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Business Segments
 12 Months Ended
Dec. 30, 2023
Segment Reporting [Abstract]  
BUSINESS SEGMENTS BUSINESS SEGMENTS
The Company sells its products domestically and internationally and operates within three industry segments: Feed Ingredients, Food Ingredients and Fuel Ingredients. The measure of segment profit (loss) includes all revenues, operating expenses (excluding certain amortization of intangibles), and selling, general and administrative expenses incurred at all operating locations and excludes general corporate expenses.

Included in corporate activities are general corporate expenses and the amortization of intangibles. Assets of corporate activities include cash, unallocated prepaid expenses, deferred tax assets, prepaid pension, and miscellaneous other assets.

Feed Ingredients
Feed Ingredients consists principally of (i) the Company’s U.S. ingredients business, including the Company’s fats and proteins, used cooking oil, trap grease, the Company’s Canada ingredients business, and the ingredients and specialty products businesses conducted by Darling Ingredients International under the Sonac and FASA names (proteins, fats, and blood products) and (ii) the Company’s bakery residuals business. Feed Ingredients operations process animal by-products and used cooking oil into fats, proteins and hides.

Food Ingredients
Food Ingredients consists principally of (i) the collagen business conducted by Darling Ingredients International under the Rousselot and Gelnex names, (ii) the natural casings and meat-by-products business conducted by Darling Ingredients International under the CTH name and (iii) certain specialty products businesses conducted by Darling Ingredients International under the Sonac name.

Fuel Ingredients
The Company’s Fuel Ingredients segment consists of (i) the Company’s investment in the DGD Joint Venture and (ii) the bioenergy business conducted by Darling Ingredients International under the Ecoson and Rendac names.

Business Segments (in thousands):

Feed IngredientsFood IngredientsFuel IngredientsCorporateTotal
Fiscal Year Ended December 30, 2023
Net Sales$4,472,592 $1,752,065 $563,423 $— $6,788,080 
Cost of sales and operating expenses3,385,859 1,310,581 446,620 — 5,143,060 
Gross Margin1,086,733 441,484 116,803 — 1,645,020 
Loss/(gain) on sale of assets814 (8,144)(91)— (7,421)
Selling, general and administrative expenses310,363 128,464 23,543 80,164 542,534 
Restructuring and asset impairment charges4,026 14,527 — — 18,553 
Depreciation and amortization360,249 94,991 34,466 12,309 502,015 
Acquisition and integration costs— — — 13,884 13,884 
Change in fair value of contingent consideration(7,891)— — — (7,891)
Equity in net income of Diamond Green Diesel— — 366,380 — 366,380 
Segment operating income/(loss)419,172 211,646 425,265 (106,357)949,726 
Equity in net income of other unconsolidated subsidiaries5,011 — — — 5,011 
Segment income/(loss)424,183 211,646 425,265 (106,357)954,737 
Total other expense(234,780)
Income before income taxes$719,957 
Segment assets at December 30, 2023$4,702,593 $2,646,702 $2,589,145 $1,122,644 $11,061,084 
Feed IngredientsFood IngredientsFuel IngredientsCorporateTotal
Fiscal Year Ended December 31, 2022
Net Sales$4,539,000 $1,459,630 $533,574 $— $6,532,204 
Cost of sales and operating expenses3,473,506 1,102,250 426,853 — 5,002,609 
Gross Margin1,065,494 357,380 106,721 — 1,529,595 
Gain on sale of assets(3,426)(1,008)(60)— (4,494)
Selling, general and administrative expenses258,781 101,681 13,690 62,456 436,608 
Restructuring and asset impairment charges8,557 21,109 — — 29,666 
Depreciation and amortization295,249 59,029 29,500 10,943 394,721 
Acquisition and integration costs— — — 16,372 16,372 
Equity in net income of Diamond Green Diesel— — 372,346 — 372,346 
Segment operating income/(loss)506,333 176,569 435,937 (89,771)1,029,068 
Equity in net income of other unconsolidated subsidiaries5,102 — — — 5,102 
Segment income/(loss)511,435 176,569 435,937 (89,771)1,034,170 
Total other expense(140,452)
Income before income taxes$893,718 
Segment assets at December 31, 2022$4,866,351 $1,251,473 $2,307,199 $777,347 $9,202,370 


Feed IngredientsFood IngredientsFuel IngredientsCorporateTotal
Fiscal Year Ended January 1, 2022
Net Sales$3,039,500 $1,271,629 $430,240 $— $4,741,369 
Cost of sales and operating expenses2,206,248 979,232 313,905 — 3,499,385 
Gross Margin833,252 292,397 116,335 — 1,241,984 
Gain on sale of assets(550)(88)(320)— (958)
Selling, general and administrative expenses220,078 97,555 16,999 56,906 391,538 
Restructuring and asset impairment charges— — 778 — 778 
Acquisition costs— — — 1,396 1,396 
Depreciation and amortization218,942 60,929 25,436 11,080 316,387 
Equity in net income of Diamond Green Diesel— — 351,627 — 351,627 
Segment operating income/(loss)394,782 134,001 425,069 (69,382)884,470 
Equity in net income of other unconsolidated subsidiaries5,753 — — — 5,753 
Segment income/(loss)400,535 134,001 425,069 (69,382)890,223 
Total other expense(68,827)
Income before income taxes$821,396 
 
Business Segment Property, Plant and Equipment (in thousands):
         
 December 30,
2023		December 31,
2022		January 1,
2022
Capital expenditures for the year ended:
Feed Ingredients$413,831 $270,157 $187,445 
Food Ingredients92,704 72,301 54,799 
Fuel Ingredients39,053 37,568 26,078 
Corporate Activities9,892 11,283 5,804 
Total (a)$555,480 $391,309 $274,126 

(a)    Excludes capital assets acquired by acquisition in fiscal 2023 and fiscal 2022 of approximately $155.5 million and $588.8 million, respectively.

Long-lived assets related to the Company’s operations in North America, Europe, China, South American and other were as follows (in thousands):
        
FY 2023FY 2022
Long-Lived AssetsLong-Lived Assets
North America$5,667,606 $5,229,906 
Europe1,329,466 1,276,333 
China116,698 120,801 
South America2,072,840 920,827 
Other18,808 16,406 
Total$9,205,418 $7,564,273