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General
We are a major manufacturer of recycled paperboard and converted
paperboard products. We operate in three business segments. The
paperboard segment manufactures 100% recycled uncoated and clay-coated
paperboard and collects recycled paper and brokers recycled paper
and other paper rolls. The tube, core and composite container segment
produces spiral and convolute-wound tubes, cores and cans. The carton
and custom packaging segment produces printed and unprinted folding
and set-up cartons and provides contract manufacturing and packaging
services.
Our business is vertically integrated to a large extent. This means
that our converting operations consume a large portion of our own
paperboard production, approximately 38% in 2000. The remaining
62% of our paperboard production is sold to external customers in
any of the four recycled paperboard end-use markets: tube, core
and composite containers; folding cartons; gypsum wallboard facing
paper and other specialty products. We are the only major manufacturer
to serve all four end-use markets. As part of our strategy to maintain
optimum levels of production capacity, we regularly purchase paperboard
from other manufacturers in an effort to minimize the potential
impact of demand declines on our own mill system. Additionally,
each of our mills can produce recycled paperboard for more than
one end-use market. This allows us to shift production between mills
in response to customer or market demands.
Recovered fiber, which is derived from recycled paper stock, is
our most significant raw material. Historically, the cost
of recovered fiber has fluctuated significantly due to market
and industry conditions. For example, our average recovered fiber
cost per ton of paperboard produced increased from $43 per ton in
1993 to $144 per ton in 1995, an increase of 235%, before dropping
to $66 per ton in 1996. Recovered fiber cost per ton averaged $84
during 1999 and $101 during 2000.
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We raise our selling prices in response to increases in raw material
costs. However, we often are unable to pass the full amount of these
costs through to our customers on a timely basis, and as a result
often cannot maintain our operating
margins in the face of dramatic cost increases. We experience margin
shrinkage during all periods of price increases due to customary
time lags in implementing our price increases. We cannot assure
you that we will be able to recover any future increases in the
cost of recovered fiber by raising the prices
of our products. Even if we are able to recover future cost increases,
our operating margins and results of operations may still be materially
and adversely affected by time delays in the implementation of price
increases.
Excluding labor, energy is our most significant manufacturing cost.
Energy is used to generate steam used in the paper making process
and to operate our paperboard machines and all of our other converting
machinery. Our energy costs increased steadily throughout 2000 due
primarily to increases in natural gas and fuel oil costs. In 1999,
the average energy cost in our mill system was approximately $45
per ton. In 2000, energy costs increased by 15.5% to $52 per ton.
Until recently, our business had not been significantly affected
by energy costs, and we historically have not passed energy costs
through to our customers. We were not able to pass through to our
customers all of the energy cost increases we incurred in 2000.
As a result, our operating margins were adversely affected. We continue
to evaluate our energy costs and consider ways to factor energy
costs into our pricing. However, we cannot assure you that our operating
margins and results of operations will not continue to be adversely
affected by rising energy costs.
Historically, we have grown our business, revenues and production
capacity to a significant degree through acquisitions. Based on
the difficult operating climate for our industry and our financial
position in 2000, our acquisition activity in 2000 slowed compared
to 1999. We anticipate that the pace of our acquisition activity,
and accordingly, our revenue growth, will continue to decrease as
we focus on conserving cash and maximizing the productivity of our
existing facilities.
We are a holding company that currently operates our business through
34 subsidiaries. We also own a 50% interest in two joint ventures
with Temple-Inland, Inc. We account for these interests in our joint
ventures under the equity method.
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