairment testing and determined that an impairment existed in the goodwill of its consumer products reporting unit. The consumer products unit operates in a highly competitive and fragmented industry. During the course of 2003, a number of the product lines within this reporting unit experienced price reductions, principally as a result of the Companys strategy to preserve and expand market share. The reduced pricing, along with continued capital expenditures, caused the Company to lower its earnings and cash flow projections for the consumer products reporting unit for several years following the measurement date (October 1, 2003) resulting in an estimated fair value for the unit that was lower than its book value. Following a review of the valuation of the units identifiable assets, the Company recorded an impairment charge of $670.0 million to reduce the reported value of its goodwill.
15. Discontinued Operations On October 7, 2004, the Company announced that it had completed the sale of its blow-molded plastic container operations in North America, South America and Europe, to Graham Packaging Company.
Included in the sale were 24 plastics manufacturing plants in the U.S., two in Mexico, two in Europe and two in South America, serving consumer products companies in the food, beverage, household, chemical and personal care industries. The blow-molded plastic container operations were part of the consumer products business unit of the plastics packaging segment.
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853.7
1,025.9
861.3
1,034.9
736.8
897.8
19.6
22.8
32.0
59.4
679.7
842.2
1,688.5
Earnings before items below
19.1
26.5
73.8
Net earnings from discontinued operations
The sale of the blow-molded plastic business resulted in a substantial capital loss, primarily related to previous goodwill write downs that were not deductible when recorded. The gain on the sale of discontinued operations of $73.8 million includes a credit for income taxes of $39.7 million, representing the tax benefit from offsetting a portion of the loss against otherwise taxable capital gains.
Net earnings of discontinued operations of $1.2 million in 2005 relates to an adjustment of the 2004 gain on the sale of the blow-molded plastic container operations principally from finalizing certain tax allocations.
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Pursuant to the requirements of Section 13 or 15(d) of the Securities Exchange Act of 1934, the Registrant has duly caused this report to be signed on its behalf by the undersigned thereunto duly authorized.
(Registrant)
By:
/s/ Edward C. White
Edward C. White
Senior Vice President, and Chief Financial Officer (Principal Financial Officer)
Date: March 16, 2006
227
Signatures
Pursuant to the requirements of the Securities Exchange Act of 1934, this report has been signed below by the following persons on behalf of Owens-Illinois, Inc. and in the capacities and on the dates indicated.
Title
Gary F. Colter
Director
Robert J. Dineen
Anastasia D. Kelly
Steven R. McCracken
Chairman of the Board of Directors and Chief Executive Officer(Principal Executive Officer); Director
John J. McMackin, Jr.
Corbin A. McNeill, Jr.
Albert P.L. Stroucken
Helge H. Wehmeier
Thomas L. Young
/s/ James W. Baehren
James W. Baehren
Attorney-in-fact
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INDEX TO FINANCIAL STATEMENT SCHEDULE
Financial Statement Schedule of Owens-Illinois, Inc. and Subsidiaries:
PAGE
II Valuation and Qualifying Accounts (Consolidated)
S-1
229
SCHEDULE II VALUATION AND QUALIFYING ACCOUNTS (CONSOLIDATED)
Years ended December 31, 2005, 2004, and 2003
(Millions of Dollars)
Reserves deducted from assets in the balance sheets:
Allowances for losses and discounts on receivables
Additions
Balance at
Charged to
Balance
beginning
costs and
Deductions
at end of
of period
expenses
(Note 1)
period
50.3
71.1
69.7
47.4
44.5
76.9
7.2
78.3
80.1
80.4
(1) Deductions from allowances for losses and discounts on receivables represent uncollectible notes and accounts written off.