ITEM 1
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BUSINESS
GENERAL
Crown Holdings, Inc. (the Company or
the Registrant) is a worldwide leader in the design, manufacture and
sale of packaging products for consumer goods. The Companys primary products
include steel and aluminum cans for food, beverage, household and other consumer
products and a wide variety of metal and plastic caps, closures and dispensing
systems. At December 31, 2004, the Company operated 185 plants along with sales and
service facilities throughout 43 countries and had approximately 27,600
employees. Consolidated net sales for the Company in 2004 were $7.2 billion with over 70%
of 2004 net sales derived from operations outside the United States, of which 78% of
these non-U.S. revenues were derived from operations in the European operating segment.
In connection with debt refinancing and a corporate reorganization in 2003, Crown Cork
& Seal Company, Inc. a Pennsylvania corporation founded in 1892 (Crown Cork),
formed the Company as a new public holding company. Crown Cork is now a wholly-owned
subsidiary of the Company. The Company is a Pennsylvania corporation.
OPERATING SEGMENTS
The Companys business is organized
on the basis of geographic regions with three reportable segments: Americas, Europe and
Asia-Pacific. The Americas includes the United States, Canada, Mexico and Central and South
America. Europe includes Europe, Africa and the Middle East. Asia-Pacific includes China
and Southeast Asia.
Financial information concerning the
Companys operations in its three operating segments, Americas, Europe and
Asia-Pacific, and within selected geographic areas is set forth in Part II herein under
Net Sales
and under
Segment Income
within Item 7, Managements
Discussion and Analysis of Financial Condition and Results of Operations of this Report and within Item 8
herein under
Note W
to the consolidated financial statements, which information is
incorporated herein by reference.
AMERICAS
The Americas operating segment
manufactures beverage, food and aerosol cans, specialty packaging, metal closures
and caps, plastic closures and health and beauty care packaging. At December 31, 2004,
the Americas operated 68 plants and had approximately 8,400 employees. During
2002, the Company divested its U.S. fragrance pumps business and sold 89.5% of
its interest in Constar International Inc. in an initial public offering. These
divested operations accounted for $499 million of segment net sales in 2002. There were
additional divestitures in 2002, but sales from these operations were not material.
For 2004, the Americas had net
sales of $2.9 billion (40% of consolidated net sales) and segment income (as defined in
Note W to the consolidated financial statements, which information is incorporated
herein by reference) of $188 million. Approximately 75% of segment net sales were
derived from within the United States. Approximately 76% of segment net sales were for
beverage and food cans and ends.
EUROPE
The European operating segment, which
includes the Middle East and Africa, manufactures beverage, food and aerosol cans,
specialty packaging, metal closures and caps, high density polyethylene (HDPE)
containers, plastic closures, health and beauty care packaging and canmaking equipment. At
December 31, 2004, the segment operated 100 plants and had approximately 16,600 employees.
During 2002, the Company divested its European pharmaceutical packaging business, its
operations in Central and East Africa and its Constar beverage plastics business. These
divested operations accounted for $175 million of segment net sales in 2002.
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Crown Holdings, Inc.
For 2004, Europe had net sales of
$4.0 billion (55% of consolidated net sales) and segment income of $386 million. Net
sales in the United Kingdom of $916 million and France of $792 million represented
23% and 20%, respectively, of segment net sales. Sales in 2004 for food and beverage
cans and ends accounted for 62% of segment net sales.
ASIA-PACIFIC
The Asia-Pacific operating segment
manufactures beverage, food and aerosol cans, plastic closures and metal caps. At December
31, 2004, the segment operated 17 plants and had approximately 2,300 employees.
Asia-Pacific had net sales in 2004 of $379 million (5% of consolidated net sales) and
segment income of $62 million.
PRODUCTS
Beverage Cans
The Company supplies beverage
cans and other packaging products to a variety of
beverage and beer companies, including Anheuser-Busch, Cadbury Schweppes, Coca-Cola,
Cott Beverages, Heineken, InBev, Kroger, Pepsi-Cola and Scottish Courage. The Companys
beverage business is built around local, regional and global markets which has
served to develop its understanding of global consumer expectations.
The beverage market is dynamic and
highly competitive, with each packaging manufacturer striving to satisfy consumers ever-changing
needs. The Company competes by offering its customers broad market knowledge,
resources at all levels of its worldwide organization and extensive research and
development capabilities that have enabled the Company to provide its customers with
innovative products. The Company meets its customers beverage packaging needs with
an array of two-piece beverage cans and ends, plastic closures and metal bottle caps.
Recent innovations include the SuperEnd beverage can end and shaped beverage cans.
Beverage can manufacturing is
capital intensive, requiring significant investment in tools and machinery. The
Company seeks to effectively manage its invested capital and is continuing its
efforts to reduce can and end diameter, lighten its
cans, reduce non-metal costs and restructure production processes.
Food Cans
The Company manufactures a variety
of food cans, including two-and three-piece cans in numerous shapes and sizes, and sells
food cans to food marketers such as Bonduelle, Campbell Soup, Continentale, H. J. Heinz, Mars, Menu
Foods, Nestlé and Premier Foods.
Technologies used to produce these
cans include three-piece welded, two-piece drawn and wall-ironed, and two-piece drawn
and redrawn. The Company has also introduced its Lift Off series of food ends,
including its EOLE (easy-open low energy) full pull-out steel food can ends and
Peel Seam, a flexible aluminum foil laminated end. The Companys commitment
to innovation has led to developments in packaging materials, surface finishes, can
shaping, lithography, sealing and opening techniques and environmental performance.
The Company manufactures
conventional and easy-open ends for a variety of heat-processed and dry food products
including fruits and vegetables, meat and seafood, soups, ready-made meals, infant
formula, coffee and pet food. In addition, the Company supplies a range of coil shearing,
specialty coating, advanced printing and decoration services.
Aerosol Cans
The Companys customers for
aerosol cans include manufacturers of personal care, food, household and industrial
products, including CCL Industries, Gillette, S.C. Johnson and Unilever. The
aerosol can business, while highly competitive, is marked by its high value-added
service to customers. Such value-added services include, among others, the ability to
manufacture multiple sizes and design customer labels and multiple color schemes.
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Crown Holdings, Inc.
Plastic Closures
The Company offers a variety of choices
in plastic closures for the beverage (including soft drinks, mineral water and wines and
spirits), food (wet and dry), health and beauty care, household and industrial markets.
The Company manufactures plastic closures for consumer products marketers such as
Coca-Cola, Colgate Palmolive, Danone, Diageo UDV, Nestlé, Pepsi-Cola, Procter &
Gamble and Unilever.
Specialty Packaging
The Companys specialty packaging
business is located primarily in Europe and serves many major European and multinational
companies. The Company produces a wide variety of specialty containers, with numerous lid
and closure variations. The Companys specialty packaging customers include Altria
Group (Kraft Foods), Akzo Nobel, Bristol-Meyers Squibb, Nestlé, Teisseire and United
Biscuits.
In the consumer market, the Company
manufactures a wide variety of tinplate containers for cookies and cakes, tea and coffee,
confectionery, giftware, personal care, tobacco, wines and spirits, as well as
non-processed food products. In the industrial market, the Company manufactures tinplate
containers for paints and inks, do-it-yourself products, and chemical, automotive and
household products.
Metal Closures
The Company offers a wide variety of
metal closures and sealing equipment solutions to leading marketers such as Abbott
Laboratories, Anheuser Busch, H. J. Heinz, Nestlé, Novartis and Unilever from a network of metal
closure plants around the world. The Company supplies total packaging solutions, including
closures, capping systems and services while working closely with customers, retailers and
glass manufacturers to develop innovative closure solutions and meet customer
requirements.
The Company strives to continuously
improve its metal closure design and printing technology to better support customers
marketing programs and promotional activities. The Company offers expertise in closure
design and decoration, ranging from high quality printing of the closure in up to nine
colors, to inside-the-cap printing, which offers customers new promotional possibilities.
Health and Beauty Care
The Company produces fragrance closures
and packaging for lipsticks and eyecare products for leading cosmetics
and beauty care companies. As a global, single-source packaging partner, the Company
strives to use innovative design and engineering coupled with advanced manufacturing and
decorating capabilities to meet the high quality standards and the demanding deadlines of
its global customers. The Companys health and beauty customers include Avon,
Estée Lauder, LOreal and Procter & Gamble.
SALES AND DISTRIBUTION
Global marketers continue to demand the
consolidation of their supplier base under long-term arrangements and qualify those
suppliers on the basis of their ability to provide global service to create innovative
designs and technologies in a cost-effective manner.
With its global reach, the Company
markets and sells products to customers through its own sales and marketing staff located
within each operating segment. Regional sales personnel support the segments sales
staffs. Contracts with global suppliers are centrally negotiated, although products are
ordered through and distributed directly by each plant. Facilities are generally located
in proximity to their respective major customers. The Company maintains contact with
customers in order to develop new business and to extend the terms of its existing
contracts.
Many customers provide the Company with
quarterly or annual estimates of product requirements along with related quantities
pursuant to which periodic commitments are given. Such estimates assist the Company in
managing production and controlling working capital levels. The Company schedules its
production to meet customer requirements. Because the production time for the
Companys products is short, any backlog of customer orders in relation to overall
sales is immaterial.
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Crown Holdings, Inc.
COMPETITION
Most of the Companys products are
sold in highly competitive markets, primarily based on price, quality, service, and
performance. The Company competes with other packaging manufacturers as well as with
fillers, food processors and packers who manufacture containers for their own use and for
sale to others. The Companys multinational competitors include, but are not limited
to, Alcoa Inc., Amcor Limited, AptarGroup Inc., Ball Corporation, BWAY Corporation, Impress Holdings
B.V., Metal Container Corporation, Owens-Illinois Inc., Rexam Plc, Silgan Holdings Inc.,
and U.S. Can Corporation.
CUSTOMERS
The Companys largest customers
consist of many of the leading manufacturers and marketers of packaged products in the
world. Consolidation trends among beverage and food marketers has led to a concentrated
customer base. The Companys top ten global customers represented approximately 23%
of its 2004 net sales.
In each of the years in the period 2002
through 2004, no one customer of the Company accounted for more than ten percent of the
Companys net sales. Each operating segment of the Company has major customers and
the loss of one or more of these major customers could have a material adverse effect on
an individual segment or the Company as a whole. Major customers include those listed above under the Products
discussion. In addition to sales to Coke and Pepsi, the Company also supplies independent
licensees of Coke and Pepsi.
RESEARCH AND DEVELOPMENT
The Companys principal Research,
Development & Engineering (RD&E) centers are located in Alsip, Illinois and
Wantage, England. The Company uses its RD&E capabilities to (i) promote development of
value-added packaging systems, (ii) design cost-efficient manufacturing systems and
materials that also provide continuous quality improvement, (iii) support technical needs
in customer and vendor relationships, and (iv) provide engineering services for the
Companys worldwide packaging activities. These capabilities allow the Company to
identify market opportunities by working directly with customers to develop new products,
such as the creation of new packaging shapes.
Recent innovations include:
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High value-added shaped beverage,
food and aerosol cans, such as Heinekens keg can and the WD-40 aerosol can. This
technology has the capability of reducing counterfeiting and improving product image.
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The SuperEnd for beverage cans,
which requires less metal than existing ends without any reduction in strength. The
SuperEnd also offers improved pourability, drinkability, ease-of-opening and appearance.
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Patented composite (metal and plastic)
closures including the Companys Ideal product line. These closures offer improved
barrier performance and tamper resistance while requiring less strength
to open than standard closures. The Company supplies composite closures to customers including
Abbott Laboratories (Ensure), PepsiCo (Tropicana), Tree Top and Unilever (Ragu).
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Next generation Easy-open low energy
(EOLE) full pullout steel food can ends. The end design allows the end to be removed by hand
with less strength than competing easy open food ends.
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New foamed synthetic stoppers for spirits.
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A family of Peel Seam flexible
lidding for cans that provides exceptional ease of opening, high quality graphics and can
still be applied with traditional closing technology.
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The Company intends to
selectively license its proprietary technologies and has licensed SuperEnd,
can shaping and BiCan technology to Amcor Limited in Australia and New Zealand and
SuperEnd to Nampak Ltd. in South Africa.
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Crown Holdings, Inc.
The Company spent $47 million in 2004,
$44 million in 2003 and $43 million in 2002 on RD&E activities. Certain of these
activities are expected to improve and expand the Companys product lines in the
future. Expenditures were also made to improve manufacturing efficiencies and reduce
unit costs, principally raw material costs, by reducing the material content of
containers while improving or maintaining other physical properties, such as material
strength. The costs incurred were associated with a number of products in varying
stages of development.
MATERIALS AND SUPPLIERS
The Company in its manufacturing
operations uses various raw materials, including aluminum and steel for metals
packaging, and various types of resins, which are petrochemical derivatives, for
plastics packaging. In general, these raw materials are purchased in highly
competitive, price-sensitive markets which have historically exhibited price and
demand cyclicality. These materials and others used in the manufacturing process have
historically been available in adequate supply from multiple sources. Generally, the
Companys principal raw materials are obtained from the major suppliers in the countries
in which it operates plants. Some plants in developing countries, which do not have
local mills, obtain raw materials from nearby, more-developed countries. The Company
has agreements for what it considers adequate supplies of raw materials. However,
sufficient quantities may not be available in the future due to, among other things,
temporary shortages due to weather or other factors, including disruptions in supply
caused by raw material transportation or production delays. From time to time, some
of the raw materials have been in short supply, but to date, these shortages have not had
a significant impact on the Companys operations.
In 2004, consumption of steel,
aluminum and resin represented approximately 27% , 24% and 4%, respectively, of
consolidated cost of products sold, excluding depreciation and amortization. Due to the
significance of these raw materials to overall cost of products sold, raw material
efficiency is a critical cost component of the products manufactured. Supplier
consolidations, recent government regulations, political unrest and global or local
demand for raw materials in the packaging and other industries, among other risk
factors, provide uncertainty as to the level of prices at which the Company might be able to
source such raw materials in the future. Moreover, the prices of certain of these raw
materials, such as aluminum, steel and resin, have at times been subject to
volatility. Generally, the Company has sales contracts in place which allow it to
pass-through higher raw material costs. However, there can be no assurance that the
Company will be able to fully recover higher raw material costs from its customers.
The Companys average steel
price increased 5% in 2004. Price increases in the United States were significantly
higher as the suppliers commenced assessing a price surcharge on the Companys
purchases of steel. Suppliers have indicated that a shortage of raw materials to produce
steel and increased global demand, primarily in China, have combined to create the need
for steel price increases for their customers. Several suppliers have also indicated
that they intend to further increase steel prices, and that the current market
environment has resulted in a tighter supply of steel which could require allocation
among their steel purchasing customers. As a result of the steel price increases,
the Company in 2004 has implemented significant price increases in all of its
steel product categories. To date, the impact on the Companys earnings has
not been material as a result of the pass-through of increased cost to customers.
However, there can be no assurance that the Company will be able to fully recover
from its customers the impact of steel surcharges
or price increases. In addition, if
the Company is unable to purchase steel for a significant period of time, its
steel-consuming operations would be disrupted and if the Company is unable to fully
recover the higher cost of steel, its financial results may be adversely affected.
The Company continues to monitor this situation and the effect on its operations.
The average price of aluminum ingot on the
London Metal Exchange (LME) increased approximately 15% in 2004 compared to 5% in 2003.
In an effort to reduce
the impact of volatile aluminum prices on North American operations, the Company in
North America has entered into contracts with its suppliers of aluminum can and end sheet
that, by formula, guarantee prices for a period of six months. The pricing structure
is directly tied to a rolling average of the prior six months market price of aluminum
ingot on the LME. Further, ceiling prices have been
established under these contracts that set maximum prices that the Company would pay
for aluminum. The Companys beverage can and end sales contracts in North America
contain similar provisions that adjust selling prices to the customers based on changes
in the market price of aluminum.
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Crown Holdings, Inc.
Based on petrochemical and resin
industry data, average high density polyethylene (HDPE) resin prices
increased approximately 21% in 2004 compared to 29% in 2003 and average polyethylene
resin prices increased approximately 58% in 2004 compared to 21% in 2003. The
increases have been driven primarily by the significant increase in oil prices.
In response to the volatility of raw
material prices, ongoing productivity and cost reduction efforts in recent years have
focused on improving raw material cost management.
The Companys manufacturing
facilities are dependent, in varying degrees, upon the availability of processed
energy, such as natural gas and electricity. Certain of these energy sources may become
difficult or impossible to obtain on acceptable terms due to external factors, and the
Company cannot predict the effects, if any, of such occurrences on its future operations.
SEASONALITY
Food packaging products accounted for 32% of 2004 consolidated net sales.
The food can business is somewhat seasonal with the first
quarter tending to be the slowest period as the autumn packing period in the Northern Hemisphere
ends and new crops
are not yet planted. The industry enters its busiest period in the third quarter when the
majority of fruits and vegetables are harvested. Weather represents a substantial
uncertainty in the yield of food products and is a major factor in determining the demand
for food cans in any given year.
The Companys metal beverage
container and plastic beverage closures businesses are predominantly located in the
Northern Hemisphere. Generally, beverage products are consumed in greater amounts during
warmer months of the year and sales and earnings have generally been higher in the second
and third quarters of the calendar year.
The Companys other businesses
include aerosol, specialty and health and beauty care packaging, canmaking equipment and
various other products which tend not to be significantly affected by seasonal variations.
ENVIRONMENTAL MATTERS
The Companys operations are subject
to numerous laws and regulations governing the protection of the environment, disposal of
waste, discharges into water, emissions into the atmosphere and the protection of employee
health and safety. Future regulations may impose stricter environmental requirements on
the packaging industry and may require additional capital investment. Anticipated future
restrictions in some jurisdictions on the use of certain coatings may require the Company
to employ additional control equipment or process modifications. The Company has a
Corporate Environmental Protection Policy, and environmental considerations are among the
criteria by which the Company evaluates projects, products, processes and purchases. While
the Company does not believe that any of the foregoing matters are likely to have a
material effect on the financial statements, there can be no assurance that current or future environmental laws or
remediation liabilities will not have a material effect on the Companys financial
condition, liquidity or results of operations. Discussion of the Companys
environmental matters is contained within Part II, Item 7, Managements Discussion
and Analysis of Financial Condition and Results of Operations of this Report under the
caption
Environmental Matters
, and within Item 8 herein under
Note L
to the
consolidated financial statements, which information is incorporated herein by reference.
WORKING CAPITAL
The Company generally uses cash
during the first nine months of the year to finance seasonal working capital needs. The Companys
working capital requirements are funded by its receivables securitization and factoring
programs, its revolving credit facility and from operations.
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Crown Holdings, Inc.
In 2003, the Company completed a
refinancing that improved its liquidity through the
repayment of debt due in 2003 from the proceeds and the extension of maturities to 2006
and beyond. In September and October 2004, the Company completed an additional
refinancing. The funds received in the 2004 refinancing were used to refinance the credit
and term loan facilities entered into in 2003 and to pay fees and expenses associated
with the refinancing. The 2004 refinancing extended maturities on the Companys credit facilities to
2010.
Further information relating to
the Companys liquidity and capital resources and the refinancing is set forth within
Part II, Item 7, Managements Discussion and Analysis of Financial Condition
and Results of Operations, of this Report under the caption
Debt Refinancing
and
within Item 8 herein under
Note Q
and
Note R
to the
consolidated financial statements, which information is incorporated herein by reference.
Collection and payment periods tend
to be longer for the Companys operations located outside the U.S. due to local business
practices.
EMPLOYEES
At December 31, 2004, the Company
employed approximately 27,600 people. Collective bargaining agreements with
varying terms and expiration dates cover approximately 18,800 employees. The Company
does not expect that renegotiations of the agreements expiring in 2004 will have a
material adverse effect on its results of operations, financial position or cash flow.
AVAILABLE INFORMATION
The Companys Internet web site
address is
www.crowncork.com
. The Companys Annual Report on Form 10-K,
Quarterly Reports on Form 10-Q, Current Reports on Form 8-K and all amendments to those
reports filed by the Company with the Securities and Exchange Commission pursuant to
sections 13(a) and 15(d) of the Securities Exchange Act of 1934, as amended, are
accessible free of charge through the Companys web site as soon as reasonably
practicable after the documents are filed with, or otherwise furnished to, the Securities
and Exchange Commission.
The Companys Code of Business
Conduct and Ethics, its Corporate Governance Guidelines, and the charters of its Audit,
Compensation and Nominating and Corporate Governance committees are available on the
Companys web site. These documents are also available in print to any shareholder
who requests them. The Company intends to disclose amendments to and waivers of the Code of
Business Conduct and Ethics on the Companys web site.