-----BEGIN PRIVACY-ENHANCED MESSAGE----- Proc-Type: 2001,MIC-CLEAR Originator-Name: webmaster@www.sec.gov Originator-Key-Asymmetric: MFgwCgYEVQgBAQICAf8DSgAwRwJAW2sNKK9AVtBzYZmr6aGjlWyK3XmZv3dTINen TWSM7vrzLADbmYQaionwg5sDW3P6oaM5D3tdezXMm7z1T+B+twIDAQAB MIC-Info: RSA-MD5,RSA, Nz2ioGzGh3NwtXgKaEkAT0r7tELyMhXjCVZZIiJd3cNc5W3xeLTCkIhc4mOubnz4 TGVXG9rvliD5mqplxTgjqA== 0001193125-05-245107.txt : 20051220 0001193125-05-245107.hdr.sgml : 20051220 20051219193905 ACCESSION NUMBER: 0001193125-05-245107 CONFORMED SUBMISSION TYPE: 8-K/A PUBLIC DOCUMENT COUNT: 3 CONFORMED PERIOD OF REPORT: 20051004 ITEM INFORMATION: Financial Statements and Exhibits FILED AS OF DATE: 20051220 DATE AS OF CHANGE: 20051219 FILER: COMPANY DATA: COMPANY CONFORMED NAME: Aleris International, Inc. CENTRAL INDEX KEY: 0000202890 STANDARD INDUSTRIAL CLASSIFICATION: SECONDARY SMELTING & REFINING OF NONFERROUS METALS [3341] IRS NUMBER: 752008280 STATE OF INCORPORATION: DE FISCAL YEAR END: 1231 FILING VALUES: FORM TYPE: 8-K/A SEC ACT: 1934 Act SEC FILE NUMBER: 001-07170 FILM NUMBER: 051273995 BUSINESS ADDRESS: STREET 1: 25825 SCIENCE PARK DRIVE STREET 2: SUITE 400 CITY: BEACHWOOD STATE: OH ZIP: 44122 BUSINESS PHONE: 2169103400 MAIL ADDRESS: STREET 1: 25825 SCIENCE PARK DRIVE STREET 2: SUITE 400 CITY: BEACHWOOD STATE: OH ZIP: 44122 FORMER COMPANY: FORMER CONFORMED NAME: IMCO RECYCLING INC DATE OF NAME CHANGE: 19920703 FORMER COMPANY: FORMER CONFORMED NAME: FRONTIER TEXAS CORP DATE OF NAME CHANGE: 19881012 FORMER COMPANY: FORMER CONFORMED NAME: PIONEER TEXAS CORP DATE OF NAME CHANGE: 19850416 8-K/A 1 d8ka.htm AMENDMENT NO. 2 TO FORM 8-K Amendment No. 2 to Form 8-K

SECURITIES AND EXCHANGE COMMISSION

Washington, D.C. 20549

 


 

FORM 8-K/A

Amendment No. 2

 


 

CURRENT REPORT PURSUANT TO SECTION 13 OR 15(d)

OF THE SECURITIES EXCHANGE ACT OF 1934

 

Date of Report (Date of earliest event reported): December 19, 2005 (October 4, 2005)

 


 

ALERIS INTERNATIONAL, INC.

(Exact name of Registrant as specified in charter)

 


 

Delaware   1-7170   75-2008280

(State or other jurisdiction

of incorporation)

  (Commission File Number)  

(I.R.S. Employer

Identification No.)

 

25825 Science Park Drive, Suite 400

Beachwood, Ohio

  44122
(Address of principal executive offices)   (Zip Code)

 

Registrant’s telephone number, including area code: (216) 910-3400

 


 

Check the appropriate box below if the Form 8-K filing is intended to simultaneously satisfy the filing obligation of the registrant under any of the following provisions:

 

¨ Written communications pursuant to Rule 425 under the Securities Act (17 CFR 230.425)

 

¨ Soliciting material pursuant to Rule 14a-12 under the Exchange Act (17 CFR 240.14a-12)

 

¨ Pre-commencement communications pursuant to Rule 14d-2(b) under the Exchange Act (17 CFR 240.14d-2(b))

 

¨ Pre-commencement communications pursuant to Rule 13e-4(c) under the Exchange Act (17 CFR 240.13e-4(c))

 



Explanatory Note

 

This Amendment No. 2 on Form 8-K/A to the Aleris International, Inc. (“Aleris”) Current Report on Form 8-K originally filed on October 4, 2005, is being filed solely to provide historical financial statements of ALSCO Holdings, Inc. (“ALSCO”) and pro forma financial information related to the acquisition of ALSCO, all as required by item 9.01 of Form 8-K.

 

Article 3-05 of Regulation S-X requires that we file historical audited financial statements of ALSCO covering at least 33 months by December 19, 2005. Such historical audited financial statements are only available for approximately 28 months and consist of the period from ALSCO’s acquisition by SunCapital Partners, Inc. from Owens Corning on May 23, 2003 through December 31, 2003, the year ended December 31, 2004 and the nine months ended September 30, 2005. As a result of not being able to timely file with the SEC the required historical audited financial statements of ALSCO, we are not in technical compliance with the requirements of the Securities Exchange Act of 1934. Such noncompliance will prevent us from registering debt or equity securities with the SEC until ALSCO’s results are included in our audited consolidated financial statements for a sufficient period of time.

 

ITEM 9.01 Financial Statements and Exhibits

 

(a)     Financial Statements of Business Acquired

    

Attached as Exhibit 99.1 hereto are audited consolidated financial statements of ALSCO Holdings, Inc. as of September 30, 2005, December 31, 2004 and 2003 and for the nine months ended September 30, 2005, the year ended December 31, 2004, and the period from inception through December 31, 2003, and unaudited consolidated financial statements of ALSCO Holdings, Inc. for the three months ended September 30, 2005 and for the three and nine months ended September 30, 2004.

    

(b)     Pro Forma Financial Information

    

Unaudited Pro Forma Condensed Combined Balance Sheet as of September 30, 2005

    

Notes to Unaudited Pro Forma Condensed Combined Balance Sheet

    

Unaudited Pro Forma Condensed Combined Statement of Operations for the Nine Months Ended September 30, 2005

    

Unaudited Pro Forma Condensed Combined Statement of Operations for the Year Ended December 31, 2004

    

Notes to Unaudited Pro Forma Condensed Combined Statements of Operations

    

(c)     Exhibits

    

23.1  Consent of Grant Thornton LLP

    

99.1  Consolidated financial statements of ALSCO Holdings, Inc. as of September 30, 2005, December 31, 2004 and 2003 and for the nine months ended September 30, 2005, the year ended December 31, 2004, and the period from inception through December 31, 2003 with report of Independent Certified Public Accountants, and unaudited consolidated financial statements of ALSCO Holdings, Inc. for the three months ended September 30, 2005 and for the three and nine months ended September 30, 2004.

    


SIGNATURES

 

Pursuant to the requirements of the Securities Exchange Act of 1934, the registrant has duly caused this Amendment No. 2 to its Current Report on Form 8-K/A to be signed on its behalf by the undersigned hereunto duly authorized.

 

    ALERIS INTERNATIONAL, INC.
Dated: December 19, 2005  

/s/ Michael D. Friday


    Name:   Michael D. Friday
    Title:   Executive Vice President and Chief Financial Officer

 

3


UNAUDITED PRO FORMA CONDENSED COMBINED FINANCIAL STATEMENTS

 

The following unaudited pro forma condensed combined financial statements as of and for the nine months ended September 30, 2005 and for the year ended December 31, 2004 are presented to give effect to the October 2005 acquisition of ALSCO Holdings, Inc. (“ALSCO”) by Aleris International, Inc. (“Aleris”) and the December 2004 merger of Aleris and Commonwealth Industries, Inc. (“Commonwealth”) and to reflect the combination of the consolidated historical financial data of Aleris, Commonwealth and ALSCO.

 

The following unaudited pro forma condensed combined financial statements have been derived from the historical financial statements of Aleris, Commonwealth and ALSCO. The unaudited pro forma condensed combined financial statements should be read in conjunction with:

 

    Aleris’s historical audited consolidated financial statements as of and for the year ended December 31, 2004 and unaudited consolidated financial statements as of and for the nine months ended September 30, 2005, as included in Aleris’s Annual Report on Form 10-K for the fiscal year ended December 31, 2004, and in Aleris’s Quarterly Report on Form 10-Q for the quarterly period ended September 30, 2005;

 

    Commonwealth’s historical unaudited consolidated financial statements for the nine months ended September 30, 2004, as included in Commonwealth’s Quarterly Report on Form 10-Q for the quarterly period ended September 30, 2004; and

 

    ALSCO’s historical audited consolidated financial statements as of and for the year ended December 31, 2004 and as of and for the nine months ended December 31, 2005, both included in this current report.

 

The unaudited pro forma condensed combined balance sheet is derived from the historical unaudited consolidated balance sheets of Aleris and ALSCO as of September 30, 2005 and is presented as if the acquisition had occurred on September 30, 2005. The unaudited pro forma condensed combined statements of operations was derived from the historical consolidated statements of operations of Aleris, Commonwealth and ALSCO assuming the merger with Commonwealth and the acquisition of ALSCO had occurred on January 1, 2004. The pro forma adjustments reflect the preliminary adjustments to state the acquired assets and liabilities of ALSCO at their estimated fair values. The actual adjustments that will result from the acquisition will be based on further evaluations and may differ from the adjustments reflected herein. The unaudited pro forma condensed combined financial statements also reflect the financing transactions related to the merger with Commonwealth and the acquisition of ALSCO as if they had occurred on January 1, 2004 for results of operations data, and on September 30, 2005 for balance sheet data.

 

The unaudited pro forma condensed combined financial statements are prepared for illustrative purposes only, and are not necessarily indicative of the operating results or financial position that would have occurred if the merger with Commonwealth or the acquisition of ALSCO had been consummated at the beginning of the periods or the dates indicated, nor are they necessarily indicative of any future operating results or financial position. The unaudited pro forma condensed combined financial statements do not include any adjustments related to any restructuring charges, profit improvements, potential cost savings or one-time charges which may result from the merger with Commonwealth (except to the extent they have been incurred or realized) or the acquisition of ALSCO or the result of final valuations of certain acquired tangible and intangible assets and liabilities of ALSCO.

 

4


ALERIS INTERNATIONAL, INC. AND SUBSIDIARIES

UNAUDITED PRO FORMA CONDENSED COMBINED BALANCE SHEET

SEPTEMBER 30, 2005

(In thousands)

 

     Aleris
Historical


    ALSCO
Historical


    Pro Forma
Adjustments


    Pro Forma
Combined


 

ASSETS

                                

Current Assets

                                

Cash and cash equivalents

   $ 64,444     $ 486     $ (44,438 )(A)   $ 20,492  

Accounts receivable, net

     260,362       39,880       (119 )(B)     300,123  

Inventories

     251,680       42,903       2,500 (C)     297,083  

Deferred income taxes

     5,347       1,341       (1,341 )(H)     5,347  

Prepaid expenses

     6,491       862       —         7,353  

Derivative financial instruments

     42,856       —         —         42,856  

Other current assets

     3,949       431       —         4,380  
    


 


 


 


Total Current Assets

     635,129       85,903       (43,398 )     677,634  

Property and equipment, net

     427,095       20,266       26,750 (G)     474,111  

Goodwill

     72,950       —         44,438 (A)     113,204  
                       100,000 (A)        
                       (55,608 )(D)        
                       (931 )(E)        
                       569 (A)        
                       (2,500 )(C)        
                       68 (F)        
                       (46,690 )(G)        
                       908 (H)        

Restricted cash

     6,166       —         —         6,166  

Other assets

     29,470       383       (270 )(D)     49,466  
                       (57 )(F)        
                       19,940 (G)        
    


 


 


 


     $ 1,170,810     $ 106,552     $ 43,219     $ 1,320,581  
    


 


 


 


LIABILITIES AND STOCKHOLDERS’ EQUITY

                                

Current Liabilities

                                

Accounts payable

   $ 161,871     $ 19,342     $ (119 )(B)   $ 181,094  

Accrued liabilities

     103,376       11,988       569 (A)     115,933  

Revolving line of Credit

     —         38,645       (38,645 )(D)     —    

Current maturities of long-term debt

     8,882       17,658       (17,233 )(D)     9,307  
    


 


 


 


Total Current Liabilities

     274,129       87,633       (55,428 )     306,334  

Long-term debt

     364,334       1,341       100,000 (A)     465,675  

Deferred income taxes

     11,325       433       (433 )(H)     11,325  

Accrued pension benefits and other

     50,139       1,595       (8 )(F)     51,726  

Accrued post retirement benefits

     37,675       11,331       19 (F)     49,025  

Other long-term liabilities

     20,457       3,288       —         23,745  

STOCKHOLDERS’ EQUITY

                                

Common stock

     3,109       10       (10 )(E)     3,109  

Additional paid-in capital

     291,820       438       (438 )(E)     291,820  

Deferred stock compensation

     (4,983 )     —         —         (4,983 )

Retained earnings

     101,096       853       (853 )(E)     101,096  

Accumulated other comprehensive income

     21,764       (370 )     370 (E)     21,764  

Treasury stock

     (55 )     —         —         (55 )
    


 


 


 


Total Stockholders’ Equity

     412,751       931       (931 )     412,751  
    


 


 


 


     $ 1,170,810     $ 106,552     $ 43,219     $ 1,320,581  
    


 


 


 


 

See Notes to Unaudited Pro Forma Condensed Combined Balance Sheet.

 

5


Notes to Unaudited Pro Forma Condensed Combined Balance Sheet

(In thousands)

 

The unaudited pro forma condensed combined balance sheet reflects the following pro forma adjustments and Aleris’s preliminary purchase price allocation as further described below:

 

A) To record the excess of the purchase price paid over net assets acquired as follows:

 

Cash paid

   $ 44,438  

Borrowings under senior credit facility

     100,000  

Estimated acquisition costs

     569  
    


Total acquisition consideration

   $ 145,007  

Estimated fair value of net assets acquired comprised of the following:

        

Current assets

   $ 87,062  

Property and equipment

     47,016  

Other assets

     19,996  

Current liabilities

     (31,755 )

Long-term debt

     (1,341 )

Accrued pension and post-retirement benefits

     (12,937 )

Other long-term liabilities

     (3,288 )
    


Estimated fair value of net assets acquired

   $ 104,753  

Goodwill

     40,254  
    


     $ 145,007  
    


 

B) To reflect the elimination of outstanding accounts receivables and payables between Aleris and ALSCO.

 

C) To adjust ALSCO’s inventory to estimated fair value.

 

D) To reflect the adjustment to write off ALSCO’s debt and related debt issuance costs, as all of ALSCO’s financing arrangements, with the exception of capital lease obligations, were terminated as required by the acquisition agreement.

 

E) To eliminate ALSCO’s historical stockholders’ equity.

 

F) To reflect the adjustment to ALSCO’s liabilities for pension and other postretirement benefits to their estimated fair value and eliminate ALSCO’s intangible pension asset.

 

G) To adjust the acquired property and equipment and separately identifiable intangible assets of ALSCO to their estimated fair values based on a preliminary independent third party appraisal. The final determination of the fair value of acquired property and equipment and separately identifiable intangible assets is subject to the completion of the third party appraisal and may differ from the amounts shown herein.

 

H) At September 30, 2005, Aleris had recorded valuation allowances against certain U.S. federal deferred tax assets and U.S. state net operating loss and tax credit carry forwards. As a result, the pro forma adjustments reflect a full valuation allowance against the historical net deferred tax assets of ALSCO. The final determination of the fair value of acquired deferred tax assets and liabilities as well as the extent of any required valuation allowance against the acquired deferred tax assets is subject to the completion of the purchase price allocation. The reversal of any valuation allowances established through purchase accounting would result in additional goodwill.

 

6


ALERIS INTERNATIONAL, INC. AND SUBSIDIARIES

UNAUDITED PRO FORMA CONDENSED COMBINED STATEMENT OF OPERATIONS

FOR THE NINE MONTHS ENDED SEPTEMBER 30, 2005

(In thousands, except per share data)

 

     Aleris
Historical


    ALSCO
Historical


   Pro Forma
Adjustments


    Pro Forma
Combined


 

Revenues

   $ 1,803,507     $ 218,958    $ (1,251 )(A)   $ 2,021,214  

Cost of sales

     1,610,688       195,302     
 
(1,251
2,679
)(A)
(K)
    1,807,418  
    


 

  


 


Gross profit

     192,819       23,656      (2,679 )     213,796  

Selling, general and administrative expense

     64,880       9,638     
 
(1,304
834
)(B)
(K)
    74,048  

Restructuring and other charges

     4,821       —        —         4,821  

Interest expense

     30,053       3,872      2,691 (C)     36,616  

Unrealized losses on derivative financial instruments

     10,389       —        —         10,389  

Other (income) expense, net

     (1,250 )     5      —         (1,245 )

Equity in net loss of affiliates

     295       —        —         295  
    


 

  


 


Earnings (loss) from continuing operations before provision for income taxes and minority interests

     83,631       10,141      (4,900 )     88,872  

Provision for income taxes

     3,806       3,810      (3,810 )(D)     3,806  
    


 

  


 


Earnings (loss) from continuing operations before minority interests

     79,825       6,331      (1,090 )     85,066  

Minority interests, net of provision for income taxes

     298       —        —         298  
    


 

  


 


Earnings (loss) from continuing operations

   $ 79,527     $ 6,331    $ (1,090 )   $ 84,768  
    


 

  


 


Net earnings (loss) per share:

                               

Basic net earnings (loss) per share:

                               

Earnings (loss) from continuing operations

   $ 2.62                    $ 2.79  

Diluted net earnings (loss) per share:

                               

Earnings (loss) from continuing operations

   $ 2.55                    $ 2.72  

Weighted average shares outstanding:

                               

Basic

     30,367                      30,367  

Diluted

     31,151                      31,151  

 

See Notes to Unaudited Pro Forma Condensed Combined Statements of Operations.

 

7


ALERIS INTERNATIONAL, INC. AND SUBSIDIARIES

UNAUDITED PRO FORMA CONDENSED COMBINED STATEMENT OF OPERATIONS

FOR THE YEAR ENDED DECEMBER 31, 2004

(In thousands, except per share data)

 

     Aleris
Historical


    Commonwealth
Historical *


   

ALSCO

Historical


   PRO FORMA ADJUSTMENTS

       
            CII Merger
Transaction


    ALSCO Acquisition
Transactions


    Pro Forma
Combined 


 

Revenues

   $ 1,226,597     $ 1,044,720     $ 266,246    $ (26,616 )(A)   $ (8,367 )(A)   $ 2,502,580  

Cost of sales

     1,152,869       985,430       240,263     
 
 
(26,616
6,216
(22,040
)(A)
(J)
)(G)
   
 
(8,367
4,109
)(A)
(K)
    2,331,864  
    


 


 

  


 


 


Gross profit

     73,728       59,290       25,983      15,824       (4,109 )     170,716  

Selling, general and administrative expense

     54,507       37,668       10,660      —        
 
(980
1,111
)(B)
(K)
    102,966  

Interest expense

     28,790       14,918       2,854      740 (H)     5,896 (C)     53,198  

Restructuring and merger related charges

     10,754       22,987       —        —         —         33,741  

Unrealized gains on derivative financial instruments

     (4,235 )     (767 )     —        —         —         (5,002 )

Other (income) expense, net

     (216 )     (1,645 )     248      —                 (1,613 )

Equity in net earnings of affiliates

     267       —         —        —         —         267  
    


 


 

  


 


 


Earnings (loss) from continuing operations before provision for (benefit from) income taxes and minority interests

     (16,139 )     (13,871 )     12,221      15,084       (10,136 )     (12,841 )

Provision for (benefit from) income taxes

     7,484       31       4,645      —   (E)     (4,645 )(F)     7,515  
    


 


 

  


 


 


Earnings (loss) from continuing operations before minority interests

     (23,623 )     (13,902 )     7,576      15,084       (5,491 )     (20,356 )

Minority interests, net of provision for income taxes

     214       —         —        —         —         214  
    


 


 

  


 


 


Earnings (loss) from continuing operations

   $ (23,837 )   $ (13,902 )   $ 7,576    $ 15,084     $ (5,491 )   $ (20,570 )
    


 


 

  


 


 


Net earnings (loss) per share:

                                               

Basic net earnings (loss) per share:

                                               

Earnings (loss) from continuing operations

   $ (1.51 )   $ (0.85 )                          $ (0.72 )

Diluted net earnings (loss) per share:

                                               

Earnings (loss) from continuing operations

   $ (1.51 )   $ (0.85 )                          $ (0.72 )

Weighted average shares outstanding (I):

                                               

Basic

     15,793       16,261                              28,384  

Diluted

     15,793       16,261                              28,384  

* Historical Commonwealth amounts are for the eleven months ended November 30, 2004 since the results of Commonwealth are included in the consolidated Aleris results beginning December 1, 2004.

 

See Notes to Unaudited Pro Forma Condensed Combined Statements of Operations.

 

8


Notes to Unaudited Pro Forma Condensed Combined Statements of Operations

(All dollar amounts, except per share amounts, are in thousands)

 

The unaudited pro forma condensed combined statements of operations reflect the following pro forma adjustments as further described below:

 

A) To eliminate revenues and cost of sales between Aleris and ALSCO for the nine months ended September 30, 2005 and Aleris, Commonwealth and ALSCO for the year ended December 31, 2004.

 

B) To eliminate management fees paid to Sun Capital by ALSCO as these fees will not be incurred by Aleris.

 

C) To record incremental interest expense associated with the ALSCO acquisition.

 

D) To eliminate the historical income tax expense of ALSCO for the nine months ended September 30, 2005 as, on a pro forma basis, the income generated by ALSCO, net of the expenses associated with the pro forma adjustments, would not have generated any incremental income tax expense to Aleris due to their net operating losses and related valuation allowance.

 

E) Substantially all of Commonwealth’s operations are in the United States. For the eleven months ended November 30, 2004, Commonwealth recorded a loss before taxes of $14,308, with income tax expense of $31. For the year ended December 31, 2004, as a result of higher interest expense and restructuring and merger related charges, Aleris reported net operating losses for U.S. federal income tax purposes. Management determined the need at year end 2004 for a valuation allowance against the domestic net deferred tax assets that existed prior to the acquisition of Commonwealth. This determination was based on the fact that we changed from a net deferred tax liability position to a net deferred tax asset position as of the end of 2004, combined with the negative evidence of the 2004 tax losses and cumulative losses in years prior to 2004. Even though we projected future taxable income, management did not believe that this subjective positive evidence was enough to overcome the objective negative evidence of current year tax losses and cumulative losses in years prior to 2004 to conclude that it is more likely than not that our future taxable income will be substantial enough to realize our net domestic deferred tax assets at December 31, 2004. The acquisition of Commonwealth resulted in $21,300 of additional net deferred tax assets. We have recorded a full valuation allowance against these net deferred tax assets through purchase accounting, again due to Commonwealth’s historical cumulative losses in years prior to the acquisition.

 

9


No additional tax effect related to the pro forma adjustments associated with the Commonwealth merger has been reflected in the pro forma condensed combined statement of operations for the year ended December 31, 2004 as a full valuation allowance has been established for the net deferred tax asset position of the Company.

 

F) As discussed in E) above, during 2004, Aleris generated net operating losses for U.S. federal income tax purposes and provided a valuation allowance against those deferred tax assets. On a pro forma basis, the income generated by ALSCO during 2004, net of the expenses associated with the pro forma adjustments, would have partially offset the operating losses generated by Aleris, eliminating the related deferred tax assets. As a result, the valuation allowance associated with those deferred tax assets would also be reversed. The reversal of the valuation allowance would offset the historical income tax expense recorded by ALSCO. The elimination of ALSCO’s historical income tax expense is reflected as a pro forma adjustment.

 

G) To reflect the impact of conforming Commonwealth’s method of accounting for inventory with Aleris’ method. Commonwealth had applied the LIFO method to value its inventories while Aleris has applied the average cost and specific identification methods.

 

H) To record incremental interest expense for the Commonwealth merger.

 

I) Pro forma combined basic and diluted shares include adjustments to reflect the impact of the exchange ratio of 0.815 of a share of Aleris common stock for each share of outstanding Commonwealth common stock and the outstanding Commonwealth stock options assumed by Aleris in connection with the merger transaction.

 

J) To reflect the incremental depreciation expense on the write-up of Commonwealth’s property and equipment based upon appraised values and useful lives.

K) To reflect estimated incremental depreciation and amortization expense on the write-up of ALSCO’s property and equipment and certain intangible assets based on preliminary appraised values and useful lives.

 

In November 2005, Aleris announced the closure of its rolled products facility located in Carson, California as the first phase of the plan to integrate ALSCO. The closure will result in estimated restructuring charges related to asset impairments, employee termination benefits and other costs ranging from $22,000 to $25,000 in the fourth quarter of 2005 and $3,000 to $5,000 in 2006. Aleris will also record an estimated $2,500 of additional non-cash cost of sales during the fourth quarter of 2005 as a result of the write-up of ALSCO’s inventory to fair value. These charges have not been included in the pro forma condensed combined statements of operations.

 

10

EX-23.1 2 dex231.htm CONSENT OF GRANT THORNTON LLP Consent of Grant Thornton LLP

Exhibit 23.1

 

CONSENT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM

 

We have issued our report dated December 19, 2005 accompanying the consolidated financial statements of ALSCO Holdings, Inc. as of September 30, 2005, December 31, 2004 and December 31, 2003 and for the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception (May 23, 2003) to December 31, 2003, included in this Form 8-K/A Current Report of Aleris International, Inc. We hereby consent to the incorporation by reference of said report in the Registration Statements of Aleris International, Inc. on Form S-8 (File No. 333-00075, effective January 5, 1996; File No. 333-07091, effective June 28, 1996; File No. 333-71339, effective January 28, 1999; File No. 333-71335, effective January 28, 1999; File No. 333-81949, effective June 30, 1999; File No. 333-55962, effective February 21, 2001; File No. 333-121106, effective December 9, 2004; and File No. 333-122566, effective February 4, 2005).

 

/s/    Grant Thornton LLP

Raleigh, North Carolina

December 19, 2005

EX-99.1 3 dex991.htm CONSOLIDATED FINANCIAL STATEMENTS OF ALSCO HOLDINGS, INC. Consolidated financial statements of ALSCO Holdings, Inc.
Table of Contents

Exhibit 99.1

 

Consolidated Financial Statements and

Report of Independent Certified Public Accountants

ALSCO Holdings, Inc. and Subsidiary

For the Nine Months Ended September 30, 2005 (audited),

For the Year Ended December 31, 2004 (audited),

For the Period from Inception (May 23, 2003) to December 31, 2003 (audited),

For the Three Months Ended September 30, 2005 (unaudited), and

For the Three and Nine Months Ended September 30, 2004 (unaudited)


Table of Contents

ALSCO Holdings, Inc. and Subsidiary

 

Table of Contents

 

Report of Independent Certified Public Accountants

    

Consolidated Financial Statements:

    

Balance Sheets

    

Statements of Income

    

Statements of Cash Flows

    

Statement of Stockholders’ Equity

    

Notes to Consolidated Financial Statements

    


Table of Contents

REPORT OF INDEPENDENT CERTIFIED PUBLIC ACCOUNTANTS

 

To ALSCO Holdings, Inc.:

 

We have audited the accompanying consolidated balance sheets of ALSCO Holdings, Inc. (a Delaware corporation) and Subsidiary as of September 30, 2005, December 31, 2004, and December 31, 2003, and the related consolidated statements of income, stockholders’ equity, and cash flows for the nine months ended September 30, 2005, the year ended December 31, 2004, and the period from Inception (May 23, 2003) to December 31, 2003. These consolidated financial statements are the responsibility of the Company’s management. Our responsibility is to express an opinion on these consolidated 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. An audit includes 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 Company’s 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, 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 consolidated financial statements referred to above present fairly, in all material respects, the financial position of ALSCO Holdings, Inc. and Subsidiary as of September 30, 2005, December 31, 2004 and December 31, 2003, and the results of its operations, its cash flows and its changes in stockholders’ equity for the nine months ended September 30, 2005, the year ended December 31, 2004, and the period from Inception (May 23, 2003) to December 31, 2003, in conformity with accounting principles generally accepted in the United States of America.

 

/s/    Grant Thornton LLP

Raleigh, North Carolina

December 19, 2005


Table of Contents

ALSCO Holdings, Inc. and Subsidiary

 

Consolidated Balance Sheets

 

    

September 30

2005


    December 31

 
       2004

    2003

 
Assets                         

Current Assets:

                        

Cash and cash equivalents

   $ 486,224     $ 353,259     $ 2,179,749  

Trade accounts receivable, net of allowance for uncollectible accounts of $481,237, $408,992 and $343,992 as of September 30, 2005 and December 31, 2004 and 2003, respectively

     39,880,130       33,534,855       26,034,088  

Note receivable – related party

     175,000       175,000       —    

Inventories

     42,903,052       47,293,399       37,517,795  

Prepaid expenses

     862,219       1,235,384       1,298,014  

Deferred income taxes

     1,341,311       334,335       813,915  

Accounts receivable, other

     254,856       1,044,126       798,275  
    


 


 


Total Current Assets

     85,902,792       83,970,358       68,641,836  

Property, plant and equipment, net

     20,265,626       17,861,469       12,670,771  

Deferred income tax asset

     —         —         626,892  

Other assets

     383,926       167,833       117,578  
    


 


 


     $ 106,552,344     $ 101,999,660     $ 82,057,077  
    


 


 


Liabilities and Stockholders’ Equity (Deficit)                         

Current liabilities:

                        

Revolving line of credit

   $ 38,644,968     $ 36,096,308     $ 30,265,997  

Accounts payable

     19,342,393       22,015,533       18,108,220  

Other accrued liabilities

     6,067,567       5,109,720       2,934,319  

Accrued customer rebates

     3,426,294       3,553,717       3,006,694  

Accrued employee compensation, including vacation

     2,493,558       3,634,126       3,271,113  

Current maturities of long-term debt

     17,233,474       1,457,196       1,457,196  

Current portion of capital lease obligations

     425,123       612,022       403,752  
    


 


 


Total current liabilities

     87,633,377       72,478,622       59,447,291  

Long-term debt, net of current maturities

     —         6,869,175       8,326,371  

Capital lease obligations, net of current portion

     1,340,670       1,391,487       2,001,556  

Accrued pension benefits

     1,595,518       1,180,941       1,381,865  

Accrued postretirement benefits

     11,330,733       10,758,401       9,803,425  

Deferred income taxes

     433,313       697,135       —    

Accrued warranty costs

     3,111,160       3,541,988       3,563,040  

Other long-term liabilities

     176,509       —         —    

Commitments and contingencies (Note I)

                        

Stockholders’ equity (deficit):

                        

Common stock, $0.01 par value, 2,900,000 shares authorized; 1,000,500 shares issued and outstanding at September 30, 2005 and 1,000,000 shares issued and outstanding as of December 31, 2004 and 2003

     10,005       10,000       10,000  

Additional paid-in capital

     438,036       435,811       435,811  

Retained earnings (accumulated deficit)

     852,972       4,664,521       (2,912,282 )

Accumulated other comprehensive loss, net of taxes of $233,163, $17,003 and $0 as of September 30, 2005 and December 31, 2004 and 2003, respectively

     (369,949 )     (28,421 )     —    
    


 


 


Total Stockholders’ Equity

     931,064       5,081,911       (2,466,471 )
    


 


 


     $ 106,552,344     $ 101,999,660     $ 82,057,077  
    


 


 


 

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

 

2


Table of Contents

ALSCO Holdings, Inc. and Subsidiary

 

Consolidated Statements of Income

 

     Three Months Ended
September 30


  

Nine Months Ended

September 30


  

Year Ended
December 31

2004


  

Period from
Inception

(May 23, 2003)
through
December 31

2003


     2005

   2004

   2005

   2004

     
     (Unaudited)    (Unaudited)    (Audited)    (Unaudited)    (Audited)    (Audited)

Revenues

   $ 73,729,481    $ 77,173,248    $ 218,957,919    $ 198,104,407    $ 266,246,457    $ 152,210,689

Cost of goods sold

     65,564,812      69,086,712      195,301,774      178,830,476      240,263,147      140,413,401
    

  

  

  

  

  

Gross margin

     8,164,669      8,086,536      23,656,145      19,273,931      25,983,310      11,797,288

Operating expenses:

                                         

General and administrative

     1,967,597      1,747,084      5,790,336      4,891,687      6,611,151      3,430,144

Selling and marketing

     1,361,973      984,448      3,847,980      3,016,160      4,048,607      1,942,352
    

  

  

  

  

  

       3,329,570      2,731,532      9,638,316      7,907,847      10,659,758      5,372,496
    

  

  

  

  

  

Income from operations

     4,835,099      5,355,004      14,017,829      11,366,084      15,323,552      6,424,792

Interest expense

     1,454,697      733,185      3,871,713      2,102,197      2,854,077      1,642,639

Other expenses

     5,244      —        5,244      —        248,100      —  
    

  

  

  

  

  

Income before income tax provision

     3,375,158      4,621,819      10,140,872      9,263,887      12,221,375      4,782,153

Income tax provision

     1,267,709      1,732,049      3,809,421      3,471,687      4,644,572      1,792,135
    

  

  

  

  

  

Net income

   $ 2,107,449    $ 2,889,769    $ 6,331,451    $ 5,792,200    $ 7,576,803    $ 2,990,018
    

  

  

  

  

  

 

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

 

3


Table of Contents

ALSCO Holdings, Inc.

 

Consolidated Statement of Cash Flows

 

     Nine Months Ended
September 30


   

Year Ended
December 31

2004


   

Period from
Inception

(May 23, 2003)
through
December 31

2003


 
     2005

    2004

     
     (Audited)     (Unaudited)     (Audited)     (Audited)  

Cash flows from operating activities:

                                

Net income

     6,331,451       5,792,200     $ 7,576,803     $ 2,990,018  

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

                                

Depreciation expense

     1,113,401       614,126       946,987       705,615  

Deferred income tax (benefit) provision

     (1,054,638 )     —         1,803,607       (1,440,807 )

Loss on sale of assets

     9,605       37,441       37,441       —    

Changes in assets and liabilities:

                                

Accounts receivable, trade and other

     (5,556,005 )     (12,841,981 )     (7,746,618 )     (9,137,363 )

Inventories

     4,390,347       (8,179,986 )     (9,775,604 )     15,340,205  

Prepaid expenses and other assets

     157,072       121,441       12,375       (1,298,014 )

Accounts payable

     (2,673,140 )     6,644,011       3,907,313       6,093,220  

Accrued liabilities

     (60,865 )     2,636,144       3,290,926       3,277,981  

Accrued warranty obligation

     (505,828 )     (165,268 )     (227,115 )     (275,960 )

Postretirement benefit and pension obligation

     433,681       212,602       726,205       960,290  
    


 


 


 


Net cash provided by (used in) operating activities

     2,585,081       (5,129,270 )     552,320       17,215,185  
    


 


 


 


Cash flows from investing activities:

                                

Advances under note receivable

     —         (175,000 )     (175,000 )     —    

Capital expenditures

     (3,416,963 )     (3,006,068 )     (6,195,126 )     (836,806 )

Proceeds from sale of assets

     —         20,000       20,000       —    

Cash paid for acquisition of assets

     —         —         —         (44,620,000 )

Acquisition, other

     —         —         —         (360,166 )

Acquisition costs

     —         —         —         (588,767 )
    


 


 


 


Net cash used in investing activities

     (3,416,963 )     (3,161,068 )     (6,350,126 )     (46,405,739 )
    


 


 


 


Cash flows from financing activities:

                                

Payments of capital leases

     (347,916 )     (297,232 )     (401,799 )     (222,772 )

Proceeds from issuance of long-term debt

     10,000,000       —         —         11,298,299  

Repayment of debt

     (1,092,897 )     (1,092,897 )     (1,457,196 )     (4,514,732 )

Net borrowings on line of credit

     2,548,660       7,920,291       5,830,311       30,265,997  

Dividends paid

     (10,143,000 )     —         —         (5,902,300 )

Issuance of common stock

     —         —         —         445,811  
    


 


 


 


Net cash provided by financing activities

     964,847       6,530,162       3,971,316       31,370,303  
    


 


 


 


Net increase (decrease) in cash

     132,965       (1,760,176 )     (1,826,490 )     2,179,749  

Cash and cash equivalents, beginning of period

     353,259       2,179,749       2,179,749       —    
    


 


 


 


Cash and cash equivalents, end of period

   $ 486,224     $ 419,573     $ 353,259     $ 2,179,749  
    


 


 


 


 

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

 

4


Table of Contents

ALSCO Holdings, Inc.

 

Consolidated Statement of Stockholders’ Equity

 

     Common Stock

   Additional
Paid-in
Capital


   Retained
Earnings


    Other
Comprehensive
loss


    Total

 
     Number of
shares


   Amount

         

Balance at Inception (May 23, 2003)

   1,000,000    $ 10,000    $ 435,811    $ —       $ —       $ 445,811  

Net income

                        2,990,018               2,990,018  

Dividends paid

                        (5,902,300 )             (5,902,300 )
    
  

  

  


 


 


Balance at December 31, 2003

   1,000,000      10,000      435,811      (2,912,282 )     —         (2,466,471 )

Comprehensive income:

                                           

Net income

                        7,576,803               7,576,803  

Minimum pension liability adjustment, net of tax of $17,003

                                (28,421 )     (28,421 )
                                       


Total comprehensive income

                                        7,548,382  
    
  

  

  


 


 


Balance at December 31, 2004

   1,000,000      10,000      435,811      4,664,521       (28,421 )     5,081,911  

Exercise of stock options

   500      5      2,225                      2,230  

Comprehensive income:

                                           

Net income

                        6,331,451               6,331,451  

Minimum pension liability adjustment, net of tax of $216,160

                                (341,528 )     (341,528 )
                                       


Total comprehensive income

                                        5,989,923  

Dividends paid

                        (10,143,000 )             (10,143,000 )
    
  

  

  


 


 


Balance at September 30, 2005

   1,000,500    $ 10,005    $ 438,036    $ 852,972     $ (369,949 )   $ 931,064  
    
  

  

  


 


 


 

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

 

5


Table of Contents

ALSCO Holdings, Inc.

 

Notes to Consolidated Financial Statements

September 30, 2005

Note A - Organization and Description of Business

 

ALSCO Holdings, Inc. (Holdings) is a Delaware corporation that was formed by an affiliate of Sun Capital Partners, Inc. (Sun Capital) in May 2003 for the purpose of acquiring a business unit from Owens Corning (Old ALSCO) through its subsidiary, ALSCO Metals Corporation (ALSCO). Collectively, Holdings and ALSCO are referred to herein as the Company.

 

The Company is the largest supplier of residential aluminum building products in North America. The Company operates in a single reportable operating segment with product lines that include fabricated products (e.g., trim coil, soffits, accessories, aluminum siding, rainware and roof moldings), painted mill product specialty coil and bare aluminum sheet. Products are sold through an extensive network of over 500 distributors, including national one-step distributors, regional independent one-step distributors, two-step distributors, original equipment manufacturers (OEMs) and fabricators. This network is comprised of many of the largest distributors in the country.

 

On May 23, 2003 (Inception), the Company acquired certain assets and assumed certain liabilities of Old ALSCO from Owens Corning (the Acquisition). Prior to the Acquisition, the Company had no operations. Accordingly, the date of the Acquisition (May 23, 2003) is deemed the Inception date for purposes of these consolidated financial statements. On October 3, 2005, the Company was acquired by Aleris International, Inc (see Note K -”Subsequent Events”).

 

The Acquisition was completed in 2003 for a purchase price of $49,029,000, including acquisition-related costs of $1,409,000. The purchase price was allocated to the assets acquired and the liabilities assumed based on their estimated fair values as summarized in the following table:

 

     2004

 

Current assets

   $ 70,553,000  

Property and equipment

     12,148,000  

Other assets

     9,000  
    


Total assets acquired

     82,710,000  
    


Current liabilities

     17,032,000  

Noncurrent liabilities

     16,018,000  
    


Total liabilities assumed

     33,050,000  
    


Net assets acquired

     49,660,000  

Less – Negative goodwill, allocated as a reduction to property and equipment acquired

     (631,000 )
    


Purchase price

   $ 49,029,000  
    


 

The Acquisition generated negative goodwill for the Company as the aggregate fair values of the net assets acquired exceeded the purchase price. This difference of $631,000 was recorded as a reduction to the values assigned to property, plant and equipment.

 

6


Table of Contents

During 2004, the Company finalized its determination of the fair values of its purchased assets and the resulting purchase price allocation. As a result of this effort, the Company allocated an additional $496,000 to the value of inventories which increased the negative goodwill created in the Acquisition to $1,127,000 and further reduced the amount assigned to property, plant and equipment. As of December 31, 2004, the Company had finalized its purchase price allocations related to the Acquisition.

 

The Acquisition was funded with equity (funded by Sun Capital and certain members of management), debt (primarily financed with one lending institution) and seller notes totaling $3,000,000 (Note F). Additionally, certain members of management and Sun Capital financed a portion of the purchase price with a note payable in the original amount of $4,012,299. In December 2003, the Company repaid the original note, plus accrued interest of $85,401 and paid a dividend to the shareholders of $5,902,300.

 

Accumulated liabilities related to certain retirement benefits of the Company’s retained employees were assumed by Owens Corning. Additionally, in connection with the Acquisition, Owens Corning retained any and all warranty obligations related to product sold prior to the Acquisition above the amount assumed by the Company in the Acquisition of $4,389,000.

 

Note B - Summary of Significant Accounting Policies

 

Basis of Presentation

 

The consolidated financial statements include the accounts of Holdings and ALSCO. All intercompany balances and transactions have been eliminated in the accompanying consolidated financial statements.

 

The accompanying unaudited consolidated financial statements for the three months ended September 30, 2005 and 2004, and for the nine months ended September 30, 2004 have been prepared in accordance with accounting principles generally accepted in the United States of America for interim financial reporting and in accordance with Rule 10-01 of Regulation S-X.

 

In the opinion of management, the unaudited interim financial statements contained in this report reflect all adjustments, consisting of only normal recurring accruals, which are necessary for a fair presentation of the financial position, and the results of operations for the interim periods presented. The results of operations for any interim period are not necessarily indicative of results for the full year.

 

Cash and Cash Equivalents

 

The Company defines cash and cash equivalents as cash and short-term investments with original maturities of three months or less.

 

Cash Flow Information

 

Noncash Investing and Financing Activities

 

The following table indicates the noncash components of the Acquisition purchase price:

 

Purchase price financed by Owens Corning

   $ 3,000,000

Accrued acquisition costs

   $ 1,409,000

 

7


Table of Contents

For the nine months ended September 30, 2005, for the year ended December 31, 2004 and for the period from Inception through December 31, 2003, the Company acquired capital assets through the execution of capital leases totaling $110,200, $0, and $674,080, respectively.

 

Cash Paid for Interest and Income Taxes

 

During the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception through December 31, 2003, the Company paid $3,480,000, $396,789 and $2,705,000, respectively, of federal and state income taxes and $4,003,715, $2,482,544 and $1,558,990, respectively, of interest and other borrowing-related charges.

 

Fair Value of Financial Instruments

 

The values the Company has recorded for financial assets and liabilities as of September 30, 2005, and December 31, 2004 and 2003, (including cash, accounts receivable, accounts payable and accrued expenses) approximate the fair market value of these assets and liabilities due to their short maturity. As the majority of all current and long-term debt, including the revolving line of credit facility, contains variable interest rates, carrying value approximates market value.

 

Major Customers and Concentrations of Credit Risk

 

The Company’s products are sold to a broad range of customers for commercial use. In the normal course of business, the Company extends credit to customers and manages its exposure to credit risk through credit approval procedures, advance deposits and monitoring procedures. The Company performs ongoing credit evaluations for all customers that are provided credit on open account. Allowances for doubtful accounts are provided based on historical experience and past due amounts as well as overall economic conditions. The Company evaluates delinquency of accounts on a specific review basis and charges off trade receivables when deemed uncollectible.

 

The following shows the movement of the reserves on accounts receivable:

 

    

Beginning

Balance


   Provision

   Utilization

   Ending
Balance


Period from Inception through December 31, 2003

   $ 149,475    $ 226,292    $ 31,775    $ 343,992

Year ended December 31, 2004

   $ 343,992      118,665      53,665    $ 408,992

Nine months ended September 30, 2005

   $ 408,992      92,774      20,529    $ 481,237

 

Two customers represented 39% of revenues for the nine months ended September 30, 2005, and 38% of accounts receivable as of September 30, 2005. Two customers represented 29% and 48% of revenues for the year ended December 31, 2004 and for the period from Inception through December 31, 2003, respectively, and 26% and 36% of accounts receivable as of December 31, 2004 and 2003, respectively.

 

Inventories

 

Inventories are valued at the lower of first-in, first-out (FIFO) cost or market.

 

8


Table of Contents

Property, Plant and Equipment

 

Property, plant and equipment are stated at the fair value of the assets acquired in the Acquisition less the negative goodwill allocation, plus the cost of assets subsequently acquired. Expenditures for maintenance and repairs are charged directly to expense when incurred and major improvements are capitalized. Depreciation is provided using the straight-line method of depreciation over the estimated useful lives, as follows:

 

Buildings

   30 years

Machinery and equipment

   12 years

Furniture and fixtures

   7 years

 

The Company reviews its long-lived assets and certain identifiable intangible assets for impairment whenever events or changes in circumstances indicate that the carrying amount of an asset may not be recoverable. If the sum of the expected future cash flows from the use of an asset and its eventual disposition is less than the carrying amount of the asset, an impairment loss is recognized based on the fair value of the asset. No such impairment losses were identified in 2005, 2004 or 2003.

 

Assets held for sale consist of excess land adjacent to one of the Company’s manufacturing facilities. Management has committed to a plan to sell this asset and has prepared the property for sale. The asset is recorded at its estimated fair value less estimated costs to sell.

 

Product Warranties

 

The Company provides a warranty accrual, as needed, based on the Company’s best estimate of product failure rates and estimated costs to repair or replace. In addition, the Company is continually releasing new products. As a result, it is possible that products could be released with certain unknown quality problems. Such an occurrence could result in higher than expected warranty and related costs, which could have a materially adverse effect on the Company’s results of operations.

 

The Company records its expected warranty costs for the next twelve months in accrued liabilities in the accompanying balance sheets. The following shows the movement of the accrual for product warranties since the Acquisition in 2003:

 

    

Beginning

Balance


   Provision

    Utilization

   Ending
Balance


Period from Inception through December 31, 2003

   $ 4,389,174    $ 81,177     $ 376,247    $ 4,094,104

Year ended December 31, 2004

   $ 4,094,104      235,000       462,115    $ 3,866,989

Nine months ended September 30, 2005

   $ 3,866,989      (225,000 )     280,829    $ 3,361,160

 

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Table of Contents

Common Stock

 

The Company has 2.9 million authorized shares of common stock. Of these, 1.2 million are classified as voting shares, with the remaining 1.7 million classified as nonvoting shares. All shares outstanding as of September 30, 2005, and December 31, 2004 and 2003, were voting shares.

 

Revenue Recognition

 

The Company recognizes revenue when it has met all significant customer obligations, which generally occurs when the product is shipped to the customer in accordance with Securities and Exchange Commission Staff Accounting Bulletin No. 101, “Revenue Recognition in Financial Statements.” Shipping and handling costs are included within cost of sales in the consolidated income statement. The Company estimates and records provisions for sales returns and allowances in the period that the sale is reported based on its historical experience or contractual agreements. The Company offers periodic rebates to customers based on levels of purchases from the Company during the year. Such rebates are redeemed through cash payments or credits granted to the customers. The Company records such rebates as a reduction of revenue on a current basis as the rebates are earned by customers. During the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception through December 31, 2003, the Company recorded reductions of revenue totaling $8,260,058, $8,556,748 and $4,777,437, respectively, related to customer rebates.

 

Additionally, the Company receives vendor rebates related to levels of purchases made during the year. The Company recognizes rebates during the period of time in which it has purchased products in accordance with the vendor agreement and has earned the right to receive the related rebate. The Company records such rebates as a reduction of cost of goods sold in the accompanying statement of operations, in accordance with Emerging Issues Task Force Issue No. 02-16 “Accounting by a Customer (Including a Resaler) for Certain Consideration Received from a Vendor.” Vendor rebates earned by the Company for the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception through December 31, 2003, totaled $383,121, $1,040,663 and $715,130, respectively. At September 30, 2005, December 31, 2004 and 2003, the Company has recorded $249,235, $1,040,663 and $715,130, respectively, of vendor rebates receivable as a component of accounts receivable, other, on the accompanying consolidated balance sheets.

 

Advertising Costs

 

Advertising costs are included in selling and marketing expenses in the accompanying consolidated statements of income and include costs of advertising, public relations, trade shows and other activities designed to enhance demand for the Company’s products. Advertising costs were approximately $841,827 for the nine months ended September 30, 2005, $827,585 for the year ended December 31, 2004 and $337,100 for the period from Inception through December 31, 2003.

 

10


Table of Contents

Income Taxes

 

The Company records deferred income tax assets and liabilities for the expected future income tax consequences of existing differences between the financial reporting and tax reporting basis of assets and liabilities and of operating loss and income tax credit carryforwards for tax purposes.

 

Use of Estimates

 

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

 

Stock-based Compensation

 

Employee stock options under the Company’s compensation plan are accounted for in accordance with Accounting Principles Board Opinion No. 25, “Accounting for Stock Issued to Employees” (APB 25), and related interpretations which states that no compensation expense is recorded for stock options or other stock-based awards to employees that are granted with an exercise price equal to or above the estimated fair value per share of the Company’s common stock on the grant date. In the event that stock options are granted with an exercise price below the estimated fair value of the Company’s common stock, the difference between the estimated fair value of the Company’s common stock and the exercise price of the stock option is recorded as deferred compensation. Deferred compensation is amortized over the vesting period of the related stock option. Management of the Company believes that all stock options granted during the period from Inception to December 31, 2003, were granted with an exercise price that equaled or exceeded the fair value of the Company’s common stock as determined by the Board of Directors. The Company did not grant any stock options during the year ended December 31, 2004 or the nine months ended September 30, 2005.

 

During 2003, the Company adopted the 2003 Stock Option Plan (the Plan) authorizing options to purchase up to 100,000 shares of nonvoting common stock to be issued under the Plan. In September 2003, the Company issued options to employees to purchase up to 79,000 shares of nonvoting common stock with an exercise price of $4.46 per share which was the Board of Directors’ estimate of the fair value of the stock on the date of grant. Twenty percent of the options vest each year on the anniversary date of the grant. As these options were issued with an exercise price equal to the fair value of the underlying common stock, no compensation is reflected in the accompanying consolidated financial statements.

 

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Table of Contents

As of September 30, 2005, 76,500 of the 79,000 options issued during 2003 were still outstanding and 42,075 were exercisable. The weighted average remaining contractual life on the Company’s outstanding stock options at September 30, 2005 was 7 years. Upon the acquisition of the Company by Aleris International, Inc. on October 3, 2005, all outstanding stock options were vested and exercised.

 

Pro forma information regarding net income is required by SFAS 123 and has been determined as if the Company had accounted for its employee stock options under the fair value method of SFAS 123. The per share weighted average fair value of stock options granted in 2003 was $1.54 on the date of the grant using the Black-Scholes option pricing model with the following weighted average assumptions:

 

Expected dividend yield

   0.00 %

Expected stock price volatility

   0.00 %

Risk-free interest rate

   4.30 %

Expected life of options

   10 years  

 

In accounting for the effect on earnings of the 79,000 stock options granted during 2003, the Company’s pro forma net income would not be significantly different from its reported net income for any period presented.

 

Impact of New Accounting Pronouncements

 

In December 2004, the Financial Accounting Standards Board (FASB) issued Statement 123 (revised 2004), “Share-Based Payment” (Statement 123(R)). This Statement is a revision to Statement 123, “Accounting for Stock-Based Compensation,” and supersedes APB 25. Statement 123(R) requires the measurement of the cost of employee services received in exchange for an award of equity instruments based on the grant-date fair value of the award. The cost will be recognized over the period during which an employee is required to provide service in exchange for the award. No compensation cost is recognized for equity instruments for which employees do not render the requisite service. As a result of the Company’s acquisition by Aleris, the adoption of Statement 123(R) will not have an effect on its financial statements.

 

In November 2004, the FASB issued Statement 151, “Inventory Costs,” an amendment of ARB No. 43, Chapter 4, which is effective for inventory costs incurred during fiscal years beginning after June 15, 2005. The amendments made by Statement 151 will improve financial reporting by clarifying that abnormal amounts of idle facility expense, freight, handling costs and wasted materials (spoilage) should be recognized as current-period charges and by requiring the allocation of fixed production overheads to inventory, based on the normal capacity of the production facilities. The Company does not believe that the adoption of Statement 151 will have a significant effect on its financial statements.

 

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Table of Contents

In December 2004, the FASB issued Statement 153, “Exchanges of Nonmonetary Assets,” an amendment of APB Opinion No. 29. This Statement is effective for nonmonetary asset exchanges occurring in fiscal periods beginning after June 15, 2005. This Statement eliminates the exception to fair value for exchanges of similar productive assets and replaces it with a general exception for exchange transactions that do not have commercial substance – that is, transactions that are not expected to result in significant changes in the cash flows of the reporting entity. The Company does not believe that the adoption of Statement 153 will have a significant effect on its financial statements.

 

In May 2005, the FASB issued Statement 154, “Accounting Changes and Error Corrections”. This Statement provides guidance on the accounting for and reporting of accounting changes and error corrections. It requires retrospective application of voluntary changes in accounting principle and changes required by the accounting pronouncement to the prior periods’ financial statements in the event the pronouncement does not include specific transition provisions. Statement 154 is effective for annual periods beginning after December 15, 2005. The Company does not expect the adoption of Statement 154 to have a material impact on the Company’s financial position or results of operations.

 

Note C - Inventories

 

The components of the Company’s inventories are:

 

    

September 30

2005


    December 31

 
       2004

    2003

 

Raw materials and production supplies

   $ 12,335,808     $ 11,093,853     $ 6,715,451  

Work-in-process

     22,446,565       28,218,423       22,748,992  

Finished goods

     8,733,920       8,586,595       8,754,583  
    


 


 


       43,516,293       47,898,871       38,219,026  

Less – Reserves

     (613,241 )     (605,472 )     (701,231 )
    


 


 


     $ 42,903,052     $ 47,293,399     $ 37,517,795  
    


 


 


 

Note D - Property, Plant and Equipment

 

Property, plant and equipment consists of the following:

 

    

September 30

2005


    December 31

 
       2004

    2003

 

Land

   $ 962,238     $ 962,238     $ 962,238  

Buildings

     3,104,796       3,104,796       2,947,647  

Machinery and equipment

     16,303,126       10,794,344       8,891,501  

Less – Accumulated depreciation

     (2,747,969 )     (1,648,499 )     (705,615 )
    


 


 


       17,622,191       13,212,879       12,095,771  

Construction in process

     2,143,435       4,148,590       75,000  

Assets held for sale

     500,000       500,000       500,000  
    


 


 


     $ 20,265,626     $ 17,861,469     $ 12,670,771  
    


 


 


 

13


Table of Contents

For the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception through December 31, 2003, depreciation expense totaled $1,113,401, $946,987 and $705,615, respectively.

 

Note E - Line of Credit

 

The Company has a revolving line of credit with a bank for the lesser of $60,000,000 less the amount outstanding on the Bank Term Loan (Note F) or 85% of eligible current trade accounts receivable plus the lesser of $28,000,000, 60% of eligible inventory, or 85% of the net liquidation percentage times the book value of inventory minus any reserves and letters of credit. As of September 30, 2005 and December 31, 2004 and 2003, the total outstanding balance was $38,644,968, $36,096,308 and $30,265,997, respectively. The total availability on the line of credit as of September 30, 2005, was $12,791,875. The purpose of this line is to finance working capital needs and other corporate requirements. The line bears interest at prime (6.25% at September 30, 2005) plus 0.5%, or LIBOR (4.4% at September 30, 2005) plus 3.0%, at the option of the Company. Interest payments are due on a monthly basis and the principal amount is due in full in May 2006. The Company pays a fee of 0.5% per annum of the unused balance each month. In connection with the acquisition of the Company by Aleris, the outstanding balance was repaid and the line of credit terminated on October 3, 2005.

 

Note F - Long-term Debt and Capital Lease Obligations

 

Long-term debt includes two outstanding term loans that were issued in connection with the Acquisition. The first note (Bank Term Loan), originally in the amount of $7,286,000, bears interest monthly at a prime rate (6.25% at September 30, 2005) plus 0.5% or LIBOR (4.4% at September 30, 2005) plus 3.0%, at the option of the Company. Monthly principal payments of $121,433, commenced in December 31, 2003. A final payment of interest and the remaining principal is due in May 2006. The term loans are secured by land and buildings owned by the Company. As of September 30, 2005 and December 31, 2004 and 2003, the outstanding balances on the term loans were $4,233,474, $5,326,371 and $6,783,567, respectively. The second term loan of $3,000,000 is a note with Owens Corning that bears interest at a rate of 4.5% payable annually. As of September 30, 2005, the outstanding balance on this term note was $3,000,000. In connection with the acquisition of the Company by Aleris, the Bank Term Loan and the note with Owens Corning were repaid on October 3, 2005.

 

On January 21, 2005, the Company entered into a $10,000,000 term note with Wells Fargo Foothill. The maturity date of the note is May 22, 2006. The note carries interest at prime plus 5%. As of September 30, 2005, the effective interest rate of the note was 11.25%. No monthly principal payments are required.

 

Additionally, the Company has certain lease obligations that are accounted for as capital leases. Under these arrangements, the Company leases equipment and a fabrication facility over terms that expire periodically from January 2005 to September 2010. Monthly payments range from $2,088 to $32,827, including interest at 10%. As of September 30, 2005 and December 31, 2004 and 2003, the net book value of assets under capital leases was $1,464,771, $1,707,636 and $2,139,631, respectively.

 

14


Table of Contents

Contractual principal payments due on the Company’s term loans and capital lease obligations are as follows:

 

Years    


   Capital Lease
Obligations


    Debt

 

Remainder of 2005

   $ 159,769     $ —    

2006

     537,028       17,233,474  

2007

     424,710       —    

2008

     393,924       —    

2009

     393,924       —    

2010

     295,443       —    
    


 


       2,204,798       17,233,474  

Less - Amount representing interest at 10%

     (439,005 )     —    
            


       1,765,793       17,233,474  

Less - Current maturities

     (425,123 )     (17,233,474 )
    


 


     $ 1,340,670     $ —    
    


 


 

The term loans and the line of credit contain certain restrictive covenants including the maintenance of certain amounts of Earnings Before Interest, Taxes, Depreciation and Amortization (EBITDA) and limitations on the amount of annual capital expenditures. As of September 30, 2005, the Company was in compliance with the covenants of the term loans and the revolving line of credit.

 

Note G - Income Taxes

 

The Company’s provision for income taxes consists of the following:

 

    

Nine months

ended

September 30,

2005


    Year ended
December 31,
2004


   Period from
Inception
through
December 31,
2003


 

Current provision:

                       

Federal

   $ 4,223,060     $ 2,446,302    $ 2,783,826  

State

     623,996       394,663      449,116  
    


 

  


     $ 4,847,056       2,840,965      3,232,942  
    


 

  


Deferred benefit:

                       

Federal

     (895,813 )     1,553,047      (1,240,648 )

State

     (141,822 )     250,560      (200,159 )
    


 

  


       (1,037,635 )     1,803,607      (1,440,807  
    


 

  


Total income tax provision

   $ 3,809,421     $ 4,644,572    $ 1,792,135  
    


 

  


 

The provision for income differs from the amount obtained by applying the United States federal income tax rate (34%) to pretax income due to the following:

 

    

Nine months

ended

September 30,

2005


   Year ended
December 31,
2004


   Period from
Inception
through
December 31,
2003


United States federal income tax statutory rate

   $ 3,447,896    $ 4,155,268    $ 1,625,932

State income taxes

     318,235      414,809      164,124

Other

     43,290      74,495      2,079
    

  

  

     $ 3,809,421    $ 4,644,572    $ 1,792,135
    

  

  

 

15


Table of Contents

The components of the Company’s deferred income tax assets and liabilities are as follows:

 

    

September 30

2005


    December 31

 
       2004

    2003

 

Deferred income tax assets:

                        

Accrued expenses

   $ 954,175     $ 429,479     $ 693,647  

Inventory

     420,006       186,113       197,085  

Postretirement benefit obligation

     1,492,637       1,246,545       930,846  

Accrued pension and compensation

     708,030       406,647       952,393  
    


 


 


       3,574,848       2,268,784       2,773,971  
    


 


 


Deferred income tax liabilities:

                        

Property and equipment

     (2,622,951 )     (2,385,137 )     (975,479 )

Other

     (43,899 )     (246,447 )     (357,685 )
    


 


 


       (2,666,850 )     (2,631,584 )     (1,333,164 )
    


 


 


Net deferred income tax (liability) asset

   $ 907,998     $ (362,800 )   $ 1,440,807  
    


 


 


 

The above net deferred income tax assets (liabilities) are classified as follows on the accompanying balance sheets:

 

    

September 30

2005


    December 31

       2004

    2003

Deferred income tax asset - Current

   $ 1,341,311     $ 334,335     $ 813,915

Deferred income tax (liability) asset - Noncurrent

     (433,313 )     (697,135 )     626,892
    


 


 

 

On October 22, 2004, the President signed the American Jobs Creation Act of 2004 (the Act). The Act provides a deduction for income from qualified domestic production activities, which will be phased in from 2005 through 2010. In return, the Act also provides for a two-year phase-out (except for certain preexisting binding contracts) of the existing Extraterritorial Income (ETI) exclusion tax benefit for foreign sales which the World Trade Organization (WTO) ruled was an illegal export subsidy. The European Union (EU) believes that the Act fails to adequately repeal the illegal export subsidies because of the transitional provisions and has asked the WTO to review whether these transitional provisions are in compliance with its prior ruling. It is not possible to predict what impact this issue will have on future earnings pending the final resolution of this matter. Additionally, the Act creates a temporary incentive for United States corporations to repatriate accumulated income earned abroad by providing an 85% dividend received deduction for certain dividends from controlled foreign corporations.

 

On December 21, 2004, FASB Staff Position (FSP) FAS 109-1, “Application of FASB Statement No. 109, Accounting for Income Taxes, to the Tax Deduction on Qualified Production Activities Provided by the American Jobs Creation Act of 2004,” was issued. FSP FAS 109-1 clarifies that this tax deduction should be accounted for as a special deduction in accordance with Statement 109. As such, the special deduction has no effect on deferred tax assets and liabilities existing at the date of enactment. Rather, the impact of this deduction will be reported in the period in which the deduction is claimed on the Company’s tax return beginning in 2005. As regulations are still pending, the Company has not been able to quantify the impact.

 

16


Table of Contents

Note H - Benefit Plans

 

Defined Benefit Pension and Postretirement Benefit Plans

 

The Company maintains two defined benefit pension plans (the Pension Plans) for the benefit of its employees. Both plans are underfunded at September 30, 2005. The Alsco Metals Corporation Cash Balance Plan covers certain salaried employees and certain unionized and non-unionized employees at the Company’s manufacturing facilities. The Alsco Metals Corporation Retirement Plan for Bargained Employees covers certain employees in certain of the Company’s manufacturing facilities that are unionized. The Pension Plans do not permit employee contributions. Rather, company contributions fund the Pension Plans’ employee benefit provisions.

 

The Company also has postretirement healthcare and life insurance plans (the Postretirement Benefit Plans) covering certain hourly employees in two of the Company’s manufacturing facilities that are unionized. At one facility, beginning in 2004, the health care plan is contributory with participants’ contributions adjusted annually. At the other facility, the health care plan is noncontributory. The Company contributes any additional amounts necessary to finance employee benefits. The life insurance plan is noncontributory.

 

For the Pension Plans, the measurement dates used to determine the actuarial present value of accumulated plan benefits were September 30, 2005 and October 1, 2004 and 2003. For the Postretirement Benefit Plans, these dates were September 30, 2005 and December 31, 2004 and 2003. Both the Pension Plans and the Postretirement Benefit Plans provide defined benefits based on employees’ years of service and certain wage levels.

 

17


Table of Contents

In connection with the Acquisition, the Company assumed opening liabilities for the Pension Plans and the Postretirement Benefit Plan totaling $1,097,694 and $9,187,764, respectively.

 

Obligations and Funded Status

 

The table below presents details about the Company’s defined benefit pension plans and other postretirement plans:

 

     Pension Benefits

    Other Benefits

 
     September 30
2005


    December 31

    September 30
2005


    December 31

 
       2004

    2003

      2004

    2003

 

Change in benefit obligation:

                                                

Benefit obligation, beginning of year

   $ 2,450,979     $ 1,546,178     $ —         8,802,235     $ 9,803,425     $ —    

Service cost

     662,996       723,474       424,072       271,815       483,722       300,322  

Interest cost

     100,886       96,637       41,259       436,905       612,799       348,746  

Actuarial (gain) loss

     584,261       89,244       (16,847 )     1,200,716       (1,448,027 )     —    

Benefits paid

     (111,993 )     (64,274 )     —         (100,534 )     (110,589 )     (33,407 )

Participant contributions

     —         —         —         1,065       3,807       —    

Plan amendments

     —         —         —         —         (542,902 )     —    

Other

     —         59,720       1,097,694       —         —         9,187,764  
    


 


 


 


 


 


Benefit obligation, end of period

   $ 3,687,129     $ 2,450,979     $ 1,546,178     $ 10,612,202     $ 8,802,235     $ 9,803,425  
    


 


 


 


 


 


Change in plan assets:

                                                

Fair value of plan assets, beginning of year

   $ 1,203,352     $ —       $ —       $ —       $ —       $ —    

Actual return

     77,652       5,402       —         —         —         —    

Employer contribution

     931,214       1,262,224       —         99,469       106,782       33,407  

Participant contributions

     —         —         —         1,065       3,807       —    

Benefits paid

     (111,993 )     (64,274 )     —         (100,534 )     (110,589 )     (33,407 )

 

18


Table of Contents
     Pension Benefits

    Other Benefits

 
     September 30
2005


    December 31

   

September 30

2005


    December 31

 
       2004

    2003

      2004

    2003

 

Fair value of plan assets, end of period

   $ 2,100,225     $ 1,203,352     $ —       $ —       $ —       $ —    
    


 


 


 


 


 


Recognition of funded status:

                                                

Funded status

   $ (1,586,904 )   $ (1,247,627 )   $ (1,546,178 )     (10,612,202 )   $ (8,802,235 )   $ (9,803,425 )

Unrecognized net actuarial (gain) loss

     594,499       109,020       164,313       (229,395 )     (1,430,111 )     —    

Unrecognized prior service cost

     56,867       59,720       —         —         —         —    

Unrecognized plan amendment

     —         —         —         (489,136 )     (526,055 )     —    
    


 


 


 


 


 


Accrued benefit cost

   $ (935,538 )   $ (1,078,887 )   $ (1,381,865 )     (11,330,733 )   $ (10,758,401 )   $ (9,803,425 )
    


 


 


 


 


 


Additional minimum liability disclosures:

                                                

Accrued benefit liability

     (1,595,518 )   $ (1,180,941 )   $ (1,381,865 )     N/A       N/A       N/A  

Intangible asset

     56,867       56,630       —         N/A       N/A       N/A  

Other comprehensive loss

     369,949       28,421       —         N/A       N/A       N/A  

Deferred income tax asset

     233,164       17,003       —         N/A       N/A       N/A  
    


 


 


 


 


 


 

19


Table of Contents

The components of net periodic benefit cost for the Pension Plans consists of the following:

 

    

Nine months

ended

September 30

2005


   

Year ended
December 31

2004


   

Period from
Inception
through
December 31

2003


        

Net periodic benefit cost:

                      

Service cost

   $ 662,996     $ 723,474     $ 424,072

Interest cost

     100,886       96,637       41,259

Expected return on plan assets

     (58,465 )     (42,000 )     —  

Recognized actuarial gain

     1,859       (25 )     —  

Amortization of prior service cost

     2,853       —         —  
    


 


 

Net periodic benefit cost

   $ 710,129     $ 778,086     $ 465,331
    


 


 

 

The components of net periodic benefit cost for the Postretirement Benefit Plans consist of the following:

 

    

Nine months

ended

September 30

2005


   

Year ended
December 31

2004


   

Period from
Inception
through
December 31

2003


        

Net periodic benefit cost:

                    

Service cost

   271,815     $ 483,722     $ 300,322

Interest cost

   436,905       612,799       348,746

Recognized actuarial gain

   —         (17,916 )     —  

Amortization of prior service cost

   (30,591 )     (16,847 )     —  
    

 


 

Net periodic benefit cost

   678,129     $ 1,061,758     $ 649,068
    

 


 

 

Assumptions

 

Weighted average assumptions used to determine net periodic benefit cost for the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception through December 31, 2003:

 

     Pension Benefits

    Other Benefits

 
    

Nine months

ended

September 30

2005


   

Year ended
December 31

2004


   

Period from
Inception
through
December 31

2003


   

Nine months

ended

September 30

2005


   

Year ended
December 31

2004


   

Period from
Inception
through
December 31

2003


 
              

Discount rate

   5.50 %   6.25 %   6.25 %   5.75 %   6.25 %   6.25 %

Expected long-term return on plan assets

   5.75 %   7.25 %   7.25 %   N/A     N/A     N/A  

Rate of compensation increase

   4.00 %   4.00 %   4.00 %   N/A     N/A     N/A  

 

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Table of Contents

The Company considers various factors in estimating the expected long-term rate of return on plan assets. Among the factors considered include the historical long-term returns on plan assets, the current and expected allocation of plan assets, input from actuaries and investment consultants and long-term inflation assumptions. The expected allocation of plan assets is based on a diversified portfolio consisting of domestic and international equity securities, fixed income securities and real estate.

 

The Company used the following pre-Medicare and post-Medicare health care inflation rate assumptions in measuring the accumulated postretirement benefit obligation:

 

     Pre-Medicare Cost (pre-65 years old)

    Post-Medicare Cost (post-65 years old)

 
    

September 30

2005


    December 31

   

September 30

2005


    December 31

 
       2004

    2003

      2004

    2003

 

Assumed health care cost trend rates at December 31:

                                    

Health care costs trend assumed for next year

   8.0 %   9.0 %   10.0 %   8.0 %   9.0 %   10.0 %

Rate to which the cost trend rate gradually declines

   5.0 %   5.0 %   5.0 %   5.0 %   5.0 %   5.0 %

Year that the rate reaches the ultimate trend rate

   2008     2008     2008     2008     2008     2008  

 

Assumed health care cost trend rates have a significant effect on the amount reported for the Postretirement Benefit Plan. A one percentage point change in assumed health care cost trend rates would have the following effects as of September 30, 2005:

 

     1 Percentage Point

     Increase

   Decrease

Effect on total service and interest cost components

   1,057,399    816,001

Effect on postretirement benefit obligation

   11,754,539    9,398,167

 

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Table of Contents

Plan Assets

 

The Company’s investment policy for its Pension Plans is to balance risk and return using a diversified portfolio consisting primarily of high-quality equity and fixed income securities. To accomplish this goal, each plan’s assets are actively managed by outside investment managers with the objective of optimizing long-term return while maintaining a high standard of portfolio quality and proper diversification. The Company monitors the maturities of fixed income securities so that there is sufficient liquidity to meet current benefit payment obligations. The Company’s Board of Directors provides oversight of the plans investments and the performance of the investment managers. The Company’s Pension Plan asset allocation as of September 30, 2005, is as follows:

 

     Pension Plans

 
     Cash
Balance
Plan


    Bargained
Employee
Plan


 

Asset category:

            

Equity securities

   21 %   51 %

Debt securities

   75 %   42 %

Real estate

   4 %   7 %
    

 

Total

   100 %   100 %
    

 

 

The Postretirement Benefit Plan was unfunded as of September 30, 2005 and December 31, 2004 and 2003, as the Company policy is to fund such benefits as they are required. The Pension Plans were unfunded at December 31, 2003.

 

Cash Flows

 

The Company funds the Company’s Pension Plans and no contributions are made by employees. The Company funds the Plans annually by making a contribution of at least the minimum amount required by applicable regulations and as recommended by the Company’s actuary. However, the Company may also fund the plan in excess of the minimum required amount. The Company expects to contribute approximately $931,214 in 2005.

 

Cash contributions in subsequent years will depend on a number of factors, including performance of plan assets.

 

The following represent expected future benefits for the periods shown:

 

Year    


   Pension
Benefits


   Other
Benefits


2006

   $ 37,000    $ 360,769

2007

     44,000      433,903

2008

     242,000      525,949

2009

     160,000      582,121

2010

     230,000      701,386

2011- 2015

     1,900,000      4,551,016
    

  

Total

   $ 2,613,000    $ 7,155,144
    

  

 

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Table of Contents

Defined Contribution Pension Plans

 

The Company also maintains defined contribution pension plans for its employees. The Board of Directors, working in accordance with the Company’s union contracts where applicable, determines the Company’s annual contributions to these plans. The Company contributed $711,982, $916,622 and $0 to its various defined contribution pension plans during the nine months ended September 30, 2005, year ended December 31, 2004 and the period from Inception through December 31, 2003, respectively.

 

Note I - Commitments and Contingencies

 

The Company leases certain equipment and facilities under operating lease arrangements with various expiration dates through 2008. The total amount charged to expense under these leases was approximately $1,048,734 for the nine months ended September 30, 2005, $1,383,679 for the year ended December 31, 2004 and $841,000 for the period from Inception through December 31, 2003. Future minimum lease payments under noncancelable operating leases with original noncancelable lease terms in excess of one year as of September 30, 2005 are as follows:

 

Remainder of 2005

   $ 272,423

2006

     1,063,030

2007

     965,160

2008

     568,610
    

     $ 2,869,223
    

 

Note J - Related-party Transactions

 

In accordance with a management services agreement, the Company pays a monthly management fee to Sun Capital Partners. For the nine months ended September 30, 2005, the year ended December 31, 2004 and the period from Inception through December 31, 2003, the Company paid management fees of $1,303,620, $979,624 and $393,018, respectively, including $43,605, $114,514 and $32,231, respectively, in reimbursement of direct expenses, to Sun Capital Partners for such services.

 

Additionally, in connection with the debt financing provided by management and Sun Capital, which was repaid during 2003, the Company incurred interest expense of $116,690.

 

Note K - Subsequent Event

 

On October 3, 2005, all of the outstanding common shares and options of Holdings were acquired by Aleris International, Inc., a global leader in aluminum recycling and the production of specification alloys and a major North American manufacturer of rolled aluminum products. Upon the consummation of the acquisition, the Company became a wholly-owned subsidiary of Aleris.

 

23

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