10-Q 1 a06-21860_110q.htm QUARTERLY REPORT PURSUANT TO SECTIONS 13 OR 15(D)

FORM 10-Q

SECURITIES AND EXCHANGE COMMISSION
Washington, D.C.  20549

(Mark One)

 

 

 

x

 

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

 

 

 

For the quarterly period ended September 30, 2006

 

OR

 

o

 

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

 

For the transition period from                      to                             

Registration Number:  333-114032

BLUE RIDGE PAPER PRODUCTS INC.
(Exact name of registrant as specified in charter)

Delaware

 

56-2136509

(State of incorporation)

 

(I.R.S. Employer Identification Number)

 

 

 

 

41 MAIN STREET
CANTON, NORTH CAROLINA  28716
(Address of principal executive office)

Registrant’s telephone number, including area code:  828-454-0676

Indicate by check mark whether the registrant (1) has filed all reports required to be filed by Section 13 or 15 (d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days.

Yes

x

 

No

o

 

 

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   o         Accelerated Filer    o         Non-Accelerated Filer   x

Indicate by check mark whether the registrant is a shell company (as defined in Rule 12b-2 of the Exchange Act).

Yes

o

 

No

x

 

 

The number of common shares outstanding at September 30, 2006 was 1,000.

 




BLUE RIDGE PAPER PRODUCTS INC.

AND SUBSIDIARIES

 

 

 

 

INDEX

 

 

 

 

 

 

 

 

 

 

PART I.

 

 

FINANCIAL INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

Item 1.

Financial Statements

 

 

 

 

 

 

 

 

 

 

 

 

 

Condensed Consolidated Balance Sheets, September 30, 2006 (unaudited) and December 31, 2005 (derived from audited financial statements)

 

 

 

 

 

 

 

 

 

 

 

 

 

Condensed Consolidated Statements of Operations, Three Months Ended September 30, 2006 and 2005 (unaudited), Nine Months Ended September 30, 2006 and 2005 (unaudited)

 

 

 

 

 

 

 

 

 

 

 

 

 

Condensed Consolidated Statements of Cash Flows, Nine Months Ended September 30, 2006 and 2005 (unaudited)

 

 

 

 

 

 

 

 

 

 

 

 

 

Notes to Condensed Consolidated Financial Statements (unaudited)

 

 

 

 

 

 

 

 

 

 

 

 

Item 2.

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

 

 

 

 

 

 

 

 

 

 

 

 

Item 3.

Quantitative and Qualitative Disclosures About Market Risk

 

 

 

 

 

 

 

 

 

 

 

 

Item 4.

Controls and Procedures

 

 

 

 

 

 

 

 

 

 

PART II.

 

 

OTHER INFORMATION

 

 

 

 

 

 

 

 

 

 

 

 

Item 1A.

Risk Factors

 

 

 

 

 

 

 

 

 

 

 

 

Item 5.

Other Information

 

 

 

 

 

 

 

 

 

 

 

 

Item 6.

Exhibits

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PART I. FINANCIAL INFORMATION

 

 

 

 

 

 

 

ITEM 1.

 

FINANCIAL STATEMENTS

 

 

 

 

2




BLUE RIDGE PAPER PRODUCTS INC.

Condensed Consolidated Balance Sheets
September 30, 2006 and December 31, 2005
(Dollars in thousands)
(unaudited)

 

 

 

September 30,

 

December 31,

 

 

 

2006

 

2005

 

Assets

 

 

 

 

 

Current assets:

 

 

 

 

 

Cash

 

$

3,752

 

$

2,110

 

Accounts receivable, net of allowance for doubtful accounts and discounts of $1,276 and $2,298 in 2006 and 2005, respectively

 

56,854

 

56,002

 

Inventories

 

51,431

 

53,988

 

Prepaid expenses

 

2,132

 

1,029

 

Insurance proceeds receivable

 

 

291

 

Income tax receivable

 

 

50

 

Deferred tax asset

 

4,373

 

4,448

 

Total current assets

 

118,542

 

117,918

 

Property, plant and equipment, net of accumulated depreciation of $116,340 and $105,253 in 2006 and 2005, respectively

 

188,406

 

190,463

 

Deferred financing costs, net

 

3,966

 

5,108

 

Other assets

 

57

 

193

 

Total assets

 

$

310,971

 

$

313,682

 

Liabilities and Stockholder’s Deficit

 

 

 

 

 

Current liabilities:

 

 

 

 

 

Current portion of senior debt

 

$

43

 

$

41

 

Current portion of capital lease obligation

 

402

 

595

 

Accounts payable

 

43,286

 

48,917

 

Accrued expenses and other current liabilities

 

31,086

 

33,987

 

Interest payable

 

5,698

 

1,875

 

Total current liabilities

 

80,515

 

85,415

 

Senior debt, net of current portion

 

161,555

 

159,749

 

Parent Pay-In-Kind (PIK) Senior Subordinated Note

 

46,424

 

44,425

 

Capital lease obligations

 

707

 

979

 

Pension and postretirement benefits

 

24,341

 

22,678

 

Deferred tax liability

 

4,373

 

4,448

 

Other liabilities

 

1,168

 

730

 

Total liabilities

 

319,083

 

318,424

 

Obligation to redeem ESOP shares

 

28,455

 

27,716

 

Obligation to redeem restricted stock units of Parent

 

1,180

 

1,631

 

Commitments and contingencies (See notes)

 

 

 

 

 

Stockholders’ equity:

 

 

 

 

 

Common stock (par value $0.01, 1000 shares authorized and outstanding in 2006 and 2005, respectively)

 

 

 

Additional paid-in capital

 

65,459

 

64,121

 

Accumulated deficit

 

(89,713

)

(86,054

)

Unearned compensation

 

 

(25

)

Accumulated other comprehensive loss

 

(4,183

)

(4,183

)

 

 

(28,437

)

(26,141

)

Receivable from Parent

 

(9,310

)

(7,948

)

Total stockholders’ deficit

 

(37,747

)

(34,089

)

Total liabilities and stockholders’ deficit

 

$

310,971

 

$

313,682

 

 

See accompanying notes to condensed consolidated financial statements.

3




BLUE RIDGE PAPER PRODUCTS INC.

Condensed Consolidated Statements of Operations
Three- and Nine-Month Periods Ended September 30, 2006 and 2005
(Dollars in thousands)
(unaudited)

 

 

Three-Month Period Ended
September 30,

 

Nine-Month Period Ended
September 30,

 

 

 

2006

 

2005

 

2006

 

2005

 

 

 

 

 

 

 

 

 

 

 

Net sales

 

$

145,242

 

$

129,781

 

$

430,205

 

$

383,534

 

Cost of goods sold:

 

 

 

 

 

 

 

 

 

Cost of goods sold, excluding depreciation and amortization, flood-related loss and repairs and insurance recoveries

 

130,815

 

117,632

 

387,316

 

344,722

 

Depreciation and amortization

 

3,760

 

3,749

 

10,998

 

11,486

 

Flood-related loss and repairs

 

 

634

 

 

1,960

 

Insurance recoveries

 

 

(257

)

 

(357

)

Gross profit

 

10,667

 

8,023

 

31,891

 

25,723

 

Selling, general and administrative expenses.

 

8,777

 

6,110

 

20,673

 

16,356

 

Loss on litigation

 

 

2,000

 

 

2,000

 

Depreciation and amortization

 

28

 

427

 

114

 

1,289

 

ESOP expense

 

 

1,630

 

1,627

 

4,892

 

Operating profit (loss)

 

1,862

 

(2,144

)

9,477

 

1,186

 

Other income (expense):

 

 

 

 

 

 

 

 

 

Interest expense, excluding amortization of deferred financing costs

 

(4,598

)

(4,333

)

(13,554

)

(12,988

)

Amortization of deferred financing costs

 

(391

)

(350

)

(1,142

)

(1,023

)

Government grant income

 

369

 

1,436

 

1,554

 

3,742

 

Gain (loss) on equity method investment

 

2

 

(1

)

6

 

(1

)

 

 

(4,618

)

(3,248

)

(13,136

)

(10,270

)

Loss before income taxes

 

(2,756

)

(5,392

)

(3,659

)

(9,084

)

 

 

 

 

 

 

 

 

 

 

Income taxes

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Net loss

 

$

(2,756

)

$

(5,392

)

$

(3,659

)

$

(9,084

)

 

See accompanying notes to condensed consolidated financial statements.

4




BLUE RIDGE PAPER PRODUCTS INC.

Condensed Consolidated Statements of Cash Flows
Nine Months Ended September 30, 2006 and 2005
(Dollars in thousands)
(unaudited)

 

 

2006

 

2005

 

Cash flows from operating activities:

 

$

(3,659

)

$

(9,084

)

Net loss

 

 

 

 

 

Adjustment to reconcile net loss to net cash provided by operating activities:

 

 

 

 

 

Depreciation and amortization

 

11,112

 

12,775

 

Compensation expense for Parent restricted stock

 

25

 

222

 

Amortization of deferred financing costs

 

1,142

 

1,023

 

ESOP expense

 

1,627

 

4,892

 

Gain on sale of assets

 

(6

)

(44

)

Parent PIK Senior Subordinated Note for interest

 

3,089

 

2,828

 

Changes in operating assets and liabilities:

 

 

 

 

 

Accounts receivable, net

 

(852

)

(16,106

)

Inventories

 

2,557

 

(3,283

)

Prepaid expenses

 

(1,103

)

744

 

Insurance proceeds receivable

 

291

 

10,282

 

Income tax receivable

 

50

 

21

 

Other current assets

 

 

(36

)

Accounts payable

 

(3,916

)

1,889

 

Accrued expenses and other current liabilities

 

(2,901

)

(857

)

Interest payable

 

2,733

 

2,822

 

Pension and postretirement benefits

 

1,663

 

1,033

 

Other assets and liabilities

 

573

 

(628

)

Net cash provided by operating activities

 

12,425

 

8,493

 

Cash flows used in investing activities:

 

 

 

 

 

Additions to property, plant and equipment

 

(9,066

)

(12,739

)

Proceeds from sale of property, plant and equipment

 

17

 

45

 

Net cash used in investing activities

 

(9,049

)

(12,694

)

Cash flows from financing activities:

 

 

 

 

 

Repurchase of Parent common and preferred stock

 

(1,362

)

(1,254

)

Proceeds from borrowings under line of credit

 

115,515

 

124,800

 

Repayment of borrowings under line of credit

 

(113,677

)

(119,530

)

Repayments of long-term debt and capital lease obligations

 

(495

)

(477

)

Other financing activities

 

(1,715

)

 

Net cash provided by (used in) financing activities

 

(1,734

)

3,539

 

Net increase (decrease) in cash

 

1,642

 

(662

)

Cash, beginning of period

 

2,110

 

2,466

 

Cash, end of period

 

$

3,752

 

$

1,804

 

Supplemental disclosures of cash flow information:

 

 

 

 

 

Cash paid for interest, including capitalized interest of $730 and $305 in 2006 and 2005, respectively

 

$

7,766

 

$

7,375

 

Noncash investing and financing activities:

 

 

 

 

 

Conversion of accrued interest to note payable

 

1,999

 

1,831

 

Issuance of restricted stock units

 

 

333

 

 

See accompanying notes to condensed consolidated financial statements.

 

 

5




NOTES TO CONDENSED CONSOLIDATED FINANCIAL STATEMENTS
(Dollars in thousands) (unaudited)

(1)  Basis of Presentation

The accompanying unaudited condensed consolidated interim financial statements have been prepared in accordance with Regulation S-X related to interim period financial statements and, in the opinion of management, include all adjustments (consisting only of normal recurring accruals) that are necessary for the fair presentation of results for the interim periods.  Results for the nine months ended September 30, 2006 may not necessarily be indicative of full-year results.  It is suggested that these condensed consolidated interim financial statements be read in conjunction with the audited consolidated financial statements of Blue Ridge Paper Products Inc. (the “Company”) included in the Company’s annual report on Form 10-K for the year ended December 31, 2005.

The preparation of financial statements in conformity with accounting principles generally accepted in the United States of America requires management to make a number of estimates and assumptions relating to the reported amounts of assets and liabilities and disclosure of contingent assets and liabilities at the date of the financial statements.  These estimates and assumptions also affect the reported amounts of revenues and expenses during the reporting period.  Actual results could differ from those estimates.

(2)  Liquidity

The Company’s working capital needs are satisfied through its $50,000 revolving credit facility, which expires December 15, 2008.  The credit agreement requires that the Company meet certain financial covenants, including a minimum borrowing availability threshold and a fixed charge coverage ratio.  At various times during 2004 and 2005, the credit agreement was amended to reduce the minimum borrowing availability threshold from $15,000 to $5,000 for specified periods of time.  On March 15, 2006, the revolving credit agreement was amended on a permanent basis to change the minimum borrowing availability threshold from $7,500 to $5,000.  For further discussion, see the Company’s annual report on Form 10-K for the year ended December 31, 2005.  In addition, the Company must meet certain affirmative and negative operating covenants.  In the event of default or if the outstanding balance of the revolving credit facility is greater than $25,000, the borrowing availability falls below $5,000 and the fixed charge coverage ratio is less than 1.1 to 1.0, the credit agreement provides for activation of controlled bank accounts to apply daily cash collections toward the outstanding revolving loan balance.  On June 9, 2006, the revolving credit facility was amended to reduce the interest and applicable margins by 50 to 75 basis points depending on the level of borrowing.  Management believes the existing credit facility is adequate for the Company’s current cash flow needs.  Continued compliance with debt covenants and sufficient liquidity is dependent upon business operations consistent with management’s plan for 2006.  However, uncertainties exist within the Company’s markets that include, but are not limited to, availability and pricing of raw materials and energy, unforeseen disruption in plant operations, labor disputes, significant competition, relationships with large customers, product demand, environmental compliance, litigation, loss of key managers and exposures to interest rate changes.

6




 

The borrowing availability at September 30, 2006 and December 31, 2005 is as follows:

 

September 30,

 

December 31,

 

 

 

2006

 

2005

 

 

 

 

 

 

 

Borrowing base

 

$

56,375

 

$

53,629

 

Credit agreement restriction

 

(5,000

)

(7,500

)

Suppressed availability (1)

 

(1,375

)

 

Credit line availability

 

50,000

 

46,129

 

Revolver balance

 

(35,903

)

(34,065

)

Letters of credit

 

(5,691

)

(6,519

)

Maximum borrowing availability

 

$

8,406

 

$

5,545

 


(1)             The excess of the value of the assets collateralized over the maximum line of credit after subtracting the credit agreement restriction.

(3)  Inventories

Components of inventory at September 30, 2006 and December 31, 2005 are as follows:

 

September 30,

 

December 31,

 

 

 

2006

 

2005

 

 

 

 

 

 

 

Raw materials

 

$

17,029

 

$

17,411

 

Work in progress

 

14,837

 

20,113

 

Finished goods:

 

 

 

 

 

Paper and paperboard

 

13,388

 

12,407

 

Cartons

 

6,177

 

4,057

 

Total

 

$

51,431

 

$

53,988

 

 

(4)  Debt

9.5% Senior Secured Notes

On December 17, 2003, the Company sold $125,000 of the 9.5% senior secured notes (the “Notes”) through a private placement offering under Rule 144A.  The Notes have a term of five years, are due on December 15, 2008 and bear interest at a stated rate of 9.5%, which is payable semiannually in arrears on June 15 and December 15.  The Notes are collateralized by a senior secured interest in substantially all of the Company’s tangible and intangible assets and have a subordinated secured interest in the outstanding trade accounts receivable and inventories.  The Company has the right to redeem the Notes at 104.75% and 100.00%, plus accrued interest on or after December 15, 2006 and December 15, 2007, respectively.  Terms of the indenture under which the Notes have been issued contain certain covenants, including limitations on certain restricted payments and the incurrence of additional indebtedness.

7




 

Revolving Credit Facility

On December 17, 2003, the Company entered into a revolving credit facility with a financial institution, which provided for maximum borrowings of $45,000, subject to a borrowing base calculated using eligible accounts receivable and inventories.  On September 15, 2004, the credit agreement was amended to increase the maximum borrowings to $50,000 on a permanent basis.  On August 5, 2005, the credit agreement was amended to include specified foreign account debtors as eligible accounts in determining borrowing base availability.  On June 9, 2006, the credit agreement was further amended to reduce the interest and applicable margins by 50 to 75 basis points depending on the level of borrowing.  The revolving credit facility is collateralized by a senior secured interest in the Company’s outstanding trade accounts receivable and inventories and by a subordinated secured interest in substantially all of the Company’s tangible and intangible assets.  The revolving credit facility matures on December 15, 2008, and requires the Company to pay an annual fee of 0.375% on the unused facility amount.  The Company had an outstanding balance of $35,903 and $34,065 at September 30, 2006 and December 31, 2005, respectively, and letters of credit outstanding as of September 30, 2006 and December 31, 2005 were $5,691 and $6,519, respectively.  The maximum borrowing availability at September 30, 2006 was $8,406, adjusting for the availability restriction described in Note 2 above.  The interest rate on the revolving credit facility at September 30, 2006 and December 31, 2005 was 7.69% and 7.71%, respectively.  This is a blended rate of LIBOR contracts plus margin.

Parent PIK Senior Subordinated Note

Blue Ridge Holding Corp. (the “Parent”) partially financed the acquisition of the Canton System from International Paper Company (formerly Champion International Corporation) with a PIK Senior Subordinated Note payable to International Paper in the principal amount of $30,000, wherein interest would accrue on the unpaid principal balance at a rate of 9% per annum until May 14, 2007.  On November 14, 2003, the Company entered into an agreement with International Paper to extend the maturation date of the Parent PIK Senior Subordinated Note to May 14, 2009 in return for a principal payment of $7,000.  This payment was made on December 17, 2003 with proceeds from the sale of the Notes.  On each semi-annual interest payment date (March 31 and September 30), the Parent records interest on this note by issuing “Secondary Notes,” which bear substantially the same terms as the original Parent PIK Senior Subordinated Note.  Payments of principal and interest under the Parent PIK Senior Subordinated Note are legal obligations of the Parent and have not been guaranteed in any way by the Company.  However, the Parent will be dependent upon the Company to settle these obligations in their entirety.  In addition, under certain circumstances, primarily future Parent equity transactions transferring at least 50% of the common stock to a third party, payment by the Parent of the Parent PIK Senior Subordinated Note would be triggered prior to its maturity.  The entire amount is due on May 14, 2009.

8




 

(5)  Retirement Plans

Pension Plan

The components of net periodic benefit costs relating to the Company’s pension plan are as follows for the three-month periods and nine-month periods ended September 30, 2006 and 2005:

 

 

Three Months Ended
September 30,

 

Nine Months Ended
September 30,

 

 

 

2006

 

2005

 

2006

 

2005

 

Service cost

 

$

414

 

$

370

 

$

1,231

 

$

1,110

 

Interest cost

 

283

 

224

 

785

 

672

 

Expected return on assets

 

(264

)

(225

)

(792

)

(675

)

Amortization of prior service cost

 

(16

)

(13

)

(48

)

(39

)

Amortization of actuarial loss

 

172

 

132

 

408

 

396

 

Total net periodic benefits costs

 

$

589

 

$

488

 

$

1,584

 

$

1,464

 

 

Management is primarily responsible for determining the cost of pension benefits for this plan.  Management considered a number of factors, including consulting with an actuarial firm, when determining this cost.  The Company estimates its benefits payments in fiscal year 2006 will be approximately $326.  Benefits payments in fiscal year 2005 were $355.

Postretirement Medical Plan

The components of net periodic benefit costs relating to the Company’s postretirement medical plan are as follows for the three-month periods and nine-month periods ended September 30, 2006 and 2005:

 

 

Three Months Ended
September 30,

 

Nine Months Ended
September 30,

 

 

 

2006

 

2005

 

2006

 

2005

 

Service cost

 

$

118

 

$

163

 

$

354

 

$

489

 

Interest cost

 

227

 

277

 

681

 

831

 

Amortization of prior service cost

 

(100

)

45

 

(300

)

135

 

Total net periodic benefits costs

 

$

245

 

$

485

 

$

735

 

$

1,455

 

 

Management is primarily responsible for determining the cost of postretirement medical benefits for this plan.  Management considered a number of factors, including consulting with an actuarial firm, when determining this cost.  The Company estimates its benefits payments for the fiscal year ending December 31, 2006 will be approximately $388.  Benefits payments for the fiscal year ended December 31, 2005 were $154.

(6)  Recent Accounting Developments

In December 2004, the Financial Accounting Standards Board (“FASB”) issued Statement of Financial Accounting Standards (“SFAS”) 123R, “Share-Based Payment,” which requires the measurement of all employee share-based payments to employees, including grants of employee stock options, using a fair-value-based method and the recording of such expense

9




 

in the Company’s consolidated statements of income.  The Company adopted the provisions of SFAS 123R using the prospective method effective January 1, 2006.  As such, there was no accounting effect on any outstanding awards.  Upon adoption of SFAS 123R, the Company has only one share-based payment arrangement as described in the following paragraph.

Certain management employees have received restricted stock awards entitling them to receive the Parent’s restricted common stock units.  These units vest over varying periods from one to five years unless the Parent’s majority stockholder sells or otherwise disposes of 80% of its shares or there is a change in control, at which time the restricted stock units vest immediately.  Restricted stock units issued under these arrangements typically contain provisions granting the holder the right, upon the occurrence of certain events or conditions or for the 90-day period commencing at least six months after becoming fully vested and share certificates being issued and not repurchased, to require the Parent to repurchase such fully vested shares of the Parent’s stock underlying the respective restricted stock awards at the then-determined fair value, which is based on an appraisal of the Parent’s common stock performed by an independent valuation specialist.  On June 30, 2006, restricted stock units totaling 230,300 became due to the employees.  These units have a put option during a 90-day period beginning January 1, 2007 if the employee has held their respective share certificate for at least six months.  The Company repurchased 76,483 of the fully vested shares in July 2006 to cover the tax withholding of the employees as allowed by the agreements.  As of September 30, 2006, the Parent had issued and not repurchased a total of 190,355 restricted stock units, net of units canceled, of which all were fully vested.  The obligation to redeem restricted stock units of the Parent was $1,180 at September 30, 2006, which is recorded in temporary equity on the condensed consolidated balance sheet.  The Company records the fair value of the units issued as unearned compensation as a separate component of stockholder’s equity and amortizes them to expense over the vesting periods of the respective units.

In November 2004, the FASB issued SFAS 151, “Inventory Costs, an Amendment of ARB No. 43, Chapter 4,” which clarifies the types of costs that should be expensed rather than capitalized as inventory.  This statement also clarifies the circumstances under which fixed overhead costs associated with operating facilities involved in inventory production should be capitalized.  The Company adopted this standard effective January 1, 2006.  The adoption of SFAS 151 did not have a material effect on the Company’s financial position or results of operations.

In June 2006, the FASB issued FAS Interpretation No. 48 (FIN 48) “Accounting for Uncertainty in Income Taxes,” which clarifies the accounting for uncertainty in income taxes recognized in an entity’s financial statements in accordance with SFAS 109, “Accounting for Income Taxes.”  The accounting provisions of FIN 48 prescribe a recognition threshold and measurement attribute for the financial statement recognition and measurement of a tax position taken or expected to be taken in a tax return.  This interpretation establishes a consistent threshold for recognizing current and deferred taxes.  The Company will adopt the provisions of FIN 48 effective January 1, 2007.  The adoption of FIN 48 will not have a material effect on the Company’s financial statements or results of operations.

On September 29, 2006, the FASB issued FASB Statement No. 158, “Employers’ Accounting for Defined Benefit Pension and Other Postretirement Plans — An Amendment of FASB Statements No. 87, 88, 106 and 132R.”  This new standard requires an employer to: (a) recognize in its statement of financial position an asset for a plan’s over funded status or a liability for a plan’s under funded status: (b) measure a plan’s assets and its obligations that determine its funded status as of the end of the employer’s fiscal year (with limited exceptions); and (c) recognize changes in the funded status of a defined benefit postretirement plan in the year in which the changes occur.  Those changes will be reported in comprehensive income.  The requirement to recognize the funded status of a benefit plan and the disclosure requirements are effective as of the end of the fiscal year ending after June 15, 2007, for entities with non-publicly traded equity securities as defined by Statement No. 158.  The Company will adopt the provisions of Statement No. 158 in December 2007.

10




In September 2006, the SEC issued Staff Accounting Bulletin No. 108 (SAB 108), “Considering the Effects of Prior Year Misstatements when Quantifying Misstatements in Current Year Financial Statements.” SAB 108 provides guidance on how uncorrected errors in previous years should be considered when quantifying errors in current-year financial statements. SAB 108 requires registrants to consider the effect of all carry over and reversing effects of prior-year misstatements when quantifying errors in current-year financial statements. SAB 108 allows registrants to record the effects of adapting the guidance as a cumulative-effect adjustment to retained earnings. The guidance in SAB 108 is effective for the Company in the fourth quarter of 2006. The Company does not anticipate that the adoption of SAB 108 will have a material effect on its consolidated financial statements.

On September 8, 2006, the FASB released FASB Staff Position (FSP AUG AIR-1), “Accounting for Planned Major Maintenance Activities,” which prohibits the use of the “accrue in advance” method of accounting for planned major maintenance activities in annual and interim financial reporting periods. The guidance in FSP AUG AIR-1 is effective for the first fiscal year beginning after December 15, 2006. The Company does not use the “accrue in advance” method of accounting for planned major maintenance, therefore, the provisions of FSP AUG AIR-1 will have no effect on the Company’s interim financial statements.

In September 2006, the FASB issued Statement of Financial Accounting Standards No. 157 (“Statement 157”), “Fair Value Measurements.” Statement 157 establishes a framework for measuring fair value in generally accepted accounting principles and enhances disclosures about fair value measurements. Statement 157 applies when other accounting pronouncements require fair value measurements; it does not require new fair value measurements. Statement 157 applies to interim reporting and will be effective for the Company in the first quarter of fiscal year 2008. The Company is currently evaluating the effects of Statement 157 but does not anticipate that it will have a material effect on its consolidated financial statements.

(7) Commitments and Contingencies

(a) Purchase Commitments

The Company has an agreement with International Paper for supply of wood chips through May 2009. The agreement requires minimum volume purchases and deliveries of 815,000 tons of wood chips during each contract year. These chips are supplied by two International Paper facilities in South Carolina and Tennessee and account for approximately 44% of the total Canton mill requirements. As of September 30, 2006, the Company had commitments to purchase wood chips of approximately $72,419 over the remaining term of the agreement. In May 2006, the agreement was amended to discontinue the invoicing of in-transit chips. The agreement states that title will transfer upon delivery at the Canton mill but risk of loss in the event of casualty while in-transit will be the responsibility of the Company.

(b) Labor Agreements

On July 7, 2006, a new labor agreement was ratified between the United Steelworkers International Union (USW) and the Company. The new contract provides for annual increases of 4%, 3% and 3% over the next three years, retroactive to May 14, 2006. In addition, the Company will increase its contribution to the bargaining unit pension plan to maintain benefits at current levels. Modifications to the employees’ healthcare plan were also made, which included eliminating the highest cost and least utilized healthcare plan, and increasing employee contributions toward healthcare.

11




 

(c) Litigation, Claims and Assessments

On April 15, 2003, a class action lawsuit was filed against the Company for the time period June 1, 1999 until the date of the verdict on behalf of certain owners of property along the Pigeon River in Cocke County, Tennessee. The demand for damages by the class participants totaled approximately $22,500. On August 17, 2005, a jury in the Circuit Court of Cocke County, Tennessee ruled in favor of the Plaintiffs awarding $2,000 for nuisance damages with no punitive damages being awarded. A liability of $2,000 was recorded in 2005. The Company has appealed the decision to the Tennessee Court of Appeals Eastern Section in Knoxville, Tennessee.

On October 11, 2005, the Company was sued by the same plaintiff group for the same cause of action for the time period August 17, 2005 until the trial date in a lawsuit filed in the Circuit Court for Cocke County, Tennessee. The plaintiffs have limited the claim for damages to $4,900. Although the complaint was designed to maintain state jurisdiction, on January 12, 2006, the Company removed the case to Federal court. On September 19, 2006, the case was remanded back to Tennessee State Court.

On June 6, 2006, the Parent received notices of tax assessment for corporate and franchise tax for tax years 1999 through 2004. The aggregate amount assessed is $806, consisting of $443 in taxes, $97 in interest and $266 in penalties for the full six-year period. The Parent formally protested the tax assessment on July 5, 2006. The Company had not recorded a liability for any amount related to this assessment as of September 30, 2006 because the ultimate loss, if any, associated with the assessment is not probable or estimable.

The Company is subject to litigation that may arise in the normal course of business. In the opinion of management, the Company’s liability, if any, under any pending litigation will not materially impact its financial condition or operations.

(d) Environmental Liabilities

As part of its environmental management program, the Company recognizes obligations for closure of landfills in accordance with SFAS No. 143, “Accounting for Asset Retirement Obligations.” The Company had accrued $1,168 and $730 for the closure of landfills at September 30, 2006 and December 31, 2005, respectively. An engineering study received in March 2006 revealed that the estimated cost to close the landfill had increased by $317. Additionally, the estimated remaining months to fill decreased by 27 months because of increased usage in the landfill due to increased production rates at the Canton mill. The Company has recorded expenses of $92 and $191 in the three-month period and nine-month period ended September 30, 2006, and $26 and $77 in the three-month period and nine-month period ended September 30, 2005 respectively, related to the closure of this landfill.

(8) Other Matters

Flood Losses and Government Grants

In 2004, the Company experienced significant losses related to floods caused by Hurricanes Frances and Ivan. Property damage losses and related repairs and maintenance from these two floods through December 31, 2005 were $25,124. No additional expenses were recorded during the nine-month period ended September 30, 2006 and all recorded insurance recoveries had been collected.

In the wake of these events, the Company was awarded three grants for repairs and maintenance of the wastewater treatment facility located within the Canton mill that is also used by the Town of Canton. The first grant was awarded by FEMA for repairs incurred from the two floods. This grant was in the amount of $1,479, all of which

12




 

was received in the first two quarters of 2005. The second grant was awarded by the State of North Carolina in the amount of $4,500 to be paid on a reimbursement basis. This grant provides for flood control repairs and improvements to the wastewater treatment facilities. The third grant for $485 was awarded under the U.S. Environmental Protection Agency that also provided for flood control repairs and improvements to the wastewater treatment facilities to be paid on a reimbursement basis. The Company has recognized these grants to the extent they have incurred costs from repairs and improvements resulting in the recognition of government grant income of $369 and $1,554 in the three-month period and nine-month period ended September 30, 2006, respectively. The Company recorded $4,910 as government grant income in the year ended December 31, 2005. Through September 30, 2006, the Company has recognized as income all of the government grants awarded.

Due Diligence Costs

The Company incurred certain due diligence costs including external legal and accounting fees associated with a potential transaction. During the three-month period ended September 30, 2006, the Company changed its estimate regarding the potential outcome of this transaction; therefore, costs and fees in the amount of $2,096 were recorded in selling, general and administrative expenses.

(9) Segment Information

The Company’s management makes financial decisions and allocates resources based on sales and operating income of the paper and packaging segments. Although raw materials, the production processes, distribution methods and the regulatory environment are similar, management believes it is appropriate to separately disclose these segments. The Company does not allocate selling, research and administration expenses to each segment, but management uses operating income to measure the performance of the segments. The financial information attributed to these segments is included in the following tables:

Blue Ridge Paper Products Inc.

Three Months Ended September 30, 2006 and 2005

(Dollars in Thousands)

 

 

 

 

Paper

 

Packaging

 

Corporate

 

Total

 

 

 

 

 

 

 

 

 

 

 

 

 

Net sales

 

2006

 

$

60,299

 

$

84,943

 

 

$

145,242

 

 

 

2005

 

54,299

 

75,482

 

 

129,781

 

 

 

 

 

 

 

 

 

 

 

 

 

Operating profit (loss)

 

2006

 

5,483

 

5,185

 

(8,806

)

1,862

 

 

 

2005

 

5,347

 

2,676

 

(10,167

)

(2,144

)

 

 

 

 

 

 

 

 

 

 

 

 

Depreciation and amortization

 

2006

 

2,900

 

860

 

28

 

3,788

 

 

 

2005

 

2,906

 

843

 

427

 

4,176

 

 

 

 

 

 

 

 

 

 

 

 

 

Total assets

 

2006

 

202,833

 

91,044

 

17,094

 

310,971

 

 

 

2005

 

201,984

 

95,653

 

15,006

 

312,643

 

 

 

 

 

 

 

 

 

 

 

 

 

Capital expenditures

 

2006

 

2,925

 

888

 

 

3,813

 

 

 

2005

 

6,917

 

1,088

 

126

 

8,131

 

 

13




 

Blue Ridge Paper Products Inc.

Nine Months Ended September 30, 2006 and 2005

(Dollars in Thousands)

 

 

 

 

Paper

 

Packaging

 

Corporate

 

Total

 

 

 

 

 

 

 

 

 

 

 

 

 

Net sales

 

2006

 

$

177,033

 

$

253,172

 

 

$

430,205

 

 

 

2005

 

158,091

 

225,443

 

 

383,534

 

 

 

 

 

 

 

 

 

 

 

 

 

Operating profit (loss)

 

2006

 

16,342

 

15,549

 

(22,414

)

9,477

 

 

 

2005

 

14,793

 

10,930

 

(24,537

)

1,186

 

 

 

 

 

 

 

 

 

 

 

 

 

Depreciation and amortization

 

2006

 

8,429

 

2,569

 

114

 

11,112

 

 

 

2005

 

8,997

 

2,489

 

1,289

 

12,775

 

 

 

 

 

 

 

 

 

 

 

 

 

Total assets

 

2006

 

202,833

 

91,044

 

17,094

 

310,971

 

 

 

2005

 

201,984

 

95,653

 

15,006

 

312,643

 

 

 

 

 

 

 

 

 

 

 

 

 

Capital expenditures

 

2006

 

6,973

 

2,053

 

40

 

9,066

 

 

 

2005

 

10,200

 

2,413

 

126

 

12,739

 

 

ITEM 2. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS

FORWARD-LOOKING STATEMENTS

This filing includes “forward-looking statements” within the meaning of the Private Securities Litigation Reform Act of 1995. Forward-looking statements are those that do not relate solely to historical fact. They include, but are not limited to, any statement that may predict, forecast, indicate or imply future results, performance, achievements or events. They may contain words such as “believe,” “anticipate,” “expect,” “estimate,” “intend,” “project,” “plan,” “will” or words or phrases of similar meaning.

These forward-looking statements are not guarantees of future performance. Forward-looking statements are based on management’s expectations that involve risks and uncertainties, including, but not limited to, economic, competitive, governmental and technological factors outside of our control, that may cause actual results to differ materially from trends, plans or expectations set forth in the forward-looking statements. Given these risks and uncertainties, actual future results may be materially different from what we plan or expect. We will not update these forward-looking statements even if our situation changes in the future.

QUARTERLY OVERVIEW; COMPARISON TO IMMEDIATELY PRECEDING QUARTER

We reported a net loss of $2.8 million for the third quarter ended September 30, 2006. This compared to a net income of $2.0 million for the second quarter ended June 30, 2006 and a net loss of $5.4 million for the third quarter ended September 30, 2005. Total net sales for the third quarter ended September 30, 2006 were $145.2 million compared to $144.9 million and $129.8 million in the second quarter ended June 30, 2006 and third quarter ended September 30, 2005, respectively.

14




 

Our net loss was attributable to an extended scheduled mill maintenance outage and $2.1 million in charges related to an acquisition opportunity that did not materialize. We continued to see significantly improved year-over-year financial performance resulting from strong productivity and improving market conditions.

Uncoated paper shipments totaled 70,829 tons in the third quarter ended September 30, 2006 compared to 70,220 tons in the second quarter ended June 30, 2006. Average pricing in the third quarter ended September 30, 2006 increased 2.2% compared to the second quarter ended June 30, 2006 and 16.0% when compared to the third quarter ended September 30, 2005. Price increases announced in the first quarter ended March 31, 2006 have been substantially implemented.

Packaging segment shipments for the quarter ended September 30, 2006 decreased 3.4% when compared to the second quarter ended June 30, 2006. Shipments decreased compared to the second quarter ended June 30, 2006 due primarily to the seasonality impact from school milk demand. Pricing for the packaging segment for the third quarter ended September 30, 2006 increased 3.0% over the second quarter ended June 30, 2006. During the third quarter ended September 30, 2006, the Company signed a multi-year contract to supply gable-top cartons to a new major premium juice customer.

Raw material costs increased in the third quarter ended September 30, 2006 compared to the second quarter ended June 30, 2006 by approximately $0.7 million. This increase was primarily due to increases in the costs of purchased pulp, wood chips and polyethylene. Recent decreases in energy prices have resulted in lower raw material and transportation costs going into the fourth quarter.

The Canton mill conducted its annual planned hardwood pulp mill maintenance outage in the third quarter ended September 30, 2006. A corresponding planned annual outage was conducted in the pine pulp mill in the second quarter ended June 30, 2006. The cost of the third quarter outage was approximately $3.7 million greater than the second quarter outage due primarily to additional planned work in the recovery boiler area and a planned maintenance outage of 3.5 days on the paperboard machine, both of which did not occur during the second quarter outage.

Through September 30, 2006, we incurred due diligence and legal fees associated with a potential growth opportunity totaling $2.1 million. The transaction was not consummated; therefore, these costs were expensed in the third quarter ended September 30, 2006.

Results of Operations

The following table sets forth certain sales and operating data for our business segments for the periods indicated:

 

15




 

(Dollars in millions, except per ton amounts)

 

 

Three-Month Period

 

Nine-Month Period  

 

 

 

Ended September 30,

 

Ended September 30, 

 

 

 

2006

 

2005

 

2006

 

2005

 

Net sales:

 

 

 

 

 

 

 

 

 

Packaging

 

$

84.9

 

$

75.5

 

$

253.2

 

$

225.4

 

Paper

 

60.3

 

54.3

 

177.0

 

158.1

 

Total

 

$

145.2

 

$

129.8

 

$

430.2

 

$

383.5

 

 

 

 

 

 

 

 

 

 

 

Segments’ operating profit:

 

 

 

 

 

 

 

 

 

Packaging

 

$

5.2

 

$

2.7

 

$

15.6

 

$

10.9

 

Paper

 

5.5

 

5.3

 

16.3

 

14.8

 

Total segments’ operating profit, excluding corporate expenses

 

$

10.7

 

$

8.0

 

$

31.9

 

$

25.7

 

 

 

 

 

 

 

 

 

 

 

Corporate expenses:

 

8.8

 

10.1

 

22.4

 

24.5

 

Total operating profit (loss)

 

$

1.9

 

$

(2.1

)

$

9.5

 

$

1.2

 

 

 

 

 

 

 

 

 

 

 

Percentage of net sales:

 

 

 

 

 

 

 

 

 

Packaging

 

58.5

%

58.2

%

58.9

%

58.8%

 

Paper

 

41.5

%

41.8

%

41.1

%

41.2

%

Total

 

100.0

%

100.0

%

100.0

%

100.0

%

 

 

 

 

 

 

 

 

 

 

Segments’ operating margin:

 

 

 

 

 

 

 

 

 

Packaging segment

 

6.1

%

3.6

%

6.2

%

4.8

%

Paper segment

 

9.1

%

9.8

%

9.2

%

9.4

%

Average margin

 

7.4

%

6.2

%

7.4

%

6.7

%

 

 

 

 

 

 

 

 

 

 

Shipments (tons):

 

 

 

 

 

 

 

 

 

Packaging segment

 

69,681

 

64,404

 

210,414

 

194,538

 

Paper segment

 

73,737

 

77,455

 

226,471

 

223,636

 

Total

 

143,418

 

141,859

 

436,885

 

418,174

 

 

 

 

 

 

 

 

 

 

 

Average price ($ per ton):

 

 

 

 

 

 

 

 

 

Packaging segment

 

$

1,218

 

$

1,172

 

$

1,203

 

$

1,159

 

Paper segment

 

818

 

701

 

782

 

707

 

Average price

 

$

1,012

 

$

915

 

$

985

 

$

917

 

 

THREE MONTHS ENDED SEPTEMBER 30, 2006 COMPARED TO THREE MONTHS ENDED SEPTEMBER 30, 2005

Net Sales.   Net sales for the three-month period ended September 30, 2006, or the 2006 three-month period, increased $15.4 million or 11.9% to $145.2 million compared to $129.8 million for the three-month period ended September 30, 2005, or the 2005 three-month period.

Net sales for our packaging segment for the 2006 three-month period increased $9.4 million or 12.5% to $84.9 million compared to $75.5 million for the 2005 three-month period.  For the 2006 three-month period, our packaging segment sold 69,681 tons of coated and converted paperboard products at an average price of $1,218 per ton, compared to 64,404 tons sold for the 2005 three-month period at an average price of $1,172 per ton.  The increase in packaging segment sales is attributable to an 8.2% increase in volume shipped and a 3.9% increase in average revenue per ton shipped.

Net sales for our paper segment for the 2006 three-month period increased $6.0 million or 11.0% to $60.3 million compared to $54.3 million in the 2005 three-month period.  Net sales volume in our paper segment declined 3,718 tons to 73,737 tons shipped in the 2006 three-month period as compared to 77,455 tons shipped

16




 

in the 2005 three-month period.  Most of the net sales volume decline was related to reduced sales of non-converted bleached board, which resulted from increased transfers to our packaging division for further converting into value-added products.  All of the increase in revenue for our paper segment in the 2006 three-month period reflects improved pricing for our products.  Average pricing in our paper segment improved to $818 per ton shipped in the 2006 three-month period as compared to $701 per ton shipped in the 2005 three-month period.

Operating Profit.  Total segments’ operating profit increased $2.7 million to $10.7 million in the 2006 three-month period compared to an operating profit of $8.0 million for the 2005 three-month period. As a percentage of sales, total segments’ operating profit increased to 7.4% in the 2006 three-month period from 6.2% in the 2005 three-month period.

The following table sets forth significant items that increased (decreased) total segments’ operating profit:

 

 

Three-Month Period Ended
September 30, 2006

 

Three-Month Period Ended
September 30, 2005

 

Change

 

Segments’ Operating Profit

 

$10.7

 

$8.0

 

$2.7

 

 

Product pricing improvement

 

$

14.9

 

 

 

 

 

Productivity improvements

 

1.9

 

 

 

 

 

Outbound transportation costs

 

(0.5

)

 

 

 

 

Sales of excess NOx credits in 2005

 

(1.3

)

 

 

 

 

Increased energy costs

 

(1.3

)

 

 

 

 

Plastic resin costs used at Waynesville coating facility

 

(2.2

)

 

 

 

 

Increased chemical and other raw material costs

 

(2.8

)

 

 

 

 

Increased wage and benefit costs

 

(3.0

)

 

 

 

 

Additional costs to execute semi-annual pulp mill maintenance outage

 

(2.7

)

 

 

 

 

Other miscellaneous and offsetting items

 

(0.3

)

 

 

 

 

Total

 

$

2.7

 

 

Operating profit for our packaging segment increased $2.5 million or 92.6% in the 2006 three-month period to $5.2 million or 6.1% of packaging segment sales, compared to $2.7 million or 3.6% of packaging segment sales for the 2005 three-month period.  The increase in operating profit for our packaging segment was due primarily to: (i) increased pricing on coated board sales of $1.7 million and on converted carton sales of $5.0 million; (ii) improved productivity of approximately $0.7 million; and (iii) other miscellaneous and offsetting variances totaling $0.3 million.  The increase in packaging segment operating profit in the 2006 three-month period was partially offset by: (i) a $2.2 million increase in purchase costs of plastic/resin, our primary raw material used at our Waynesville converting facility; (ii) a $1.5 million increase in costs of internally produced board received

17




 

from the Canton mill and passed on to the packaging division through interdivisional transfer costs; (iii) an increase of $0.2 million in energy costs; (iv) an increase of $0.8 million in costs incurred for wages and benefits; and (v) increased costs for packing materials and outbound transportation costs of $0.5 million.

Operating profit for our paper segment increased $0.2 million in the 2006 three-month period to $5.5 million or 9.1% of paper segment sales, compared to an operating profit of $5.3 million or 9.8% of paper segment sales for the 2005 three-month period.  The increase in operating profit for our paper segment was due primarily to: (i) increased pricing on uncoated paper sales of $8.0 million and on uncoated board sales of $0.2 million; (ii) improved productivity of approximately $1.2 million; and (iii) increased transfer revenue for the rawstock sent to our Waynesville facility of $1.5 million.  The increase in paper segment operating profit in the 2006 three-month period was partially offset by: (i) a $1.1 million increase in purchase costs of fuels and electricity consumed at our Canton, North Carolina mill; (ii) a $2.5 million increase in the cost of wood chips, chemicals and other primary raw material used at our Canton, North Carolina mill; (iii) the sale of excess NOx credits of approximately $1.3 million in the 2005 three-month period; (iv) a $2.2 million increase in costs incurred for wages and benefits; (v) a $0.3 million increase in outbound transportation costs due primarily to higher fuel costs; (vi) increased costs of $2.7 million to execute our fall pulp mill maintenance outage due to additional scope of work as compared to the semi-annual outage we completed in the 2005 three-month period; and (vii) other miscellaneous and offsetting variances totaling $0.6 million.

Selling, General and Administrative Expenses.  Total selling, general and administrative expenses increased $2.7 million or 44.3% to $8.8 million in the 2006 three-month period compared to $6.1 million for the 2005 three-month period.  The increase in selling, general and administrative expenses for the 2006 three-month period was attributable to increased salary payroll costs of approximately $0.6 million and the incurrence of $2.1 million in due diligence expense in the 2006 three-month period.  Through September 30, 2006, the Company incurred due diligence and legal fees associated with a potential growth opportunity totaling $2.1 million.  The transaction was not consummated; therefore, these costs were expensed in the quarter ended September 30, 2006.

Loss on Litigation.  There was no expense recognized for loss on litigation in the 2006 three-month period; however, we did establish a $2.0 million liability in the 2005 three-month period to recognize the potential liability from a class action lawsuit that was filed against us on behalf of certain owners of property along the Pigeon River in Cocke County, Tennessee.  The demand for damages by the class participants totaled approximately $22.5 million.  On August 17, 2005, a jury in the Circuit Court of Cocke County, Tennessee ruled in favor of the Plaintiffs awarding $2.0 million for nuisance damages with no punitive damages being awarded.  We have appealed this verdict to the Tennessee appellate court.

Depreciation and Amortization Expense (non-operations).  Depreciation and amortization expenses unrelated to manufacturing decreased $0.4 million or 100% to $0.0 million in the 2006 three-month compared to $0.4 million in the 2005 three-month period.  The drop in depreciation expense relates primarily to the completion of depreciation on system-related assets purchased in prior years.

ESOP Expense.  ESOP expense decreased $1.6 million or 100.0% to $0.0 million in 2006 three-month period compared to $1.6 million in the 2005 three-month period.  The ESOP expense is a non-cash expense, which results from the annual transfer of shares into the ESOP.  The amount of the ESOP expense varies with the value of the shares of our parent’s common stock, which is determined by an independent valuation specialist at the end of each year.  The decrease in the 2006 three-month period reflects the decline in annual valuation of the shares of our Parent’s common stock to $6.20 per share in fiscal year 2006 compared to $9.06 in fiscal year 2005 as well as the completion of the seven-year share distribution into the ESOP, which began in May 1999

18




 

and ended in May 2006.  Going forward, one more valuation adjustment will be recorded in the fourth quarter of 2006.  Following that adjustment, we should no longer incur ESOP expense.

Interest and Amortization Expenses.   Interest and amortization expenses increased $0.3 million to $5.0 million for the 2006 three-month period compared to $4.7 million for 2005 three-month period.  This increase is due primarily to an increased borrowing level and increased interest rate on our revolving line of credit as well as increased amounts outstanding on our Parent PIK Senior Subordinated Note.

Government Grant Income.  Flood prevention activities continue at our Canton, North Carolina mill following the flood damage incurred at the mill in 2004.  In the 2006 three-month period, we recognized government grant income of $0.4 million as compared to $1.4 million in the 2005 period.  The grant is being used to repair and more permanently protect our wastewater facility, which also serves the Town of Canton, North Carolina.  As of the end of the 2006 three-month period, we have recorded income for all grants awarded to date.

Income Tax Expense.  There was no income tax expense recorded in either the 2006 three-month period or 2005 three-month period.  This was due to our year-to-date net losses as of September 30, 2006 and 2005.

NINE MONTHS ENDED SEPTEMBER 30, 2006 COMPARED TO NINE MONTHS ENDED SEPTEMBER 30, 2005

Net Sales.  Net sales for the nine months ended September 30, 2006, or the 2006 nine-month period, increased to $430.2 million or 12.2% compared to $383.5 million for the nine months ended September 30, 2005, or the 2005 nine-month period.  This increase in total revenue is attributable to an increase in the average weighted revenue per ton shipped to $985 per ton in the 2006 nine-month period from $917 per ton in the 2005 nine-month period as well as an increase in the total volume of products shipped.  The increase in average revenue per ton sold resulted primarily from continued improvement pricing in all four of our major grade lines: paper, uncoated board, coated board and cartons.  The increase in average weighted revenue per unit sold resulted in an approximate $29.7 million increase in total revenue in the 2006 nine-month period as compared to the 2005 nine-month period.  Total sales volume increased by 18,711 tons or 4.5% to 436,885 tons in the 2006 nine-month period compared to 418,174 tons for the 2005 nine-month period.

Net sales for our packaging segment for the 2006 nine-month period increased $27.8 million or 12.3% to $253.2 million compared to $225.4 million for the 2005 nine-month period.  The increase in net sales is attributable to: (i) an average net sales price per ton increase of 9.4% for cartons and 5.9% for non-converted coated paperboard in the 2006 nine-month period compared to the 2005 nine-month period; and (ii) a 24.9% increase in volume of our non-converted coated paperboard shipments in the 2006 nine-month period as compared to the 2005 nine-month period.  The increase in net sales was partially offset by a decrease in shipment volume for our converted cartons of 7.0% in the 2006 nine-month period as compared to the 2005 nine-month period.

Sales for our paper segment for the 2006 nine-month period have increased by $18.9 million or 12.0% to $177.0 million compared to $158.1 million for the 2005 nine-month period.  This increase was attributable to an improvement in our average net sales price per ton for our products sold as well as increased shipment volume.  Our average net sales price per ton increased 10.7% for our paper grades and 6.6% for uncoated paperboard in the 2006 nine-month period as compared to the 2005 nine-month period.  Total segment outside shipment volume increased 2,835 tons or 1.3% to 226,471 tons in the 2006 nine-month period as compared to 223,636 tons in the 2005 nine-month period.  The increase in the paper segment shipment volume reflects improved productivity at our Canton, North Carolina manufacturing facility.  This improved productivity also enabled us to increase transfers of uncoated board to our packaging division for further value-added converting.

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Operating Profit.  Total segments’ operating profit increased $6.2 million to $31.9 million in the 2006 nine-month period compared to an operating profit of $25.7 million for the 2005 nine-month period. As a percentage of sales, total segments’ operating profit increased to 7.4% in the 2006 nine-month period from 6.7% in the 2005 nine-month period.

The following table sets forth significant items that increased (decreased) total segments’ operating profit:

 

 

Nine-Month Period Ended
September 30, 2006

 

Nine-Month Period Ended
September 30, 2005

 

Change

 

Segments’ Operating Profit

 

$31.9

 

$25.7

 

$6.2

 

 

Product pricing improvement

 

$

35.4

 

 

 

 

 

Net flood impact in 2005

 

2.0

 

 

 

 

 

Productivity improvements

 

4.5

 

 

 

 

 

Increased wage and benefit costs

 

(6.9

)

 

 

 

 

Outbound transportation costs

 

(1.5

)

 

 

 

 

Increased wood and purchased fiber costs

 

(5.1

)

 

 

 

 

Major raw material costs (plastic resin, chemicals and packing materials)

 

(10.2

)

 

 

 

 

Additional costs to execute semi-annual pulp mill outages

 

(2.3

)

 

 

 

 

Change in inventory valuation

 

(1.3

)

 

 

 

 

Increased energy costs

 

(4.6

)

 

 

 

 

Sales of excess NOx credits in 2005

 

(2.2

)

 

 

 

 

Other miscellaneous and offsetting items

 

(1.6

)

 

 

 

 

Total

 

$

6.2

 

 

Operating profit for our packaging segment in the 2006 nine-month period increased $4.7 million to $15.6 million compared to $10.9 million for the 2005 nine-month period.  The increase was primarily due to increases in the average net selling prices for coated paperboard and carton products of 9.4% and 5.9%, respectively, compared to the 2005 nine-month period, adding $18.7 million to revenues and operating profit for the 2006 nine-month period as compared to the 2005 nine-month period.  In addition, other miscellaneous and offsetting items totaling $0.3 million added to operating profit for the 2006 nine-month period.  The increase in packaging segment operating profit in the 2006 nine-month period was partially offset by: (i) a $3.7 million increase in purchase costs of plastic/resin, our primary raw material used at our Waynesville converting facility; (ii) reduced productivity for the segment of approximately $0.2 million and centered in our carton manufacturing volume, reflecting lower converted carton demand; (iii) a $3.7 million increase in our wage and benefits costs; (iv) increased transfer cost of rawstock paperboard of $4.3 million; (v) increased energy costs of $0.6 million;

20




 

(vi) impact of change in inventory valuation in the 2005 nine-month period of $0.9 million; (vii) a $0.1 million increase in outbound transportation costs due primarily to higher fuel costs; and (viii) increased costs for miscellaneous raw materials of $0.8 million.

Operating profit for our paper segment increased $1.5 million in the 2006 nine-month period to $16.3 million as compared to $14.8 million for the 2005 nine-month period.  The increase in operating profit for our paper segment was due primarily to: (i) increased pricing on paper sales of $16.2 million and on uncoated board sales of $0.5 million; (ii) an approximate $4.7 million from improved productivity; (iii) increased transfer cost for the rawstock sent to our Waynesville facility of $4.3 million; and (iv) flood losses, net of insurance proceeds, of $2.0 million incurred in the 2005 nine-month period.  The increase in paper segment operating profit in the 2006 nine-month period was partially offset by: (i) a $4.0 million increase in purchase costs of fuels and electricity consumed at our Canton, North Carolina mill; (ii) a $1.4 million increase in outbound transportation costs due primarily to higher fuel costs; (iii) a $4.3 million increase in the cost of wood chips, our primary raw material at our Canton, North Carolina mill; (iv) an approximate $6.5 million increase in cost of chemicals and packing materials utilized in our manufacturing process; (v) increased wage and benefits costs of $3.2 million; (vi) the sale of excess NOx credits of approximately $2.2 million in the 2005 nine-month period; (vii) impact of change in inventory valuation in the 2005 nine-month period of $0.4 million; (viii) increased costs of $2.3 million to execute our two semi-annual pulp mill maintenance outages in the 2006 nine-month period due to additional scope of work as compared to the outages conducted in the 2005 nine-month period;  and (ix) other miscellaneous and offsetting variances totaling $1.9 million.

Selling, General and Administrative Expenses.   Total selling, general and administrative expenses increased $4.3 million or 26.2% to $20.7 million in the 2006 nine-month period compared to $16.4 million for the 2005 nine-month period.  The increase in selling, general and administrative expenses for the 2006 nine-month period was primarily attributable to: (i) reduction of a $0.5 million environmental reserve in the 2005 nine-month period; (ii) increased salary payroll costs of approximately $0.8 million primarily related to merit adjustments and management incentive payments;  (iii) a $0.7 million reversal in the 2005 nine-month period of severance reserves related to the completed closure of our Fort Worth, Texas DairyPak facility and other miscellaneous severance transactions; (iv) the incurrence of $2.1 million in due diligence expenses in 2006; and (v) other miscellaneous and offsetting variance totaling $0.2 million.

Loss on Litigation.  There was no expense recognized for loss on litigation in the 2006 nine-month period; however, we did establish a $2.0 million liability in the 2005 nine-month period to recognize the potential liability from a class action lawsuit that was filed against us on behalf of certain owners of property along the Pigeon River in Cocke County, Tennessee.  The demand for damages by the class participants totaled approximately $22.5 million.  On August 17, 2005, a jury in the Circuit Court of Cocke County, Tennessee ruled in favor of the Plaintiffs awarding $2.0 million for nuisance damages with no punitive damages being awarded.  We have appealed this verdict to the Tennessee appellate court.

Depreciation and Amortization Expense (non-operations).  Depreciation and amortization expenses unrelated to manufacturing decreased $1.2 million to $0.1 million in the 2006 nine-month compared to $1.3 million in the 2005 nine-month period.  The drop in depreciation expense relates primarily to the completion of depreciation on system-related assets purchased in prior years.

ESOP Expense.  ESOP expense decreased $3.3 million or 67.3% to $1.6 million in 2006 nine-month period compared to $4.9 million in the 2005 nine-month period.  The ESOP expense is a non-cash expense, which results from the annual transfer of shares into the ESOP.  The amount of the ESOP expense varies with the value of the shares of our Parent’s common stock, which is determined by an independent valuation specialist at the end of each year.  The decrease in the 2006 nine-month period reflects the decline in annual valuation of the

21




 

shares of our Parent’s common stock to $6.20 per share in fiscal year 2006 compared to $9.06 in fiscal year 2005 as well as the completion of the seven-year share distribution into the ESOP, which began in May 1999 and ended in May 2006.  Going forward, one more valuation adjustment will be recorded in the fourth quarter of 2006.  Following that adjustment, we should no longer incur ESOP expense.

Interest and Amortization Expenses.   Interest and amortization expenses increased $0.7 million to $14.7 million for the 2006 nine-month period compared to $14.0 million for the 2005 nine-month period.  This increase is due primarily to an increased borrowing level and increased interest rate on our revolving line of credit as well as increased amounts outstanding on our Parent PIK Senior Subordinated Note.

Government Grant Income.  Flood prevention activities continue at our Canton, North Carolina mill following the flood damage incurred at the mill in the 2004.  In the 2006 nine-month period, we recognized government grant income totaling approximately $1.6 million compared to $3.7 million in the 2005 nine-month period.  The grants are being used to repair and more permanently protect our wastewater treatment facility, which also serves the Town of Canton, North Carolina.  As of the end of the 2006 nine-month period, we have recorded income for all grants awarded to date.

Income Tax Expense.  There was no income tax expense recorded in either the 2006 nine-month period or 2005 nine-month period since we had a year-to-date net loss in both of the periods.

LIQUIDITY AND CAPITAL RESOURCES

Our principal liquidity requirements are to service our debt and fund our operations and capital expenditure needs.  Our total senior debt, defined as total debt less the Parent PIK Senior Subordinated Note, at September 30, 2006 was $162.7 million.  Subject to our performance, which if adversely affected could affect the availability of funds, we expect to be able to meet our liquidity requirements for the remainder of fiscal year 2006 through cash provided by operations and through borrowings available under our working capital facility.  We cannot assure you, however, that this will be the case.  In December 2003, we issued $125.0 million of the Notes in a private offering.  Proceeds from issuance of the Notes were used to repay our Term Loans A and B and our then existing revolving credit facility under the 1999 credit agreement.  In addition, we paid $7.0 million on the Parent PIK Subordinated Note.  We entered into a $45.0 million revolving credit facility in December 2003.  On September 15, 2004, the credit agreement was amended to increase the facility from $45.0 million to $50.0 million on a permanent basis.  On August 5, 2005, the credit agreement was amended to include specified foreign account debtors as eligible accounts in determining borrowing base availability.  On March 15, 2006, the revolving credit agreement was amended on a permanent basis to change the minimum borrowing availability threshold from $7.5 million to $5.0 million.  On June 9, 2006, the credit agreement was further amended to reduce the interest and applicable margins by 50 to 75 basis points depending on level of borrowing.  The maximum borrowing availability at September 30, 2006 and December 31, 2005 was $8.4 million and $5.5 million, respectively.  Adding the maximum borrowing availability to the cash on hand increases our total liquidity to $12.2 million and $7.7 million at September 30, 2006 and December 31, 2005, respectively.  The revolving credit facility contains covenant restrictions, which require covenant availability to exceed $5.0 million (as amended March 15, 2006).  If the covenant availability does not meet the required minimum availability, a fixed charge coverage ratio covenant of 1.1 to 1.0 will be triggered.  As of September 30, 2006, we had a covenant availability of $14.8 million, which is $9.8 million in excess of the required minimum of $5.0 million.  This availability includes $1.4 million of suppressed availability.  Covenant availability is defined as borrowing base less outstanding revolver and letters of credit.

22




 

Summary of Cash Flow ($ in millions):

 

 

Nine Months Ended September 30,

 

 

 

2006

 

2005

 

Net cash provided by operating activities

 

$

12.4

 

$

8.5

 

Net cash used in investing activities

 

(9.1

)

(12.7

)

Net cash provided by (used in) financing activities

 

(1.7

)

3.5

 

Net increase (decrease) in cash

 

$

1.6

 

$

(0.7

)

Cash balance

 

$

3.8

 

$

1.8

 

 

The cash provided by operations was $12.4 million for the 2006 nine-month period.  The improvement in cash provided by operations when compared to the 2005 nine-month period was attributable to the decreased loss discussed in the Management’s Discussion and Analysis of Financial Condition and Results of Operations as well as changes in working capital as reflected in the condensed consolidated statements of cash flows included elsewhere in this quarterly report on Form 10-Q.

The cash used in investing activities for the 2006 nine-month period was $9.1 million.  Capital spending for the 2006 nine-month period was $9.1 million of which $1.6 million was reimbursed by government grants.  For the fiscal year ending December 31, 2006, we currently estimate that our capital spending will be approximately $12.2 million of which $1.6 million will be offset by government grants.

Net cash used in financing activities was $1.7 million for the 2006 nine-month period, which is primarily attributable to net borrowings on our revolving line of credit.

ITEM 3. QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

We are exposed to certain market risks, including interest rate risk.  Risk exposure relating to this market risk is summarized below.  This information should be read in connection with the condensed consolidated financial statements and the related notes thereto included elsewhere in this quarterly report on Form 10-Q.

We manage interest cost using a combination of fixed and variable rate debt.  As of September 30, 2006, we have $125.0 million of Notes outstanding at a 9.5% fixed rate of interest and a $50.0 million working capital credit facility at variable rates of interest.  As of September 30, 2006, approximately $35.9 million was outstanding under our working capital credit facility consisting of short-term interest rates of 0.25% over Applicable Revolver Index Margin and 2.00% over Applicable Revolver Libor Margin, as defined in the Credit Agreement dated as of December 17, 2003.  Our working capital facility offers two options for interest rates:  Applicable Revolver Libor Margin ranging from 2.25% - 2.75% or Applicable Revolver Index Margin ranging from 0.50% - 1.00%.  These rates were amended June 9, 2006 to reduce interest of Applicable Revolver Libor Margin to 1.50% - 2.00% and Applicable Revolver Index Margin to 0.00% - 0.25%.  The rate is based on revolver availability.  At the end of September 2006, we were at the high point of the interest rate grid for Libor and Index Margins.  In addition, as of September 30, 2006, we have a $0.7 million mortgage note with a maximum interest rate of 5.5% and a remaining duration of four years.

ITEM 4. CONTROLS AND PROCEDURES

(A) Evaluation of Disclosure Controls and Procedures

 

23




 

Our management, with the participation of our Chief Executive Officer and Chief Financial Officer, has carried out an evaluation of the effectiveness of our disclosure controls and procedures (as defined in Rules 13a-15(e) and 15d-15(e) under the Securities Exchange Act of 1934, as amended (the “Exchange Act”)), as of the end of the period covered by this report.  Our Chief Executive Officer and Chief Financial Officer have concluded that, as of the end of such period, our disclosure controls and procedures were effective in ensuring that all material information required to be disclosed by the Company in this quarterly report on Form 10-Q was recorded, processed, summarized, reported and properly disclosed in the time periods specified in the rules and forms of the Securities and Exchange Commission, and that such information was accumulated and communicated to our management (including our Chief Executive Officer and Chief Financial Officer) to allow timely decisions regarding required disclosure.  Based on such evaluation, our Chief Executive Officer and Chief Financial Officer have concluded that the Company is in compliance with Rule 13a-15(e) of the Exchange Act.

(B) Changes in Internal Controls Over Financial Reporting

There have been no significant changes in our internal controls over financial reporting during the three months ended September 30, 2006 that have materially affected or are reasonably likely to materially affect our internal control over financial reporting.

PART II.  OTHER INFORMATION

ITEM 1A.  RISK FACTORS

The risk factors included in our Annual Report on Form 10-K for the fiscal year ended December 31, 2005 have not materially changed other than as disclosed in our quarterly report on Form 10-Q ended June 30, 2006.

ITEM 5. OTHER INFORMATION

None

ITEM 6. EXHIBITS

(a) Exhibits required by Item 601 of Regulation S-K

10.1 United Steelworkers International Union Labor Agreement with Blue Ridge Paper Products Inc.

31.1 Certification of CEO pursuant to Section 302 of Sarbanes-Oxley Act of 2002

31.2 Certification of CFO pursuant to Section 302 of Sarbanes-Oxley Act of 2002

24




SIGNATURES

Pursuant to the requirements 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.

BLUE RIDGE PAPER PRODUCTS INC.

Date:  November 9, 2006

 

/S/ JOHN B. WADSWORTH

 

John B. Wadsworth

 

Chief Financial Officer

 

 

 

(On behalf of the Registrant and as

 

Principal Financial Officer)

 

25




EXHIBIT INDEX
TO
FORM 10-Q
OF
BLUE RIDGE PAPER PRODUCTS INC.
FOR THE QUARTERLY PERIOD ENDED SEPTEMBER 30, 2006
Pursuant to Section 102(d) of Regulation S-T
(17 C.F.R. Section 232.102(d))

The following exhibits are filed as part of this report:

10.1                           United Steelworkers International Union Labor Agreement with Blue Ridge Paper Products Inc.

31.1                           Certification of CEO pursuant to Section 302 of Sarbanes-Oxley Act of 2002

31.2                           Certification of CFO pursuant to Section 302 of Sarbanes-Oxley Act of 2002

26