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Note 26 - Business Segment Information
12 Months Ended
Jun. 26, 2016
Notes to Financial Statements  
Segment Reporting Disclosure [Text Block]
26. Business Segment Information
 
The Company has three reportable segments. Operations and revenues for each segment are described below:
 
 
The Polyester Segment manufactures Chip, POY, textured, dyed, twisted, beamed and draw wound yarns, both virgin and recycled, with sales primarily to other yarn manufacturers and knitters and weavers that produce yarn and/or fabric for the apparel, hosiery, automotive upholstery, home furnishings, industrial and other end-use markets. The Polyester Segment consists of sales and manufacturing operations in the U.S. and El Salvador.
 
 
The Nylon Segment manufactures textured nylon yarns and spandex covered yarns, with sales to knitters and weavers that produce fabric primarily for the apparel and hosiery markets. The Nylon Segment consists of sales and manufacturing operations in the U.S. and Colombia.
 
 
The International Segment’s products primarily include textured polyester and various types of resale yarns and staple fiber, both virgin and recycled. The International Segment sells its yarns and staple fiber to knitters and weavers that produce fabric for the apparel, automotive upholstery, home furnishings, industrial and other end-use markets primarily in the South American and Asian regions. The International Segment includes a manufacturing location and sales offices in Brazil and a sales office in China.
 
In addition to its reportable segments, the Company’s selected financial information includes an All Other category. All Other consists primarily of Renewables (an operating segment that does not meet quantitative thresholds for reporting), for-hire transportation services and consulting services. Revenue for Renewables is primarily derived from (i) facilitating the use of miscanthus grass as bio-fuel through service agreements and (ii) delivering harvested miscanthus grass to poultry producers for animal bedding. For-hire transportation services revenues are derived from performing common carrier services utilizing the Company’s fleet of transportation equipment. Revenues for consulting services are derived from providing process improvement and change management consulting services to entities across various industries.
 
The operations within All Other (i) are not subject to review by the chief operating decision maker at a level consistent with the Company’s other operations, (ii) are not regularly evaluated using the same metrics applied to the Company’s other operations and (iii) do not qualify for aggregation with an existing reportable segment. Therefore, such operations are excluded from reportable segments. Any comparative amounts relating to the All Other category in fiscal 2014 are insignificant.
 
The Company evaluates the operating performance of its segments based upon Segment Profit, which represents segment gross profit plus segment depreciation expense. This measurement of segment profit or loss best aligns segment reporting with the current assessments and evaluations performed by, and information provided to, the chief operating decision maker.
 
In fiscal 2015 and 2014, the Company evaluated the operating performance of its segments based upon a different metric, referred to as Segment Adjusted Profit, which was defined as segment gross profit, plus segment depreciation and amortization, less segment SG&A expenses, plus segment other adjustments. SG&A expenses and other adjustments are no longer significant to the segment evaluations performed by the chief operating decision maker. The Company is providing current and comparative selected financial information below under the current method of evaluating segment profitability.
 
The accounting policies for the segments are consistent with the Company’s accounting policies. Intersegment sales are omitted from the below financial information, as they are (i) insignificant to the Company’s segments and consolidated operations and (ii) excluded from segment evaluations performed by the chief operating decision maker.
 
As of the fourth quarter of fiscal 2016, the Company updated the composition of its Polyester and Nylon Segments for both the current and comparative prior periods, intending to better reflect downstream sales for the respective product lines.
 
Selected financial information is presented below:
 
 
For the Fiscal Year Ended June 26, 2016
 
 
 
Polyester
 
 
Nylon
 
 
International
 
 
All Other
 
 
Total
 
Net sales
  $ 383,167     $ 131,715     $ 122,554     $ 6,201     $ 643,637  
Cost of sales
    333,638       113,906       95,666       6,795       550,005  
Gross profit (loss)
    49,529       17,809       26,888       (594 )     93,632  
Depreciation expense
    11,188       1,899       885       820       14,792  
Segment Profit
  $ 60,717     $ 19,708     $ 27,773     $ 226     $ 108,424  
 
 
 
For the Fiscal Year Ended June 28, 2015
 
 
 
Polyester
 
 
Nylon
 
 
International
 
 
All Other
 
 
Total
 
Net sales
  $ 396,239     $ 149,612     $ 134,992     $ 6,278     $ 687,121  
Cost of sales
    345,462       130,644       113,556       6,754       596,416  
Gross profit (loss)
    50,777       18,968       21,436       (476 )     90,705  
Depreciation expense
    10,579       1,798       1,997       473       14,847  
Segment Profit (Loss)
  $ 61,356     $ 20,766     $ 23,433     $ (3 )   $ 105,552  
 
 
 
For the Fiscal Year Ended June 29, 2014
 
 
 
Polyester
 
 
Nylon
 
 
International
 
 
Total
 
Net sales
  $ 403,699     $ 149,297     $ 134,906     $ 687,902  
Cost of sales
    356,076       129,966       118,598       604,640  
Gross profit
    47,623       19,331       16,308       83,262  
Depreciation expense
    9,247       2,022       3,032       14,301  
Segment Profit
  $ 56,870     $ 21,353     $ 19,340     $ 97,563  
 
The reconciliations of segment gross profit (loss) to consolidated income before income taxes are as follows:
 
 
 
For the Fiscal Year Ended
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
Polyester
  $ 49,529     $ 50,777     $ 47,623  
Nylon
    17,809       18,968       19,331  
International
    26,888       21,436       16,308  
All Other
    (594 )     (476 )      
Total segment gross profit
    93,632       90,705       83,262  
SG&A expenses
    47,502       49,672       46,203  
Provision for bad debts
    1,684       947       287  
Other operating expense, net
    2,248       1,600       5,289  
Operating income
    42,198       38,486       31,483  
Interest income
    (610 )     (916 )     (1,790 )
Interest expense
    3,528       4,025       4,329  
Loss on extinguishment of debt
          1,040        
Other non-operating expense
                126  
Equity in earnings of unconsolidated affiliates
    (8,963 )     (19,475 )     (19,063 )
Income before income taxes
  $ 48,243     $ 53,812     $ 47,881  
 
The reconciliations of segment depreciation and amortization expense to consolidated depreciation and amortization expense are as follows:
 
 
 
For the Fiscal Year Ended
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
Polyester
  $ 11,188     $ 10,579     $ 9,247  
Nylon
    1,899       1,798       2,022  
International
    885       1,997       3,032  
Segment depreciation expense
    13,972       14,374       14,301  
All Other
    820       473        
Other depreciation and amortization expense
    2,736       3,196       3,595  
Depreciation and amortization expense
  $ 17,528     $ 18,043     $ 17,896  
 
The reconciliations of segment capital expenditures to consolidated capital expenditures are as follows:
 
 
 
For the Fiscal Year Ended
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
Polyester
  $ 44,517     $ 21,267     $ 14,701  
Nylon
    2,548       2,392       2,284  
International
    2,755       1,468       1,637  
Segment capital expenditures
    49,820       25,127       18,622  
Other capital expenditures
    2,517       839       469  
Capital expenditures
  $ 52,337     $ 25,966     $ 19,091  
 
The reconciliations of segment total assets to consolidated total assets are as follows:
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
Polyester
  $ 243,295     $ 208,416     $ 197,242  
Nylon
    63,141       66,490       70,852  
International
    73,650       63,031       81,604  
Segment total assets
    380,086       337,937       349,698  
Other current assets
    6,674       4,687       2,164  
Other PP&E
    16,597       13,544       12,250  
Other non-current assets
    6,094       6,303       5,341  
Investments in unconsolidated affiliates
    117,412       113,901       99,229  
Total assets
  $ 526,863     $ 476,372     $ 468,682  
 
Geographic Data:
Geographic information is set forth below, beginning with net sales. Brazil is reported separately from other foreign countries because its net sales exceeds 10% of consolidated net sales in fiscal 2016, 2015 and 2014, while its total assets exceeds 10% of consolidated total assets for fiscal 2015 and 2014.
 
 
 
For the Fiscal Year Ended
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
U.S.
  $ 472,287     $ 509,490     $ 512,496  
Brazil
    83,087       101,912       113,448  
Remaining Foreign
    88,263       75,719       61,958  
Total
  $ 643,637     $ 687,121     $ 687,902  
                         
Export sales from the Company’s U.S. operations to external customers
  $ 113,725     $ 119,548     $ 100,546  
 
The information for net sales is based on the operating locations from where the items were produced or distributed.
 
Geographic information for long-lived assets is as follows:
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
U.S.
  $ 294,275     $ 242,042     $ 215,910  
Brazil
    9,714       8,207       12,188  
Remaining Foreign
    8,595       9,237       7,413  
Total
  $ 312,584     $ 259,486     $ 235,511  
 
Long-lived assets are comprised of property, plant and equipment, net; intangible assets, net; investments in unconsolidated affiliates; and other non-current assets.
 
Geographic information for total assets is as follows:
 
 
 
June 26, 2016
 
 
June 28, 2015
 
 
June 29, 2014
 
U.S.
  $ 429,100     $ 388,766     $ 362,125  
Brazil
    53,993       50,300       70,581  
Remaining Foreign
    43,770       37,306       35,976  
Total
  $ 526,863     $ 476,372     $ 468,682