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Business Segments
 12 Months Ended
Dec. 28, 2024
Segment Reporting [Abstract]  
BUSINESS SEGMENTS BUSINESS SEGMENTS
In 2024, the Company adopted Accounting Standards Update (“ASU”) No. 2023-07, Segment Reporting (Topic 280): Improvements to Reportable Segment Disclosures, on a retrospective basis.

The Company sells its products through a global network of over 260 locations across five continents within three industry segments: Feed Ingredients, Food Ingredients and Fuel Ingredients. The Company's segments are determined as those operations whose results are reviewed regularly by the chief operating decision maker (“CODM”), who is the Company's Chief Executive Officer, in deciding how to allocate resources and assess performance. Each segment is organized and managed based upon the nature of the Company's markets and customers and consists of similar products and services.

The following is a description of each segment's business operations:

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 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.

The performance of the operating segments is evaluated based on segment profit (loss) which 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. The CODM uses segment profit (loss) as the measure to make resource (including financial or capital resources) allocation decisions for each segment, predominantly in the annual budget and forecasting process. The CODM considers budget-to-actual variances on a quarterly basis when evaluating performance for each segment and making decisions about capital allocation. Accounting policies have been applied consistently by all segments within the Company for all reporting periods. Intercompany revenue and expense amounts have been eliminated within each segment to report on the basis that management uses internally for evaluating segment performance.

Business Segments (in thousands):

Feed IngredientsFood IngredientsFuel Ingredients
Corporate (a)
Total
Fiscal Year Ended December 28, 2024
Total net sales$3,675,609 $1,489,101 $550,465 $— $5,715,175 
Cost of sales and operating expenses2,886,125 1,115,348 435,864 — 4,437,337 
Gross Margin789,484 373,753 114,601 — 1,277,838 
Gain on sale of assets(669)(1,758)(1,730)— (4,157)
Selling, general and administrative expenses279,095 119,604 32,370 61,036 492,105 
Restructuring and asset impairment charges3,671 2,123 — — 5,794 
Depreciation and amortization350,141 109,102 35,876 8,706 503,825 
Acquisition and integration costs— — — 7,842 7,842 
Change in fair value of contingent consideration(46,706)— — — (46,706)
Equity in net income of Diamond Green Diesel— — 149,082 — 149,082 
Segment operating income/(loss)203,952 144,682 197,167 (77,584)468,217 
Equity in net income of other unconsolidated subsidiaries11,994 — — — 11,994 
Segment income/(loss)215,946 144,682 197,167 (77,584)480,211 
Total other expense (b)(232,703)
Income before income taxes$247,508 
Segment assets at December 28, 2024$4,100,841 $1,997,827 $2,489,149 $1,482,656 $10,070,473 

(a)    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.

(b)    Total other expense includes interest expense, foreign currency gain (loss) and other income (expense). Interest expense and foreign currency gain (loss) are separately disclosed on our Statement of Operations. Other income/(expense) consists of interest income of approximately $16.0 million, casualty gain of approximately
$20.7 million, other pension expense excluding service cost of approximately $(1.8) million and other income (expense) of approximately $(12.6) million.
Feed IngredientsFood IngredientsFuel IngredientsCorporateTotal
Fiscal Year Ended December 30, 2023
Total 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 (c)(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 

(c)    Total other expense includes interest expense, foreign currency gain (loss) and other income (expense). Interest expense and foreign currency gain (loss) are separately disclosed on our Statement of Operations. Other income (expense) consists of interest income of approximately $16.4 million, casualty gain of approximately $7.8 million, other pension expense excluding service cost of approximately $(1.5) million and other expense of approximately $(6.4) million.

Feed IngredientsFood IngredientsFuel IngredientsCorporateTotal
Fiscal Year Ended December 31, 2022
Total 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 
Acquisition and integration costs— — — 16,372 16,372 
Depreciation and amortization295,249 59,029 29,500 10,943 394,721 
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 (d)(140,452)
Income before income taxes$893,718 
 
(d)    Total other expense includes interest expense, foreign currency gain (loss) and other income (expense). Interest expense and foreign currency gain (loss) are separately disclosed on our Statement of Operations. Other income (expense) consists of interest income of approximately $5.3 million, casualty loss of approximately $(4.6) million, other pension income excluding service cost of approximately $1.1 million and other expense of approximately $(5.4) million.

Business Segment Property, Plant and Equipment (in thousands):
         
 December 28,
2024		December 30,
2023		December 31,
2022
Capital expenditures for the year ended:
Feed Ingredients$219,541 $413,831 $270,157 
Food Ingredients81,808 92,704 72,301 
Fuel Ingredients27,230 39,053 37,568 
Corporate3,886 9,892 11,283 
Total (a)$332,465 $555,480 $391,309 

(a)    Excludes capital assets acquired in acquisitions in fiscal 2024, 2023 and 2022 of approximately $37.4 million, $155.5 million and $588.8 million, respectively.

Long-lived assets related to the Company’s operations by geography were as follows (in thousands):
        
FY 2024FY 2023
Long-Lived AssetsLong-Lived Assets
North America$5,518,153 $5,667,606 
Europe1,344,033 1,329,466 
China115,152 116,698 
South America1,636,246 2,072,840 
Other17,453 18,808 
Total$8,631,037 $9,205,418