BUSINESS
Overview
We believe that we are a leading producer and distributor of specialty egg
products to the foodservice, retail and industrial ingredient markets. We
believe that we are also a leading producer and distributor of refrigerated
potato products to the retail market. In addition, we distribute refrigerated
food items, primarily cheese and other dairy products, to the retail grocery
market predominantly in the central United States. For the year ended
December 31, 2003, we generated net sales of $1,180.5 million on a pro forma
basis after giving effect to the sale of the dairy products division, which the
predecessor sold effective September 30, 2003.
We believe that our largest operating division, our egg products division, is
one of the largest producers of processed egg products in the United States with
an estimated 44% share of the processed egg market, and we believe it is three
times larger than its closest competitor. We also participate in the higher
value-added sector of the U.S. processed egg market, which includes extended
shelf-life, or ESL, liquid eggs, precooked egg patties and omelets, low/no
cholesterol liquid eggs and hardcooked eggs. During the year ended December 31,
2003, we processed approximately 1.4 billion pounds of eggs through our
fully-integrated national operations, and we believe we are the lowest cost
producer of processed egg products in the United States.
Since 2000, we have grown our sales volumes of higher value-added egg products
at more than twice the industry growth rate for egg consumption. Moreover, we
have benefited from our ability to capitalize on favorable consumer and food
industry trends by introducing new, higher value-added egg products. This
ability has helped us to improve our egg products division's operating profit
margin from 3.3% in 1992 to 9.5% for the year ended December 31, 2003.
We offer our customers a wide range of products within our food categories. Our
strategy within these categories is to focus on higher-margin specialty sectors
(such as processed egg products and refrigerated potato products) which we
believe are growing at a higher rate than their respective food categories. We
also seek to develop and market products that address key food industry
concerns, including food safety, convenience, product quality and consistency
and labor and waste reduction. Our products are primarily sold through
long-standing preferred supplier relationships with major foodservice
distributors and national restaurant chains. For the year ended December 31,
2003, sales to Sysco and U.S. Foodservice accounted for approximately 13% and
15%, of our external net sales, respectively. The following charts set forth the
net sales and operating profit of our three divisions-egg products, potato
products and refrigerated distribution-as a percentage of total net sales and
operating profit for these three divisions for the year ended December 31, 2003.
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Egg Products. We believe that our egg products division, comprised primarily of
M.G. Waldbaum Company, Papetti's Hygrade Egg Products, Inc., MFI Food Canada,
Ltd. and Trilogy Egg Products, Inc., is one of the largest producers of
processed egg products and the fourth largest egg producer in the United States.
Our higher-margin specialty products include ESL liquid eggs, precooked egg
patties and omelets, low/no cholesterol
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liquid egg products and hardcooked eggs. Our retail grocery brands include
Better 'n Eggs and All Whites and our foodservice brands include Table Ready and
Easy Eggs. The egg products division's major customers include leading
foodservice distributors, such as Sysco Corporation and U.S. Foodservice,
national restaurant chains, such as Burger King Corporation, IHOP Corp.
(International House of Pancakes), Sonic Corp. and Dunkin' Donuts Incorporated,
major retail grocery store chains, such as Costco Wholesale Corporation,
Wal-Mart Stores Inc. and Ahold USA Retail Operations and major industrial
ingredient customers, such as General Mills, Inc. and Unilever Bestfoods North
America Foodservice. For the year ended December 31, 2003, the egg products
division represented approximately 70% and 75% of the net sales and the
operating profit of our three divisions, respectively.
Potato Products. Our potato products division, comprised primarily of Northern
Star Co. and Farm Fresh Foods, Inc., produces and distributes refrigerated
potato products to the retail grocery and foodservice markets. Our products
principally include hash browns and diced, sliced, mashed and other specialty
potato products. The potato products division is the national retail market
leader in refrigerated potato products with an estimated 57% share in the retail
grocery market under the Simply Potatoesand Diner's Choice brands. Our branded
retail refrigerated potato products' annual volume has doubled since 1997. Due
to their freshness and quality, refrigerated potato products are generally sold
at higher price points than frozen potato products and, according to our
consumer studies, have superior taste and texture characteristics. In addition,
we use a production process that produces a 75-day shelf-life for our potato
products, which we believe is the longest in the retail refrigerated potato
products market. Our belief is based on routine review and monitoring of
information relating to the shelf-life of our competitors' products as presented
on the containers and packaging of their products. The potato products
division's largest customers include major retail grocery store chains, such as
The Kroger Co., Publix Super Markets, Inc. and Food Lion LLC and major
foodservice distributors, such as Sysco and U.S. Foodservice. For the year ended
December 31, 2003, the potato products division represented approximately 6% and
9% of the net sales and the operating profit of our three divisions,
respectively.
Refrigerated Distribution. Our refrigerated distribution division, comprised
primarily of Crystal Farms Refrigerated Distribution Company and Wisco Farm
Cooperative, is a distributor of over 400 branded and private label refrigerator
case items to retailers and wholesale warehouses predominantly in the central
United States. The refrigerated distribution division's principal product line
is its Crystal Farms branded cheese, which has a strong presence in the upper
Midwest region of the United States and the largest market share for branded
cheese in Minnesota. Crystal Farmsbranded cheese generated approximately $135.0
million of net sales in the twelve months ended December 31, 2003. This division
also distributes shell eggs, bagels, butter, margarine and our refrigerated
potato and other products. The refrigerated distribution division's largest
customers include major grocery retailers, such as SUPERVALU Inc./Cub Foods
Stores and Roundy's, Inc. For the year ended December 31, 2003, our refrigerated
distribution division sales to SUPERVALU and its affiliates accounted for
approximately 40% of the refrigerated distribution division's net sales volume.
For the year ended December 31, 2003, the refrigerated distribution division
represented approximately 24% and 16% of the net sales and operating profit of
our three divisions, respectively.
Industry Trends
We believe that our specialty egg products are well positioned to continue
capitalizing on the growth of the foodservice industry, which is being driven by
increasing food consumption away from home. We also believe that the egg
products division will benefit from several trends, including continued
increases in processed egg consumption. Our business is influenced by the
following industry trends:
Growth in Foodservice. According to the USDA, purchases of food prepared away
from home in the United States have grown from 35.8% of total food purchases in
1975 to 46.1% in 2002, and we expect this trend to continue. The increase in
foodservice sales has been largely driven by demographic changes, including the
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increases in personal disposable income, single parent households and dual
income families. We expect this growth in foodservice sales to continue to lead
to increased demand for processed food products. Additionally, we believe that
the focus of the foodservice industry on increasing product safety, reducing
preparation costs and outsourcing more of the food preparation process
complements our product portfolio and new product development efforts.
As a producer of processed egg products and refrigerated potato products, we
believe that we meet the needs of our clients primarily for the following
reasons:
processed food products which are already partially-to-fully processed
reduce the amount of labor needed in the foodservice kitchen to prepare
a meal;
processed food products are typically processed (using processes
such as our UHT process) to reduce bacteria counts and, hence,
provide enhanced food safety;
processed food products generally exhibit longer shelf-lives than
unprocessed foods and are sold in packages which generally provide
ease-of-use and portion control, thus reducing spoilage and waste;
and
processed food products are processed in ways that increase the
consistency of the products.
Our new product development efforts are largely focused on the needs of our
foodservice clients, namely on reducing their labor costs and food waste and
enhancing food safety and consistency.
Growth in Egg Consumption. According to the USDA, egg consumption increased at a
compounded annual growth rate of 2.0% between 1991 and 2001. This growth was
partially due to a shift in consumer perception of the health attributes of
eggs, as well as new applications for eggs. In addition, we believe the recent
increase in popularity of high protein, low carbohydrate diets has had a
positive impact on egg consumption in the United States. In 2000, the American
Heart Association revised its nutritional recommendations that limited the
weekly intake of eggs. We believe this action helped improve the perception of
eggs as a healthy part of a balanced diet.
Growth in Higher Value-Added Processed Egg Products. The growth in food
consumption away from home and the development of new egg products has resulted
in an increase in the production and consumption of processed egg products.
According to the USDA, approximately 28.9% of all eggs consumed in the United
States in 2001 were processed, up from approximately 21.7% in 1991. This
represents a 4.9% compounded annual growth rate in consumption of processed eggs
from 1991 to 2001 compared with an overall increase in the consumption of eggs
at a compounded annual growth rate of 2.0% during that period. Requirements of
the foodservice industry for food safety and concerns regarding product quality,
consistency and convenience have served to increase the consumption of higher
value-added egg products such as ESL liquid eggs and precooked eggs. We have
witnessed this trend within our customer base as former shell egg purchasers
such as Burger King and IHOP recognize the operational and economic benefits of
processed egg products.
Consolidation in Foodservice Distribution Channel. Leading foodservice
distributors continue to consolidate the foodservice industry in an effort to
improve and broaden their product offerings, competitiveness and profitability.
For example, according to ID Magazine, a foodservice industry publication, the
top 20 foodservice distributors have increased their share of total industry
sales from 22.5% in 1991 to 32.6% in 2001. As foodservice distributors
consolidate, we believe they will increasingly choose to do business with
national suppliers that have broad product lines and extensive service
capabilities to meet both the scale and the scope of their operational
requirements. By using national suppliers, foodservice distributors are able to
simplify operations by dealing with fewer vendors that have the production,
warehousing and distribution capabilities necessary to meet their needs. Large
order volumes also allow foodservice distributors to benefit from favorable
pricing terms we offer our major customers.
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Market, Ranking and Other Data
The data included in this prospectus regarding markets and ranking, including
the size of certain markets and our position and the position of our competitors
within these markets, is based on reports of government agencies or published
industry sources and our estimates based on our management's knowledge and
experience in the markets in which we operate. Our estimates have been based on
information obtained from our customers, distributors, suppliers, trade and
business organizations and other contacts in the markets in which we operate.
Consumption patterns and consumer preferences can and do change rapidly, which
could result in changes in data presented in this prospectus.
Our Competitive Strengths
We believe that the following key competitive strengths will contribute to our
continued success:
Extensive Portfolio of Specialty and Branded Products with Leading Regional and
National Market Positions. We specialize in the development, production and
distribution of specialty food products that address many of the needs of the
foodservice and the retail markets. We have been successful in developing new
and innovative products as evidenced by a broad portfolio of strong market
positions and leading brands, as shown in the table below.
Market Position
Division Products Key Brands (1)
Egg Products ESL liquid eggs Easy Eggs No. 1 U.S. market
Precooked eggs Table Ready share of processed
Hardcooked eggs Better'n Eggs egg products (2)
Low/no All Whites
cholesterol
liquid eggs
Other (3)
Potato Products Refrigerated cut Northern Star No. 1 U.S. retail
and mashed potato Simply Potatoes market share
products Diner's Choice
Refrigerated Processed and Crystal Farms No. 1 Minnesota
Distribution wrapped cheeses market share for
and other branded cheese
products Strong upper
Midwest market
share
$135.0 million
retail cheese
brand
(1) Market position data is derived primarily from our own estimates,
which are based on information we obtained from customers,
distributors, suppliers and trade and business organizations. See
also "-Market, Ranking and Other Data."
(2) Market position for processed egg products is not derived
from a third party source but rather is reflective of our own
belief, which is based on the estimate we calculated by
comparing the volume of processed eggs we produced in 2003
against the data provided by the USDA for the total market
volume of processed eggs produced in 2003. See also "-Market,
Ranking and Other Data."
(3) "Other" egg products include short shelf-life liquid eggs,
dried eggs, frozen eggs and shell eggs.
Long-Standing Customer Relationships. Our high quality products, manufacturing
scale and capability, extensive focus on customer service and customer-focused
product development have helped us to build and retain a strong and diverse
customer base. We have long-standing preferred supplier relationships with the
major broad-line foodservice distributors, serving as their leading supplier of
specialty egg and refrigerated potato products. In addition, we have
long-standing relationships with many national restaurant chains that serve
breakfast, major industrial ingredient companies and major retail grocery store
chains. Our average length of
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relationship with our top ten egg products and potato products customers exceeds
10 years. We believe these long-standing relationships are the result of our
high quality products and service levels.
Large Scale Operator with Efficient Manufacturing Operations. During the year
ended December 31, 2003, we processed approximately 1.4 billion pounds of eggs.
We believe our significant annual volume combined with our diversified egg
procurement and highly automated manufacturing facilities provide us with a cost
advantage in the marketplace. Over the last six years, we have invested to
expand our manufacturing capacity for value-added egg products, to upgrade our
potato product operations, to improve and expand our distribution centers, to
install a new company-wide management information system and to otherwise
position ourselves for future growth. These investments include the installation
of new precooked egg production lines, a new dried egg facility, automated
packaging equipment and quality control systems. Additionally, our diverse
geographic presence, with core manufacturing facilities in the Midwest and
eastern United States, allows us to serve customers cost-effectively throughout
the United States. We believe that our operational scale, product breadth and
geographic scope make us an attractive and important strategic partner for
foodservice distributors, major restaurant chains and industrial ingredient
companies.
Industry Leading Product Development Capability. We leverage our innovation and
product development capabilities to develop new specialty products and improve
existing specialty products. We conduct our research and development activities
through designated facilities, including our state-of-the-art pilot plant for
egg products in Gaylord, Minnesota. Our staff works closely with current and
prospective customers to either adapt existing products to meet specific
customer applications or to create and commercialize new customized specialty
food products. Over the last few years, we have introduced, both independently
and in conjunction with our customers, several new products and line extensions
including precooked puffed egg patties and specialty dried eggs products.
Products currently being test marketed include omelets for the retail market,
precooked egg fillings for breakfast wraps, refrigerated French fries and French
toast sticks.
Strong, Proven Management Team with Significant Equity Interest. We have an
experienced and successful senior management team that has an average of over 20
years of food industry experience, each of whom has been with Michael Foods for
over 10 years. The management team is headed by Gregg A. Ostrander, who has been
our president and chief executive officer since 1994 and has 28 years of food
industry experience, including management positions with Beatrice Foods Company
and Armour Swift-Eckrich, a division of ConAgra Foods, Inc. Our management team
has a strong track record of product innovation, cost containment and operating
excellence during periods of both rising and falling commodity prices and while
operating under a high degree of financial leverage. Our management team
successfully executed an operational turnaround and subsequent sale of our dairy
products division. Furthermore, our senior management's commitment to the
business is evidenced by their equity investment of $33.0 million, representing,
after the transactions, approximately 10.2% of the total equity invested in our
company.
Stable Free Cash Flow Generation. Our business has generated stable free cash
flow due to the combination of our sales growth, strong operating margins,
stable egg products business and low capital expenditure and working capital
requirements.
Our Business Strategy
Our strategy has enabled us to capitalize upon key industry trends, specifically
the increases in both food prepared away from the home and the consumption of
further-processed eggs. The primary components of our business strategy include
the following:
Encouraging Customers to Purchase our Higher-Margin Products. We seek to
continually transition our customers from lower value-added products to higher
value-added, higher-margin products that offer improved food safety, reduced
labor and waste and improved product quality and consistency. For example, in
1989 we worked with Burger King to help it transition from shell eggs to our
value-added ESL liquid eggs and then, in
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1998, to our higher value-added precooked egg patties. In 2002, we assisted IHOP
in transitioning from shell eggs to ESL liquid eggs, and became its exclusive
supplier of ESL liquid eggs. We believe assisting customers in these transitions
will continue to drive our future financial performance. In addition, we are
actively encouraging and assisting current and prospective customers who may
wish to enter into, or expand their presence in, the profitable foodservice
breakfast category. For example, Sonic and Dunkin' Donuts are using our
precooked egg products as part of their evolving breakfast strategies. Our sales
force identifies customers and potential customers that either do not serve
breakfast or that do not serve a hot breakfast. We are able to increase our
customer's sales volumes through one or more of the following:
Increasing reach (consumer trial),
Increasing frequency (consumer visits),
Increasing party size (larger groups), and/or
Increasing check average (check average being the average revenue per
transaction).
Adding breakfast to our clients' product offerings and introducing new menu
items increases their reach. If a customer already serves breakfast but is not
offering hot breakfast, adding a hot breakfast sandwich generally increases
reach, frequency and check average. With regard to potential customers looking
to add breakfast to their menu offerings, we add value by identifying and
demonstrating the potential opportunity, offering culinary expertise, menu
development and assistance in equipment selection when needed.
Capitalizing On Growth Opportunities. We believe that significant growth
opportunities exist in each of our divisions. We are focused on increasing our
specialty egg products sales to quick service restaurants, coffee- oriented
venues and convenience stores that are seeking to grow revenues by either
broadening their existing breakfast offerings or introducing a breakfast menu to
add to their existing lunch and dinner offerings. For example, we have had
success working with Sonic and Dunkin' Donuts to introduce hot breakfast menus
that include our higher value-added egg products. We are also currently working
with several major national restaurants to introduce a breakfast menu that
includes our higher value-added egg products. In our potato products division,
we plan to continue to participate in the fast growing refrigerated potato
products market. Demonstrating this trend, according to the U.S. Potato Board's
2004-2006 Long Range Plan the fresh potatoes retail market grew (in pounds) by
only 5.8% from 2000 to 2001, compared with a 25% growth (in pounds) in the
refrigerated potatoes retail market during the same period according to AC
Nielsen Corporation. In our refrigerated distribution division, we intend to
expand our geographic reach and increase existing market penetration for our
Crystal Farms branded cheese, while introducing new products and line extensions
under the Crystal Farms label.
Continuing Strategic Sourcing and Cost Reduction Programs. We began a strategic
sourcing program in our egg products division in 2002 in an effort to improve
efficiency in our procurement operations and reduce overall costs. Our strategy
involves focusing our procurement efforts on our key suppliers and working with
them on improving all aspects of the procurement process, including the egg and
grain purchasing function and farm and plant operations. Enhanced communication
and coordination with these key suppliers has served to streamline the
procurement process and has already resulted in benefits to both our suppliers
and to us. Additionally, we have increased volume commitments with our key
suppliers in exchange for improved pricing and terms. We believe the strategic
sourcing program will continue to provide us with operational and financial
benefits, and we expect we will continue to see improved results from this
program over the next several years.
In mid-2003, we began a purchasing and supply chain management, or PSM,
initiative, with the goal of reducing our effectable spending in areas other
than raw material procurement for our egg products division by a cumulative
amount of $55.0 million between 2003 and 2007. We have formed a dedicated task
force, which includes key managers from each of our divisions, to administer
this initiative. This cost reduction initiative is focused on areas where we
believe there are significant opportunities for cost improvement, such as potato
and cheese purchases, freight, packaging materials, technology costs and other
fixed overhead categories. The task
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force has initiated programs which have already resulted in cost savings in the
areas of container procurement, sanitation costs, office supplies and
market-based egg purchases.
Pursuing Attractive Acquisition and Joint Venture Opportunities. We will
continue to evaluate and selectively pursue acquisitions and joint ventures that
expand our product offerings and/or geographic reach and broaden our
technological expertise to complement our existing businesses. Since 1988, we
have completed 17 acquisitions and three joint ventures, including the $106
million acquisition of Papetti's Hygrade Egg Products, Inc. in 1997. The
acquisition of Papetti's significantly increased our market share, scale,
geographic scope and offerings for our egg products division. In recent years,
we have focused on making small strategic acquisitions. For example, in the past
four years, we acquired Ingredient Supply LLC, which expanded our egg products
division's hardcooked eggs product line, acquired the egg products division of
Canadian Inovatech, Inc., one of the largest providers of processed egg products
in Canada, which greatly expanded our presence in international markets,
particularly for the industrial ingredient market, and invested in foreign egg
products joint ventures to expand the geographic coverage of our egg products
division and pursue new technologies.
Egg Products Division
Our egg products division produces, processes and distributes a variety of egg
products and shell eggs. We believe that our egg products division is one of the
largest producers of processed egg products in the United States with an
estimated 44% share of the processed egg market and we believe it is three times
larger than its closest competitor. We also participate in the higher
value-added sector of the United States processed egg market, which includes ESL
liquid eggs, precooked egg patties and omelets, low/no cholesterol liquid eggs
and hardcooked eggs. We serve all significant market channels-foodservice,
retail and industrial ingredient-with a comprehensive product line. During the
year ended December 31, 2003, the egg products division processed approximately
1.4 billion pounds of eggs through its integrated facilities. The division
focuses on producing higher value-added egg products that we believe are safe,
easy to prepare and consistent in quality.
Demand for higher value-added egg products in both the retail and foodservice
markets has been driven by the following factors:
Food Safety Processed egg products are
pasteurized and quality controlled,
which reduces the likelihood of
contamination. As a result,
foodservice companies and major
restaurant chains are choosing
processed egg products as a
lower-risk alternative to unprocessed
eggs.
Labor Reduction/Ease of Use Processed egg products require less
preparation time, reducing labor
costs for foodservice companies and
increasing convenience for individual
purchasers.
Product Quality and Consistency Foodservice companies and national
restaurant chains require consistency
of products throughout their
operations. Processed egg products,
particularly precooked egg products
which are produced to distinct
specifications, provide foodservice
companies and national restaurant
chains with a processed egg product
that provides a more consistent
taste, quality and serving size than
shell eggs.
Efficiency/Waste Reduction Processed egg products reduce the
need for disposal of partially used
product and have fewer packaging and
space requirements.
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Products. Our higher value-added processed egg products are detailed below:
ESL liquid eggs: These products are packaged in cartons and bag-in-box packaging
principally for use in foodservice markets. We use proprietary ultra-high
temperature pasteurization processes to produce our ESL liquid eggs. These
processes produce an egg product that is salmonella and listeria-negative, as
defined by federal law, with a refrigerated shelf-life of up to three months.
Our ESL egg products are marketed under the Easy Eggs and Table Ready brand
names.
Precooked eggs: These products are fully-cooked and packaged at the
manufacturing facility and then reheated at the point of consumption.
Foodservice companies and quick service restaurant chains find these products
attractive because they can reduce labor costs and waste, improve consistency
and require only a minimal infrastructure investment. We will continue to direct
significant production and marketing resources to this product as usage
increases.
Low/no cholesterol eggs: These egg products consist primarily of egg whites sold
in retail grocery market under the names Better 'n Eggs, and All Whites. Egg
substitutes are increasingly popular among health conscious consumers, and are
developing a high level of acceptance in the retail market.
Hardcooked eggs: These products are hard-boiled eggs, which are packaged in
pails with brine solution or in modified atmosphere packs that are designed to
increase both shelf-life and food safety. Hardcooked eggs are sold primarily to
foodservice accounts for use in salads and other dishes.
In addition, our other egg products include frozen eggs, short shelf-life liquid
eggs and dried eggs that we supply in order to provide our customers with a
broad range of egg products. Frozen eggs are used primarily by foodservice and
industrial ingredient customers. Short shelf-life liquid eggs are liquid eggs
packaged with standard pasteurization and are convenient for industrial
ingredient customers, such as bakeries, who will use a large quantity of eggs
within a short time period to produce other products. Dried eggs are used
primarily by industrial ingredient customers in the production of mayonnaise,
salad dressings and baking mixes.
Customers. The egg products division has long-standing preferred supplier
relationships with many of its customers. Our customers include many of the
major broad-line foodservice distributors and many national restaurant chains
that serve breakfast. As the largest processed egg producer in the industry, we
offer our customers a broad product selection, large-scale manufacturing
capabilities and specialized service. The egg products division's major
customers in each of its market channels include leading foodservice
distributors, such as Sysco and U.S. Foodservice, national restaurant chains,
such as Burger King, International House of Pancakes, Sonic Corp. and Dunkin'
Donuts, major retail grocery store chains, such as Costco, Wal-Mart and Ahold
group stores and major industrial ingredient customers, such as General Mills,
Inc. and Unilever Bestfoods North America Foodservice.
The strength of the egg products division's customer base is demonstrated by low
turnover and the long-standing nature of the relationships, exemplified by an
average relationship length in excess of ten years for its top ten customers. As
an example of this type of relationship, the egg products division has a five
year preferred supplier contract (terminable upon six months notice) with U.S.
Foodservice pursuant to which we supply a substantial majority of U.S.
Foodservice's egg products needs. This relationship is over 20 years old. Our
volume with U.S. Foodservice grew 7% during 2002 and we estimate it will be up
approximately 9% in 2003.
Competition. The egg processing industry is heavily concentrated, especially
when compared to the shell egg industry. Sunny Fresh Foods, a subsidiary of
Cargill, is our largest higher value-added egg products competitor. We also
compete with other egg products processors including Sonstegard Foods Company,
Rose Acre Farms, Inc., Echo Lake Farm Produce, Cutler Egg Products, Inc. and
ConAgra Foods.
Sales and Marketing. The division distributes its egg products to food
processors and foodservice customers primarily throughout the United States,
with international sales in the Far East, South America and Europe. The
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largest selling product line within the egg product division, ESL liquid eggs,
and other egg products are marketed nationally to a wide variety of food service
and industrial ingredient customers. Most of the division's annual shell egg
sales (approximately $19.3 million in 2003) are made to our refrigerated
distribution division, which, in turn, distributes them predominantly in the
central United States.
In 2002, the egg products division derived approximately 97% of net sales from
egg products, with 3% of net sales coming from shell eggs. Pricing for shell
eggs and certain egg products in the United States reflects levels reported by
Urner Barry. Prices of certain higher value-added egg products, such as ESL
liquid eggs, egg substitutes, and hardcooked and precooked egg products,
typically are not significantly affected by Urner Barry quoted price levels.
These products accounted for approximately 64% of the egg product division's
2002 sales. Prices for the egg products division's other products, including
frozen and short shelf-life liquid eggs, certain dried products and,
particularly, shell eggs, are significantly affected by frequently changing
market levels as reported by Urner Barry.
Sales Dynamics. The egg products division's supply agreements with its customers
typically last one year. These contracts generally stipulate a number of
conditions including the types of products to be supplied, volume targets,
pricing levels (with weekly, monthly, quarterly or annual revision options),
discount options, delivery and other logistical and administrative parameters.
The contracts generally do not provide for any minimum volume or financial
commitment and typically can be terminated early without penalty. We sell our
egg products based on a mix of variable, semi-variable and fixed price
contracts, of which variable contracts account for approximately 60% of the egg
products division's net sales. Sales of egg products under variable priced sales
contracts are tied to a pricing index, either an Urner Barry egg market or grain
index. Price changes under these sales contracts are based on a formula and
generally allow for a pass-through of cost increases. Our semi-variable sales
contracts generally allow us to change prices by giving 30 to 60 days notice.
These contracts are with major broad-line foodservice distributors who are
generally less sensitive to price increases because their customers purchase
food products from them on a cost-plus basis. Our fixed price egg products sales
contracts generally have durations of up to one year and maturity dates that are
generally staggered throughout the year, effectively reducing our commitment to
fixed priced contracts. We use fixed price contracts because our large national
foodservice customers require fixed pricing in order to manage the prices at
which they sell their products. As a result, we bear commodity risks. To
mitigate these risks, we have established a risk management strategy. For more
information relating to our risk management strategy, see "Management's
Discussion and Analysis of Financial Condition and Results of
Operations-Commodity Risk Management."
Suppliers. In 2002, the egg products division produced approximately a third of
its shell egg requirements at multiple internal egg production facilities. A
majority of the remainder of the division's egg requirements are purchased under
contracts with numerous cooperatives and egg producers at prices primarily
derived from grain-based costs and Urner Barry market indices. No egg supplier
provides more than 10% of the division's annual egg requirements.
Commodity Risk Management. Since variable costs, principally feed costs and the
cost to purchase eggs, represent a large percentage of the total costs of our
egg products, significant price fluctuations in these raw materials could have
an adverse affect on our results of operations. See "Risk Factors-Risk Relating
to Our Company and the Industries We Serve-Our operating results are
significantly affected by egg, potato and cheese market prices and the prices of
other raw materials, such as grain, which can fluctuate widely." Historically,
feed costs have generally been less volatile than egg market prices. Internally
produced eggs typically cost less than eggs we purchase from our suppliers. We
partially hedge key feed costs, such as corn and soybean meal, by using futures
and other purchase contracts. There is no market mechanism for hedging egg
prices. The egg products division has endeavored to moderate the effects of egg
market commodity factors through an emphasis on value-added products and the
internal production of eggs, where egg cost is somewhat controllable. Further,
the egg products division attempts to match market-affected egg sourcing with
the production of egg products whose selling prices are also market-affected,
and cost-affected egg sourcing, as best can be managed, with higher value-added
products priced over longer terms, generally 6-12 months. The former
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allows the division to typically realize a modest processing margin on such
sales, even though there are notable commodity influences on both the egg
sourcing cost and the egg products pricing, with each changing as frequently as
daily. Shell eggs are essentially a commodity and are sold based upon reported
egg prices. Egg prices are significantly influenced by modest shifts in supply
and demand. Pricing of shell eggs is also typically affected by seasonal demand
related to increased consumption during holiday periods. Our operating profit is
significantly affected by egg market prices and prices of other raw materials,
such as grain, which can fluctuate widely. We have a risk management strategy to
mitigate these risks which includes hedging a significant percentage of our
grain commodity requirements, aligning our procurement and sales volumes by
matching the percentage of variable pricing contracts and the percentage of raw
materials procured on a variable basis, negotiating agreements with fixed price
customers to allow us to raise prices in response to increased commodity prices
and transitioning customers from lower value-added egg products to higher
margin, higher value-added specialty products. For more information on our risk
management strategy, see "Management's Discussion and Analysis of Financial
Condition and Results of Operations-Commodity Risk Management."
Facilities. Our principal egg processing plants are located in New Jersey,
Minnesota, Nebraska, Pennsylvania, Iowa, Manitoba and Ontario. Certain of our
facilities are fully integrated from the production and maintenance of laying
flocks through the processing of eggs products. Fully automated laying barns,
housing approximately 13.5 million producing hens, are located in Nebraska,
Minnesota and South Dakota, of which approximately 1.6 million are housed in
contract facilities. Major laying facilities also maintain their own grain and
feed storage facilities. We also maintain facilities with approximately 2.8
million pullets, or hens that are less than 16 weeks old.
Potato Products Division
The potato products division produces and distributes refrigerated potato
products to the retail grocery and foodservice markets. This division's products
principally include hash browns and diced, sliced, mashed and other specialty
potato products. The potato products division is the national retail market
leader in refrigerated potato products with an estimated 57% share in the retail
grocery market under the Simply Potatoes and Diner's Choice brands. Our branded
retail refrigerated potato products' annual volume has doubled since 1997. Due
to their freshness and quality, refrigerated potato grocery products are
generally sold at higher price points than frozen potatoes and, according to our
consumer studies, have superior taste and texture characteristics. In addition,
we use a production process that produces refrigerated potato products for
retail having a shelf-life of 75 days, which we believe to be the longest
shelf-life in this category. The shelf-life of our competitors' retail products
are advertised as being approximately 45 to 60 days.
Products. The potato products division produces and sells refrigerated hash
browns, diced, sliced, mashed and other specialty potato products which are
marketed to the foodservice market under the Northern Star, Farm Fresh and
Quality Farms brand names and under the Simply Potatoes and Diner's Choice brand
names to the retail market. Historically, the Simply Potatoes brand has achieved
consistent growth despite minimal consumer advertising expenditures consisting
in the last five years of less than $1.0 million annually.
Growth in the potato products division is the result of several factors,
including the growth in specialty potato products and increasing consumer
awareness of the refrigerated potato category. For example, refrigerated mashed
potatoes continue to be a popular category in both the retail and foodservice
markets, particularly special recipe mashed potatoes, including deluxe mashed
potatoes (prepared with butter and sour cream), seasoned mashed, red skin garlic
mashed and mashed with onion. The potato products division's ability to create
such customized mashed potato products has attracted interest from chain
restaurants in the foodservice market, such as International House of Pancakes,
which use these blends as signature menu items. In addition, we have had success
with other products such as special cut potatoes, including thick-sliced russets
and red skin wedges, and seasoned hash browns.
Since 1997, we have invested significant capital of approximately $20.0 million
in our Minneapolis potato processing facility, including investing in the
re-design of the plant layout and the upgrade of equipment. Since
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1997, production yields have improved, labor costs have declined and gross
profit per pound has increased to 31.4% for the year ended December 31, 2003
compared to 22.5% in 1997.
Customers. The potato products division leverages existing relationships with
national foodservice distributor customers of our egg products division. Many of
our top potato products division's customers are also long-standing customers of
the egg products division. We provide foodservice distributors the convenience
of centrally sourcing many different types of refrigerated potato and egg
products. The potato products division's largest customers include major
foodservice distributors, such as Sysco and U.S. Foodservice and major retail
grocery store chains, such as Kroger, Publix and Food Lion. These relationships
provide a foundation for our potato products division and provide potential
growth opportunities.
Competition. We were the first to introduce nationally branded refrigerated
potato products in the late 1980s to the United States' foodservice and retail
markets. We believe we are the largest processor and distributor by volume in
the United States of refrigerated potato products to the retail market. The
potato products division's largest competitor is Reser's Fine Foods Inc., a
national producer of refrigerated products. Other competitors include Bob Evans
Farms Inc. and local and regional processors, including I&K Distributors, Inc.
and Naturally Potatoes. In the broader potato products category, other large
national producers, particularly those that produce frozen potato products,
compete indirectly with our potato products division.
Suppliers. A high-quality, consistent-cost potato supply is important to the
potato products division's profitability. Historically, potato prices have
remained relatively stable. A substantial portion of our annual potato
requirements are met through contracts with potato producers, with a high
percentage of such production coming from irrigated land, allowing for
relatively consistent raw material quality. In addition, the potato products
division contracts with a geographically diverse supplier group to hedge weather
and quality risk. The remaining portion of the potato products division's potato
requirements are purchased on the spot market. Potatoes are mainly sourced from
Minnesota, North Dakota and Wisconsin, with lesser quantities sourced from
California, Idaho, Oregon and Nevada.
Refrigerated Distribution Division
The refrigerated distribution division is a leading distributor of refrigerated
products to retailers and wholesale warehouses predominantly in the central
region of the United States. The refrigerated distribution division distributes
its own Crystal Farms branded cheese, with sales for the year ended December 31,
2003 of approximately $135.0 million. With a reputation for quality and a market
position between national brands such as Kraft and private label brands, Crystal
Farms cheese drives this division's sales and profitability. In addition, the
refrigerated distribution division distributes a wide range of refrigerated food
products primarily on a direct-store-delivery basis, offering customers a high
level of service and quality alternatives to nationally branded products. The
refrigerated distribution division has strong distribution capabilities with
over 400 different branded and private label refrigerated food products.
Products. The refrigerated distribution division offers a broad selection of
refrigerated products, which consist principally of cheese, eggs, bagels,
butter, margarine, muffins, potato products, juice and ethnic foods, such as
corn and flour tortillas. Cheese products are the refrigerated distribution
division's most significant entry point with new customers. While most of the
division's products are supplied by vendors or our other divisions, the
refrigerated distribution division operates a cheese packaging facility in Lake
Mills, Wisconsin, which processes and packages various cheese products acquired
in bulk from third-party suppliers for its Crystal Farms brand and its private
label customers.
The refrigerated distribution division has historically taken its products to
market on a direct-to-store delivery basis and it has more recently experienced
success dealing with larger chains and wholesalers through warehouse delivery of
goods. The refrigerated distribution division is working with retailers and
wholesalers to develop partnerships and to respond to the changing needs of the
food industry.
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Customers. The refrigerated distribution division has customer relationships
with large food store chains that rely on us to deliver a variety of dairy case
products in a timely and efficient manner. For the year ended December 31, 2003,
the division served approximately 5,000 retail locations, inclusive of stores
receiving products through warehouse delivery. SUPERVALU Inc., or SUPERVALU, the
food industry's largest distributor, is the refrigerated distribution division's
largest customer. For the year ended December 31, 2003, sales to warehouse
operations of SUPERVALU and SUPERVALU-owned and franchised stores, including Cub
Foods Stores, bigg's, Shopper's Food Warehouse and Farm Fresh, accounted for
approximately 40% of the refrigerated distribution division's net sales. Other
principal customers include Roundy's, Coborn's Inc., Nash-Finch Company and
Wal-Mart Stores, Inc.
Competition. While the division competes with the refrigerated products of
larger suppliers such as Beatrice, Kraft, Land O' Lakes, Inc. and Sargento Foods
Inc., we believe that we have successfully positioned Crystal Farms as an
alternative mid-priced brand, operating at price points below national brands
and above retail store brands. The refrigerated distribution division's emphasis
on a high level of service and lower-priced branded products has enabled it to
compete effectively with much larger national brand companies. We believe that
Crystal Farms branded cheese currently has an estimated 2% market share in the
United States and an estimated 42% market share in Minnesota.
Suppliers. This division obtains products from a number of different co-packers
and, in the case of cheese, purchases the product in bulk and repackages it
under the Crystal Farms brand and private labels.
Sales, Marketing and Customer Service
Each of our three divisions has developed a marketing strategy, which emphasizes
high product quality and superior customer service. Michael Foods Sales, an
internal sales group, coordinates the foodservice and retail sales of the egg
products and potato products divisions, primarily for national and regional
accounts, and is supported by a centralized order entry and customer service
staff. A group of foodservice brokers is used by Michael Foods Sales to
supplement its internal sales efforts. In addition, the egg products division
uses a separate nationwide system of brokers for the retail market. That
division also maintains a small sales group which handles frozen, dried and
short shelf-life liquid egg product sales to industrial customers. We employ a
small marketing staff, which executes marketing plans in the foodservice market,
with additional resources available from outside agencies and consultants as
needed. In addition, the egg products division has a consumer support program to
support several of its egg products which are sold in the retail market.
The refrigerated distribution division's internal and external sales personnel
obtain orders from retail stores which are usually placed no more than one day
ahead of the requested delivery date. That division's marketing efforts are
primarily focused on in-store and cooperative advertising programs, which are
executed with grocers on a market-by-market basis. Beginning in 1999, Crystal
Farms increased its consumer marketing support efforts by using television,
radio, outdoor and in-store programs, with favorable sales volume results.
Proprietary Technologies and Trademarks
We use a combination of patent, trademark and trade secrets laws to protect the
intellectual property for our products. We own patents and have exclusive
license agreements for several patents and technologies. In 1988, we obtained an
exclusive license agreement to use patented processes developed and owned by
North Carolina State University involving the ultrapasteurization of liquid
eggs. Four of the five patents licensed to us under this agreement expire in
2006. Our license to use these four patents will continue until the expiration
of the patents. The patented technology produces liquid eggs that are salmonella
and listeria-negative, as defined by federal law, and extends the shelf-life of
liquid eggs from less than two weeks to over ten weeks.
We also own an exclusive license to use a patented process, owned and developed
by the University of Missouri, to eliminate salmonella from shell eggs. The
licensed patents are set to expire in 2014. Our license to
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use these patents will also continue until the expiration of the patents. We
currently use this technology for processing in-shell pasteurized eggs sold
through our refrigerated distribution division. We also have acquired licenses
to other patents and technology from other third parties, including the
University of Nebraska.
We believe that certain of our competitors infringe upon some of our patents and
the patents licensed to us. We, along with North Carolina State University, have
initiated litigation against several processors of competing liquid egg products
claiming infringement of the original and subsequent related process patents
licensed to us by North Carolina State University relating to ultrapasteurized
liquid egg production. In 1992, a jury for the United States District Court for
the Middle District of Florida found the original patent to be valid and that a
processor, Bartow Food Co., willfully and deliberately infringed one of the
patents. In another action, the United States District Court for the District of
New Jersey found in 1992 and 1993 that Papetti's had infringed certain of the
patents and that the licensed patents are valid and enforceable. In 1994, the
Court of Appeals for the Federal Circuit upheld this judgment. In 1993, Nulaid
Foods Inc., or Nulaid Foods, sought a declaratory judgment that the licensed
patents are invalid. This action was subsequently settled, and Nulaid Foods
agreed that it would not contest the validity and enforceability of the patents
as well as their past infringement of the patents. Nulaid Foods is currently
using the patented process by operating under a sublicense agreement. Reissue
and reexamination proceedings were initiated by us and our competitors with the
U.S. Patent and Trademark Office, or PTO, seeking to determine the scope and
validity of some of the patents that we license from North Carolina State
University. The PTO ruled that claims in the licensed patents are valid and in
full force and effect. On September 13, 2000, Sunny Fresh Foods, a division of
Cargill, filed a declaratory judgment action in the United States District Court
for the District of Minnesota requesting the adjudication of the
unenforceability and invalidity of those patents exclusively licensed to us by
North Carolina State University. In August 2003, a jury found the patents to be
valid and enforceable, but ruled that Sunny Fresh Foods has not infringed the
licensed patents. We have filed an appeal to reverse the non-infringement
ruling. Infringement litigation actions were recently settled with two other egg
processors, Rose Acre Farms and Cutler Egg Products. Both parties agreed that
the patents are valid and enforceable. Both parties are now operating under
sublicense agreements. For more information, see "-Legal Proceedings."
Although we believe that our competitors may be deterred from competing with us
because of our active enforcement of our patent rights, we do not believe that
the expiration of our patent rights will have a material adverse affect on our
business or market share within the corresponding market because of our
processing expertise, strong market position and cost-efficiencies due, in part,
to scale.
The egg products division maintains numerous trademarks and/or trade names for
its products, including "Logan Valley," "Sunny Side Up," "Michael Foods," "Deep
Chill," "Simply Eggs Brand," "Better 'n Eggs," "All Whites," "Chef's Omelet
Brand," "Express Eggs," "Quaker State Farms," "Broke N' Ready," "Canadian
Inovatech," "Centromay," "Emulsa," and "Inovatech." Ultrapasteurized liquid eggs
are marketed using the "Easy Eggs" and "Table Ready" trade names.
Within the potato products division, we market our refrigerated potato products
to foodservice customers under a variety of brands, including "Northern Star,"
"Farm Fresh" and "Quality Farms." The "Simply Potatoes" and "Diner's Choice"
brands are used for retail refrigerated products.
Refrigerated distribution division products are marketed principally under the
"Crystal Farms" trade name.
Food Safety
We believe that we take extensive precautions to ensure the safety of our
products. In addition to routine inspections by state and federal regulatory
agencies, including continuous USDA inspection of many facilities, we have
instituted quality systems plans in each of our divisions which address topics
such as supplier control, ingredient, packaging and product specifications,
preventive maintenance, pest control and sanitation. Each of our facilities also
has in place a hazard analysis critical control points plan which identifies
critical pathways
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through which contaminants may enter our facilities and mandates control
measures that must be used to prevent, eliminate or reduce all relevant
foodborne hazards. For example, at our egg products division facilities,
sanitization steps are in place to eliminate the risk of microbial contamination
of our employees entering certain facilities, including the use of foot baths to
reduce the risk of product contamination. Each of our divisions has also
instituted a product recall plan, including lot identifiability and traceability
measures, that allows us to act quickly to reduce the risk of consumption of any
product of which we suspect may be problem.
In 2003, we engaged Keller and Heckman LLP, an unaffiliated law firm to assess
our food regulatory compliance. We spent approximately $42,000 on this
engagement in 2003. This law firm focused on our ability to ensure the safety of
our food products for human consumption. Based on its review of our regulatory
reports and documents, as well as site visits, the law firm concluded that no
significant food safety issues existed.
In March 2003, Belovo S.A., our egg products joint venture in Belgium, in which
we hold a 35.63% interest, notified the Belgian governmental health authorities
of a potential processed egg powder contamination issue. Following the
notification, production ceased for a month and the egg powders were recalled.
The Belgian health authority placed the egg powder in quarantine. As of
December 31, 2003, approximately 60% of the quarantined inventory (measured by
value) has been released. Belovo is working with the Belgian health authority to
resolve the status of the remaining inventory. The potential loss, if any,
related to this matter has not been determined. However, we expect that
governmental relief and product liability insurance coverage will mitigate the
financial impact of this recall.
In November 2000, the refrigerated distribution division initiated a recall of
60,000 pounds of two cheese products manufactured by a co-packer due to a
possible contamination of listeria. No illnesses were reported with the recall,
and the impact on the refrigerated distribution division's sales and earnings
was minimal. Our co-packer paid all costs associated with the recall. We were
the first company to recall the cheese, which had been produced for numerous
firms nationally, and through our direct share distribution network we were able
to rapidly collect the recalled product.
We currently maintain general liability insurance, which includes product
liability insurance coverage, which we believe to be sufficient to cover
potential product liabilities.
Government Regulation
All of our divisions are subject to federal, state and local government
regulations relating to grading, quality control, product branding and labeling,
waste disposal and other aspects of their operations. Our divisions are also
subject to USDA and FDA regulation regarding grading, quality, labeling and
sanitary control. The processing plants of our egg products division that break
eggs, and some of our other egg processing operations, are subject to continuous
on-site USDA inspection. All of our other processing plants are subject to
periodic inspections by the USDA, FDA and state regulatory authorities.
Crystal Farms cheese and butter products are affected by milk price supports
established by the USDA. The support price serves as an artificial minimum price
for these products, which may not be indicative of market conditions that would
prevail if these supports were abolished. A substantial portion of the egg
production operations of our egg products division are located in the State of
Nebraska. With certain exceptions, a provision of the Nebraska constitution
generally prohibits corporations from engaging in farming or ranching in
Nebraska. Although the constitutional provision contains an exemption for
agricultural land operated by a corporation for the purpose of raising poultry,
the Nebraska Attorney General has, in written opinions, taken the position that
facilities devoted primarily to the production of eggs do not fall within such
exemption and therefore are subject to the restrictions contained in the
constitutional provision. We believe that our egg production facilities in
Nebraska are part of integrated facilities for the production, processing and
distribution of egg products, and therefore, that any agricultural land
presently owned by us in Nebraska is being used for non-farming and non-ranching
purposes.
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The constitution empowers the Nebraska Attorney General, or if the Attorney
General fails to act, a Nebraska citizen, to obtain a court order to, among
other things, force a divestiture of land held in violation of this
constitutional provision. If land subject to such a court order is not divested
within a two-year period, the constitutional provision directs the court to
declare the land escheated, or forfeited, to the State of Nebraska. We are not
aware of any proceedings under this over 75 year-old constitutional provision
pending or threatened against us or any other companies engaging in farming or
ranching activities in Nebraska. We believe that we have adequate contingency
arrangements in place in the event a determination is made that we engage in
farming and/or ranching activities proscribed by the Nebraska constitution.
Until the scope of such provision has been clarified by further judicial,
legislative, or executive action, there can be no assurance as to the effect, if
any, that it may have on our egg products division.
Environmental Regulation
We are subject to federal, state and local environmental regulations and
requirements, including those governing discharges to air and water, the
management of hazardous substances, the disposal of solid and hazardous wastes,
and the remediation of contamination.
We have ongoing relationships with Hatch Mott MacDonald, Environ International
Corporation and Liesch Associates, Inc., environmental consulting firms that aid
us in our environmental compliance efforts. In 2003, two of the environmental
consulting firms completed environmental site assessments for all of our
facilities. As a result of our efforts, except as noted below, we believe we are
currently in material compliance with all environmental regulations and
requirements. Nonetheless, as is the case with any business, if we do not fully
comply with environmental regulations, or if a release of hazardous substances
occurs at or from one of our facilities, we may be subject to penalties and/or
held liable for the cost of remedying the condition.
Many of our facilities discharge wastewater pursuant to wastewater discharge
permits. We dispose of our waste from our internal egg production primarily by
providing it to farmers for use as fertilizer. We dispose of our solid waste
from potato processing by selling the waste to a processor who converts it to
animal feed.
We received a request for information from the U.S. Environmental Protection
Agency, or the EPA, in July 2003 regarding the wastewater disposal practices and
procedures of all of our facilities in and around Wakefield, Nebraska. We
responded to this request for information in September 2003. We recently
received a supplemental request for information from the EPA regarding our two
egg processing facilities in Wakefield, Nebraska and responded to that request.
On May 11, 2004, the EPA issued an Administrative Compliance Order finding that
discharges from the Wakefield, Nebraska facilities on specified occasions
exceeded our permit limits and caused the City of Wakefield's waste treatment
facility to violate its permit. The order directs us to develop a plan to
address these issues and we expect to provide a timely response.
We have made, and will continue to make, expenditures to comply with
environmental requirements. We have upgraded the wastewater treatment system at
our Klingerstown, Pennsylvania facility. We have paid the city of Lenox, Iowa
the cost to construct and have agreed to continue to pay Lenox to operate a
wastewater treatment plant used by our facility located there. In addition, we
updated our wastewater system at our egg production facility in Bloomfield,
Nebraska in 2002. These expenditures have reduced the current and future risk of
wastewater violations at these facilities. We are reviewing the adequacy of our
wastewater treatment systems at the egg products division's facility in Gaylord,
Minnesota. We may elect to upgrade the wastewater controls at this facility or
we may be required to upgrade such controls in the future.
In response to ongoing discussions with environmental regulators in New Jersey
relating to wastewater discharges at our Elizabeth, New Jersey facilities, we
may be required to upgrade the wastewater treatment systems at these facilities.
Recently, New Jersey environmental regulatory authorities had proposed that our
Papetti's subsidiary pay a $200,000 fine to settle a waste water non-compliance
matter relating to one of our facilities in Elizabeth, New Jersey. We paid this
fine on April 20, 2004.
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Under the Comprehensive Environmental Response, Compensation, and Liability Act,
or CERCLA, liability for contamination is imposed, regardless of fault, on
current owners and operators of a contaminated facility. CERCLA also imposes
liability on any person who owned or operated the facility at the time of the
disposal and on any person who arranged for the disposal of hazardous waste at
the facility. Moreover, liability is imposed jointly and severally; that is, the
full cost of cleanup can be imposed on any one responsible party, although
liability is often allocated equitably among responsible parties. As a
consequence of this liability scheme, CERCLA liability attaches to all
facilities a corporation currently owns or operates, without regard to whether
it was the owner or operator at the time the hazardous substances were disposed
of at the facilities, although the current owner may have a right of
contribution against the prior owners for their equitable share of the
liability. The Resource Conservation and Recovery Act and many state laws
similarly impose liability, regardless of fault, on current owners and
operators.
We are aware of contaminations in two of the facilities currently operated by
our Northern Star subsidiary in Minnesota. A parcel adjacent to Northern Star,
which was sold in 2002 to CSM Investors II, Inc., is undergoing remediation
pursuant to the Minnesota voluntary cleanup program. Portions of the property
were contaminated with components of linseed oil stemming from industrial
activities that occurred prior to Northern Star's operation of the plant. After
the contamination was discovered, Northern Star entered into settlement
agreements with Archer Daniels Midland and Burlington Northern Railroad in 1993
and 1994, pursuant to which those parties agreed to investigate and remediate
the contaminated soil to levels acceptable to the Minnesota Pollution Control
Agency. When it acquired the land in 2002, CSM Investments contractually agreed
to carry out the remediation on behalf of Archer Daniels Midland and Burlington
Northern Railroad. In exchange, Archer Daniels Midland and Burlington Northern
Railroad placed funds in escrow to cover CSM's remediation costs. CSM is
currently remediating the soil in connection with its development of the parcel
as part of an office park. Northern Star does not believe it has any liability
for this divested parcel.
In addition, investigations of a vacant parcel behind the Northern Star plant
owned by an affiliate of Northern Star, Minnesota Products, Inc., revealed the
presence of waste linseed oil, petroleum hydrocarbons, and buried ash below the
ground surface. The investigations were performed by RESPEC Consulting &
Services and Barr Engineering, Inc., both environmental consulting firms. The
contamination relates to a period prior to Northern Star's operation of the
adjoining facility. A land-use restriction has been recorded with the deed for
this parcel prohibiting any significant soil disturbance on this surplus parcel
without the approval of the Minnesota Pollution Control Agency. The restriction
can be lifted if soil and groundwater sampling shows that the intended use of
the property poses no significant risk to human health or the environment.
Currently, Northern Star has no plans to develop the vacant parcel.
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Facilities
Corporate. We maintain leased space for our corporate headquarters in suburban
Minneapolis, Minnesota. Leased space within the same building houses the
headquarters, financial and administrative service staffs of the egg products
and potato products divisions, as well as our customer service, distribution,
sales, marketing and information services groups. The office space lease expires
in 2012 and the annual base rent is approximately $750,000.
Egg Products Division. The following table summarizes information relating to
the primary facilities of our egg products division:
Owned/ Lease Annual
Location Principal Use Size (square feet) Leased Expiration Base Rent
Elizabeth, New Jersey(a) Processing 75,000 Leased 2007 $ 432,000
Elizabeth, New Jersey(a) Processing 125,000 Leased 2007 681,000
Bloomfield, Nebraska Processing 80,000 Owned - -
LeSueur, Minnesota Processing 29,000 Owned - -
Wakefield, Nebraska Processing 380,000 Owned - -
Klingerstown, Pennsylvania(b) Processing and
Distribution 139,000 Leased 2017 526,000
Klingerstown, Pennsylvania(b) Processing and
Distribution 19,000 Leased 2017 14,000
Lenox, Iowa Processing and
Distribution 143,000 Owned - -
Gaylord, Minnesota Processing and
Distribution 230,000 Owned - -
Elizabeth, New Jersey(a) Sales and
Distribution 80,000 Leased 2007 480,000
Bloomfield, Nebraska Egg Production 619,000 Owned - -
Wakefield, Nebraska Egg Production 658,000 Owned - -
LeSueur, Minnesota Egg Production 345,000 Owned - -
Gaylord, Minnesota Egg Production 349,000 Owned - -
Gaylord, Minnesota Pullet Houses 130,000 Owned - -
Wakefield, Nebraska Pullet Houses 432,000 Owned - -
Plainview, Nebraska Pullet Houses 112,000 Owned - -
Winnipeg, Manitoba(c) Processing 102,000 Leased 2013 614,000
St. Mary's, Ontario(c) Processing 42,000 Leased 2012 238,000
Mississauga, Ontario(c) Distribution 8,000 Leased 2005 68,000
Abbotsford, British Columbia(c) Sales Office 5,000 Leased 2005 20,000
(a) There are two five year extensions available on these leases.
(b) The two five year extensions of these leases have already been accepted.
(c) There are four five year extensions available on these leases.
The egg products division also owns or leases, primarily for egg production
operations, approximately 1,600 acres of land in Nebraska and Minnesota.
Potato Products Division. The potato products division owns a processing plant
and land located in Minneapolis, Minnesota, consisting of approximately 175,000
square feet of production area. This division leases a building in North Las
Vegas, Nevada, consisting of approximately 31,000 square feet. This lease
expires in 2006 and has the option to extend the lease three successive five
year periods. The annual base rent is approximately $330,000.
Refrigerated Distribution Division. The refrigerated distribution division
leases administrative and sales offices in suburban Minneapolis and several
small warehouses across the United States. The leases expire between 2005 and
2006. The administrative and sales office lease has the option to extend the
lease for five
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years. The annual base rent for all of the leases is $210,000. The division owns
a distribution center located near LeSueur, Minnesota, which is approximately
33,000 square feet. The refrigerated distribution division also owns and
operates a 48,200 square foot refrigerated warehouse and a 19,000 square foot
cheese packaging facility on a 19 acre site in Lake Mills, Wisconsin.
The total annual base rent of the facilities described above is approximately
$4.3 million. The leases for these facilities have varying length terms ranging
from month-to-month to 2017. We believe that our owned and leased facilities,
together with budgeted capital projects in each of our three operating
divisions, are adequate to meet anticipated requirements for our current lines
of business for the foreseeable future. All of our owned property is pledged to
secure repayment of our senior credit facility.
For additional information on contractual obligations relating to operating
leases see "Management's Discussion and Analysis of Financial Condition and
Results of Operations-Liquidity and Capital Resources."
Employees
At December 31, 2003, we had 3,806 employees. The egg products division employed
2,694 full-time and 208 part-time employees none of whom are represented by a
union. The potato products division employed 254 persons, 183 of whom were
represented by the Bakery, Laundry, Allied Sales Drivers and Warehousemen Union,
which is affiliated with the Teamsters. The refrigerated distribution division
employed 514 employees, none of whom are represented by a union. Our corporate,
sales, distribution and customer service and information systems groups
collectively employed 136 employees at December 31, 2003. We believe our
relations with our employees to be good.
Legal Proceedings
Four patents for ultrapasteurizing liquid eggs licensed to us by North Carolina
State University were involved in proceedings before the PTO. In 1996, an
examiner rejected certain claims under these patents as a result of challenges
from competitors. We and North Carolina State University appealed this rejection
to the PTO's Board of Patent Appeals and Interferences, or the PTO Board. In
September 1999, we and North Carolina State University received a favorable
ruling whereby the PTO Board reversed the examiner's rejection of the claims
made under the patents. As a result of these proceedings, process claims of all
four patents continue to be valid and in full force and effect. Also, the fourth
patent was reissued in 2001 to include product claims.
On September 13, 2000, Sunny Fresh Foods, a division of Cargill, filed a
declaratory judgment action in the United States District Court for the District
of Minnesota requesting the adjudication of the unenforceability and invalidity
of those patents exclusively licensed to us by North Carolina State University.
In August 2003, a jury found the patents to be valid and enforceable, but ruled
that Sunny Fresh Foods has not infringed the licensed patents. We have filed an
appeal to reverse the non-infringement ruling. We also settled litigation
regarding infringement of these patents with Rose Acre Farms and Cutler Egg
Products in January 2004.
In addition, we are from time to time party to litigation, administrative
proceedings and union grievances that arise in the ordinary course of our
business. We do not have pending any litigation that, separately or in the
aggregate, would in the opinion of management have a material adverse effect on
our results of operations or financial condition.
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