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Employee Benefit Plans
12 Months Ended
Dec. 29, 2012
Employee Benefit Plans [Abstract]  
EMPLOYEE BENEFIT PLANS
EMPLOYEE BENEFIT PLANS

The Company has retirement and pension plans covering substantially all of its employees.  Most retirement benefits are provided by the Company under separate final-pay noncontributory and contributory defined benefit and defined contribution plans for all salaried and hourly employees (excluding those covered by union-sponsored plans) who meet service and age requirements. Defined benefits are based principally on length of service and earnings patterns during the five years preceding retirement. During the third quarter of fiscal 2011, as part of the initiative to combine the Darling and Griffin retirement benefit programs, the Company's Board of Directors authorized the Company to proceed with the restructuring of its retirement benefit program effective January 1, 2012, to include the closing of Darling's salaried and hourly defined benefit plans to new participants as well as the freezing of service and wage accruals thereunder effective December 31, 2011 (a curtailment of these plans for financial reporting purposes) and the enhancing of benefits under the Company's defined contribution plans. However, the Company-sponsored hourly union plan has not been curtailed.

Effective January 1, 2012, the Griffin hourly 401(k) plan merged into the Darling International Inc. Hourly 401(k) Savings Plan.  Effective January 1, 2012, all of the Company’s hourly employees are eligible to participate in this plan, which allows for elective deferrals, an employer match equal to 25% up to 6% of a participants deferrals each pay period and an employer contribution based on age (ranging from 2-5% of compensation per year). Previously, the Company's employer match was equal to 100% of the first $10 per pay period deferred by a participant, with a maximum of $520 per year, and an employer contribution equal to $520 per year.  Effective January 1, 2012, Darling International Inc.'s Hourly 401(k) Savings Plan accepted the transfer of assets and liabilities of the hourly employees of Griffin that had account balances in the Griffin plans which existed prior to January 1, 2012.  The Company's matching portion and annual employer contribution to the Darling International Inc. Hourly 401(k) Savings plan for fiscal 2012, 2011 and 2010 was approximately $2.3 million, $0.7 million and $0.7 million, respectively.

Effective January 1, 2012, the Griffin salaried 401(k) plan merged into the Darling International Inc. Salaried 401(k) Savings Plan, a defined contribution plan, which was amended and now includes an employer match equal to 25% up to 6% of a participants deferrals each pay period and an employer contribution based on age (ranging from 3-6% of compensation per year). Previously, the Darling International Inc. Salaried 401(k) Savings Plan included an employer contribution based on age (ranging from 2-5% of compensation per year).  Effective January 1, 2012, Darling International Inc.'s Salaried 401(k) Savings Plan accepted the transfer of assets and liabilities of the salaried employees of Griffin that had account balances in the Griffin plans which existed prior to January 1, 2012. The Company’s matching portion and annual employer contribution portion to the Darling International Inc. Salaried 401(k) Savings Plan for fiscal 2012, 2011 and 2010 was approximately $4.9 million, $1.5 million and $1.5 million, respectively.

Under Griffin's old defined contribution plans the Company made matching contributions for fiscal 2011 of approximately $0.5 million and immaterial amounts in fiscal 2010.

The Company recognizes the over-funded or under-funded status of the Company's defined benefit post-retirement plans as an asset or liability in the Company's balance sheet, with changes in the funded status recognized through comprehensive income in the year in which they occur.

The following table sets forth the plans’ funded status and amounts recognized in the Company's consolidated balance sheets based on the measurement date (December 29, 2012 and December 31, 2011) (in thousands):

 
December 29,
2012
 
December 31,
2011
Change in projected benefit obligation:
 
 
 
Projected benefit obligation at beginning of period
$
123,553

 
$
111,376

Service cost
326

 
1,178

Interest cost
5,451

 
6,052

Actuarial loss
13,084

 
18,028

Benefits paid
(4,617
)
 
(4,336
)
Effect of curtailment

 
(8,911
)
Other

 
166

Projected benefit obligation at end of period
137,797

 
123,553

 
 
 
 
Change in plan assets:
 

 
 

Fair value of plan assets at beginning of period
96,235

 
93,308

Actual return on plan assets
13,026

 
(3,274
)
Employer contribution
1,875

 
10,537

Benefits paid
(4,617
)
 
(4,336
)
Fair value of plan assets at end of period
106,519

 
96,235

 
 
 
 
Funded status
(31,278
)
 
(27,318
)
Net amount recognized
$
(31,278
)
 
$
(27,318
)
 
 
 
 
Amounts recognized in the consolidated balance
   sheets consist of:
 

 
 

Non-current liability
$
(31,278
)
 
$
(27,318
)
Net amount recognized
$
(31,278
)
 
$
(27,318
)
 
 
 
 
Amounts recognized in accumulated other
   comprehensive loss consist of:
 

 
 

Net actuarial loss
$
50,714

 
$
48,702

Prior service cost
174

 
277

Net amount recognized  (a)
$
50,888

 
$
48,979



(a)
Amounts do not include deferred taxes of $19.4 million and $18.6 million at December 29, 2012 and December 31, 2011, respectively.

 
December 29,
2012
 
December 31,
2011
Projected benefit obligation
$
137,797

 
$
123,553

Accumulated benefit obligation
137,797

 
123,553

Fair value of plan assets
106,519

 
96,235


 
Net pension cost includes the following components (in thousands):

 
December 29,
2012
 
December 31,
2011
 
January 1,
2011
Service cost
$
326

 
$
1,178

 
$
1,056

Interest cost
5,451

 
6,052

 
5,959

Expected return on plan assets
(6,709
)
 
(6,888
)
 
(6,389
)
Net amortization and deferral
4,845

 
2,814

 
3,242

Curtailment
14

 
63

 

Net pension cost
$
3,927

 
$
3,219

 
$
3,868




Amounts recognized in accumulated other comprehensive income (loss) for the year ended (in thousands):

 
2012
 
2011
Actuarial (loss)/gain recognized:
 
 
 
Reclassification adjustments
$
2,912

 
$
1,668

Actuarial (loss)/gain recognized during the period
(4,145
)
 
(11,806
)
Prior service (cost) credit recognized:
 

 
 

Reclassification adjustments
64

 
55

Prior service cost arising during the period

 
(63
)
 
$
(1,169
)
 
$
(10,146
)


The estimated amount that will be amortized from accumulated other comprehensive loss into net periodic pension cost in fiscal 2013 is as follows (in thousands):

 
 
2013
Net actuarial loss
 
$
5,202

Prior service cost
 
59

 
 
$
5,261



Weighted average assumptions used to determine benefit obligations were:

 
December 29,
2012
 
December 31,
2011
 
January 1,
2011
Discount rate
3.90%
 
4.50%
 
5.55%
Rate of compensation increase
—%
 
—%
 
4.16%

Weighted average assumptions used to determine net periodic benefit cost for the employee benefit pension plans were:

        
 
December 29,
2012
 
December 31,
2011
 
January 1,
2011
Discount rate
4.50%
 
5.55%
 
5.90%
Rate of increase in future compensation levels
—%
 
4.16%
 
4.08%
Expected long-term rate of return on assets
7.35%
 
7.85%
 
7.85%


Consideration was made to the long-term time horizon for the plans' benefit obligations as well as the related asset class mix in determining the expected long-term rate of return.  Historical returns are also considered, over the long-term time horizon, in determining the expected return.  Considering the overall asset mix of approximately 60% equity and 40% fixed income, several years in the last ten years (except for 2008) having strong double digit returns as well as several years of single digit losses, the Company believes it is reasonable to expect a long-term rate of return of 7.35% for the plans' investments as a whole.
 
Plan Assets

The Company's pension plan weighted-average asset allocations at December 29, 2012 and December 31, 2011, by asset category, are as follows:

            
 
Plan Assets at
Asset Category
December 29,
2012
 
December 31,
2011
Equity Securities
61.3%
 
59.7%
Debt Securities
38.7%
 
40.3%
Total
100.0%
 
100.0%

 
The investment objectives have been established in conjunction with a comprehensive review of the current and projected financial requirements.  The primary investment objectives are:  1) to have the ability to pay all benefit and expense obligations when due; 2) to maximize investment returns within reasonable and prudent levels of risk in order to minimize contributions; and 3) to maintain flexibility in determining the future level of contributions.

Investment results are the most critical element in achieving funding objectives, while reliance on contributions is a secondary element.

The investment guidelines are based upon an investment horizon of greater than ten years; therefore, interim fluctuations are viewed with this perspective.  The strategic asset allocation is based on this long-term perspective and the plans' funded status.  However, because the participants’ average age is somewhat older than the typical average plan age, consideration is given to retaining some short-term liquidity.  Analysis of the cash flow projections of the plans indicates that benefit payments will continue to exceed contributions.  The results of a thorough asset-liability study completed during 2012 established a dynamic asset allocation glide path (the "Glide Path") by which the plans' asset allocations are determined. The Glide Path designates intervals based on funded status which contain a corresponding allocation to equities/real assets and fixed income. As the plans' funded status improves, the allocations become more conservative, and the opposite is true when the funded status declines.

Based upon the plans’ funded status, time horizon, risk tolerances, performance expectations, asset class constraints and asset-liability study results, target asset allocation ranges are as follows:

            
Fixed Income
35% - 80%
Equities
20% - 65%


The fixed income allocation is primarily invested in corporate and government bonds denominated in U.S. dollar, private and publicly traded mortgages, private placement debt and cash equivalents.  The average duration of the issues is managed to closely match the duration of the plans' liabilities.   The portfolio is expected to be well-diversified.

The domestic equity allocation is invested in stocks traded on one of the U.S. stock exchanges.  Securities convertible into such stocks, convertible bonds and preferred stock, may also be purchased.  The majority of the domestic equities are invested in mutual funds that are well-diversified among growth and value stocks categorized in large, mid and small cap asset classes.  By definition, small cap investments carry greater risk than large and mid cap, but also are expected to create greater returns over time than large and mid cap.  By definition large cap investments carry less risk than small and mid cap, and are expected to return less than small and mid cap over time.  By definition mid cap investments fall between small and large cap stocks concerning riskiness and expected return.  Small company definitions fluctuate with market levels but generally will be considered companies with market capitalizations between $300 million and $2 billion.  The portfolio will be diversified in terms of individual company securities and industries.  No individual equity or individual fixed income investment comprised more than 1.5% of the defined benefit plans' total assets (excluding U.S. government issues).

The international equity allocation is invested in companies whose stock is traded outside the U.S. and/or companies that conduct the major portion of their business outside of the U.S.  The portfolio may invest in ADR's.  The emerging market portion of the international equity investment is held below 10% due to greater volatility in the asset class.  The portfolio is well-diversified in terms of companies, industries and countries.


The diversified asset portion of the allocation will invest in securities with a goal to outpace inflation and preserve their value. The securities in this allocation may consist of inflation-indexed bonds, securities of real estate companies, commodity index-linked notes, fixed-income securities, securities of natural resource companies, master limited partnerships, publicly-listed infrastructure companies, and floating rate debt.

All investment objectives are expected to be achieved over a market cycle anticipated to be a period of five to seven years.  Reallocations are performed on a monthly basis to retain target allocation ranges. On a quarterly basis the plans' funded status will be recalculated to determine which Glide Path interval allocation is appropriate.

The following table presents fair value measurements for the Company's defined benefit plans’ assets as categorized using the fair value hierarchy under FASB authoritative guidance (in thousands):

    
 
Total
 
Quoted Prices in
Active Markets for
Identical Assets
 
Significant Other
Observable
Inputs
 
Significant
Unobservable
Inputs
(In thousands of dollars)
Fair Value
 
(Level 1)
 
(Level 2)
 
(Level 3)
Balances as  December 31, 2011
 
 
 
 
 
 
 
Fixed Income:
 
 
 
 
 
 
 
Long Term
$
33,872

 
$
33,872

 
$

 
$

Short Term
4,918

 
4,461

 
457

 

Equity Securities:
 

 
 

 
 

 
 

Domestic equities
47,122

 
47,122

 

 

International equities
10,323

 
10,323

 

 

Totals
$
96,235

 
95,778

 
$
457

 
$

 
 
 
 
 
 
 
 
Balances as December 29, 2012
 

 
 

 
 

 
 

 
 
 
 
 
 
 
 
Fixed Income:
 

 
 

 
 

 
 

Long Term
$
40,255

 
$
14,064

 
$
26,191

 
$

Short Term
954

 
542

 
412

 

Equity Securities:
 

 
 

 
 

 
 

Domestic equities
44,997

 
43,563

 
1,434

 

International equities
20,313

 
19,551

 
762

 

Totals
$
106,519

 
$
77,720

 
$
28,799

 
$



During fiscal 2010 the Company increased its pension investment options allowing for investing directly into mutual funds whereby the Company believes it gives the pension plan assets more options and a greater long term return potential.  As a result the Company has transferred its pension assets in fiscal 2010 from pooled separate accounts ("PSA") accounts to assets comprised primarily of mutual funds, which are publicly traded in an active market.  The particular shares used in the defined benefit plans are either retirement plan shares or A-shares with no loads.  The fair value of each mutual fund is based on the market value of the underlying investments. In fiscal 2012, the Glide Path directed the Company to invest in certain PSA's in an effort to minimize the plans' funded status variability as compared to fiscal 2011.
 
Contributions

The Company's funding policy for employee benefit pension plans is to contribute annually not less than the minimum amount required nor more than the maximum amount that can be deducted for federal income tax purposes.  Contributions are intended to provide not only for benefits attributed to service to date but also for those expected to be earned in the future.

Based on current actuarial estimates, the Company expects to make payments of approximately $0.4 million to meet funding requirements for its pension plans in fiscal 2013.
 
Estimated Future Benefit Payments

The following benefit payments, which reflect expected future service, as appropriate, are expected to be paid (in thousands):
 
            
Year Ending
Pension Benefits
2013
$
5,220

2014
5,760

2015
6,030

2016
6,260

2017
6,490

Years 2018 – 2022
36,480



Multiemployer Pension Plans

The Company participates in various multiemployer pension plans which provide defined benefits to certain employees covered by labor contracts.  These plans are not administered by the Company and contributions are determined in accordance with provisions of negotiated labor contracts to meet their pension benefit obligations to their participants.  The Financial Accounting Standards Board ("FASB") issued guidance requiring companies to provide additional disclosures related to individually significant multiemployer pension plans. The Company's contributions to each individual multiemployer plan represent less than 5% of the total contributions to each such plan. Based on the most currently available information, the Company has determined that, if a withdrawal were to occur, withdrawal liabilities on two of the plans in which the Company currently participates could be material to the Company. The following table provides more detail on these two significant multiemployer plans (contributions in thousands):

 
 
 
 
 
 
 
 
Expiration
Pension
EIN Pension
Pension Protection Act Zone Status
FIP/RP Status Pending/
Contributions
Date of Collective Bargaining
Fund
Plan Number
2012
2011
Implemented
2012
2011
2010
Agreement
Western Conference of Teamsters Pension Plan
91-6145047 / 001
Green
Green
No
$
1,371

$
1,386

$
1,401

April 2015 (b)
Central States, Southeast and Southwest Areas Pension Plan (a)
36-6044243 / 001
Red
Red
Yes
746

705

630

December 2014 (c)
All other multiemployer plans
 
 
 
 
1,083

1,009

869

 
 
 
Total Company Contributions
$
3,200

$
3,100

$
2,900

 

(a)
In July 2005 this plan received a 10 year extension from the IRS for amortizing unfunded liabilities.

(b)
The Company has several plants that participate in the Western Conference of Teamsters Pension Plan under collective bargaining agreements that require minimum funding contributions. Certain of these agreements have expired and are being renegotiated with others having expiration dates through April 1, 2015.

(c)
The Company has several processing plants that participate in the Central States, Southeast and Southwest Areas Pension Plan under collective bargaining agreements that require minimum funding contributions. Certain of these agreements have expired and are being renegotiated with others having expiration dates through December 15, 2014.

With respect to the other multiemployer pension plans in which the Company participates and which are not individually significant, four plans have certified as critical or red zone, one plan has certified as endangered or yellow zone and one plan has certified as seriously endangered or orange zone as defined by the Pension Protection Act of 2006. The Company's portion of contributions to all plans amounted to $3.2 million, $3.1 million and $2.9 million for the years ended December 29, 2012, December 31, 2011 and January 1, 2011, respectively.

In June 2009, the Company received a notice of a mass withdrawal termination and a notice of initial withdrawal liability from a multiemployer plan in which it participated.  The Company had anticipated this event and as a result had accrued approximately $3.2 million as of January 3, 2009 based on the most recent information that was probable and estimable for this plan.  The plan had given a notice of redetermination liability in December 2009.  In fiscal 2010, the Company received further third party information confirming the future payout related to this multiemployer plan.  As a result, the Company reduced its liability to approximately $1.2 million.  In fiscal 2010, another underfunded

multiemployer plan in which the Company participates gave notification of partial withdrawal liability.  As of December 29, 2012, the Company has an accrued liability of approximately $1.0 million representing the present value of scheduled withdrawal liability payments under this multiemployer plan.  While the Company has no ability to calculate a possible current liability for under-funded multiemployer plans that could terminate or could require additional funding under the Pension Protection Act of 2006, the amounts could be material.