Form 10-K
Table of Contents
Index to Financial Statements

UNITED STATES

SECURITIES AND EXCHANGE COMMISSION

Washington, D.C. 20549

 


 

FORM 10-K

 


 

ANNUAL REPORT PURSUANT TO SECTION 13 OR 15(d) OF THE SECURITIES

EXCHANGE ACT OF 1934

 

For the Fiscal Year Ended January 1, 2005

 

Commission File Number 1-3506

 


 

GEORGIA-PACIFIC CORPORATION

(Exact name of registrant as specified in its charter)

 

Georgia   93-0432081

(State or other jurisdiction of

incorporation or organization)

 

(I.R.S. Employer

Identification Number)

 

133 Peachtree Street, N.E.,

Atlanta, Georgia 30303

(Address of Principal Executive Offices) (Zip Code)

 

Registrant’s telephone number, including area code: (404) 652-4000

 

Securities registered pursuant to Section 12(b) of the Act:

 


 

Title of Each Class


  

Name of Each Exchange on which Registered


Georgia-Pacific Corporation—Georgia-Pacific Common Stock
($.80 par value)

   New York Stock Exchange

Georgia-Pacific Rights to Purchase Series B Junior
Preferred Stock (no par value)

   New York Stock Exchange

 

Securities registered pursuant to Section 12(g) of the Act:    None

 


 

Indicate by check mark whether the registrant: (1) has filed all reports required to be filed by Section 13 or 15(d) of the Securities Exchange Act of 1934 during the preceding 12 months (or for such shorter period that the registrant was required to file such reports), and (2) has been subject to such filing requirements for the past 90 days.    Yes x    No ¨

 

Indicate by check mark if disclosure of delinquent filers pursuant to Item 405 of Regulation S-K is not contained herein, and will not be contained, to the best of registrant’s knowledge, in definitive proxy or information statements incorporated by reference in Part III of this Form 10-K or any amendment to this Form 10-K.     ¨

 

Indicate by check mark whether the registrant is an accelerated filer (as defined in Rule 12b-2 of the Act).    Yes x    No ¨

 

The aggregate market value of the voting and non-voting common equity held by non-affiliates of the registrant on July 2, 2004 (assuming, for the sole purpose of this calculation that all executive officers and directors of the registrant are “affiliates”) was $9,117,926,678 for Georgia-Pacific Common Stock.

 

As of the close of business on February 23, 2005, the registrant had 259,808,325 shares of Georgia-Pacific Common Stock outstanding.

 



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Index to Financial Statements

DOCUMENTS INCORPORATED BY REFERENCE

 

Portions of Georgia-Pacific Corporation’s definitive Proxy Statement for use in connection with its Annual Meeting of Shareholders, scheduled to be held on May 3, 2005, are incorporated by reference in answer to Part III of this Form 10-K.


Table of Contents
Index to Financial Statements

GEORGIA-PACIFIC CORPORATION

 

ANNUAL REPORT ON FORM 10-K

For the Fiscal Year Ended January 1, 2005

 

TABLE OF CONTENTS

 

PART I

 

          Page

Item 1.

  

Business

   1

Item 2.

  

Properties

   12

Item 3.

  

Legal Proceedings

   12

Item 4.

  

Submission of Matters to a Vote of Security Holders

   12

 

PART II

Item 5.

  

Market for Registrant’s Common Equity, Related Stockholder Matters

   13

Item 6.

  

Selected Financial Data

   13

Item 7.

  

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

   13

Item 7A.

  

Quantitative and Qualitative Disclosures About Market Risk

   38

Item 8.

  

Financial Statements and Supplementary Data

   39

Item 9.

  

Changes in and Disagreements With Accountants on Accounting and Financial Disclosure

   123

Item 9A.

  

Controls and Procedures

   123

Item 9B.

  

Other Information

   125

 

PART III

Item 10.

  

Directors and Executive Officers of the Registrant

   125

Item 11.

  

Executive Compensation

   127

Item 12.

  

Security Ownership of Certain Beneficial Owners and Management and Related Stockholder Matters

   128

Item 13.

  

Certain Relationships and Related Transactions

   128

Item 14.

  

Principal Accountant Fees and Services

   128

 

PART IV

Item 15.

  

Exhibits and Financial Statement Schedules

   128


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Index to Financial Statements

PART I

 

ITEM 1.    BUSINESS

 

Georgia-Pacific Corporation was organized in 1927 under the laws of the State of Georgia and is headquartered in Atlanta, Georgia.

 

We are engaged in four principal businesses:

 

    Consumer Products—Manufacturing and marketing of tissue products, which include bath and facial tissue, paper towels, and napkins, in North America and many countries in Europe, as well as disposable tabletop products such as cups, plates and cutlery, in North America;

 

    Building Products—Manufacturing and marketing building products, which include plywood, oriented strand board, various industrial wood products and lumber, as well as non-wood products such as gypsum products and chemicals;

 

    Packaging—Manufacturing containerboard and packaging, which include linerboard, medium and corrugated packaging; and

 

    Paper—Manufacturing paper and pulp, which include office papers, bleached board, bleached and unbleached kraft papers and hardwood and softwood pulp.

 

Our four principal businesses are reported in six operating segments:

 

    North America Consumer Products;

 

    International Consumer Products;

 

    Building Products Manufacturing;

 

    Packaging;

 

    Bleached Pulp and Paper; and

 

    Building Products Distribution, which was sold in May 2004.

 

Strategy and Recent Developments

 

During the past several years, we have been pursuing a strategy of improving our return to shareholders by focusing on higher value-added products. We began implementing this strategy by acquiring and investing in businesses that position us closer to the consumer, and by selling and exiting non-strategic businesses. Our acquisition of Fort James Corporation in 2000 was a key component of this strategy and provided us a leadership position in the higher value-added consumer tissue business. Recent asset sales have reduced our exposure to cyclical businesses, such as office papers and market pulp, while providing additional cash to reduce debt.

 

In addition to these acquisitions and divestitures, we have focused our traditional businesses—containerboard and packaging, building products, and bleached paper—on emphasizing products and services that are differentiated from those of our competitors and, we believe, preferred by consumers. In all of our business lines, we continue to focus on our relationships with large mass, or “big box”, retailers.

 

We continue to execute our financial strategy while at the same time maintaining our strict operating discipline. We believe the result of this determined focus ultimately will improve our financial flexibility by allowing us to achieve investment grade financial metrics and improving our return on capital.

 

We have engaged in a number of transactions intended to further these strategies:

 

   

During 2004, we sold our building products distribution business, our stand-alone market pulp mills in Brunswick, Georgia, and New Augusta, Mississippi, a short-line railroad, our interest in a Brazilian

 

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Index to Financial Statements
 

pulp business, and four hardwood lumber mills. Cash proceeds from the sale of assets totaled approximately $1.5 billion, pretax, which we used to reduce our debt.

 

    During 2004, we redeemed $1.5 billion of debentures, which were scheduled to mature from 2021 to 2023.

 

    In July 2004, we entered into a new $2.5 billion, five-year, senior unsecured credit facility that includes a $500 million non-amortizing term loan. This new credit facility matures July 2, 2009 and replaces a $2.25 billion, five-year credit facility that would have matured November 3, 2005.

 

    During the fourth quarter of 2004, we entered into interest rate exchange agreements that effectively converted $500 million of fixed-rate debt to floating rate debt.

 

    During 2003, we refinanced a large portion of our corporate debt. As part of this refinancing, we significantly improved the maturity schedule of our debt, resulting in greater financial flexibility going forward. We issued $2.5 billion of new, longer-term debt and, with those proceeds, together with free cash flow, reduced borrowings under our bank credit agreements by $2.8 billion and repaid approximately $600 million of other debt that matured in 2003.

 

    In November 2002, we sold a 60% controlling interest in our paper distribution business, Unisource Worldwide, Inc., a leading distributor of paper products, packaging and facility supplies. In connection with the sale, we received $471 million in cash along with notes with a recorded book value of $105 million.

 

    In October 2001, we completed the spin off of the entities that owned and operated our timberlands and their merger with Plum Creek Timber Company, Inc.

 

    In August 2001, we completed the sale of four pulp and paper mills for $1.65 billion. These facilities produced office paper as well as specialty printing and writing papers.

 

    On March 2001, we completed the sale of a portion of our commercial tissue manufacturing assets for approximately $850 million, pursuant to a consent decree executed with the United States Department of Justice in connection with the Fort James acquisition.

 

    In November 2000, we completed our acquisition for Fort James for approximately $6,186 million in cash and approximately 53.9 million shares of Georgia-Pacific common stock valued at $1,485 million. In addition, we assumed $3.3 billion of Fort James debt in the acquisition.

 

Consumer Products

 

North America

 

Tissue.    With an estimated 30% volume market share at the end of 2004, we are the largest producer of tissue products in North America. Our strategy in this business is to improve operating margins through product improvements and enhancements that lead to preference for our brands and through leverage of our size to achieve operating and distribution efficiencies. This business produces bath and facial tissue, paper towels and napkins, which are made from both virgin and recycled fibers. Our products are sold under our brands and customer brands in both retail and commercial channels. Fourteen tissue production and converting facilities located throughout the United States and two converting facilities in Mexico produce finished goods to serve the North America market; these facilities have nine of the world’s 12 largest, lowest-cost tissue machines. Most of our tissue facilities are integrated with onsite pulping operations, which strengthens our low-cost position by eliminating pulp drying and shipping costs. Approximately 54% of our tissue pulp is made from virgin fiber and 46% is made from recycled paper, most of which is used in commercial tissue products. Our total production capacity in North America is approximately 3.1 million tons.

 

The markets for our tissue products are significantly influenced by growth in population and employment levels, along with changes in per capita consumption, and the levels of general economic activity in the geographic markets we serve.

 

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We take a careful approach to balancing supply with demand for all of our principal products, and have reduced or eliminated production from less efficient equipment in recent years. In 2004, we shut down two tissue machines, one at our Green Bay, Wisconsin (Broadway) mill and another at our Plattsburgh, New York mill, shifting production to more cost-efficient equipment in other parts of the country. Together, the two machines had capacity of over 45,000 tons per annum, or “tpa”.

 

In 2003, we shut down tissue paper machines at Plattsburgh, New York, Bellingham, Washington, Camas, Washington and Old Town, Maine, resulting in total primary tissue reduction of 134,000 tpa, or over 4% of our capacity at the time. Our Old Town, Maine paper machine, with a capacity of 45,000 tpa, is scheduled to resume production in 2005.

 

North America Consumer Products

 

LOGO   LOGO

 

Retail Tissue.    In the retail channel, which accounted for 69% of our domestic tissue sales in 2004, we produce our own branded products and customer branded products. Product market share in both branded and customer branded products, and rankings of our principal retail brands based on dollar share, are:

 

Product    Market Share*    

North America Market Size

(In millions)

 

Consumer bath tissue

   36 %   $ 4,600  

Paper towels

   31 %     2,900  

Consumer napkins

   54 %     520  
Brand    Market Position/Share*  

Quilted Northern® bath tissue

   #2       15 %

Angel Soft® bath tissue

   #3       14 %

Sparkle® paper towels

   #4       9 %

Brawny® paper towels

   #3       10 %

Mardi Gras® napkins

   #1       15 %

*   (based on A.C. Nielsen data, including Wal-Mart, for the 52 weeks ending Jan. 8, 2005)

 

Other retail brands include Brawny® napkins, Soft ‘n Gentle® bathroom and facial tissue, Mardi Gras® towels and Zee® napkins (number one on the West Coast). We also supply customer branded products to some of the largest retailers in the United States. We believe we are the leading supplier to the United States customer brand tissue, towel and napkin market, with an estimated market share of 39% (based on A.C. Nielsen data, including Wal-Mart, for the 52 weeks ending Jan. 8, 2005).

 

We also believe that through our own branded products and our customer branded products we are the leading supplier of tissue, towel and napkin products to mass retail and warehouse club stores, two of the fastest growing channels in the consumer products industry. Additionally, we have strong, long-term relationships with major retailers in the grocery channel.

 

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Commercial Tissue.    In 2004, the remaining 31% of our domestic tissue sales came from commercial and industrial markets. These sales were made through paper distributors, food service and janitorial distributors, and to national fast food accounts for use in restaurants. Our principal commercial brands include: Quilted Northern PS® and Angel Soft PS® bath and facial tissues; BigFold® and Signature® towels; Preference®, Acclaim® and Envision® brands of folded, hardwound roll and perforated roll towels, bath and facial tissue; Compact®, HACCP Guardian®, MAX 3000®, enMotion®, SofPull®, and Cormatic® controlled usage dispensing systems for a range of towel, tissue, soap, air freshener and toilet seat cover products; Easy Nap®, Essence®, Impressions®, MORNAP®, and Preference® brands of dispenser or single-service napkins; and ShopMaster®, DynaMAX®, TuffMate®, and TaskMate® wipers.

 

According to the American Forest & Paper Association, during 2004, we sold more tissue products in the commercial channel than any other company in the United States and, based on volume, had an estimated 40% share in this market. We have developed proprietary dispensing systems, such as our enMotion® automatic dispensing system, which use only Georgia-Pacific-produced towels. We believe we are the market leader in proprietary systems and that we hold the primary position in foodservice, healthcare, lodging, education, recreation, and retail/convenience end-use markets. Our commercial market share leadership and innovative proprietary systems position us favorably in a fluctuating economic environment.

 

Dixie®.    Our Dixie business, with the best-known brand name in disposable consumer plates and cups, holds a 25% share of the consumer tabletop market (based on the 52 week A.C. Nielsen Homescan data, including Wal-Mart and club, ending September 24, 2004). Dixie® is the number one brand in the North America disposable consumer tableware market. Through 11 production facilities in North America, we manufacture a full range of products for both retail and foodservice markets including disposable plates, cups and cutlery. We supply tabletop products to the warehouse and club channels and disposable cups, plates and related products to the foodservice industry. Foodservice customers include distributors, restaurants, hotels, office buildings and institutions. Approximately 60% of Dixie sales are into retail distribution channels and the remaining 40% of the business’ sales are into foodservice distribution channels. In 2004, Dixie’s net sales to third party customers were $985 million.

 

International

 

The international consumer products segment is a leading supplier of paper-based consumer products in many European countries. Product lines in both the retail and commercial markets include bathroom and facial tissue, paper towels and napkins. Retail sales include both our branded products and customer branded products. We also market feminine hygiene products and ancillary products such as health care, cosmetic cotton and pharmacy supplies, in certain countries.

 

International Consumer Products

 

LOGO   LOGO

 

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Our principal European brands and their estimated market positions are:

 

Country      Brand/Product   

Market Position

(unit share data)*

    

Total
Market Size

(in millions)

      

France

     Lotus®/Moltonel® bath tissue    #1/#2      $856       

France

     O’kay® kitchen towels    #1        384       

Netherlands

     Lotus® kitchen towels    #1          69       

Spain

     Colhogar® bath tissue/kitchen towels    #1        670       

Ireland

     KittenSoft® towels and bath tissue    #1        158       

Finland

     EMBO® bathroom tissue    #1          97       

Italy

     Tenderly® bathroom tissue    #2        782       

Greece

     Delica® towels    #1          58       

Greece

     Delica® bath tissue    #2        150       

*   (based on A.C. Nielsen data, for the 52 weeks ending Oct. 31, 2004)

 

Our international consumer products are manufactured across Europe in ten primary production mills, with an annual capacity of over 899,000 tons, or are purchased from others. Eight separate converting plants supplement converting operations carried out at our primary production mills. This combined network provides cost-effective market reach, which lowers distribution cost and provides greater distribution capacity.

 

During 2004, tissue-based products accounted for 78% of our annual international consumer products sales, with the balance comprised of feminine hygiene products and ancillary products such as health care, cosmetic cotton and pharmacy items. We sell our tissue, towel and napkin products through both retail and commercial distribution channels. Approximately 72% of our European towel and tissue sales were into retail distribution channels and 28% were into commercial and other channels.

 

In 2004, we worked to reduce operating costs and improve efficiencies in our European operations. We relocated an inefficient converting facility in Wrexham, Wales, and relocated a high-cost converting facility in Athens, Greece, to Patras, Greece, where we believe its cost position will improve significantly. Additionally, during 2004, we announced plans to begin tissue production and expand existing converting operations in Russia to serve that growing market. In 2005, we intend to permanently close our converting facility at Newcastle, United Kingdom. The facility has the capacity to convert 12,000 tons of tissue products. We anticipate relocating the Newcastle equipment by October 2005.

 

Building Products Manufacturing

 

We are one of the leading manufacturers of building products in the United States. We manufacture products used in residential, commercial and industrial construction. Our building products line-up includes wood panels, such as plywood, oriented strand board and industrial panels; lumber; gypsum products; and chemicals. These products are sold directly to large home improvement mass retailers, wholesalers, independent dealers and industrial customers. We are the largest supplier of wood panels to the home improvement mass retailers channel. Our building products are manufactured at 94 locations in the United States, six in Canada, four in South America, and a joint venture facility in South Africa.

 

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Building Products Manufacturing

 

LOGO   LOGO

 

Our building products business is affected by the level of new housing starts; the level of home repairs, remodeling and additions; industrial and commercial building activity; the availability and cost of financing; and changes in industry capacity. The demand for building products tends to be stronger during the second and third quarters when weather conditions favor construction. Exports by this segment in 2004 were $17 million (1% of segment sales), primarily to the Caribbean and Europe.

 

In May 2004, we completed the sale of our building products distribution business to BlueLinx Holdings, Inc. In connection with this divestiture, we entered into a six-year agreement to sell structural panels, lumber, and other building products manufactured by us to BlueLinx. This supply agreement contains substantially similar terms as the previous arrangement between our building products manufacturing and building products distribution businesses. In 2004, sales from building products distribution, prior to its sale, totaled $1.9 billion. Operating results from this business are included in historical data through April 2004.

 

Structural Panels.    Based on annual capacity of 8.3 billion square feet, we are the largest producer of structural wood panels in North America and are the leading supplier of wood panels to the home improvement mass retailers channel. In order to distinguish our plywood products, we branded our family of southern plywood products under the name Plytanium®. Our 18 softwood plywood plants have an annual capacity of approximately 6.1 billion square feet, and our six oriented strand board plants can produce 2.2 billion square feet. In 2004, structural panels sales of $2.5 billion, including both structural and industrial wood panels, were 36% of total building products manufacturing segment sales to third parties.

 

With most of our structural panel plants located in the southeastern United States, we normally benefit from an ample supply of timber, favorable weather conditions, and regional population growth. However, during the fourth quarter of 2004, our building products business was negatively impacted by constrained supplies of timber due to heavy rainfall in parts of the southeastern United States.

 

Two of our facilities manufacture engineered lumber products. Demand for engineered lumber products has increased in recent years as wood I-joists (made from veneer, oriented strand board and sawn lumber) have increasingly become the product of choice for floor joist applications. GP Lam, our laminated veneer lumbers, and Fiberstrong® Rim Board and Wood I Beam® joists are designed to meet the precise structural performance requirements of roofing and flooring systems.

 

Industrial Wood Products.    We also manufacture industrial wood panels and hardwood plywood for use in ready-to-assemble furniture, cabinets, retail fixtures, mobile homes and other industrial products. Sixteen mills manufacture composite panels of particleboard, medium-density fiberboard, hardboard and softboard, as well as hardwood plywood, interior decorative panels and thermally fused melamine panels.

 

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Lumber.    We have the capacity to manufacture approximately 2.3 billion board feet of lumber annually. In 2004, lumber sales to third-party customers were $1.2 billion, or 18% of total segment sales. Most of our 25 lumber mills are located in the southeastern United States. Lumber products are primarily manufactured from southern pine, hemlock and Douglas fir.

 

We are one of the top producers of pressure-treated lumber in the nation. Approximately 31% of our southern pine lumber production is pressure-treated for use in outdoor applications such as decks, fences, bridges and playground equipment. We own six pressure-treated lumber plants, two of which are currently idle. An unaffiliated company operates four of those treating plants, as well as seven additional plants that it owns. With production from those facilities, we can produce more than one billion board feet of treated lumber annually. We are the primary supplier of pressure-treated lumber to one of North America’s fastest-growing home improvement mass retailers.

 

In 2004, we sold four hardwood lumber mills. In 2003, we closed one southern pine sawmill and sold a hardwood sawmill.

 

Gypsum Products.    We operate 18 gypsum product plants throughout the United States and Canada, and have the third largest gypsum wallboard capacity in North America of 6.5 billion square feet annually. During 2004, gypsum product sales of $909 million represented 13% of total segment sales. Gypsum products include wallboard, specialty panels, fire-door cores, industrial plasters and joint compound. The business is substantially vertically integrated in paper and gypsum rock, operating three recycled gypsum paperboard mills and nine gypsum quarries/mines. Our gypsum reserves total approximately 284 million recoverable tons, an estimated 72-year supply at current production rates.

 

As part of our strategy to grow businesses with higher value-added products, we are continuing to develop our Dens TechnologyTM group of products. Dens TechnologyTM products are highly differentiated in the marketplace and are based on a patented, innovative glass mat technology that offers exclusive performance features such as unmatched moisture and mold resistance and strength characteristics. In 2004, we restarted our idled Savannah gypsum plant to produce additional Dens TechnologyTM products to meet demand. We have enhanced our manufacturing capabilities to produce Dens wallboard at multiple facilities, thereby reducing distribution costs and delivery times. Also in 2004 we introduced DensGlass SilverTM, a mold and mildew resistant exterior sheathing targeted at single and multi-family residential construction markets.

 

Chemicals.    Our chemical business is a leading supplier of wood bonding resins, industrial thermosetting resins, formaldehyde, paper chemicals, and tall oil-based chemicals. These chemicals and resins are used in a variety of specialty applications, including the production of wood panels, papermaking, roofing, thermal insulation, metalworking, coatings, fertilizers and transportation. The chemical business ships more than four billion pounds of bonding and thermosetting resins, formaldehyde, pine chemicals, and paper chemicals annually from 17 plants in the United States and four plants in Chile, Argentina and Brazil. The business also operates through a joint venture in South Africa. In 2004, chemical sales of $588 million were 9% of total segment sales.

 

In 2003, we idled our White City, Oregon, thermosetting resin and formaldehyde plant. The White City plant’s annual capacity of thermosetting resins and formaldehyde represented 6% and 10%, respectively, of the total capacity of the division. Also in October 2003, we acquired a thermosetting resin business in Brazil, including one formaldehyde plant with 120 million pounds of annual capacity and two resin plants with 163 million pounds of annual capacity.

 

Packaging

 

Our packaging segment focuses on providing packaging solutions for a wide variety of customers, including the food, consumer products, paper and other manufacturing industries, as well as independent packaging

 

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converters and rollstock customers for containerboard. We develop and maintain relationships with national account customers and operate with a customer-focused approach that emphasizes value-added packaging solutions. We are growing our high-graphics packaging business, which is improving our total product mix.

 

Packaging

 

LOGO   LOGO

 

Our four containerboard mills have a total capacity of 3.7 million tons. These mills produce unbleached linerboard and medium in roll form that is shipped to converting facilities. Our containerboard mills produce approximately 70 to 75% of their products from virgin fiber, with the remaining fiber derived from old corrugated containers.

 

Our converting facilities consume between 70 and 75% of the containerboard produced by our mills. The rest is typically sold to independent corrugated converters in North America, Latin America and Asia. In addition to standard corrugated boxes, our converting facilities supply many specialty packaging products. These include display-ready corrugated packaging that works interchangeably with our line of reusable plastic containers, double and triple-wall boxes, bulk bins, water-resistant packaging, and high-graphics and pre-printed packaging for point-of-sale displays.

 

Our Color-Box subsidiary produces high quality litho-laminated packaging at eight specialty printing, coating and converting facilities. We believe that our Innovation Institute differentiates us from our competition. This unique facility is focused on collaborating with our customers to develop supply chain solutions that improve efficiencies and reduce costs.

 

Markets for our containerboard and packaging products are affected primarily by changes in industry capacity, the level of industrial activity in the United States, and export markets. In 2004, we sold $2.2 billion of packaging and $617 million of containerboard to third-party customers, representing 15% of total company sales. Containerboard exports totaled 340,000 tons in 2004, compared to 287,000 tons in 2003. In 2004, total exports were $133 million, or 5% of segment net sales.

 

Bleached Pulp and Paper

 

Our bleached pulp and paper segment produces office paper, bleached board, bleached and unbleached kraft paper, as well as pulp, at eight facilities in North America. The segment also includes a recycled fiber sourcing operation which purchases and resells waste fiber both for our use and for third-party customers. We have sold a large portion of our stand-alone pulp and office paper facilities in recent years. Our remaining paper machines

 

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are integrated into our tissue facilities and help absorb fixed costs. Our combined production capacity for office paper, bleached board and kraft papers is 2.0 million tons.

 

We produce primarily office papers sold in retail channels such as mass retailers and warehouse club stores, as well as in office supply, merchant and paper distributor channels. We are the largest supplier of branded office papers to the mass retailer and warehouse club store channels, and hold the leading dollar share of branded office papers used in the home. As we have shifted to higher value-added products, our bleached paper operations have focused on office paper that is sold primarily through many of the same retail channels that sell our consumer products, and much of this paper is shipped along with our tissue products in “mixed” truckloads from a single mill. We consider our ability to ship such mixed truckloads to be one of our competitive advantages as we continue to develop specific and unique supply chain solutions for our mass retailer customers.

 

Bleached Pulp and Paper

LOGO   LOGO

 

We manufacture approximately 600,000 tons of bleached paperboard annually for use in frozen food containers, food service items and other products. This business supplies a significant portion of its production capacity to our Dixie® business for manufacturing paper cups, plates and bowls. We also manufacture approximately 300,000 tons of bleached and unbleached kraft paper sold primarily to industrial users for conversion into multi-wall paper bags that are ultimately used to package a variety of consumer and commercial products. Our remaining market pulp manufacturing capacity consists of approximately 200,000 tons at our Old Town, Maine facility.

 

In 2004, pulp sales of $74 million were 5% of total segment sales to third party customers. In 2004, exports for the bleached pulp and paper segment were $119 million, or 5%, of segment sales. Markets for our bleached pulp and paper segment are affected primarily by levels of white-collar employment and economic growth, industry production capacity and inventory levels, and fluctuations in currency exchange rates.

 

Our Harmon Associates subsidiary is responsible for buying and supplying recycled fiber to all of our tissue and containerboard facilities. Harmon is the largest recycler in the world without plant operations. The company purchased over 5 million tons of recycled fiber in 2004, and supplied 2 million tons of de-inked fiber to our tissue mills and 1.3 million tons of brown grade material to our containerboard mills.

 

The operating results from our 38.85% equity investment in Unisource, our former paper distribution business sold in 2002, are reported in the bleached pulp and paper segment.

 

Competition

 

Each of our operating segments participates in markets that are highly competitive. Because many of our competitors sell their products at prices lower than ours, we compete primarily on the basis of product quality

 

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and performance, product innovation, supply chain efficiencies, value, brand strength (including brand recognition and loyalty) and advertising.

 

In our consumer products markets, we compete primarily against The Procter & Gamble Company, Kimberly-Clark Corporation, and Svenska Cellulosa Aktiebolaget (SCA), both in North America and in Europe. Competition in these markets is intense. The pricing elements and methods of competition include brand recognition and loyalty, product innovation, quality and performance, price and marketing and distribution capabilities. In our building products business, where competition for commodity products is based primarily on price, quality and performance, and distribution capabilities, Louisiana-Pacific Corporation, Weyerhaeuser, U.S. Gypsum Corporation and National Gypsum Corporation are our primary competitors. In packaging, International Paper Company, Weyerhaeuser, Smurfit-Stone Container Corporation, Temple-Inland, and Packaging Corporation of America are our key competitors, while our competition in the bleached pulp and paper segment includes International Paper, Weyerhaeuser, Boise Cascade, LLC, MeadWestvaco and Domtar Inc.

 

Significant Customers

 

We consider major mass retailers, warehouse club stores and supermarket chains in both North America and Europe to be significant customers for several of our operating segments. We have developed specific and unique approaches to working with these customers, which include Wal-Mart Stores Inc., Costco Wholesale Corp., Sam’s Wholesale, Carrefour SA, The Home Depot, Inc., Lowe’s Companies Inc., Royal Ahold N.V., Target Corp., Sysco Corp., Kroger Co., Unisource, US Foodservice and Staples Inc. We face strong competition for the business of these significant customers.

 

No single customer accounts for more than 10% of our consolidated revenue. We believe our relationships with our key customers are good. Nevertheless, if any one of our significant customers reduces, delays or cancels substantial orders for any reason, our business and results of operations could be negatively affected, particularly for the quarter in which the delay or cancellation occurs.

 

We generally do not have long-term sales agreements or other contractual assurances as to future sales to any of our major customers. In addition, continued consolidation in the retail industry has resulted in an increasingly concentrated retail base. To the extent such concentration continues to occur, our net sales and operating income may be increasingly sensitive to deterioration in the financial condition of, or other adverse developments involving our relationship with, one or more customers. Another result of consolidation in the retail industry is that our customers are able to exercise more leverage on us with respect to pricing and payment terms.

 

Environment

 

Information pertaining to environmental issues and our expenditures for pollution control facilities and equipment is set forth under the captions “Management’s Discussion and Analysis of Financial Condition and Results of Operations—Environmental Matters,” “Management’s Discussion and Analysis of Financial Condition and Results of Operations—Liquidity and Capital Resources—Investing Activities” and Note 17 of the Notes to Consolidated Financial Statements, which are included under Items 7 and 8 of this Form 10-K.

 

Employees

 

We employ approximately 55,000 people. Approximately 22,000 of our employees in the United States and Canada are members of unions. We consider our relationship with our employees to be good. During 2005, 23 union contracts will be subject to negotiation and renewal, including five at large facilities.

 

Raw Materials

 

Most of our products are made of solid wood, virgin and recycled wood fiber, or wood by-products. We purchase the majority of these raw materials from timber owners, independent log merchants and brokers, and

 

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recycled fiber brokers. No single supplier supplies more than 10% of our timber requirements. During 2004, Plum Creek Timber Company, Inc. supplied 6% of our overall timber requirements under the terms of a timber supply agreement. We purchase our remaining timber requirements from third-party landowners in the open market. Because of our reliance on timber supplies in the southeastern United States, our building products business was negatively impacted by constrained supplies of timber due to heavy rainfall in this area during the fourth quarter of 2004.

 

Every year, Georgia-Pacific uses millions of tons of recycled fiber to make products ranging from boxes to paper towels and tissue, which is supplied by our Harmon Associates subsidiary.

 

Information pertaining to our gypsum reserves is set forth under the captions “Building Products Manufacturing—Gypsum Products” in this item.

 

Research and Development

 

We perform research into tissue papermaking, tableware manufacturing and tissue and towel dispensing technology in order to develop improved consumer products for the North America and Europe markets. This research and product development is conducted at technical centers in Neenah, Wisconsin, and Kunheim, France. These centers have developed critical new papermaking and converting techniques that have allowed us to improve or expand our product lines, improve fiber efficiency and reduce raw material costs.

 

We also have a research facility located in Decatur, Georgia where we perform research into adhesives for composite wood products, binders for non-wood industrial applications, performance paper chemicals and pine chemicals. The Gypsum Division’s technical center is also in Decatur, Georgia, developing and supporting our specialty gypsum products. In addition, we have central technology services in support of wood products manufacturing.

 

Research and development costs are expensed as incurred and totaled $61 million, $64 million and $65 million in 2004, 2003 and 2002, respectively.

 

Patents, Copyrights, Licenses, Trade Secrets and Trademarks

 

We own or license a broad range of technology protected by patents, copyrights, and trade secrets, and maintain a substantial body of know-how (herein collectively referred to as “technology”) relating to our products and the processes for their production, the packages used for our products, and the design and operation of various processes and equipment used in our businesses. We also own or license a wide range of manufacturing, quality assurance and financial software. The methods for manufacturing and processing our products are among our important trade secrets.

 

We also own numerous trademarks, which are important to our business, especially our consumer products businesses. Depending upon the jurisdiction, trademarks are valid as long as they are in use and they have not become generic. We have licensed the right to use certain of our trademarks to third parties in conjunction with selected products we do not manufacture. In part, our success can be attributed to the existence of our trademarks.

 

Additional Information

 

Additional information pertaining to our businesses, including operating segments, is set forth under the caption “Management’s Discussion and Analysis of Financial Condition and Results of Operations—Results of Operations and Related Information” under Item 7 of this Form 10-K and in Supplemental Information under the caption “Georgia-Pacific Corporation and Subsidiaries—Sales and Operating Profit by Operating Segment” and in Note 3 of the Notes to Consolidated Financial Statements, which are included under Item 8 of this Form 10-K.

 

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Our reports on Form 10-K, along with all other reports and amendments filed with or furnished to the SEC, are publicly available free of charge on the Investor Information section of our Internet website, at www.gp.com. The information contained on or connected to our Internet website is not incorporated by reference into this Form 10-K and should not be considered part of this or any other report that we file with or furnish to the SEC. Shareholders may also contact Investor Relations, Georgia-Pacific Corporation, 133 Peachtree Street, N.E., Atlanta, Georgia 30303 or telephone (800) 654-2582 to obtain a copy of any of these reports without charge.

 

Factors That May Affect Future Results

 

Some of the matters discussed in this Form 10-K concerning, among other things, our business outlook, anticipated financial and operating results, strategies and contingencies, constitute forward-looking statements and are based upon our expectations and beliefs concerning future events. There can be no assurance that these events will occur or that our results will be as estimated. Please see “Management’s Discussion and Analysis of Financial Condition and Results of Operations—Factors That May Affect Future Results” under Item 7 of this Form 10-K for a more detailed discussion of the factors and additional considerations that may affect our future results.

 

ITEM 2.    PROPERTIES

 

The geographic location and capacity of our manufacturing facilities by segment is set forth on Exhibit 99.1 to this Form 10-K, which is incorporated herein by this reference.

 

Our manufacturing and support facilities are designed according to the requirements of the products to be manufactured. Therefore, the type of construction varies from facility to facility. We believe that our manufacturing facilities are well-maintained and generally adequate for current operations.

 

Utilization of a particular facility varies based upon demand for the product. We have included the estimated capacity of our principal facilities in Exhibit 99.1, which is incorporated herein this reference.

 

We generally own our manufacturing and other facilities, although warehouse and office facilities are often leased. We examine alternatives for our higher cost facilities, including modernizing, replacing or closing such facilities. We continually review many business opportunities and alternatives, including possible acquisitions or sales of properties.

 

Information concerning our mineral resources is presented under Item 1 of this Form 10-K.

 

ITEM 3.    LEGAL PROCEEDINGS

 

Information pertaining to material legal proceedings in which we are involved is set forth in Note 17 of the Notes to Consolidated Financial Statements, which are included under Item 8 of this Form 10-K and are incorporated herein by this reference.

 

ITEM 4.    SUBMISSION OF MATTERS TO A VOTE OF SECURITY HOLDERS

 

Not applicable.

 

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PART II

 

ITEM 5. MARKET FOR REGISTRANT’S COMMON EQUITY AND RELATED STOCKHOLDER MATTERS AND ISSUER PURCHASES OF EQUITY SECURITIES

 

Georgia-Pacific common stock is listed on the New York Stock Exchange and trades under the symbol GP. As of the close of business on February 23, 2005, the closing stock price of one share of Georgia-Pacific common stock was $34.75 and there were approximately 35,868 record holders of such stock.

 

The information with respect to historical dividend and market price data in Note 19 of the Notes to Consolidated Financial Statements and in “Selected Financial Data—Financial Position, End of Year” that follows Note 20 of the Notes to Consolidated Financial Statements, included in Item 8 of this Form 10-K, are incorporated herein by this reference.

 

On February 3, 2005, we announced that our Board of Directors increased our quarterly cash dividend by 40% to 17.5 cents per share from 12.5 cents per share. The increased dividend is equal to an annual rate of 70 cents per share compared with the previous annual rate of 50 cents per share. We expect to continue to pay quarterly dividends.

 

Information related to our equity compensation plans is incorporated herein by reference to our 2005 Proxy Statement, which will be filed with the Securities and Exchange Commission within 120 days of the end of our fiscal year.

 

ITEM 6. SELECTED FINANCIAL DATA

 

Selected Financial Data information is set forth under the captions “Georgia-Pacific Corporation and Subsidiaries—Supplemental Information—Selected Financial Data—Operations” and “Georgia-Pacific Corporation and Subsidiaries—Supplemental Information—Selected Financial Data—Financial Position, End of Year,” which follow Note 20 of the Notes to Consolidated Financial Statements, and is incorporated herein by this reference.

 

ITEM 7. MANAGEMENT’S DISCUSSION AND ANALYSIS OF FINANCIAL CONDITION AND RESULTS OF OPERATIONS

 

The purpose of the following discussion is to provide investors with enhanced financial disclosure and provide the context within which our financial statements should be analyzed. Accordingly, our intent in this section is to provide investors with an understanding of our past performance and financial condition by focusing on changes in a number of key areas from year to year. Additionally, we discuss our prospects and strategies for the future and provide insights into our critical accounting estimates.

 

Executive Overview

 

We are one of the world’s leading manufacturers and marketers of tissue, packaging, paper, building products, and related chemicals. With 2004 sales of $19.7 billion, we employ approximately 55,000 people at more than 300 locations in North and South America and Europe. Our operations break down into four principal businesses:

 

    Consumer Products.    Our consumer products business is the world’s second largest manufacturer of retail and commercial tissue products. We rank first in North America and are a leading manufacturer in Europe. We also manufacture and market our Dixie® line of disposable tabletop products such as cups, plates, and cutlery for sale throughout North America;

 

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    Building Products.    We are a leading producer of building products in the United States, with a portfolio of traditional and technologically advanced products, such as our leading moisture and mildew-resistant exterior sheathing, DensGlass Gold®, and our Plytanium® structural wood panels;

 

    Packaging.    We believe our packaging business, which is built around some of the lowest cost containerboard mills in the United States, yields us the highest return on assets and sales in this industry; and

 

    Paper.    Our office paper brands are sold through retailers throughout the United States. We are the largest supplier of office paper to the warehouse club and mass retailer channels, and the fifth-largest office paper producer in North America.

 

As the following chart illustrates, two of our businesses—consumer products and building products—largely drive our operations. The chart excludes the net sales from our building products distribution segment, which we sold in May 2004. Sales to third-party customers during 2004 and 2003 include $550 million and $1.2 billion, respectively, in sales from our building products manufacturing segment to the building products distribution segment.

 

Third-Party Sales by Principal Business

 

LOGO   LOGO

 

Our four principal businesses are reported in six operating segments:

 

    North America Consumer Products;

 

    International Consumer Products;

 

    Building Products Manufacturing;

 

    Packaging;

 

    Bleached Pulp and Paper; and

 

    Building Products Distribution, which was sold in May 2004.

 

Since our acquisition of Fort James in late 2000, our principal goal has been to reduce our debt from its peak of approximately $16 billion. By the end of 2004, we had reduced our debt to $8.7 billion. We believe our debt reduction is a significant achievement given the difficult economic environment in which a number of our businesses, particularly our consumer products business, have been operating over the last several years. During 2004, we sold several non-strategic businesses and assets, including our building products distribution business, our market pulp mills in Brunswick, Georgia, and New Augusta, Mississippi and our interests in a Brazilian pulp business. Proceeds from these sales were used to reduce our debt. Although we believe our most significant asset sales have now been completed, we will continue to divest smaller, non-strategic businesses and assets that are not providing sufficient returns on our investment.

 

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A key strategic emphasis has been improving our consumer products business, especially our branded tissue and towel portfolio. Since our acquisition of Fort James in 2000, we have worked to differentiate our premium brands through product improvements and new advertising, while also capturing higher revenue. In 2004, we significantly improved our two flagship brands, Brawny® paper towels and Quilted Northern® bath tissue, and successfully completed their re-launch in the marketplace.

 

One of our most innovative concepts for the commercial tissue market, our patented enMotion® touchless towel-dispensing technology, was developed in response to heightened concerns about hygiene in public places. Used primarily by hospitals, foodservice customers, and in other high-traffic public spaces, enMotion® dispensers help to lower waste and reduce maintenance expense. Launched first in the United States, and then in the Netherlands and other European countries, enMotion® has been enjoying significant growth since its launch in late 2002. It clearly has been one of the drivers of our proprietary dispensing strategy. Innovation also has been driving our Dixie® brand. Dixie® continues to be the fastest-growing cup and plate brand in the United States, largely as a result of innovations such as the performance upgrade of our heavy duty plate line and continued expansion of our patented PerfecTouch® cup line. In 2005 and beyond, we must continue making these types of successful innovations throughout our consumer products business.

 

In our building products business, we will continue with a similar strategy of product differentiation. As in 2004, we will continue to focus our building products business on specialty and value-added products. Furthermore, we will continue to capitalize on the increasing trend toward do-it-yourself building and remodeling through our solid relationships with the fastest-growing retail home improvement centers in the United States. The emergence of these mass retailers is a profound change in the building products business and, because over one third of our sales of building products are sold through them, continuing to focus on this channel is a critical component of our future success. We continue to target this channel in order to attract consumers to our premium branded Plytanium® plywood. As our own surveys have indicated, when given the choice, more than 70% of consumers prefer plywood over oriented strand board panels.

 

Our packaging segment is focused on selling packaging solutions that are applicable across the entire supply chain from consumer products manufacturers, through distributors and retailers, to customers. One of the services we provide is the Packaging Systems Optimization (PSO) audit. We use PSO to identify and implement cost savings for our customers. We take a total cost perspective and look beyond the package to include all the processes that packaging touches. By doing this, we are able to develop solutions that lower total system cost, not just shift cost from one member of the supply chain to another. Our process is collaborative with our customers and their customers—the retailers.

 

A number of factors can affect our businesses, including the effectiveness of our operating initiatives, our relationship with several significant customers, and changes in global and local business and economic conditions. These and other risks are noted in the section entitled “Factors That May Affect Future Results” at the end of this discussion and analysis.

 

Industry Conditions

 

In addition to our strategic initiatives, the primary issues that will affect us going forward are general economic and operating conditions in the United States and Europe and the levels of supply and demand in the paper and forest product industry. All of our businesses have experienced, and continue to experience, inflationary cost pressures for raw materials and energy costs.

 

Most of our businesses experienced weak industry conditions during 2002 and the first half of 2003. Industry production capacity generally exceeded demand, resulting in cyclically low prices and declining operating results for our consumer products, packaging, and bleached pulp and paper businesses. We shut down a number of facilities and machines in an effort to maximize the efficiency of our manufacturing and logistics systems, resulting in asset impairment charges and severance costs, which are more specifically discussed in the following segment discussions and in the Notes to Consolidated Financial Statements.

 

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Industry conditions were stronger during the second half of 2003 and throughout 2004. In our building products manufacturing segment, results were driven by very strong demand for building materials and low industry inventories. This positive momentum continued throughout most of 2004 as residential housing starts maintained high levels. Plywood and oriented strand board prices fell sharply in the fourth quarter as we experienced our normal seasonal slowdown, though they have since recovered. We believe housing starts will remain high in the near-term, primarily because mortgage rates are likely to remain historically low, and U.S. immigration trends for the next several years indicate continued growth in new housing starts. We believe that any decline in residential building would be partially offset by commercial and industrial sector gains as the economy improves.

 

During 2004, particularly in the second half of the year, market conditions improved for our consumer products businesses in North America, as well as our bleached pulp and paper and packaging businesses, driven by improving economic and employment conditions in the United States. Market conditions in Europe remained sluggish during 2004, as we continued to experience declining prices in local currencies coupled with flat sales volumes.

 

Asbestos

 

We, and many other companies, are defendants in suits brought in various courts around the nation by plaintiffs who allege that they have suffered personal injury as a result of exposure to asbestos-containing products. Our asbestos liabilities relate primarily to joint systems products manufactured by Bestwall Gypsum Company and our gypsum business that contained small amounts of asbestos fiber. We acquired Bestwall in 1965, and discontinued using asbestos in the manufacture of these products in 1977. These suits allege a variety of lung and other diseases based on alleged exposure to our products. In many cases, the plaintiffs are unable to demonstrate that they have suffered any compensable loss as a result of such exposure, or that any injuries they have incurred did in fact result from exposure to our products. Virtually all asbestos suits involve multiple claimants seeking money damages from multiple defendants. Historically, the vast majority of claims against us have been resolved either by settlement or a dismissal, rather than by jury verdicts.

 

Beginning in 2001, and again at the end of 2002, 2003, and 2004, we retained National Economic Research Associates (“NERA”), nationally recognized consultants in projecting asbestos liabilities, and Navigant Consulting, nationally recognized consultants in insurance allocation analysis, to work with us to estimate the amounts, net of insurance, that we would pay for our asbestos-related liabilities and defense costs for the following ten-year periods. NERA has reviewed our asbestos indemnity payments and claims activity in 2004 and compared them to the forecast NERA prepared in 2002 of our total asbestos liabilities for 2003 through 2012 and subsequently extended in 2003 though 2013. Based on this review, NERA has determined that our indemnity payments in 2004 are in line with its 2002 forecast. NERA has concluded, as it did at the end of 2003, that the assumptions used in its 2002 forecast to estimate our future asbestos indemnity payments remain valid, and that no changes to the underlying forecast are necessary with respect to that portion of our total liability, other than extending it through 2014. NERA also advised that there is a reasonable basis for estimating that $48 million be added to our reserves to cover estimated indemnity payments in 2014 so that our total reserves cover the next ten years.

 

Beginning in late 2003 and continuing throughout 2004, we significantly increased our spending to defend asbestos claims because the number of new mesothelioma claims being filed against us increased, and because plaintiffs’ lawyers made higher settlement demands in these cases. During 2004, we developed additional affirmative defenses, conducted more extensive discovery into the medical condition of plaintiffs and their allegations that our products caused such conditions, and significantly increased the number of cases we took to trial. We anticipate that our future defense spending will be significantly more than previously estimated as we respond to plaintiffs’ settlement demands. Accordingly, we worked with NERA to develop a revised projection of our defense costs based on our historical defense spending. At the end of 2004, with NERA’s concurrence, we added $109 million to our overall asbestos reserve for additional defense costs through 2014.

 

 

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During 2004, we reduced our asbestos insurance receivable by $2 million to reflect the insolvencies of two small insurers, largely offset by a settlement with another insurer that was more favorable than expected. Cash receipts in 2004 were significantly lower than in 2003, since we are currently drawing on a layer of excess insurance where there are significant insolvencies. In addition, the $156 million of insurance receivables we sold in 2003 covered certain payments that would have been received during 2004 and 2005. Although insurance receipts will remain low during 2005 for the same reasons, beginning in 2006 and continuing through 2008 they are expected to increase significantly, and should substantially offset amounts we forecast spending for indemnity and defense costs in those years. All of our available insurance is included in an insurance receivable.

 

Several events have occurred over the past year in the area of asbestos and tort reform legislation that we believe could potentially have a positive effect on the amount of asbestos claims we pay in the future. A bill to establish a trust fund to pay pending and future asbestos-related disease claims, and remove such cases from federal and state courts, was extensively negotiated by the leadership of both political parties in the United States Senate during 2004, although no vote on the legislation occurred before the elections. A similar bill is expected to be introduced in the Senate early in 2005. Tort reform legislation was enacted in several states during 2004, as it had been in other states in 2003. Generally, such legislation has significantly reduced the number of non-malignant claims being filed against us, and has also required plaintiffs to show that they reside, or were injured, in the jurisdiction in which they bring claims.

 

For further information regarding our asbestos matters, see Note 17 of the Notes to Consolidated Financial Statements, which information is incorporated by reference.

 

Overview of 2004 Results

 

Cash flow and liquidity continue to be strong.

 

    Cash flow from operations was $1,474 million.

 

    Proceeds from the sale of assets were $1,507 million.

 

    Total debt was reduced by $1,953 million.

 

    We entered into a new $2,500 million five-year, senior unsecured credit facility, which matures in 2009. This replaces a $2,250 million credit facility, which was scheduled to mature in November 2005.

 

Net sales were up in each of our business operating segments.

 

    After adjusting for the sale of our building products distribution segment, net sales increased by $1,757 million, or 11%, over 2003.

 

    Selling prices and volumes for building products we manufacture were significantly higher due to exceptionally strong demand.

 

Operating profit and income from continuing operations increased.

 

    Operating profit increased from $1,252 million to $1,624 million, an increase of 30%.

 

    Income from continuing operations increased from $324 million to $626 million, an increase of 93%.

 

    Raw materials and energy inflation increased our operating costs approximately $300 million during 2004.

 

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The following chart shows the change in operating profit by segment.

 

LOGO

 

Our fiscal year ends on the Saturday closest to December 31. Typically our fiscal year consists of 52 weeks ending on Saturday. However, because our 2003 fiscal year ended on January 3, 2004, our 2003 fiscal year consisted of 53 weeks.

 

Liquidity and Capital Resources

 

We believe it is important to manage our debt and equity to keep our weighted average cost of capital low while retaining the flexibility needed to ensure that we can meet our financial obligations and finance capital spending and attractive business opportunities. We continuously review the appropriate level of debt to employ in our capital structure so that we have the necessary flexibility to finance future growth. Historically, we set debt targets based on our ability to generate cash under various business scenarios.

 

We maintain a high portion of our debt as long-term at fixed interest rates. We intend to manage the maturities of our long-term debt (excluding bank debt) so that generally no more than $500 million matures in any one year and, if it does, so that the sum of the maturities in any two consecutive years does not significantly exceed $1 billion. Our current maturities are in substantial compliance with these guidelines. Generally, we seek to have 75% of our aggregate debt at fixed rates so as to minimize exposure to fluctuating interest rates. Currently, approximately 77% of our aggregate debt is at fixed rates.

 

Short-term debt is generally used to fund seasonal working capital needs. We utilize bank credit for temporary short- to intermediate-term financing, and to bridge known or expected events. Additionally, we maintain committed, available borrowing capacity to allow for seasonal, timing or unexpected needs.

 

We are focused on reducing the amount of debt that we carry and minimizing the interest costs on that debt. During 2004, our total debt level was reduced by $1,953 million using proceeds from asset sales and operating cash flows. We expect our cash flow from operations and financing activities will be sufficient to fund planned capital investments, pay dividends and make scheduled debt repayments for the foreseeable future. The following discussion provides further details of our liquidity and capital resources.

 

Operating Activities

 

In 2004, we generated cash from operations of $1,474 million compared to $1,792 million a year ago. Cash flow from operations in 2004 was impacted by $250 million of normal working capital buildup in our building

 

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products distribution business prior to its sale and a $100 million increase in pension-related payments. During 2003, cash from operations included a $354 million income tax refund.

 

Investing Activities

 

Capital expenditures for property, plant and equipment for 2004 were $713 million, compared to $710 million in 2003. Our capital spending for 2005 is expected to be approximately $820 million and will be funded primarily by cash flows from operations. This includes a new oriented strand board facility in Hosford, Florida, which is expected to begin operating in the first half of 2005. Other major projects for 2005 include the installation of a boiler and a turbine generator at our Port Hudson, Louisiana facility and the installation of wastewater treatment equipment at our Palatka, Florida facility. The following charts show our capital expenditures by business operating segment.

 

LOGO

 

On April 15, 1998, the United States Environmental Protection Agency (“EPA”) promulgated a set of regulations known as the “Cluster Rule” that established new requirements for air emissions and wastewater discharges from pulp and paper mills. The Cluster Rule requires pulp and paper mills to eliminate elemental chlorine in the pulp bleaching process. The Cluster Rule imposes Maximum Achievable Control Technology, or MACT, regulations, with MACT I regulations covering pulping and bleaching and MACT II regulations covering combustion sources. We estimated that we would make capital expenditures of up to approximately $534 million through April 2007 in order to comply with the Cluster Rule’s requirements. Of that total, approximately $428 million was spent through 2004, including $43 million in 2004, and an additional $95 million is expected to be spent in 2005. The work performed in 2004 was a combination of MACT II requirements and installation of several systems for the second part of MACT I. The remainder of that total will be spent on requirements under MACT II at Big Island, Virginia and the second part of the MACT I regulations (to be completed in 2006 and 2007).

 

In February 2004, the EPA finalized two new MACT requirements that establish air emission limits for plywood and composite panel facilities (“PCWP MACT”) and for certain boilers at both wood products and pulp and paper facilities (“Boiler MACT”). Compliance with these standards will be required by mid-2007. We currently estimate compliance costs for the PCWP MACT standard to be approximately $80 million at 19 plants, and for the Boiler MACT standard to be approximately $50 million on 40 boilers at various manufacturing locations.

 

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During 2004, we sold our building products distribution segment, our stand-alone market pulp mills in Brunswick, Georgia, and New Augusta, Mississippi, along with a short-line railroad, our interest in a Brazilian pulp business, and four hardwood lumber mills, as well as several non-strategic packaging assets and an aircraft. The table below shows the financial impacts of these and other asset sales during 2004:

 

In millions    Proceeds   

Pre-tax gain

included in
other income

  

Pre-tax gain
included in

discontinued
operations

  

Debt assumed by

purchaser

Building products distribution segment

   $ 808    $ 20    $     –      $     –  

Non-integrated pulp mills

     520      –        6      73

Brazilian pulp business

     70      24      –        –  

Packaging assets

     46      30      –        –  

Other

     63      5      –        –  

Total

   $ 1,507    $ 79    $ 6    $ 73

 

During the second quarter of 2004, we purchased packaging facilities in Ontario, California and Harrington, Delaware for approximately $21 million.

 

Financing Activities

 

Our debt decreased by $1,953 million to $8,695 million at January 1, 2005 from $10,648 million at January 3, 2004. This decrease includes the effect of changes in foreign currency exchange rates of $8 million. For 2004, the weighted average interest rate on our total debt, including outstanding interest rate exchange agreements, was 7.0%. The following table details changes in our short and long-term debt balances during 2004:

 

In millions    Short-term     Long-term(1)     Total  

Beginning balances:

   $ 689     $ 9,959     $ 10,648  

Maturities:

                        

Eurobond

     –         (363 )     (363 )

Industrial revenue bonds

     –         (30 )     (30 )

Money markets

     (400 )     –         (400 )

Notes

     –         (336 )     (336 )

Assumed by buyer

     –         (73 )     (73 )

Repayments(2)

     (1,302 )     (6,039 )     (7,341 )

Borrowings(2)

     1,581       5,050       6,631  

Other:

                        

Amortization of debt discount

     –         (33 )     (33 )

Effect of foreign currency exchange rates

     –         (8 )     (8 )


Ending balance

   $ 568     $ 8,127     $ 8,695  


(1)   Includes current portion of long-term debt.
(2)   Includes repayments and re-borrowings under our senior credit facility of $4,485 million and $4,940 million, respectively.

 

For a detailed discussion of our debt position and the financing activities, see Note 9 of the Notes to Consolidated Financial Statements.

 

Our borrowing arrangements contain a number of financial and non-financial covenants. The more significant financial covenants are discussed in Note 9 of the Notes to Consolidated Financial Statements. In addition, certain agreements contain cross-default provisions. Our continued compliance with these covenants is dependent on a number of factors, many of which are outside of our control. Should events occur that result in noncompliance, we believe there are remedies available that are acceptable to our lenders and us.

 

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On July 2, 2004, we entered into a new $2.5 billion, five-year, senior unsecured credit facility that includes a $500 million non-amortizing term loan. This new credit facility matures July 2, 2009 and replaces a $2.25 billion, five-year credit facility that would have matured November 3, 2005. Amounts outstanding under this facility include the following:

 

In millions    January 1,
2005
 

Commitments:

        

Revolving loans

   $ 2,000  

Term loans

     500  


Credit facilities available

     2,500  


Amounts Committed and Outstanding:

        

Letter of credit agreements(1)

     (606 )

Revolving loans due July 2009, average rate of 3.1%

     (205 )

Term loans due July 2009, average rate of 3.5%

     (500 )


Total committed and outstanding

     (1,311 )


Total credit available

   $ 1,189  


(1)   The letter of credit agreements include only standby letters of credit issued pursuant to the senior credit facility.

 

As of January 1, 2005, we had $1.5 billion of debt and equity securities available for issuance under a shelf registration statement filed with the Securities and Exchange Commission.

 

The following table presents principal (or notional) amounts and related weighted average interest rates by year of expected maturity for our debt obligations and interest rate exchange agreements as of January 1, 2005.

 

In millions, except percentages       2005             2006             2007             2008             2009         Thereafter         Total        

Fair Value

January 1,

2005

 

Secured borrowings and short-term notes

  $ 568       –         –         –         –         –       $ 568     $ 568  

Average interest rates

    2.8 %     –         –         –         –         –         2.8 %     2.8 %

Credit facilities

    –         –         –         –       $ 705       –       $ 705     $ 705  

Average interest rates

    –         –         –         –         3.4 %     –         3.4 %     3.4 %

Notes and debentures

    –       $ 605     $ 300     $ 350       –       $ 5,069     $ 6,324     $ 7,179  

Average interest rates

    –         7.4 %     6.9 %     7.4 %     –         8.4 %     8.2 %     5.4 %

Revenue bonds

  $ 21     $ 1     $ 29     $ 21     $ 9     $ 704     $ 785     $ 773  

Average interest rates

    5.6 %     5.7 %     4.9 %     5.0 %     5.8 %     5.3 %     5.3 %     4.8 %

Capital leases

  $ 16     $ 17     $ 20     $ 25     $ 25     $ 189     $ 292     $ 345  

Average interest rates

    8.8 %     13.8 %     7.1 %     6.9 %     7.1 %     6.8 %     8.4 %     5.5 %

European debt

  $ 10     $ 7     $ 4     $ 3     $ 4     $ 16     $ 44     $ 44  

Average interest rates

    4.5 %     4.7 %     3.9 %     3.8 %     3.9 %     2.9 %     3.7 %     3.9 %

Other loans

  $ 10       –         –         –         –         –       $ 10     $ 10  

Average interest rates

    3.1 %     –         –         –         –         –         3.1 %     3.1 %


       

Debt subtotal

  $ 625     $ 630     $ 353     $ 399     $ 743     $ 5,978     $ 8,728          


               

Less: unamortized debt discount

                                                    (33 )        
                                                   


       

Total debt balance

                                                  $ 8,695          
                                                   


       

Notional amount of interest rate exchange agreements (fixed to floating)

  $ –       $ –       $ 75     $ 125     $ –       $ 300     $ 500     $ (6 )

Notional amount of interest rate exchange agreements (rate collar)

  $ 47     $ –       $ –       $ –       $ –       $ –       $ 47     $ 1  

Average interest rate cap

    7.5 %     –         –         –         –         –         7.5 %     7.5 %

Average interest rate floor

    5.5 %     –         –         –         –         –         5.5 %     5.5 %

 

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Index to Financial Statements

For obligations with variable interest rates, the preceding table sets forth payout amounts based on weighted average rates as of January 1, 2005, and does not attempt to project future interest rates. Approximately $109 million of our revenue bonds are supported by letters of credit that expire within one year. We have the intent and the ability to renew these letters of credit annually. Therefore, maturities of these obligations are reflected above in accordance with their stated terms.

 

The following table details activity in our debt ratings during 2004:

 

Rating Agency   Current Rating   Prior Rating   Date of Change

Standard & Poor’s:

           

Long-term debt

  BB+ (stable)   BB+ (negative)   May 4, 2004

Moody’s Investor Services:

           

Liquidity rating

  SGL-2 (good)   SGL-3 (adequate)   July 14, 2004

Senior implied and guaranteed debt

  Ba2 (positive)   Ba2 (stable)   December 16, 2004

Georgia-Pacific senior unsecured notes

  Ba3 (positive)   Ba3 (stable)   December 16, 2004

Georgia-Pacific debt guaranteed by Fort James

  Ba2 (positive)   Ba2 (stable)   December 16, 2004

Fitch Ratings:

           

Senior unsecured long-term debt

  BB+ (stable)   BB (negative)   April 27, 2004

 

In 2004, we redeemed the following debentures:

 

Face Amount (in millions)    Coupon     Date Redeemed    Maturity Date

$243

   9.875 %   February 27, 2004    November 1, 2021

  250

   9.625 %   March 31, 2004    March 15, 2022

  250

   9.500 %   April 20, 2004    May 15, 2022

  240

   9.125 %   May 6, 2004    July 1, 2022

  250

   8.250 %   October 28, 2004    March 1, 2023

  250

   8.125 %   October 28, 2004    June 15, 2023

 

During 2004, we recorded a pretax charge of $76 million for call premium fees and to write off deferred debt issuance costs due to early extinguishment of debt including prior credit facility fees.

 

Dividends

 

During 2004 and 2003, we paid dividends totaling $129 million and $126 million, respectively. On February 3, 2005, we announced that our Board of Directors increased our quarterly cash dividend by 40 percent to 17.5 cents per share from 12.5 cents per share. The increased dividend is equal to an annual rate of 70 cents per share compared with the previous annual rate of 50 cents per share.

 

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Index to Financial Statements

Contractual Obligations

 

The following table presents commitment amounts by year of expected expiration for our total debt, standby letter of credit agreements, operating leases, purchase obligations, and other long-term liabilities.

 

In millions    2005    2006    2007    2008    2009    Thereafter    Total

Total debt from above(1)

   $ 625    $ 630    $ 353    $ 399    $ 743    $ 5,978    $ 8,728

Standby letters of credit(2)

     –        –        –        –        –        19      19

Operating leases

     79      73      58      54      46      405      715

Purchase obligations:(3)

                                                

Operating

     380      259      227      207      161      273      1,507

Capital spending

     101      3      –        –        2      13      119

Other long-term liabilities(4)

     332      391      280      281      489      525      2,298

Total

   $ 1,517    $ 1,356    $ 918    $ 941    $ 1,441    $ 7,213    $ 13,386


(1)   Balance excludes unamortized debt discounts of $33 million.
(2)   Standby letters of credit that are not included above under the credit facilities. Because of our intent and ability to renew the standby letters of credit as they mature, they have been presented with no definitive maturity date.
(3)   The majority of our purchase obligations are take-or-pay contracts made in the ordinary course of business related to raw material purchases and utilities contracts. Other significant items included in the above table reflect purchase obligations related to advertising agreements and legally binding commitments for capital projects. Purchase orders made in the ordinary course of business are excluded from the above table. Any amounts for which we are liable under purchase orders are reflected in our consolidated balance sheet as accounts payable and accrued liabilities.
(4)   Other long-term liabilities are liabilities reflected in our consolidated balance sheets that have known payment streams. Payments include: workers’ compensation reported case reserves; environmental cases where we have received a decree with scheduled payments from the regulating agency; legal liabilities that have been settled or where a judgment has been issued; premium payments associated with self-insurance and postretirement benefits; and pension contributions and asset retirement obligations. Amounts also include notes payable from monetizations of notes receivable.

 

Off-Balance Sheet and Other Arrangements

 

We currently do not have any non-consolidated special purpose arrangements.

 

Guarantees and Indemnifications

 

We are a party to contracts in which we agree to indemnify third parties for certain liabilities that arise out of or relate to the subject matter of the contract. In some cases, this indemnity extends to related liabilities arising from the negligence of the indemnified parties, but usually excludes any liabilities caused by gross negligence or willful misconduct. We cannot estimate the potential amount of future payments under these indemnities until events arise that would trigger a liability under the indemnities.

 

Additionally, in connection with the sale of assets and the divestiture of businesses, we typically agree to indemnify the buyer of the assets and related parties for certain losses or liabilities incurred by the buyer with respect to (i) the representations and warranties made by us to the buyer in connection with the sale and (ii) the pre-closing operations of the assets sold. Indemnities related to pre-closing operations generally include environmental liabilities, tax liabilities, and other liabilities not assumed by the buyer in the transactions. See Note 17 of the Notes to Consolidated Financial Statements for a discussion of these indemnities.

 

Other Financing Arrangements

 

We have an accounts receivable secured borrowing program. G-P Receivables, our wholly-owned subsidiary, is the special purpose entity into which the receivables of participating domestic subsidiaries are sold. G-P Receivables, in turn, sells an interest in the receivables to various banks and entities. This program is accounted for as a secured borrowing. The receivables outstanding under these programs and the corresponding debt are included as “Receivables” and “Secured borrowings and short-term notes,” respectively, in the accompanying consolidated balance sheets. Under the borrowing program, as collections reduce previously pledged interests, new receivables may be pledged. See Note 6 of the Notes to Consolidated Financial Statements.

 

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Index to Financial Statements

Prior to 1996, we sold certain operating assets to an unrelated third party for $354 million and agreed to lease the assets back from the purchaser/lessor over a period of 30 years. Under the agreement with the purchaser, we agreed to maintain a deposit (initially in the amount of $322 million) that, together with interest earned thereon, was expected to be sufficient to fund our lease obligation, including the repurchase of assets at the end of the term. This transaction was accounted for as a financing arrangement. At the inception of the agreement, we recorded an asset for the deposit from the sale of $305 million and a liability for the lease obligation of $346 million on our balance sheet. The subsequent sale of these assets to Domtar Inc. in 2001 required us to repurchase these assets from the lessor. Accordingly, we agreed with the lessor to a deferred payment arrangement essentially under the same terms as the original lease obligation. We agreed to maintain the original deposit under our existing terms and create a second deposit. The sum of these deposits (approximately $400 million at December 29, 2001) approximates the deferred payment amount. A legal right of set off exists between the deferred payment amount owed and the deposits and, accordingly, we have recorded these transactions net in the accompanying consolidated balance sheets as “Other long-term liabilities.”

 

In conjunction with the pre-2000 sales of timberlands located in California and Maine, we received notes from the purchasers totaling $718 million. The notes received from the California sales were monetized through the issuance of notes payable in a private placement and through the issuance of commercial paper. The notes received from the Maine sale (the “Maine Notes”) were monetized through the issuance of notes payable in a private placement. The proceeds from such monetizations were used to repay debt. Proceeds from the notes received from the purchasers are being used to fund payments required for the notes payable and commercial paper. The notes receivable are classified as “Other assets” and the notes payable are classified as “Other long-term liabilities” on the accompanying consolidated balance sheets. The Maine Notes were issued by G-P Maine, Inc., an indirect, wholly owned subsidiary of ours. It is a separate corporate entity from us, and its assets will be available first and foremost to satisfy the claims of its creditors.

 

Results of Operations and Related Information

 

In this section, we discuss and analyze our 2004 net sales, operating profit and other information relevant to an understanding of our 2004 results of operations. In this discussion and analysis, we compare our 2004 results to 2003, and our 2003 results to 2002.

 

Analysis of Net Sales By Business Segment—Three Years Ended January 1, 2005

 

     Fiscal Year Ended

 
In millions    2004     2003     2002  

Net sales:

                        

North America consumer products

   $ 5,656     $ 5,434     $ 5,455  

International consumer products

     2,072       1,941       1,663  

Packaging

     2,968       2,787       2,740  

Bleached pulp and paper

     2,230       2,053       1,962  

Paper distribution

     –         –         4,755  

Building products manufacturing

     6,892       5,885       5,165  

Building products distribution(1)

     1,886       4,266       3,737  

Other(2)

     (2,048 )     (2,710 )     (2,762 )


Total net sales

   $ 19,656     $ 19,656     $ 22,715  


(1)   Represents sales prior to the sale of the building products distribution segment on May 7, 2004.
(2)   Includes the elimination of intersegment sales.

 

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Index to Financial Statements

Comparison of 2004 to 2003:

 

In millions   

Change in

Net Sales

North America consumer products

   $ 222      4%

International consumer products

     131      7%

Packaging

     181      6%

Bleached pulp and paper

     177      9%

Building products manufacturing

     1,007      17%

Building products distribution

     (2,380 )    (56)%

Other

     662      24%

Consolidated

   $ –        –  %

 

Consolidated net sales were flat in 2004 compared to 2003. We sold our building products distribution business on May 7, 2004 and, therefore, our 2004 operating results for this segment represent four months of operations compared with a full year in 2003. Excluding the net sales by the building products distribution segment and treating our intrasegment sales to this segment as outside sales, consolidated net sales for 2004 from our ongoing operations increased approximately 11% compared to 2003.

 

    North America consumer products net sales increased 4% due primarily to an average price increase of approximately 5% throughout 2004 across all channels for retail tissue and Dixie products. Average prices for commercial products were flat. Volumes across all business lines remained relatively flat.

 

    International consumer products net sales increased 7% primarily due to a weaker U.S. dollar relative to the Euro, which benefited reported net sales by approximately $199 million. The positive effect of currency movements was partially offset by a 3% decrease in pricing in local currency. In contrast to the positive effect of currency movements, competitive market conditions in most countries caused our sales volumes to remain flat and put downward pressure on selling prices in local currencies.

 

    Packaging net sales increased 6% as a result of increased demand and higher pricing for all products. Sales volumes were up approximately 2% for containerboard and boxes.

 

    Bleached pulp and paper net sales increased 9% as a strengthening U.S. economy and a weaker U.S. dollar drove increased volumes and price improvements.

 

    Building products manufacturing net sales increased 17% due to higher average selling prices and volumes from exceptionally strong demand for building materials as a result of the strength in both residential and non-residential construction in 2004. In addition, we also experienced higher demand as a result of an active 2004 hurricane season.

 

    Other sales primarily represent the elimination of intersegment sales and some miscellaneous businesses.

 

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Index to Financial Statements

Comparison of 2003 to 2002:

 

In millions   

Change in

Net Sales

North America consumer products

   $ (21)      –  

International consumer products

     278      17%

Packaging

     47      2%

Paper distribution

     (4,755)      NM

Bleached pulp and paper

     91      5%

Building products manufacturing

     720      14%

Building products distribution

     529      14%

Other

     52      2%

Consolidated

   $ (3,059)      (13)%

 

Consolidated net sales decreased 13% due to the November 2002 sale of a controlling 60% interest in Unisource, our paper distribution business. Excluding the net sales from this business, consolidated net sales for 2003 increased 9% compared to 2002.

 

    North America consumer products net sales remained flat, as industry growth in the retail tissue and commercial tissue was below historical averages. Our retail business maintained bath tissue market share, while growing towel market share. However, retail selling prices declined 3% during the year as a result of heavy trade promotion activity. The commercial tissue market suffered from excess capacity in 2003, caused in part by the restarting of production at tissue mills that had been idled. Commercial tissue selling prices improved 2% during 2003. Our Dixie® business improved its market share in the retail channel through the growth of its core cup and plate franchise and implemented price increases.

 

    International consumer products net sales increased 17% due to a $279 million impact of a weaker United States dollar against local currencies, primarily the Euro and British pound.

 

    Packaging net sales increased 2% despite market pricing pressures experienced during the year.

 

    Bleached pulp and paper net sales increased 5% primarily due to higher selling prices for bleached board and recycled fiber. Pricing within our office paper and kraft businesses was contrastingly weak as a soft economy drove demand levels significantly below production capacity.

 

    Building products manufacturing net sales increased 14% primarily due to increases in average selling prices for plywood and oriented strand board of 15% and 74%, respectively. Prices increased due to strong growth in residential housing starts in the second half of 2003, combined with low inventories in the distribution channels. Sales volumes for plywood, treated lumber and gypsum increased 5%, 13% and 7%, respectively. These increases were offset by a 13% decline in sales volumes for oriented strand board, a portion of which is due to the sale of the Woodland, Maine plant during the third quarter of 2002.

 

    Building products distribution net sales increased 14%, primarily due to increased selling prices for plywood and oriented strand board, combined with a 12% increase in lumber shipments due to strong market demand.

 

    Other sales primarily represent the elimination of intersegment sales and some miscellaneous businesses.

 

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Index to Financial Statements

Analysis of Operating Profit (Loss) By Business Segment—Three Years Ended January 1, 2005

 

     Fiscal Year Ended

 
In millions    2004     Return on
Net Sales(2)
    2003     Return on
Net Sales(2)
    2002     Return on
Net Sales(2)
 

Operating profit (loss):

                                          

North America consumer products(a)

   $ 698     12 %   $ 601     11 %   $ 851     16 %

International consumer products(b)

     174     8       160     8       141     8  

Packaging(c)

     304     10       345     12       321     12  

Bleached pulp and paper(d)

     51     2       (48 )   (2 )     36     2  

Paper distribution(e)

     –       –         –       –         (516 )   (11 )

Building products manufacturing(f)

     997     14       378     6       129     3  

Building products distribution(g)

     111     6       98     2       50     1  

Other(1)

     (711 )   NM       (282 )   NM       (703 )   NM  


Total operating profit (loss)

   $ 1,624     8     $ 1,252     6     $ 309     1  

Interest expense

     701             819             827        


Income (loss) from continuing operations before income taxes

     923             433             (518 )      

Provision (benefit) for income taxes

     297             109             (318 )      


Income (loss) from continuing operations

     626             324             (200 )      

(Loss) income from discontinued operations, net of tax

     (3 )           (98 )           10        


Income (loss) before accounting changes

     623             226             (190 )      

Cumulative effect of accounting changes, net of tax

     –               28             (545 )      


Net income (loss)

   $ 623           $ 254           $ (735 )      


(1)   Includes the elimination of intersegment sales.
(2)   Return on Net Sales percentage is calculated by dividing the respective operating profit (losses) by net sales for each segment.
NM   Not meaningful
(a)   Operating profit for 2004 includes asset impairment/restructuring charges of $46 million, offset by a $9 million adjustment of environmental reserves and a $5 million gain on asset sales; operating profit for 2003 includes asset impairment/restructuring charges of $81 million offset by a $66 million credit adjustment of environmental reserves; operating profit for 2002 includes restructuring charges of $18 million.
(b)   Operating profit for 2004 includes asset impairment/severance charges of $4 million; operating profit for 2003 includes restructuring charges of $15 million.
(c)   Operating profit for 2004 includes $30 million of gains on asset sales, offset by $8 million of severance charges; operating profit for 2003 includes $68 million of gains on asset sales.
(d)   Operating profit for 2004 includes $24 million of gains on asset sales, offset by $1 million of asset impairment/severance charges and a $21 million loss from our equity investment in Unisource; operating profit for 2003 includes asset impairment charges of $56 million and a $24 million loss from our equity investment in Unisource; operating profit for 2002 includes a $3 million loss from our equity investment in Unisource.
(e)   Operating loss for 2002 includes asset impairment charges of $208 million and a loss on the sale of the business of $298 million.
(f)   Operating profit for 2004 includes asset impairments and severance of $19 million, offset by a $5 million gain on asset sales; operating profit for 2003 includes asset impairment/restructuring charges of $40 million.
(g)   Operating profit for 2004 includes $20 million of gains on asset sales.

 

27


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Index to Financial Statements

Comparison of 2004 to 2003:

 

In millions   

Change in

Operating

Profit/Loss

North America consumer products

   $ 97      16%

International consumer products

     14      9%

Packaging

     (41 )    (12)%

Bleached pulp and paper

     99      206%

Building products manufacturing

     619      164%

Building products distribution

     13      13%

Other

     (429 )    (152)%

Consolidated

   $ 372      30%

 

Consolidated operating profit for 2004 increased 30% compared to 2003.

 

North America Consumer Products

 

    The increase in operating profit was primarily driven by improved pricing and product mix for retail tissue and Dixie products, combined with lower selling, general and administrative expenses. These improvements were partially offset by cost inflation for waste paper, resin and natural gas; advertising and promotion costs due to the re-launch of our Brawny® paper towels and Quilted Northern® bathroom tissue; and higher distribution costs driven primarily by fuel and transportation inflation and changes in the sourcing patterns for our new Brawny® paper towels. Case shipments were relatively flat in 2004, as market conditions were competitive in all businesses.

 

    Included in the 2004 results was a $46 million charge for employee termination costs, asset impairments and asset write-offs primarily related to restructuring in the Dixie® business and at the Green Bay, Wisconsin and Bellingham, Washington paper mills. Also reflected in 2004 results is a $5 million gain from the sale of warehouse assets of our Dixie® business and a credit of $9 million from an increase in an insurance receivable related to an environmental remediation site. Included in the 2003 operating results were a credit of $66 million related to the reversal of excess environmental reserves and charges of $67 million for asset impairment, severance and business reorganization costs related to the closure of tissue manufacturing and converting operations at our Old Town, Maine mill (see Note 5 of the Notes to Consolidated Financial Statements) and at our Dixie and tissue businesses, and $14 million of various restructuring charges.

 

International Consumer Products

 

    The increase in segment operating profit resulted primarily from the $17 million positive impact of a weaker United States dollar against the functional currencies of the businesses in the segment. Excluding this favorable impact, operating profit was relatively flat. We experienced higher costs for purchased pulp in 2004, but we were largely able to offset this by cost reduction efforts in other areas of our business.

 

    Included in the 2004 results is a $4 million charge primarily related to the relocation of our Athens, Greece converting facility and a fire at our Russian facility. Included in the 2003 operating results were charges of $15 million for employee termination costs as a result of a significant overhead reduction and the relocation of converting assets in our United Kingdom business.

 

Packaging

 

    Operating profit for 2004 included gains on the sale of packaging assets of $30 million, offset by a charge of $8 million for relocation costs. Operating profit for 2003 included gains on the sale of packaging assets of $68 million.

 

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Index to Financial Statements
    Excluding the gains and relocation costs, the 2004 increase in operating profit was due to 2% higher sales volumes for containerboard and boxes, and price increases for all products offset by higher secondary fiber costs and energy costs.

 

Bleached Pulp and Paper

 

    Operating profit for 2004 included a gain of $24 million related to the sale of our interest in a Brazilian pulp business. Our 2003 operating loss included an impairment charge of $49 million related to our Old Town, Maine pulp mill and other impairment charges of $7 million.

 

    Excluding these items, the increase in operating profit was due to higher average selling prices and sales volumes along with cost reduction from the shutdown of a high cost paper machine at the Camas, Washington mill. This was partially offset by higher cost levels for natural gas, and transportation. Losses related to our minority interest in Unisource were $21 million in 2004, compared to $24 million in 2003.

 

Building Products Manufacturing

 

    The increase in operating profit resulted from significantly higher selling prices and volumes. This was offset slightly by higher costs for wood, natural gas, and resin.

 

    Operating profit for 2004 included asset impairments and severance costs of $19 million related to the closing of certain plants and a gain of $5 million from the sale of four hardwood mills. Included in the 2003 operating profit were charges of $40 million, primarily for asset impairments and facility closure costs.

 

Building Products Distribution

 

    This segment was sold on May 7, 2004, and, therefore, our 2004 operating results for this segment represent four months of operations compared with the full year in 2003. The increase in operating profit for 2004 is due to a $20 million gain on the sale of the distribution business and exceptionally strong markets in building materials in the first part of 2004.

 

Other

 

    Operating loss includes some miscellaneous businesses, unallocated corporate operating expenses and the elimination of profit on intersegment sales.

 

    The results for 2004 included a $159 million charge to the asbestos liability reserve and a $76 million loss from early extinguishment of debt including prior credit facility fees.

 

    During 2004, stock-based compensation expense increased by approximately $75 million due to the increase in the market value of our common stock and the recognition of expense related to 2002 performance awards earned in 2004. In addition, other compensation expenses, which vary based on our financial performance increased by $39 million.

 

    Included in 2003 was a net credit of $102 million to increase the estimated amount that we expect to receive from asbestos liability insurance (net of a $54 million charge to extend the projection of our asbestos liability through 2013).

 

During 2004, we recorded pension expense of $177 million and made cash pension contributions of $207 million. Pension expense for 2005 is estimated to be $161 million, primarily as a result of the favorable investment returns on plan assets in 2004. Cash pension contributions for 2005 are estimated to be $193 million, reflecting quarterly contributions to certain plans as required by the IRS Code, as well as certain voluntary contributions.

 

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Index to Financial Statements

Comparison of 2003 to 2002:

 

In millions   

Change in

Operating

Profit/Loss

North America consumer products

   $ (250 )    (29)%

International consumer products

     19        13%

Packaging

     24          7%

Bleached pulp and paper

     (84 )    (233)%

Paper distribution

     516      NM

Building products manufacturing

     249      193%

Building products distribution

     48        96%

Other

     421        60%

Consolidated

   $ 943      305%

 

Consolidated operating profit improved in 2003, due in large part to the lack of operating losses from Unisource, our paper distribution business, including impairment charges and a loss on sale of our controlling 60% interest in this business in November 2002.

 

North America Consumer Products

 

    Operating profit for 2003 decreased 29% primarily due to a decline in commercial tissue sales volumes; lower selling prices for retail tissue; higher fiber, natural gas and petroleum-based resin costs; and start-up costs associated with the launch of our improved Brawny towels.

 

    Included in the 2003 operating results were a credit of $66 million related to the reversal of excess environmental reserves, charges of $67 million for asset impairment, severance and business reorganization costs related to the closure of tissue-manufacturing and converting operations at our Old Town, Maine mill (see Note 5 of the Notes to Consolidated Financial Statements) and our Dixie® and other tissue businesses, and $14 million of other various restructuring charges. Included in the 2002 operating results were charges of $18 million primarily related to severance and facility closure costs.

 

International Consumer Products

 

    Operating profit for 2003 increased 13% over 2002 due to a $27 million favorable impact of a weaker United States dollar compared to functional currencies of the businesses in this segment.

 

    Included in the 2003 operating results were charges of $15 million related to employee termination costs caused by a significant overhead reduction in our United Kingdom business.

 

Packaging

 

    Operating profit for 2003 increased 7% due to an $18 million gain on the sale of packaging assets, and a $50 million gain on the sale of most of our railroad operations (see Note 4 of the Notes to Consolidated Financial Statements).

 

    Net of asset sales, the decline in operating profit of $45 million is primarily due to pricing pressure experienced during the year, and higher labor, benefits, wood and natural gas costs.

 

Bleached Pulp and Paper

 

   

Operating losses for 2003 increased 233% primarily due to an impairment charge of $49 million related to our Old Town, Maine pulp mill, other impairment charges of $7 million, a $15 million loss from our equity investment in Unisource, and $9 million of other expenses related to Unisource. The decision to

 

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Index to Financial Statements
 

close the tissue-manufacturing and converting operations at our Old Town, Maine mill caused certain pulp assets at this location to be impaired (see Note 5 of the Notes to Consolidated Financial Statements).

 

    Included in the 2002 operating results is a $1 million loss from our equity investment in Unisource and other related costs.

 

Building Products Manufacturing

 

    Operating profit for 2003 increased 193% primarily due to increases in average selling prices for plywood and oriented strand board when compared with the prior year. Included in the 2003 operating profit were charges of $40 million, primarily for asset impairments and facility closure costs.

 

    Due to excess production capacity in the building products manufacturing industry, we closed or indefinitely curtailed production at certain facilities in our structural panels, industrial wood products and lumber businesses during 2003. In connection with these closures and curtailments, we recorded charges of $22 million for asset impairments and losses on disposal of assets, and $4 million of employee termination costs.

 

    Additionally, we recorded an impairment charge of $12 million related to the closure of our White City, Oregon facility in 2003.

 

Building Products Distribution

 

    Operating profit for 2003 increased 96% from 2002 primarily as a result of increased selling prices and profit margins for plywood and oriented strand board, combined with an increase in lumber shipments.

 

Paper Distribution

 

    Operating losses of this segment for 2002 totaled $516 million, including an impairment charge of $208 million and a loss on the sale of a 60% interest in this business of $298 million. During 2003, losses related to our remaining 40% investment in Unisource totaled $24 million.

 

Other

 

    This segment includes some miscellaneous businesses, unallocated corporate operating expenses, and the elimination of profit on intersegment sales. Other operating loss decreased 60% in 2003 compared to 2002.

 

    Included in the 2003 loss was a net credit of $102 million to increase the estimated amount that we expect to receive from asbestos liability insurance (net of a $54 million charge to extend the projection of our asbestos liability through 2013), a charge of $36 million for costs to settle lawsuits, a charge of $10 million for pension settlement costs, and $9 million of costs to monetize a portion of the asbestos insurance receivable. See Note 17 of the Notes to Consolidated Financial Statements. Included in the 2002 loss are $378 million of pre-tax charges primarily for asbestos and business separation costs. During 2003, we also incurred $46 million higher stock-based compensation expense related principally to the increase in the market value of our common stock, offset by reduced corporate administrative expenses, higher foreign currency transaction gains, higher insurance refunds, and lower legal and environmental expenses. The increase in stock-based compensation expense was not related to the adoption in 2003 of Statement of Financial Accounting Standards (“SFAS”) No. 123, Accounting for Stock-Based Compensation (“SFAS No. 123”) (see Note 1 of the Notes to Consolidated Financial Statements).

 

Consolidated Statement of Operations Discussion:

 

Interest:

 

    Interest expense, net, in 2004 decreased $118 million compared to 2003 principally as a result of lower debt levels, offset somewhat by higher average interest rates. Debt decreased $1,953 million during 2004. Interest expense allocated to discontinued operations was $5 million and $14 million in 2004 and 2003, respectively.

 

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    Interest expense, net, decreased $8 million in 2003 compared to 2002 as a result of lower debt levels, offset somewhat by higher average interest rates. The higher average interest rates resulted primarily from refinancing $2.5 billion of lower rate, shorter-term debt in 2003 to $2.5 billion of higher rate, longer-term debt.

 

Income Tax:

 

    The effective tax rate in 2004 was lower than the statutory rate primarily because of lower international income tax rates, the utilization of tax credits and favorable changes in the status of tax audits, partially offset by taxes related to the sale of our interest in a Brazilian pulp business (see Note 13 to the Notes to Consolidated Financial Statements).

 

    The effective tax rate in 2003 was lower than the statutory rate primarily because of lower international income tax rates, the utilization of foreign tax credits and favorable changes in the status of tax audits. (See Note 13 to the Notes to Consolidated Financial Statements)

 

    The effective tax rate in 2002 was different from the statutory rate primarily because of the write-off of nondeductible goodwill (see Note 13 of the Notes to Consolidated Financial Statements) and because of tax benefits resulting from the loss on the sale of a 60% interest in our paper distribution business (see Note 4 of the Notes to Consolidated Financial Statements).

 

Related-Party Transactions

 

Unisource:

 

In November 2002, we sold a 60% controlling interest in Unisource, our paper distribution business, to an affiliate of Bain Capital Partners, LLC, and retained the remaining 40% equity interest. As of January 1, 2005, we own a 38.85% interest in Unisource. We account for our investment in Unisource using the equity method. As a result, Unisource meets the definition of a related party under SFAS No. 57, Related Party Disclosures. Subsequent to the sale of our controlling interest, Unisource has been, and continues to be, a customer with sales totaling $295 million and $291 million in 2004 and 2003, respectively. Sales terms are negotiated at arms’ length and reflect market prices.

 

As part of the sale, we received two payment-in-kind notes from Unisource with face amounts of $70 million and $100 million. These notes accrue interest at an annual interest rate of 7% and 8%, respectively, and mature in November 2012. At the time of the transaction, we discounted these notes using an effective weighted- average interest rate of 12.33%, resulting in a recorded book value of $105 million. The book value of the notes at January 1, 2005 was approximately $136 million due to the accrual of interest.

 

With the sale, we entered into a sublease with Unisource for certain warehouses retained by us. The balance of our sublease receivable at January 1, 2005 was $142 million. We also agreed to provide certain insurance coverage (including related letters of credit) to Unisource, generally for a period of five years, for workers’ compensation, general liability, automobile liability and property insurance. In addition, we entered into a loan agreement pursuant to which we agreed to provide Unisource with a $100 million subordinated secured loan. Any amounts drawn under the loan agreement will mature in May 2008 bearing interest at a fluctuating rate based on LIBOR. No amounts were outstanding under this loan at January 1, 2005.

 

GA-MET:

 

We are a 50% partner in a joint venture (“GA-MET”) with Metropolitan Life Insurance Company (“Metropolitan”). GA-MET owns and operates our main office building in Atlanta, Georgia. We account for the investment in GA-MET under the equity method. At January 1, 2005, GA-MET had an outstanding mortgage loan payable to Metropolitan in the amount of $122 million. The note bears interest at 9.5%, requires monthly

 

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payments of principal and interest through 2011, and is secured by the land and building owned by the joint venture. In the event of foreclosure, each partner has severally guaranteed payment of one-half of any shortfall of collateral value to the outstanding secured indebtedness. Based on present market conditions and building occupancy, the likelihood of any obligation to us with respect to this guarantee is considered remote.

 

Discontinued Operations

 

Our discontinued operations had a net loss in 2003 of $98 million, compared to net income of $10 million in 2002, primarily as a result of a charge of $106 million for the write-off of goodwill related to our pulp operations.

 

Environmental Matters

 

As is the case with other companies in similar industries, we face exposure from actual or potential claims and legal proceedings involving environmental matters. Liability insurance in effect during recent years provides only very limited coverage for environmental matters.

 

Fox River Site

 

The Fox River Site in Wisconsin is comprised of 39 miles of the Fox River and Green Bay. The site was nominated by the EPA (but never finally designated) as a Superfund Site due to contamination of the river by PCBs through wastewater discharged from the recycling of carbonless copy paper from 1953 to 1971. We became a PRP following our acquisition of Fort James in 2000 because a Fort James mill in Green Bay, Wisconsin discharges into the Fox River.

 

In late July of 2003, the EPA and the Wisconsin Department of Natural Resources (“WDNR”) issued a Record of Decision (“ROD”) setting forth a cleanup plan for the Fox River, including the area into which a Fort James mill discharged wastewater. The ROD estimated the total cost of the Fox River Site cleanup at approximately $324 million. Subsequently, we analyzed the ROD to understand its critical assumptions, including among others the volume of sediment to be dredged, the assumed cost of such dredging, the methods of disposing of the dredged wastes, and the use of remedies other than dredging. In late 2003, we concluded that our share of the costs to clean up the portion of the Fox River Site for which we are responsible was less than we originally estimated. Accordingly, in the fourth quarter of 2003, we reduced the related environmental reserve for this site and recorded a pre-tax credit of $66 million.

 

For further discussion regarding commitments and contingencies, including our environmental liabilities, see Note 17 of the Notes to Consolidated Financial Statements.

 

Critical Accounting Estimates

 

In applying our accounting policies, we are often required to make certain assumptions about matters that are uncertain at the time. In some instances, our use of different assumptions might have resulted in different accounting estimates that could have had a material impact on the presentation of our financial condition or results of operations. Although many of our accounting policies require us to make assumptions, detailed below are the accounting policies which we believe involve our most critical accounting estimates. For a complete discussion of our significant accounting policies, refer to Note 1 of the Notes to the Consolidated Financial Statements. We have reviewed these accounting policies and related estimates with the Audit Committee of our Board of Directors and our external auditors.

 

Pension Plans

 

Our pension costs and obligations are dependent on various actuarial assumptions. We make assumptions relating to discount rates, rates of compensation increases, and expected returns on plan assets. Refer to Note 14 of the Notes to the Consolidated Financial Statements for further information on these assumptions. We base our

 

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discount rate assumption, used to determine the projected benefit obligations for our U.S. and Canadian pension plans, on Moody’s Investor Service Aa bond yield as of October 31 of each year. For our European pension plans, we base the discount rate on indices comparable to the Aa bond yield within each country. The expected return on plan assets is determined based on historical portfolio results and expectations of future rates of return. Actual results that differ from estimated assumptions are accumulated and amortized over the estimated future working life of the plan participants, and could therefore affect expense recognized and obligations recorded in future periods.

 

If the discount rate used to determine the 2004 projected benefit obligation for these plans were decreased by 100 basis points, our projected benefit obligation would have increased by approximately $498 million at January 1, 2005, and the 2005 pension expense would increase by approximately $30 million. If such discount rate were increased by 100 basis points, our projected benefit obligation would have decreased by approximately $430 million at January 1, 2005, and the 2005 pension expense would decrease by approximately $28 million. If the expected long-term rate of return on assets used to determine the 2005 expected pension expense for these plans were decreased by 100 basis points, our 2005 pension expense would increase by approximately $36 million. If the expected long-term rate of return on assets were increased by 100 basis points, our 2005 pension expense would decrease by approximately $36 million. The above sensitivities reflect the impact of changing one assumption at a time. It should be noted that economic factors and conditions often affect multiple assumptions simultaneously.

 

Environmental and Legal Matters

 

Other areas in which significant uncertainties exist include, but are not limited to, projected costs to be incurred in connection with environmental and legal matters, including our asbestos liabilities. The more important assumptions in assessing our asbestos liability are the projection of the number of claims that will be filed against us in the future, which are influenced by the population potentially exposed to asbestos-containing products manufactured by us, the expected occurrence of various diseases in these potentially exposed populations, the rate at which these potentially exposed populations actually file claims, and activities of the asbestos plaintiffs bar designed to maximize its profits from such claims. The cost of settling claims is driven by these same assumptions, as well as by prevailing judicial and social environments in the jurisdictions in which claims are filed, the rulings by judges and the attitudes of juries in those jurisdictions, the demands of the asbestos plaintiffs bar with respect to the value of each such claim, the insolvencies of other defendants to a particular claim, and the impact of verdicts against or settlements by other defendants on settlement demands against us. The unique nature of our asbestos claims and the calculation of the liability does not lend itself to a sensitivity analysis.

 

We recognize a liability for environmental remediation and legal indemnification and defense costs when we believe it is probable a liability has been incurred and the amount can be reasonably estimated. The liabilities are developed based on currently available information and reflect the participation of other potentially responsible parties, depending on the parties’ financial condition and probable contribution. The accruals are recorded at undiscounted amounts and are reflected as liabilities on the accompanying consolidated balance sheets. We also have insurance that covers various portions of our asbestos liabilities and defense costs and losses on certain environmental claims. We record insurance recoveries as a receivable to the extent that the realization of the insurance is deemed probable. Such receivables are recorded at an undiscounted amount and are reflected as an asset in the accompanying consolidated balance sheets.

 

Environmental remediation costs are generally expensed. Environmental compliance costs are generally capitalized when the costs improve the condition of the property or prevent or mitigate future contamination.

 

Goodwill and Long-Lived Assets

 

Management uses judgment in assessing goodwill and other long-lived assets for impairment. Goodwill totaled $7.6 billion at January 1, 2005 and represented 33% of our total assets. In accordance with SFAS No. 142, we annually assess the recoverability of our goodwill. We review the recorded value of our goodwill

 

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annually at the beginning of the third fiscal quarter of each year, or sooner if events or changes in circumstances indicate that the carrying amount may exceed fair value. Recoverability is determined by comparing the estimated fair value of the reporting unit to which the goodwill applies to the carrying value, including goodwill, of that reporting unit. We utilize the present value of expected net cash flows to determine the estimated fair value of our reporting units. This present value model requires us to estimate future net cash flows, the timing of these cash flows, and a discount rate (or weighted average cost of capital) representing the time value of money and the inherent risk and uncertainty of the future cash flows. The discount rate, adjusted for inflation, is based on independently calculated beta risks for a composite group of consumer products companies and forest products peer companies, our target capital mix, and an estimated market risk premium. The assumptions used in estimating future cash flows were consistent with the reporting unit’s internal planning. If the estimated fair value of the reporting unit exceeds its carrying amount, goodwill of the reporting unit is not impaired. If the carrying amount of the reporting unit exceeds its estimated fair value, the implied fair value of the reporting unit’s goodwill is compared to the carrying amount of that goodwill. If the carrying amount of the reporting unit’s goodwill exceeds the implied fair value of that goodwill, an impairment loss is recognized in an amount equal to that excess. If the discount rate used to estimate the fair value of each reporting unit were increased by 100 basis points, the fair value would continue to exceed the carrying value for all of our reporting units.

 

We assess our long-lived assets other than goodwill for impairment whenever facts and circumstances indicate that the carrying amount may not be fully recoverable. To analyze recoverability, we project undiscounted net future cash flows over the remaining life of the assets. If these projected cash flows are less than the carrying amount, an impairment is recognized, resulting in a write-down of assets with a corresponding charge to earnings. The impairment loss is measured based upon the difference between the carrying amount and the fair value of the assets.

 

See Note 1 of the Notes to Consolidated Financial Statements for additional information on our accounting policies and accounting standards changes.

 

Factors That May Affect Future Results

 

Some of the matters discussed in this Form 10-K concerning, among other things, our business outlook, anticipated financial and operating results, strategies and contingencies, constitute forward-looking statements and are based upon management’s expectations and beliefs concerning future events. There can be no assurance that these events will occur or that our results will be as estimated. In some cases, the forward-looking statements contained in this Form 10-K can be identified by terminology such as “may,” “will,” “should,” “expects,” “plans,” “anticipates,” “believes,” or “estimates,” or the negative of these terms or other comparable terminology.

 

Forward-looking statements are only predictions. Therefore, readers are cautioned not to place undue reliance on these forward-looking statements, which are based on information known today and speak only as of the date of the filing of this Form 10-K. Moreover, in the future, we, through our senior management team, may make additional or different forward-looking statements about the matters described in this Form 10-K. We undertake no obligation to publicly revise any of these forward-looking statements to reflect changes in the facts or information on which they are based or any events or circumstances occurring after the date hereof. Actual events or future results may differ materially as a result of the following factors, as well as other factors described elsewhere in this Form 10-K and below, and in our other SEC filings, which are incorporated herein by this reference. Events that could cause actual results to differ materially from our forward-looking statements include the following: the realization of announced price increases for many of our products; continued strength in new home building and home renovation; the effect of general economic conditions on the demand for consumer products, building products, and pulp and paper; the corresponding level of demand for and cost of wood fiber, wastepaper, energy and other costs; the success of the branding and marketing strategies we are pursuing for our consumer products; the effect of changes in the productive capacity of manufacturers of

 

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competitive products; unanticipated expenditures with respect to environmental, safety and health laws; our ability to continue to reduce debt; and actions taken or to be taken by the United States or other governments as a result of the situation in Iraq and acts or threats of terrorism.

 

The following more detailed factors, which we again caution are not exclusive, are additional considerations that may affect our future results.

 

Litigation

 

We are subject to significant asbestos litigation liabilities and costs, as discussed below, and to other litigation risks that are similar to other corporations of our size and complexity in an increasingly litigious environment. While we do not believe that any of these matters will be material to our long-term financial status, certain litigation-related matters may be material to our results of operations in certain reporting periods.

 

As of January 1, 2005, we have recorded reserves for asbestos liabilities and defense costs totaling $984 million and insurance receivables of $525 million reflecting our expected payments and insurance receipts through 2014. Projecting liabilities for asbestos litigation is subject to a number of important risks and uncertainties, including the possibility that the number of asbestos claims filed against us in the future will be greater than projected; the risk that the cost of defending and settling current and future asbestos claims will be higher than projected, resulting in more rapid depletion of available insurance coverage and higher out-of-pocket costs; the possibility of additional insolvencies among insurance carriers; the risk that final resolution of allocation, coverage or other issues affecting available insurance coverage will result in lower insurance recoveries than forecast; the possibility that adverse jury verdicts could require us to pay damages in amounts greater than the amounts for which we now settle cases; and the risk that bankruptcies of other asbestos defendants may increase our liabilities in the future.

 

These or other factors could cause our actual liabilities to be materially higher, and our insurance recoveries to be materially lower, than those projected and recorded to date. If these or other factors cause us to determine that the assumptions used to project our asbestos liabilities and defense costs, and insurance recoveries, through 2014 are no longer reasonable, or if we determine that our asbestos liabilities, net of insurance recoveries, for years after 2014 will be material, we may have to establish additional reserves relating to asbestos beyond the charges already taken, and the amount of these reserves may be material. We cannot estimate the amount of any such additional reserves at this time.

 

Competition, Business Volatility and Ability to Achieve Business Plans

 

We face intense competition from both large international and small domestic producers in each of our operating segments.

 

In our consumer products businesses, we face competition from established, global consumer products competitors. Aggressive actions by these competitors can lead to decreased pricing and/or increased advertising and promotional spending by us in order to maintain market share. In order to achieve and/or maintain leadership positions in key product categories, we must continue to develop brand recognition and loyalty through the development and introduction of new products and product line extensions, enhance product quality and performance, and develop our marketing and distribution capabilities to serve our customers.

 

Operating results in our building products, packaging and paper businesses are typically more volatile than in our consumer products businesses. Most of the products in these businesses are commodities, whose selling prices tend to be the principal competitive factor. We cannot control such factors as decreasing demand from customers or increasing supply from competitors, both of which may cause rapid price decreases for such products and in turn adversely affect our net sales, operating income and cash flows.

 

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Dependence on Significant Customers

 

We consider major mass retailers, warehouse club stores and supermarket chains in both North America and Europe to be significant customers across one or more of our operating segments and we have developed specific and unique approaches to working with these individual customers, which include Wal-Mart Stores Inc., Costco Wholesale Corp., Sam’s Wholesale, Carrefour SA, The Home Depot, Inc., Lowe’s Companies Inc., Royal Ahold N.V., Target Corp., Sysco Corp., Kroger Co., Unisource, US Foodservice and Staples Inc.

 

We face strong competition for the business of these significant customers. Although no single customer accounts for more than 10% of our consolidated revenues, if any one of our significant customers reduces, delays or cancels substantial orders for any reason, our business and results of operations could be negatively affected, particularly for the quarter in which the delay or cancellation occurs.

 

We generally do not have long-term sales agreements or other contractual assurances as to future sales to any of our major customers. In addition, continued consolidation in the retail industry has resulted in an increasingly concentrated retail base. To the extent such concentration continues to occur, our net sales and operating income may be increasingly sensitive to deterioration in the financial condition of, or other adverse developments involving our relationship with, one or more customers. Another result of consolidation in the retail industry is that our customers are able to exert increasing pressure on us with respect to pricing and payment terms.

 

Substantial Indebtedness

 

As described elsewhere in this Form 10-K, we have substantial indebtedness. Our ability to meet our debt service obligations and to repay our outstanding indebtedness will depend in part on cash from operations. There can be no assurance that our businesses will be able to generate sufficient cash flows from operations, as they are subject to general economic, business, financial, competitive, legislative, regulatory and other factors beyond our control.

 

Costs Associated with Environmental Compliance and Remediation

 

Our operations are subject to significant regulation by federal, state and local environmental and safety authorities. The costs of compliance with existing and new regulatory schemes could require significant capital expenditures that would decrease the amount of funds available for investment in other areas of our operations. For example, the EPA has recently issued the MACT regulations as described in “Management’s Discussion and Analysis of Financial Condition and Results of Operations—Liquidity and Capital Resources.” The costs of compliance with these regulations, and additional or supplementary regulations, cannot be quantified in all cases, and there can be no assurance that the costs of such compliance will not be material to our results of operations in certain reporting periods. In addition, the costs of remediating known environmental sites, as described above and in Note 17 of the Notes to Consolidated Financial Statements, in some instances has been significant, and remediation of future sites could also be significant. There can be no assurance that the final remediation costs of various environmental sites will not exceed currently estimated costs, or that additional sites will not require significant remediation expenses.

 

Energy Costs

 

Our manufacturing operations utilize large amounts of electricity, natural gas and petroleum-based fuels. To insure that we use all forms of energy cost-effectively, we maintain ongoing energy efficiency improvement programs at all of our manufacturing sites. Our contracts with energy suppliers vary as to price, payment terms, quantities and duration. Energy costs are also affected by various market factors, including the availability of supplies of particular forms of energy, energy prices and local and national regulatory decisions. There can be no

 

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assurance that there will not be substantial increases in the price, or less availability, of energy sources in the future, especially in light of recent instability in some energy markets, or that we can pass on any such increases through increases in the price of our products.

 

The reader should not place undue reliance on any forward-looking statements, which are based on current expectations. See the “Factors that May Affect Future Results” above.

 

ITEM 7A.    QUANTITATIVE AND QUALITATIVE DISCLOSURES ABOUT MARKET RISK

 

As a multinational enterprise, we are exposed to risks such as changes in interest rates, commodity prices and foreign currency exchange rates. We employ a variety of practices to manage these risks, including operating and financing activities and, where deemed appropriate, the use of derivative instruments. Derivative instruments are used only for risk management purposes and not for speculation or trading, and are not used to address risks related to foreign currency exchange rates.

 

In accordance with SFAS No. 133, Accounting for Derivative Instruments and Hedging Activities, as amended, we record all derivative instruments as assets or liabilities on the balance sheet at fair value. Changes in the fair value of derivatives are either recorded in income or other comprehensive income, as appropriate. The gain or loss on derivatives designated as fair value hedges and the offsetting loss or gain on the hedged item attributable to the hedged risk are included in current income in the period that changes in fair value occur. The gain or loss on derivatives designated as cash flow hedges is included in other comprehensive income in the period that changes in fair value occur and is reclassified to income in the same period that the hedged item affects income. The gain or loss on derivatives that have not been designated as hedging instruments is included in current income in the period that changes in fair value occur.

 

Presented below is a description of our most significant risks (interest rate risk, commodity price risk and foreign currency risk) together with a sensitivity analysis of each of these risks based on selected changes in market rates and prices. These analyses reflect our view of changes, which are reasonably possible to occur over a one-year period.

 

Interest Rate Risk

 

Interest rate risk is managed through the maintenance of a portfolio of variable- and fixed-rate debt composed of short- and long-term instruments. The objective is to maintain a cost-effective mix that management deems appropriate. At January 1, 2005, the debt portfolio was composed of approximately 23% of variable-rate debt, adjusted for the effect of interest rate exchange agreements, and 77% of fixed-rate debt. Our strategy to manage exposure to interest rate fluctuations did not change significantly during 2004 and management does not foresee or expect any significant changes in its exposure to interest rate fluctuations or in how such exposure is managed in the near future. See Note 12 of the Notes to Consolidated Financial Statements.

 

Our debt portfolio is sensitive to changes in interest rates. Interest rate changes would result in gains or losses in the market value of our debt portfolio due to differences in market interest rates and the rates in effect based on the debt agreements. Based on our indebtedness and interest rates in effect as of January 1, 2005, a 100 basis point interest rate increase is estimated to impact the fair value of the debt portfolio by $300 million and annual interest expense by $20 million.

 

Commodity Price Risk

 

We are exposed to material commodity price risks through our purchases of wood, recycled fiber and pulp, which we use to make our products. Total purchases of these commodities were approximately $1,879 million in 2004. Costs for these raw materials are driven by industry supply and demand, weather, environmental and

 

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logging regulations, the demand for materials from overseas markets, and many other factors. Increases in the prices of wood, recycled fiber and pulp prices will adversely affect our earnings if we cannot increase the selling prices of products that we manufacture or if such increases significantly trail the increases in these costs. Derivative instruments have not been used to manage these risks.

 

During the third quarter of 2004, we began a natural gas hedging program to manage fluctuations resulting from commodity price risk in the procurement of natural gas. Our objective is to fix the price of a portion of our forecasted purchases of natural gas used in the manufacturing process. Excluding the impact of future hedging contracts, the potential change in our expected 2005 natural gas cost, based upon our expected annual usage and unit cost, resulting from a hypothetical 10% adverse change in the price of natural gas would be approximately $42 million. See Note 12 of the Notes to Consolidated Financial Statements.

 

Foreign Currency Risk

 

The translation of the balance sheets of our non-U.S. operations from local currencies into U.S. dollars is sensitive to changes in foreign currency exchange rates. These translation gains or losses are recorded as foreign currency translation adjustments within stockholders’ equity. We also have transactional gains and losses that are caused by changes in foreign currency exchange rates compared to the U.S. dollar. These transaction gains or losses flow through the consolidated statement of operations.

 

We perform an annual test to quantify the effects that possible changes in foreign currency exchange rates would have on our annual operating profit and on the translation of the balance sheets of our non-U.S. operations into U.S. dollars. A 10% unfavorable change in the exchange rate of the U.S. dollar as of January 1, 2005, against the then-prevailing exchange rates of applicable foreign currencies would have resulted in a reduction of stockholders’ equity of approximately $23 million, which in the view of management is not material to our consolidated financial position, results of operations or cash flows.

 

ITEM 8.    FINANCIAL STATEMENTS AND SUPPLEMENTARY DATA

 

Index to Financial Statements

 

     Page

Financial Statements

    

Management’s Responsibility For Financial Statements

   41

Report of Independent Registered Public Accounting Firm

   42

Consolidated Statements of Operations

   43

Consolidated Statements of Cash Flows

   44

Consolidated Balance Sheets

   45

Consolidated Statements of Shareholders’ Equity

   46

Consolidated Statements of Comprehensive Income (Loss)

   47

Notes to Consolidated Financial Statements

   48

Supplemental Information:

    

Selected Financial Data—Operations

   117

Selected Financial Data—Financial Position, End of Year

   119

Sales and Operating Profit by Operating Segment

   121

Schedule II—Valuation and Qualifying Accounts

   122

 

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MANAGEMENT’S RESPONSIBILITY FOR FINANCIAL STATEMENTS

 

Management is responsible for the integrity and objectivity of all financial information included in this Form 10-K. The consolidated financial statements have been prepared in accordance with U.S. generally accepted accounting principles. The financial statements include amounts that are based on the best estimates and judgments of management. All financial information in this Form 10-K is consistent with that in the consolidated financial statements.

 

Ernst & Young LLP, an independent registered public accounting firm, has audited these consolidated financial statements in accordance with the standards of the Public Company Accounting Oversight Board (United States) and has expressed herein its unqualified opinion on those financial statements.

 

The Audit Committee of the Board of Directors, which oversees our financial reporting process on behalf of the Board of Directors, is composed entirely of independent directors (as defined by the New York Stock Exchange). The Audit Committee meets periodically with management, the independent accountants, and our internal auditors to review matters relating to the Company’s financial statements and financial reporting process, annual financial statement audit, engagement of independent accountants, internal audit function, system of internal controls, and legal compliance and ethics programs as established by our management and the Board of Directors. The internal auditors and the independent accountants periodically meet alone with the Audit Committee and have access to the Audit Committee at any time.

 

LOGO

Robert P. Nelson

Vice President and Controller

 

LOGO

Danny W. Huff

Executive Vice President—Finance and Chief Financial Officer

 

LOGO

A.D. Correll

Chairman and Chief Executive Officer

 

February 25, 2005

 

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REPORT OF INDEPENDENT REGISTERED PUBLIC ACCOUNTING FIRM

 

The Board of Directors and Shareholders of Georgia-Pacific Corporation:

 

We have audited the accompanying consolidated balance sheets of Georgia-Pacific Corporation and subsidiaries as of January 1, 2005 and January 3, 2004 and the related consolidated statements of operations, shareholders’ equity, comprehensive income (loss), and cash flows for each of the three years in the period ended January 1, 2005. Our audits also included the financial statement schedule listed in the index at Item 15(a). These financial statements and schedule are the responsibility of the Corporation’s management. Our responsibility is to express an opinion on these financial statements and schedule based on our audits.

 

We conducted our audits in accordance with the standards of the Public Company Accounting Oversight Board (United States). Those standards require that we plan and perform the audit to obtain reasonable assurance about whether the financial statements are free of material misstatement. An audit includes examining, on a test basis, evidence supporting the amounts and disclosures in the financial statements. An audit also includes assessing the accounting principles used and significant estimates made by management, as well as evaluating the overall financial statement presentation. We believe that our audits provide a reasonable basis for our opinion.

 

In our opinion, the financial statements referred to above present fairly, in all material respects, the consolidated financial position of Georgia-Pacific Corporation and subsidiaries at January 1, 2005 and January 3, 2004 and the consolidated results of their operations and their cash flows for each of the three years in the period ended January 1, 2005, in conformity with U.S. generally accepted accounting principles. Also, in our opinion, the related financial statement schedule, when considered in relation to the basic financial statements taken as a whole, presents fairly in all material respects the information set forth therein.

 

As discussed in Notes 1, 7, and 8 to the consolidated financial statements, in 2003, the Corporation adopted the expense recognition provisions of Statement of Financial Accounting Standards (SFAS) No. 123, Accounting for Stock-Based Compensation, as amended, and SFAS No. 143, Accounting for Asset Retirement Obligations; in 2002, the Corporation adopted SFAS No. 142, Goodwill and Other Intangible Assets.

 

We also audited, in accordance with the standards of the Public Company Accounting Oversight Board (United States), the effectiveness of Georgia-Pacific Corporation’s internal control over financial reporting as of January 1, 2005, based on criteria established in Internal Control-Integrated Framework issued by the Committee of Sponsoring Organizations of the Treadway Commission and our report dated February 25, 2005 expressed an unqualified opinion thereon.

 

LOGO

 

Atlanta, Georgia

February 25, 2005

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

CONSOLIDATED STATEMENTS OF OPERATIONS

 

     Fiscal Year Ended

 
In millions, except per share amounts    2004     2003     2002  

Net sales

   $ 19,656     $ 19,656     $ 22,715  


Costs and expenses:

                        

Cost of sales

     14,831       15,376       17,685  

Selling and distribution

     1,183       1,291       1,854  

Depreciation, amortization and accretion

     938       973       958  

General and administrative

     887       850       1,040  

Other losses (income), net

     193       (86 )     869  


Operating profit

     1,624       1,252       309  


Interest, net

     701       819       827  


Income (loss) from continuing operations before income taxes

     923       433       (518 )

Provision (benefit) for income taxes

     297       109       (318 )


Income (loss) from continuing operations

     626       324       (200 )

(Loss) income from discontinued operations, net of taxes

     (3 )     (98 )     10  


Income (loss) before accounting changes

     623       226       (190 )

Cumulative effect of accounting changes, net of taxes

     –         28       (545 )


Net income (loss)

   $ 623     $ 254     $ (735 )


Basic per share:

                        

Income (loss) from continuing operations

   $ 2.45     $ 1.29     $ (0.84 )

(Loss) income from discontinued operations, net of taxes

     (0.01 )     (0.39 )     0.04  


Income (loss) before accounting changes

     2.44       0.90       (0.80 )

Cumulative effect of accounting changes, net of taxes

     –         0.11       (2.29 )


Net income (loss)

   $ 2.44     $ 1.01     $ (3.09 )


Diluted per share:

                        

Income (loss) from continuing operations

   $ 2.38     $ 1.29     $ (0.84 )

(Loss) income from discontinued operations, net of taxes

     (0.01 )     (0.39 )     0.04  


Income (loss) before accounting changes

     2.37       0.90       (0.80 )

Cumulative effect of accounting changes, net of taxes

     –         0.11       (2.29 )


Net income (loss)

   $ 2.37     $ 1.01     $ (3.09 )


Average number of shares outstanding:

                        

Basic

     255.3       250.4       237.6  

Diluted

     262.8       251.4       237.6  

 

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

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

CONSOLIDATED STATEMENTS OF CASH FLOWS

 

     Fiscal Year Ended

 
In millions    2004     2003     2002  

Cash flows from operating activities:

                        

Net income (loss)

   $ 623     $ 254     $ (735 )

Adjustments to reconcile net income (loss) to cash provided by operations, excluding the effects of acquisitions and divestitures:

                        

Cumulative effect of accounting changes, net of taxes

     –         (28 )     545  

Depreciation

     913       1,009       1,000  

Amortization of intangible assets, deferred charges and accretion

     52       60       54  

Stock compensation expense

     110       46       2  

Deferred income taxes

     38       (110 )     (24 )

Other losses, net

     187       21       870  

Increase in receivables

     (300 )     (42 )     (94 )

Increase in inventories

     (24 )     (19 )     (3 )

Increase in accounts payable

     350       33       49  

Change in other working capital

     37       128       (161 )

Change in taxes receivable/payable

     (160 )     341       (288 )

Change in other assets and other long-term liabilities

     (369 )     80       (154 )

Other, net

     17       19       (54 )


Cash provided by operations

     1,474       1,792       1,007  


Cash flows from investing activities:

                        

Property, plant and equipment investments

     (713 )     (710 )     (693 )

Acquisitions

     (24 )     (10 )     (6 )

Proceeds from sales of assets

     1,507       92       668  

Other

     (16 )     (15 )     (20 )


Cash provided by (used for) investing activities

     754       (643 )     (51 )


Cash flows from financing activities:

                        

Repayments and maturities of long-term debt

     (6,801 )     (8,090 )     (5,030 )

Additions to long-term debt

     5,027       7,142       4,975  

Fees paid to issue debt

     (15 )     (55 )     (14 )

Fees paid to retire debt

     (52 )     –         –    

(Decrease) increase in bank overdrafts

     (44 )     (45 )     71  

Decrease in accounts receivable secured borrowings and short-term notes

     (121 )     (21 )     (900 )

Proceeds from option plan exercises

     68       18       4  

Proceeds from employee stock purchase plan

     –         23       37  

Cash dividends paid

     (129 )     (126 )     (118 )

Other, net

     –         (1 )     7  


Cash used for financing activities

     (2,067 )     (1,155 )     (968 )


Effect of exchange rate changes on cash and equivalents

     13       15       15  


Increase in cash and equivalents

     174       9       3  

Balance at beginning of year

     51       42       39  


Balance at end of year

   $ 225     $ 51     $ 42  


Supplemental disclosures of cash flow information:

                        

Total interest costs, net—continuing operations

   $ 706     $ 827     $ 841  

Interest capitalized

     (5 )     (8 )     (14 )


Interest expense, net—continuing operations

     701       819       827  

Interest expense, net—discontinued operations

     5       14       14  


Total interest expense, net

   $ 706     $ 833     $ 841  


Interest paid

   $ 762     $ 791     $ 885  


Income tax paid (refunds received), net

   $ 451     $ (131 )   $ 51  


Non-cash investing and financing activity:

                        

Redemption of senior deferrable notes and issuance of common stock (see Note 10)

   $ –       $ –       $ 863  


Unisource sale/leaseback transaction (see Note 4)

   $ –       $ –       $ 169  


Debt assumed by buyer in divestiture

   $ 73     $ –       $ –    


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

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

CONSOLIDATED BALANCE SHEETS

 

In millions, except shares and per share amounts    January 1,
2005
    January 3,
2004
 

ASSETS

                

Current assets:

                

Cash and equivalents

   $ 225     $ 51  


Receivables, less allowances of $26 and $36, respectively

     1,766       1,542  


Inventories

                

Raw materials

     685       625  

Finished goods

     743       832  

Supplies

     278       270  

LIFO reserve

     (158 )     (98 )


Total inventories

     1,548       1,629  


Deferred income tax assets

     28       117  

Taxes receivable

     56       –    

Current assets held for sale

     –         739  

Other current assets

     324       300  


Total current assets

     3,947       4,378  


Property, plant and equipment

                

Land and improvements

     466       478  

Buildings

     2,057       1,997  

Machinery and equipment

     15,044       15,007  

Construction in progress

     367       276  


Property, plant and equipment, at cost

     17,934       17,758  

Accumulated depreciation

     (9,529 )     (9,176 )


Property, plant and equipment, net

     8,405       8,582  

Goodwill, net

     7,551       7,484  

Intangible assets, net

     701       716  

Assets held for sale

     –         757  

Other assets

     2,468       2,488  


Total assets

   $ 23,072     $ 24,405  


LIABILITIES AND SHAREHOLDERS’ EQUITY

                

Current liabilities:

                

Secured borrowings and short-term notes

   $ 568     $ 689  

Current portion of long-term debt

     57       789  

Accounts payable

     1,668       1,404  

Accrued compensation

     323       244  

Current liabilities held for sale

     –         189  

Other current liabilities

     1,000       1,107  


Total current liabilities

     3,616       4,422  

Long-term debt, excluding current portion

     8,070       9,074  

Liabilities held for sale

     –         206  

Other long-term liabilities

     3,692       3,826  

Deferred income tax liabilities

     1,469       1,483  

Commitments and contingencies (Note 17)

                

Shareholders’ equity:

                

Preferred stock, no par value; 10,000,000 shares authorized; no shares issued or outstanding

     –         –    

Junior preferred stock, no par value; 25,000,000 shares authorized; no shares issued or outstanding

     –         –    

Common stock, par value $0.80; 400,000,000 shares authorized; 256,992,000 shares and 252,980,000 shares issued and outstanding at January 1, 2005 and January 3, 2004, respectively

     205       202  

Additional paid-in capital

     3,610       3,473  

Retained earnings

     2,090       1,596  

Long-term incentive plan deferred compensation

     –         (1 )

Accumulated other comprehensive income

     320       124  


Total shareholders’ equity

     6,225       5,394  


Total liabilities and shareholders’ equity

   $ 23,072     $ 24,405  


 

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

 

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CONSOLIDATED STATEMENTS OF SHAREHOLDERS’ EQUITY

 

     Fiscal Year Ended

 
In millions, except shares in thousands and per share amounts    2004     2003     2002  

Common stock:

                        

Beginning balance

   $ 202     $ 200     $ 184  

Common stock issued:

                        

Stock option plans and directors plan

     2       1       –    

Employee stock purchase plans

     –         1       1  

Restricted stock issuance

     1       –         –    

Common stock issued for PEPS conversion

     –         –         15  

Common stock issued for acquisitions

     –         –         –    


Ending balance

     205       202       200  


Additional paid-in capital:

                        

Beginning balance

     3,473       3,413       2,521  

Common stock issued:

                        

Stock option plans and directors plan

     88       28       8  

Employee stock purchase plans

     –         22       36  

Restricted stock issuance

     49       10       –    

Common stock issued for PEPS conversion

     –         –         848  

Common stock issued for acquisitions

     –         –         –    


Ending balance

     3,610       3,473       3,413  


Retained earnings:

                        

Beginning balance

     1,596       1,468       2,321  

Net income (loss)

     623       254       (735 )

Cash dividends declared ($0.50, per common share for each of the three years presented)

     (129 )     (126 )     (118 )


Ending balance

     2,090       1,596       1,468  


Long-term incentive plan deferred compensation:

                        

Beginning balance

     (1 )     (2 )     (3 )

Restricted stock issuance

     1       1       1  


Ending balance

     –         (1 )     (2 )


Accumulated other comprehensive income (loss):

                        

Beginning balance

     124       (519 )     (118 )

Activity, net of taxes

     196       643       (401 )


Ending balance

     320       124       (519 )


Total shareholders’ equity

   $ 6,225     $ 5,394     $ 4,560  


Common stock shares issued and outstanding:

                        

Beginning balance, common stock outstanding

     252,980       250,238       230,095  

Common stock issued:

                        

Stock option plans and directors plan

     2,634       1,050       230  

Employee stock purchase plans

     –         1,530       1,696  

Restricted stock issuance

     1,373       137       –    

Common stock issued for PEPS conversion

     –         –         18,206  

Common stock issued for acquisitions

     5       25       11  


Ending balance, common stock outstanding

     256,992       252,980       250,238  


 

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

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

CONSOLIDATED STATEMENTS OF COMPREHENSIVE INCOME (LOSS)

 

     Fiscal Year Ended

 
In millions    2004     2003     2002  

Net income (loss)

   $ 623     $ 254     $ (735 )

Other comprehensive income (loss) before taxes:

                        

Foreign currency translation adjustments

     223       456       154  

Derivative instruments:

                        

Fair market value adjustments on derivatives

     4       –         6  

Reclassification adjustments for (gains) losses included in net income

     (4 )     9       35  

Unrealized gains (losses) on securities:

                        

Unrealized gains (losses) arising during the period

     9       6       (4 )

Reclassification adjustment for impairment included in net income

     –         –         4  

Minimum pension liability adjustment

     (57 )     255       (941 )

Income tax benefit (expense) related to items of other comprehensive income (loss)

     21       (83 )     345  


Comprehensive income (loss)

   $ 819     $ 897     $ (1,136 )


 

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

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS

 

NOTE 1.    SUMMARY OF SIGNIFICANT ACCOUNTING POLICIES

 

Nature of Operations

 

We are a Georgia corporation, broadly engaged in four business operations: the manufacture of tissue products (including bath and facial tissue, paper towels, and napkins) and disposable tabletop products (including disposable cups, plates and cutlery); the manufacture of containerboard and packaging (including linerboard, medium and corrugated packaging); the manufacture of paper (including office paper and writing papers, bleached board, and bleached and unbleached kraft papers); and the manufacture of building products (including plywood, oriented strand board, various industrial wood products, and softwood and hardwood lumber as well as certain non-wood products including gypsum products and chemicals).

 

On May 7, 2004, we completed the sale of our building products distribution business and the sale of our non-integrated pulp mills at Brunswick, Georgia, and New Augusta, Mississippi, as well as affiliated assets. The related assets and liabilities for both the building products distribution operation and the non-integrated pulp operations were retroactively classified as held for sale for all periods presented. The non-integrated pulp operations are reported as discontinued operations for all periods presented. The non-integrated pulp operations were previously reported in the bleached pulp and paper segment (see Note 4).

 

Prior to November 2, 2002, we were engaged in the distribution of paper products, packaging and facility supplies through our paper products distribution business, Unisource Worldwide, Inc. (“Unisource”). Effective November 2, 2002, we sold a 60% controlling interest in Unisource (see Note 4).

 

Principles of Consolidation

 

Our consolidated financial statements include the accounts of the Georgia-Pacific Corporation and those entities which we control, principally majority-owned domestic and foreign subsidiaries. All significant intercompany accounts and transactions are eliminated in consolidation. The equity method of accounting is used for investments in companies over which we exercise significant influence but do not control, generally where we have a 20% to 50% ownership interest. The equity method of accounting is also used in instances where we may have an ownership interest greater than 50% and the investing partner has substantive participating rights. Certain of our subsidiaries and equity investments are reported on a lag of one month to allow adequate time to compile their results. We recorded net losses related to our equity method investments of $8 million, $10 million and $4 million in 2004, 2003 and 2002 respectively. Minority interests in income of less than wholly-owned consolidated subsidiaries totaled $11 million, $17 million and $9 million in 2004, 2003 and 2002, respectively. These amounts are included in cost of sales on our consolidated statements of operations.

 

Revenue Recognition

 

We recognize revenue when the following criteria are met: persuasive evidence of an agreement exists, delivery has occurred or services have been rendered, our price to the buyer is fixed and determinable, and collectibility is reasonably assured. Delivery is not considered to have occurred until the customer takes title and assumes the risks and rewards of ownership. The timing of revenue recognition is largely dependent on shipping terms. Revenue is recorded at the time of shipment for terms designated free on board (“f.o.b.”) shipping point. For sales transactions designated f.o.b. destination, revenue is recorded when the product is delivered to the customer’s delivery site. We do not recognize revenue from “bill and hold” transactions until the product is delivered to the customer’s delivery site (for sales with terms of f.o.b. destination) or until the product is shipped

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

to the customer (for sales with terms of f.o.b. shipping point). Revenue is recognized net of discounts and allowances, which are comprised of trade allowances, cash discounts and sales returns. Reserves for cash discounts, trade allowances, credit losses and sales returns are estimated using historical experience.

 

Foreign Currency Translation

 

The functional currency for most international subsidiaries is the local currency for the country in which the subsidiaries own their primary assets. The translation of the applicable currencies into United States dollars is performed for balance sheet accounts using current exchange rates in effect at the balance sheet date and for revenue and expense accounts using a weighted-average exchange rate during the period. Any related translation adjustments are recorded directly in other comprehensive income. Foreign currency transaction gains (losses) are reflected in our consolidated statements of operations and were $8 million, $9 million, and $(10) million in 2004, 2003, and 2002, respectively, and reported in “cost of sales” in the accompanying consolidated statements of operations.

 

Income (Loss) Per Share

 

Basic income (loss) per share is computed based on net income (loss) and the weighted-average number of common shares outstanding. Diluted earnings per share reflect the assumed issuance of common shares under long-term incentive, stock option and stock purchase plans, and, prior to the third quarter of 2002, our Premium Equity Participating Security Units (“PEPS Units”) (see Note 10). The computation of diluted earnings per share does not assume conversion or exercise of securities that would have an antidilutive effect on earnings per share.

 

Income (Loss) Per Share

 

     Fiscal Year Ended

 
In millions, except shares and per share amounts    2004     2003     2002  

Basic and diluted income (loss) available to shareholders (numerator):

                        

Income (loss) from continuing operations

   $ 626     $ 324     $ (200 )

(Loss) income from discontinued operations, net of taxes

     (3 )     (98 )     10  

Cumulative effect of accounting changes, net of taxes

     –         28       (545 )


Net income (loss)

   $ 623     $ 254     $ (735 )


Shares (denominator):

                        

Weighted average shares outstanding

     255,277,587       250,416,181       237,639,025  

Dilutive securities:

                        

Options and other equity securities(1)

     7,529,013       748,770       –    

Employee stock purchase plans

     –         253,797       –    


Total assuming conversion

     262,806,600       251,418,748       237,639,025  


(1)   Additional options to purchase 944,205 shares, 14,530,921 shares and 22,205,895 shares of stock were outstanding during 2004, 2003, and 2002 respectively. However, these were not included in the computation of diluted earnings per share because the options’ exercise prices were greater than the average market price of the common shares.

 

Stock-Based Compensation

 

Effective December 29, 2002, we adopted Statement of Financial Accounting Standards (“SFAS”) No. 148, Accounting for Stock-Based Compensation—Transition and Disclosure (“SFAS No. 148”), an amendment of SFAS No. 123, Accounting for Stock-Based Compensation (“SFAS No. 123”). SFAS No. 148 provides

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

alternative methods of transition to SFAS No. 123’s fair value method of accounting for stock-based compensation and amends the disclosure provisions of SFAS No. 123. We utilized the prospective method in accordance with SFAS No. 148 and applied the expense recognition provisions of SFAS No. 123 to stock options awarded or modified in 2003 and thereafter. Compensation expense recognized in 2003 was reduced by approximately $2 million due to 2003 stock option awards. Prior to 2003, we accounted for our stock-based compensation plans under APB Opinion No. 25, Accounting for Stock Issued to Employees (“APB No. 25”), and disclosed pro forma effects of the plans on net income and earnings per share as provided under SFAS No. 123. In most cases, because the fair market value on the date of grant was equal to the exercise price, no compensation expense was recognized under APB No. 25 for stock options issued prior to 2003. Had compensation cost for stock-based compensation awards issued prior to 2003 been determined based on the fair value at the grant dates consistent with the method of SFAS No. 123, the pro forma net income and earnings per share would have been:

 

     Fiscal Year Ended

 
In millions, except per share amounts    2004     2003     2002  

Net income (loss) as reported

   $ 623     $ 254     $ (735 )

Less total stock-based employee compensation expense determined under the fair value method, net of taxes, for all awards prior to the adoption of SFAS No. 123

     (3 )     (8 )     (25 )


Pro forma net income (loss)

   $ 620     $ 246     $ (760 )


Stock-based employee compensation cost, net of taxes, included in the determination of net income as reported

   $ 77     $ 29     $ 1  


Net income (loss) per share

                        

Basic:

                        

As reported

   $ 2.44     $ 1.01     $ (3.09 )

Pro forma

     2.43       0.98       (3.20 )

Diluted:

                        

As reported

   $ 2.37     $ 1.01     $ (3.09 )

Pro forma

     2.36       0.98       (3.20 )

 

The fair value method of accounting for stock-based compensation plans under SFAS No. 123 recognizes the value of options and other equity securities granted as compensation over the option’s vesting period. For purposes of calculating the pro forma effects of stock-based awards, we recognize compensation expense for awards with pro rata vesting on a straight-line basis.

 

The weighted average assumptions used in connection with the Black-Scholes option pricing model to estimate the fair value of stock-based awards granted in 2004, 2003 and 2002 are:

 

     Fiscal Year Ended

 
     2004     2003     2002  

Risk-free interest rate

     4.2 %     4.1 %     5.0 %

Expected dividend yield

     1.8 %     3.3 %     2.0 %

Expected life

     10 years       10 years       10 years  

Expected volatility

     0.51       0.54       0.45  

Forfeiture rate

     4.0 %     0.0 %     5.0 %

Weighted average fair value

   $ 14.25     $ 6.85     $ 11.86  

 

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GEORGIA-PACIFIC CORPORATION AND SUBSIDIARIES

 

NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

Cash and Equivalents

 

Cash equivalents include time deposits and other securities with original maturities of three months or less.

 

Inventory Valuation

 

Inventories are valued at the lower of cost or market and include the costs of materials, labor and manufacturing overhead. The last-in, first-out (“LIFO”) method was used to determine the cost of approximately 60% and 59% of inventories at January 1, 2005 and January 3, 2004, respectively. The cost of other inventories, primarily inventories of foreign subsidiaries and supplies, generally are determined using the first-in, first-out method or weighted-average cost. The value of inventories as presented in our consolidated balance sheets, before reduction for the LIFO reserve, approximates replacement cost at the respective dates.

 

Property, Plant and Equipment

 

Property, plant and equipment are recorded at cost. Lease obligations for which we assume or retain substantially all the property rights and risks of ownership are capitalized. Replacements of major units of property are capitalized, and the replaced properties are retired. Replacements of minor components of property and repair and maintenance costs are charged to expense as incurred. Planned shutdown maintenance costs are charged to earnings ratably during the year.

 

Depreciation is computed using the straight-line method over the estimated useful lives of the related assets. Useful lives are 25 years for land improvements, 20 to 45 years for buildings, and 3 to 20 years for machinery and equipment. Upon retirement or disposition of assets, cost and accumulated depreciation are removed from the related accounts and any gain or loss is included in “Other losses (income), net” on the accompanying consolidated statements of operations.

 

We capitalize interest on significant projects when construction takes considerable time and entails major expenditures. Such interest is charged to the property, plant and equipment accounts and amortized over the approximate lives of the related assets.

 

Income Taxes

 

Deferred income taxes are recognized for the tax consequences of temporary differences by applying enacted statutory tax rates, applicable to future years, to differences between the financial reporting and the tax basis of existing assets and liabilities. With respect to deferred tax assets, we maintain valuation allowances where it is likely that all or a portion of a deferred tax asset will not be realized. Changes in valuation allowances from period to period are included in our income tax provision in the period of change. In determining whether a valuation allowance is warranted, we take into account such factors as prior earnings history, expected future earnings, unsettled circumstances that, if unfavorably resolved, would adversely affect utilization of a deferred tax asset, carry-back and carry-forward periods, and tax strategies that could potentially enhance the likelihood of a realization of a deferred tax asset.

 

Interest, net

 

Interest, net is interest expense of $795 million, $885 million, and $886 million, net of interest income of $94 million, $66 million, and $59 million in 2004, 2003, and 2002, respectively, a majority of which income is associated with the notes received in connection with the sale of a 60% controlling interest in Unisource and the sale of our timberlands.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

Asset Retirement Obligations

 

We accrue for asset retirement obligations, which consist primarily of landfill closure costs including waste treatment, storage or disposal costs, in the period in which the obligations are incurred. These costs are accrued at estimated fair value. When the related liability is initially recorded, we capitalize the cost by increasing the carrying amount of the related long-lived asset. Over time, the liability is accreted to its settlement value and the capitalized cost is depreciated over the useful life of the related asset. Upon settlement of the liability, we recognize a gain or loss for any difference between the settlement amount and the liability recorded. Asset retirement obligations with indeterminate settlement dates are not recorded until such dates can be reasonably estimated.

 

Identifiable Intangible Assets

 

We amortize identifiable intangible assets such as patents, trademarks, and trade names using the straight-line method over their estimated useful lives ranging from 5 to 75 years.

 

Impairment of Long-Lived Assets Other Than Goodwill

 

We assess our long-lived assets other than goodwill for impairment whenever facts and circumstances indicate that the carrying amount may not be fully recoverable. To analyze recoverability, we project undiscounted net future cash flows over the remaining life of such assets. If these projected cash flows are less than the carrying amount, an impairment loss is recognized, resulting in a charge to earnings. The impairment loss would be measured as the difference between the carrying amount and the fair value of the assets.

 

Goodwill

 

Goodwill represents costs in excess of fair values assigned to the underlying net assets of acquired businesses. Goodwill is not subject to any method of amortization, but is tested for impairment annually (at the beginning of the third quarter) and when events and circumstances indicate that an impairment may have occurred. When the fair value is less than the related carrying value of the related reporting unit, entities are required to reduce the amount of goodwill through a charge to earnings (see Note 7). Fair value is estimated based on projected discounted cash flows.

 

Derivative Instruments

 

We use derivative instruments to manage certain interest rate and commodity price exposures. We have established policies and procedures for risk assessment and the approval, reporting and monitoring of derivative instrument activities. Derivative instruments are entered into for periods consistent with the related underlying exposure and are not entered into for trading or speculative purposes.

 

All derivatives are recognized on the balance sheet at their fair value. On the date a derivative contract is entered into, we designate the derivative as either a fair value hedge, a cash flow hedge, the hedge of a net investment in a foreign operation, a non-designated derivative instrument, or a normal purchase/sale contract. Derivatives used to hedge forecasted cash flows associated with forecasted commodity purchases and forecasted interest payments are accounted for as cash flow hedges. Gains and losses on derivatives designated as cash flow hedges are recorded in other comprehensive income and reclassified into earnings in a manner that matches the timing of the earnings impact of the hedged transaction. Changes in the fair value of derivatives used to hedge the fair value of our fixed rate debt are reported in the statements of operations along with the offsetting

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

changes in fair value of the items being hedged. Changes in the fair value of any non-designated derivative instruments and any ineffectiveness in cash flow and fair value hedges are reported in current period earnings. In the event a designated hedged item is sold, extinguished or matures prior to the termination of the related derivative instrument, the derivative instrument would be closed and the resulting gain or loss would be recognized in income.

 

We formally document all relationships between hedging instruments and the hedged items, as well as our risk-management objectives and strategy for undertaking various hedge transactions. We formally assess, both at the hedge’s inception and on an ongoing basis, whether the derivatives that are used in hedging transactions are highly effective in offsetting changes in the hedged items.

 

Shipping and Handling Costs

 

Certain shipping and handling costs are classified as selling and distribution expenses. Shipping and handling costs included in selling and distribution expenses were $319 million, $414 million and $525 million in 2004, 2003, and 2002, respectively.

 

Advertising Costs

 

Advertising costs are expensed as incurred and totaled $233 million, $219 million and $222 million in 2004, 2003 and 2002, respectively.

 

Research and Development Costs

 

Research and development costs are expensed as incurred and totaled $61 million, $64 million and $65 million in 2004, 2003 and 2002, respectively.

 

Environmental and Legal Matters

 

We recognize a liability for environmental remediation and legal indemnification and defense costs when we believe it is probable a liability has been incurred and the amount can be reasonably estimated. The liabilities are developed based on currently available information and reflect the participation of other potentially responsible parties, depending on the parties’ financial condition and probable contribution. The accruals are recorded at undiscounted amounts and are reflected as liabilities on the accompanying consolidated balance sheets. We also have insurance that covers losses on certain environmental claims and legal matters and we record a receivable to the extent that the realization of the insurance is deemed probable. These receivables are recorded at undiscounted amounts and are reflected as assets in the accompanying consolidated balance sheets.

 

Environmental costs are generally capitalized when the costs improve the condition of the property or prevent or mitigate future contamination. All other costs are expensed.

 

Use of Estimates

 

The preparation of financial statements in conformity with generally accepted accounting principles requires management to make estimates and assumptions. These estimates and assumptions affect the reported amounts of assets and liabilities and disclosure of contingent assets and liabilities at the date of the financial statements as well as reported amounts of revenues and expenses during the reporting period. Actual results could differ from these estimates and such differences could be material.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

Accounting Standards Changes

 

In December 2004, the Financial Accounting Standards Board (“FASB”) issued SFAS No. 123 (revised 2004), Share-Based Payment (“SFAS No. 123R”) which is a revision of SFAS No. 123. SFAS No. 123R supersedes APB No. 25 and amends SFAS No. 95, Statement of Cash Flows. Generally, the approach in SFAS No. 123R is similar to the approach described in SFAS No. 123. However, SFAS No. 123R requires all share-based payments to employees, including grants of employee stock options, to be recognized in the income statement based on their fair values. Pro forma disclosure will no longer be an alternative. SFAS No. 123R is effective for the first interim or annual period beginning after June 15, 2005. We expect to adopt SFAS No. 123R effective July 3, 2005.

 

SFAS No. 123R permits public companies to adopt its requirements using one of two methods:

 

  1.   A ‘modified prospective’ method in which compensation cost is recognized beginning with the effective date (a) based on the requirements of SFAS No. 123R for all share-based payments granted after the effective date and (b) based on SFAS No. 123 for all awards granted to employees prior to the effective date of SFAS No. 123R that remain unvested on the effective date.

 

  2.   A ‘modified retrospective’ method which includes the requirements of the modified prospective method described above, but also permits entities to restate the amounts previously recognized under SFAS No. 123 for purposes of pro forma disclosures either for (a) all prior periods presented or (b) prior interim periods in the year of adoption.

 

We plan to adopt SFAS No. 123R using the modified prospective method.

 

Effective December 29, 2002, we adopted SFAS No. 148 using the prospective method. Because SFAS No. 123R must be applied not only to new awards but to previously granted awards that are not fully vested on the effective date, and because we adopted SFAS No. 123 using the prospective transition method (which applied only to awards granted, modified or settled after the adoption date), compensation cost for some previously granted awards that were not recognized under SFAS No. 123 will be recognized under SFAS No. 123R. However, had we adopted SFAS No. 123R in prior periods, the impact of that standard would have approximated the impact of SFAS No. 123 as previously described in the disclosure of pro forma net income and earnings per share. SFAS No. 123R also requires that the benefits of tax deductions in excess of recognized compensation cost be reported as a financing cash flow, rather than as an operating cash flow as required under current literature. This requirement will reduce net operating cash flows and increase net financing cash flows in periods after the effective date. While we cannot estimate what those amounts will be in the future (because they depend on, among other things, when employees exercise stock options), the amounts of operating cash flows recognized in prior periods for such excess tax deductions were $9 million, $4 million, and nil in 2004, 2003 and 2002, respectively.

 

In December 2004, the FASB issued FASB Staff Position (“FSP”) 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 (“FSP 109-1”). The American Jobs Creation Act (“AJCA”) introduces a special tax deduction related to qualified production activities. This deduction is equal to 3% of qualified income for years 2005 and 2006, then is scheduled to increase to a 6% deduction for years 2007 through 2009, and finally, is fully phased-in as a 9% deduction beginning in year 2010. FSP 109-1 clarifies that this tax deduction should be accounted for as a special tax deduction in accordance with SFAS No. 109, Accounting for Income Taxes. Pursuant to the AJCA, we will not be able to claim this tax benefit until the first quarter of fiscal 2005. We do not expect the adoption of these new tax provisions to have a material impact on our consolidated financial position, results of operations or cash flows.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

In December 2004, the FASB issued Staff Position No. 109-2, Accounting and Disclosure Guidance for the Foreign Earnings Repatriation Provision within the American Jobs Creation Act of 2004 (“FSP 109-2”). The AJCA, signed into law on October 22, 2004, provides for a special one-time tax deduction, or dividend received deduction (“DRD”), of 85% of qualifying foreign earnings that are repatriated in either a company’s last tax year that began before the enactment date or the first tax year that begins during the one-year period beginning on the enactment date. FSP 109-2 provides entities additional time to assess the effect of repatriating foreign earnings under the AJCA for purposes of applying SFAS No. 109 which typically requires the effect of a new tax law to be recorded in the period of enactment. We may elect, if applicable, to apply the DRD to qualifying dividends of foreign earnings repatriated in our 2005 fiscal year.

 

We are awaiting further clarifying guidance from the U.S. Treasury Department on certain provisions of the AJCA. Once this guidance is received, we expect to complete our evaluation of the effects of the AJCA during fiscal 2005. Under the limitations on the amount of dividends qualifying for the DRD of the AJCA, the maximum repatriation of our foreign earnings that may qualify for the special one-time DRD is approximately $670 million. Therefore, the range of possible amounts of qualifying dividends of foreign earnings is between zero and approximately $670 million. The related potential range of income tax is between zero and approximately $55 million. The potential tax could be significantly higher if certain provisions of a proposed technical corrections bill are not enacted. The failure to enact such provisions would also be a significant factor in our evaluation of whether to repatriate earnings under the AJCA.

 

In November 2004, the FASB issued SFAS No. 151, Inventory Costs—an Amendment of ARB No. 43, Chapter 4 (“SFAS No. 151”), which is the result of the FASB’s efforts to converge U.S. accounting standards for inventory with International Accounting Standards. SFAS No. 151 requires abnormal amounts of idle facility expense, freight, handling costs, and wasted material to be recognized as current-period charges. It also requires that allocation of fixed production overheads to the costs of conversion be based on the normal capacity of the production facilities. SFAS No. 151 is effective for inventory costs incurred during fiscal years beginning after June 15, 2005. We do not expect the adoption of SFAS No. 151 to have a material impact on our results of operations.

 

During the second quarter of 2004, we adopted FSP No. 106-2, Accounting and Disclosure Requirements Related to the Medicare Prescription Drug, Improvement and Modernization Act of 2003 (“FSP 106-2”). FSP 106-2 provides specific guidance on how to account for the subsidy provided by the Medicare Prescription Drug, Improvement and Modernization Act of 2003 (“the Act”). FSP 106-2 provides for either retroactive application to the date of enactment or prospective application from the date of adoption. We have elected retroactive application to the date of enactment, the impact of which was a reduction to net postretirement benefit cost of approximately $6 million during 2004 and a reduction of the accumulated postretirement benefit obligation of approximately $67 million.

 

In March 2004, the FASB issued EITF Issue No. 03-1, The Meaning of Other-Than-Temporary Impairment and Its Application to Certain Investments (“EITF 03-1”), which provides new guidance for assessing impairment losses on debt and equity investments. Additionally, EITF 03-1 includes new disclosure requirements for investments that are deemed to be temporarily impaired. In September 2004, the FASB delayed the accounting provisions of EITF 03-1; however, the disclosure requirements remain effective. We will evaluate the effect, if any, of EITF 03-1 when final guidance is released.

 

In January 2003, the FASB released Interpretation No. 46, Consolidation of Variable Interest Entities (“FIN 46”) which requires the primary beneficiary of a variable interest entity (“VIE”) to consolidate such entity. In December 2003, the FASB published a revision to FIN 46 (“FIN 46R”) to clarify some of the provisions of the interpretation and to defer the effective date of implementation for certain entities. Under the guidance of

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

FIN 46R, entities that do not have interests in structures that are commonly referred to as special purpose entities are required to apply the provisions of the interpretation in financials statements for periods ending after March 14, 2004. We do not have interests in any variable interest entities.

 

On December 29, 2002, we adopted SFAS No. 143, Accounting for Asset Retirement Obligations (“SFAS No. 143”). SFAS No. 143 requires that entities record the fair value of an asset retirement obligation in the period in which it was incurred. The cumulative effect of adopting SFAS No. 143 was an after-tax credit of $28 million effective at the beginning of 2003.

 

Effective in the first quarter of 2002, we adopted SFAS No. 142, Goodwill and Other Intangible Assets (“SFAS No. 142”). In accordance with the transition provisions of SFAS No. 142, we completed our initial assessment of the fair value of all acquisition-related goodwill during the second quarter of 2002. The cumulative effect of the adoption of this principle was an after-tax charge to earnings of $545 million effective at the beginning of 2002. The $545 million goodwill impairment related only to our paper distribution segment. The principal facts and circumstances leading to this impairment included a diminution of the synergies we originally expected to receive in our bleached pulp and paper segment after the sale of our stand-alone paper mills sold to Domtar, Inc. in 2001, and worsening conditions in the coated and office paper industry subsequent to the acquisition of Unisource.

 

Reclassifications

 

Certain 2003 and 2002 amounts have been reclassified to conform with the 2004 presentation.

 

Fiscal Year

 

Our fiscal year ends on the Saturday closest to December 31. Typically, our fiscal year consists of 52 weeks ending on Saturday. Our fiscal year ended January 3, 2004 consisted of 53 weeks.

 

Discontinued Operations

 

On May 7, 2004, we sold our stand-alone market pulp mills at Brunswick, Georgia, and New Augusta, Mississippi, and a short-line railroad (see Note 4). The results of operations associated with these businesses have been reported as discontinued operations in the accompanying consolidated statements of operations.

 

The accompanying consolidated statements of cash flows include the effects of both continuing and discontinued operations.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

NOTE 2.    OTHER LOSSES (INCOME), NET

 

The following amounts are included in “Other losses (income), net” in the accompanying consolidated statements of operations:

 

     Fiscal Year Ended

In millions        2004             2003             2002    

Asset impairments:

                      

Bellingham (see Note 5)

   $ 27     $ –       $ –  

Bancroft (see Note 5)

     17       –         –  

Old Town (see Note 5)

     –         74       –  

Dixie (see Note 5)

     –         9       –  

North America Tissue (see Note 5)

     –         21       –  

Unisource (see Note 7)

     –         –         208

Other

     5       31       22

Adjustments to Fox River environmental reserves and insurance receivables (see Note 17)

     (9 )     (66 )     –  

Adjustments to asbestos liabilities and insurance receivables, net (see Note 17)

     159       (93 )     315

(Gain) loss on asset sales:

                      

Sale of railroads (see Note 4)

     –         (50 )     –  

Sales of packaging assets (see Note 4)

     (30 )     (18 )     –  

Sale of 60% interest in Unisource (see Note 4)

     –         –         298

Sale of building products distribution (see Note 4)

     (20 )     –         –  

Sale of interests in a Brazilian pulp business (see Note 4)

     (24 )     –         –  

Sale of lumber mills (see Note 4)

     (5 )     –         –  

Other

     –         6       26

Cost associated with early extinguishment of debt

     76       –         –  

Other

     (3 )     –         –  

Other losses (income), net

   $ 193     $ (86 )   $ 869

 

NOTE 3.    OPERATING SEGMENT INFORMATION

 

During 2004, we had six reportable operating segments: North America consumer products, international consumer products, packaging, bleached pulp and paper, building products manufacturing, and building products distribution.

 

    The North America consumer products segment produces and sells retail and commercial tissue products and the Dixie® line of disposable plates, cups, containers and cutlery.

 

    The international consumer products segment consists of the European retail and commercial tissue businesses and certain joint ventures located internationally.

 

    The packaging segment produces and sells linerboard, medium and corrugated packaging.

 

    The bleached pulp and paper segment produces and sells office paper and writing papers, bleached board, bleached and unbleached kraft papers, and pulp.

 

    The building products manufacturing segment produces and sells wood panels (plywood, oriented strand board, hardboard and particleboard), lumber, gypsum products and chemicals.

 

    The building products distribution segment, which sold a wide range of building products manufactured by us or purchased from others, was sold in May of 2004.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

Markets for the North America consumer products, international consumer products, packaging, and bleached pulp and paper segments are affected primarily by fluctuations in raw material costs such as wood, recycled paper and pulp, competition from companies of various sizes on the basis of brand recognition and loyalty, the overall level of economic growth in the United States and export markets, and fluctuations in currency exchange rates.

 

Markets for the building products segment are affected primarily by the level of housing starts, the level of repairs, remodeling and additions, industrial markets, industrial and commercial building activity, the availability and cost of financing, and changes in industry capacity. Recent consolidations in the building products business among our competitors and increased access to the United States market by foreign competitors also affect the markets for the building products segments.

 

The accounting policies of the segments are substantially the same as those described in the summary of significant accounting policies. We evaluate performance based on profit or loss from operations before interest and income taxes, i.e., operating profit or loss.

 

We account for intersegment sales and transfers as if the sales or transfers were to third parties, that is, at current market prices.

 

Our reportable segments are strategic business units that offer different products and services. They are managed separately because each business has different customers and requires different production processes.

 

The “Other” nonreportable segment includes some miscellaneous businesses, unallocated corporate operating expenses, and the elimination of intersegment sales and related profit.

 

We have a large and diverse customer base, which includes numerous customers located in foreign countries. No single unaffiliated customer accounted for more than 10% of total sales in any year during the three years ended January 1, 2005. However, our top 10 customers accounted for approximately 23% of our accounts receivable balance at January 1, 2005. Sales in foreign markets in 2004, 2003 and 2002 were 14% in each of the past three years. These sales were primarily to customers in Europe. Information on operations in the United States and foreign markets is:

 

Geographic Data

 

     Fiscal Year Ended

In millions    2004    2003    2002

Revenues(1)

                    

United States

   $ 16,882    $ 17,186    $ 19,848

Foreign countries

     2,774      2,470      2,867

Net sales

   $ 19,656    $ 19,656    $ 22,715

Property, plant and equipment

                    

United States

   $ 6,971    $ 7,228    $ 7,540

Foreign countries

     1,434      1,354      1,179

Property, plant and equipment

   $ 8,405    $ 8,582    $ 8,719

(1)   Revenues are attributed to countries based on location of customer.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

The following summarizes certain financial information by segment:

 

In millions    2004    2003    2002

Net sales to third-party customers:

                    

North America consumer products:

                    

Tissue

   $ 4,662    $ 4,478    $ 4,440

Dixie

     985      942      897

Other

     8      10      8

Total North America consumer products

     5,655      5,430      5,345

International consumer products

     2,072      1,941      1,663

Packaging:

                    

Containerboard

     617      565      536

Packaging

     2,244      2,104      2,062

Railroads

     –        2      1

Total packaging

     2,861      2,671      2,599

Bleached pulp and paper:

                    

Market pulp

     74      45      39

Bleached board

     247      224      200

Paper

     951      960      802

Other

     352      292      273

Total bleached pulp and paper

     1,624      1,521      1,314

Paper distribution:

                    

Fine paper

     –        –        2,911

Supply systems

     –        –        1,826

Total paper distribution

     –        –        4,737

Building products manufacturing:

                    

Wood panels

     2,500      1,372      1,060

Lumber

     1,242      1,009      973

Gypsum products

     909      712      625

Chemicals

     588      494      445

Other

     314      243      225

Total building products manufacturing

     5,553      3,830      3,328

Building products distribution:

                    

Wood panels

     890      1,976      1,655

Lumber

     651      1,501      1,362

Other

     342      782      710

Total building products distribution

     1,883      4,259      3,727

Corporate and other(1)

     8      4      2

Total net sales

   $ 19,656    $ 19,656    $ 22,715

(1)   Includes net sales from miscellaneous businesses.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

In millions   

North America

Consumer
Products

  

International

Consumer
Products

   Packaging    Bleached Pulp
and Paper(4)
   

Paper

Distribution

 

2004

                                     

Net sales to third-party customers

   $ 5,655    $ 2,072    $ 2,861    $ 1,624     $ –    

Intersegment sales

     1      –        107      606       –    


Net sales

   $ 5,656    $ 2,072    $ 2,968    $ 2,230     $ –    


Operating profit (loss)

   $ 698    $ 174    $ 304    $ 51     $ –    

Depreciation, amortization and accretion

     396      122      132      104       –    

Property, plant and equipment investments

     231      88      154      74       –    

Acquisitions

     –        –        21      –         –    

Assets

     10,968      3,421      2,360      1,396       –    

2003

                                     

Net sales to third-party customers

   $ 5,430    $ 1,941    $ 2,671    $ 1,521     $ –    

Intersegment sales

     4      –        116      532       –    


Net sales

   $ 5,434    $ 1,941    $ 2,787    $ 2,053     $ –    


Operating profit (loss)

   $ 601    $ 160    $ 345    $ (48 )   $ –    

Depreciation, amortization and accretion

     378      106      163      120       –    

Property, plant and equipment investments

     364      65      100      49       –    

Acquisitions

     –        –        5      –         –    

Assets

     11,246      3,224      2,281      1,435       –    

2002

                                     

Net sales to third-party customers

   $ 5,345    $ 1,663    $ 2,599    $ 1,314     $ 4,737  

Intersegment sales

     110      –        141      648       18  


Net sales

   $ 5,455    $ 1,663    $ 2,740    $ 1,962     $ 4,755  


Operating profit (loss)

   $ 851    $ 141    $ 321    $ 36     $ (516 )

Depreciation, amortization and accretion

     356      88      161      122       19  

Property, plant and equipment investments

     363      62      70      47       7  

Acquisitions

     –        –        6      –         –    

Assets

     11,350      2,673      2,325      1,506       –    

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

In millions   

Building Products

Manufacturing

  

Building Products

Distribution

   All
Other
    Consolidated

2004

                            

Net sales to third-party customers

   $ 5,553    $ 1,883    $ 8 (1)   $ 19,656

Intersegment sales

     1,339      3      (2,056 )(2)     –  

Net sales

   $ 6,892    $ 1,886    $ (2,048 )   $ 19,656

Operating profit (loss)

   $ 997    $ 111    $ (711 )(3)   $ 1,624

Depreciation, amortization and accretion

     159      3      22       938

Property, plant and equipment investments

     112      –        54       713

Acquisitions

     –        –        3       24

Assets

     2,379      –        2,548       23,072

2003

                            

Net sales to third-party customers

   $ 3,830    $ 4,259    $ 4 (1)   $ 19,656

Intersegment sales

     2,055      7      (2,714 )(2)     –  

Net sales

   $ 5,885    $ 4,266    $ (2,710 )   $ 19,656

Operating profit (loss)

   $ 378    $ 98    $ (282 )(3)   $ 1,252

Depreciation, amortization and accretion

     163      19      24       973

Property, plant and equipment investments

     57      –        75       710

Acquisitions

     5      –        –         10

Assets

     2,319      –        3,900 (5)     24,405

2002

                            

Net sales to third-party customers

   $ 3,328    $ 3,727    $ 2 (1)   $ 22,715

Intersegment sales

     1,837      10      (2,764 )(2)     –  

Net sales

   $ 5,165    $ 3,737    $ (2,762 )   $ 22,715

Operating profit (loss)

   $ 129    $ 50    $ (703 )(3)   $ 309

Depreciation, amortization and accretion

     164      22      26       958

Property, plant and equipment investments

     61      –        83       693

Acquisitions

     –        –        –         6

Assets

     2,283      –        4,492 (5)     24,629

(1)   Amounts include net sales from miscellaneous businesses.
(2)   Elimination of intersegment sales.
(3)   Includes some miscellaneous businesses, unallocated corporate operating expenses and the elimination of profit on intersegment sales.
(4)   Amounts in 2004, 2003 and 2002 include losses of $16 million, $15 million and $1 million, respectively, from our equity investment in Unisource.
(5)   Includes net assets held for sale of $1,496 million and $1,647 million in 2003 and 2002, respectively.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

Reconciliation to Net Income (Loss)

 

     Fiscal Year Ended

 
In millions    2004     2003     2002  

Total operating profit

   $ 1,624     $ 1,252     $ 309  

Interest, net

     701       819       827  


Income (loss) from continuing operations before income taxes

     923       433       (518 )

Provision (benefit) for income taxes

     297       109       (318 )


Income (loss) from continuing operations

     626       324       (200 )

(Loss) income from discontinued operations, net of taxes

     (3 )     (98 )     10  


Income (loss) before accounting changes

     623       226       (190 )

Cumulative effect of accounting changes, net of taxes

     –         28       (545 )


Net income (loss)

   $ 623     $ 254     $ (735 )


 

NOTE 4.    DIVESTITURES

 

Building Products Distribution

 

On May 7, 2004, we completed the sale of our building products distribution segment to BlueLinx Holdings Inc., for $808 million. In addition, we received $173 million in cash in June to settle an intercompany payable related to product sold to the building products distribution business prior to closing. This transaction resulted in a pre-tax gain of $20 million, a portion of which was recognized in the third quarter upon final working capital settlement with the buyer. The gain is included in “Other losses (income), net” in the consolidated statements of operations.

 

In connection with the sale, we entered into a six-year agreement whereby BlueLinx Holdings Inc. will continue purchasing structural panels, lumber and other building products manufactured by us. This supply agreement contains substantially similar terms as the previous arrangement between our building products manufacturing and building products distribution businesses. Because our continuing involvement with this business via this supply agreement is considered significant, the building products distribution business is not permitted to be reported as a discontinued operation in accordance with SFAS No. 144, Accounting for the Impairment and Disposal of Long-Lived Assets. The building products distribution business was deemed to be held for sale and the related assets and liabilities were retroactively classified as such in our January 3, 2004 balance sheet. We ceased depreciation of the related assets on March 12, 2004 (the date of the definitive agreement).

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

The following are the major classes of assets and liabilities for the building products distribution business that were reflected in our balance sheet as assets held for sale and liabilities related to assets held for sale at January 3, 2004:

 

BUILDING PRODUCTS DISTRIBUTION ASSETS AND LIABILITIES HELD FOR SALE

CONDENSED BALANCE SHEETS

 

In millions     

ASSETS

      

Current assets

   $ 571

Property, plant and equipment, net

     201

Total assets

   $ 772

LIABILITIES:

      

Current liabilities

   $ 126

Deferred income tax liabilities

     3

Total liabilities

   $ 129

Net assets

   $ 643

 

Stand-Alone Market Pulp Mills

 

On May 7, 2004, we completed the sale of our stand-alone market pulp mills at Brunswick, Georgia, and New Augusta, Mississippi, along with a short-line railroad, to Koch Cellulose, LLC (“Koch”) and its subsidiaries for $520 million in cash. In addition, Koch assumed $73 million of indebtedness. This transaction resulted in a pre-tax gain of $6 million and an after-tax loss of $12 million that are included in “Loss (income) from discontinued operations, net of taxes” on the consolidated statements of operations.

 

These pulp businesses were reported as discontinued operations through the date of the sale and the related assets and liabilities were retroactively classified as held for sale in our January 3, 2004 balance sheet. We ceased depreciation of the related assets on February 26, 2004 (the date of the definitive agreement). These pulp businesses were previously reported in the bleached pulp and paper segment.

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

The following are major classes of assets and liabilities for these discontinued operations that were held for sale at January 3, 2004:

 

DISCONTINUED OPERATIONS CONDENSED BALANCE SHEETS

 

In millions     

ASSETS

      

Current assets

   $ 168

Property, plant and equipment, net

     338

Goodwill, net

     172

Other assets

     1

Total assets

   $ 679

LIABILITIES:

      

Current liabilities

   $ 63

Long-term debt

     97

Deferred income tax liabilities

     100

Other long-term liabilities

     6

Total liabilities

   $ 266

Net assets

   $ 413

 

Operating results of these discontinued operations are shown below:

 

     Fiscal Year Ended

In millions        2004             2003             2002    

Net sales

   $ 220     $ 599     $ 556

Costs and expenses:

                      

Cost of sales

     179       473       432

Selling and distribution

     6       16       14

Depreciation, amortization and accretion

     13       73       71

General and administrative

     4       15       14

Interest, net

     5       14       14

Other (income) losses, net

     (6 )     106       1

Total costs and expenses

     201       697       546

Income (loss) from discontinued operations before income taxes

     19       (98 )     10

Provision for income taxes

     22       –         –  

(Loss) income from discontinued operations, net of taxes

   $ (3 )   $ (98 )   $ 10

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

In addition to our building products distribution business and our stand-alone market pulp mills, we sold the following other non-strategic assets, and included the related gains and losses in “Other losses (income), net” on the consolidated statements of operations. These sales are detailed in the following table:

 

In millions    Proceeds   

Pre-tax gain/(loss)

included in
other income

 
2004:                

Brazilian pulp business

   $ 70    $ 24  

Packaging assets

     46      30  

Other

     63      5  
   

2003:

               

Short line railroads

   $ 56    $ 50  

Packaging assets

     15      18  

Other

     21      (6 )
   

2002:

               

Other

   $ 23    $ (26 )

 

Effective November 2, 2002, we sold a 60% controlling interest in Unisource, our paper distribution business, to an affiliate of Bain Capital Partners, LLC, and retained the remaining 40% equity interest in Unisource. In connection with the sale, we received $471 million in cash and notes with a recorded book value of $105 million. As of January 1, 2005, we own a 38.85% interest in Unisource. In connection with this disposal, we recorded a pre-tax loss of $298 million in 2002 in the paper distribution segment. In addition, we entered into a financing lease arrangement with a third party regarding certain warehouse facilities used by Unisource under which we received $169 million in cash. We then subleased these facilities to Unisource.

 

In the second quarter of 2003, we received a cash refund of more than $193 million from the related income tax benefit of the Unisource sale. For further information, see Note 18.

 

As part of this transaction, we entered into a loan agreement with Unisource pursuant to which we agreed to provide, subject to certain conditions, a $100 million subordinated secured loan to Unisource. This subordinated loan, if drawn, will mature in May 2008 and bears interest at a fluctuating rate based on LIBOR. No amounts were outstanding under this loan at January 1, 2005. In addition, we have also agreed to provide certain employee benefits and other administrative services to Unisource pursuant to an agreement with a two-year term. We also agreed to allow Unisource to participate in certain insurance coverage (including related letters of credit) to Unisource, generally for a period of five years, including workers’ compensation, general liability, automobile liability and property insurance.

 

Beginning in November 2002, we have accounted for our investment in Unisource using the equity method and have reported its results in the bleached pulp and paper segment.

 

NOTE 5.    RESTRUCTURING AND ASSET IMPAIRMENTS

 

During the fourth quarter of 2004, we made the decision to permanently close our previously-idled Bancroft, Ontario particleboard plant due to industry oversupply. As a result of this decision, we wrote down the value of the facility and related equipment through a pre-tax charge of $20 million for asset impairment. Following the impairment charge, the carrying value of these assets was approximately $3 million. The estimate of the fair value of the impaired assets was based on an analysis of previous sales of similar facilities taking into consideration circumstances specific to this facility. We also recorded a pre-tax charge of approximately $1 million for employee

 

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NOTES TO CONSOLIDATED FINANCIAL STATEMENTS—(Continued)

 

severance. Of the total charges of $21 million, $17 million was recorded in “Other losses (income), net” with the remainder recorded as cost of sales in the accompanying consolidated statements of operations.

 

In December 2004, we signed a definitive agreement with the Bellingham Port Authority (the “Port”) to sell and leaseback the land associated with our Bellingham, Washington facilities. The transaction closed in January 2005. Under the terms of the agreement, we received no cash but the Port assumed substantially all of our environmental liabilities associated with the facility. Because the value of the liabilities assumed by the Port was less than the carrying value of the assets sold, we recorded pre-tax asset impairment charges of $27 million in “Other losses (income), net” in the accompanying consolidated statement of operations. Following the impairment charge, the carrying value of these assets was approximately $6 million, the balance of our environmental liability being assumed.

 

In December 2003, we shut down certain high cost tissue machines and shifted production to lower cost facilities, including those using through-air-dried technology. As a result of these shut downs, we wrote off the value of the machines and recorded a pre-tax charge of $21 million in the North America consumer products segment in the fourth quarter in 2003. The determi