CONSOLIDATED STATEMENTS OF OPERATIONS (USD $) In Thousands, except Per Share data, unless otherwise specified	12 Months Ended
	Dec. 31, 2011	Jan. 01, 2011	Jan. 02, 2010
Consolidated Statements of Operations [Abstract]
Net sales	$ 1,909,187	$ 1,708,529	$ 1,614,596
Cost of sales	1,546,173	1,385,702	1,317,443
Selling, general and administrative expenses	217,136	203,983	202,791
Amortization of intangible assets	10,306	10,638	9,178
Restructuring, impairment and other charges	17,812	226,150	68,034
Operating income (loss)	117,760	(117,944)	17,150
Gain on bargain purchase	(11,720)	0	0
Interest expense, net	115,968	121,037	106,063
(Gain) loss on early extinguishment of debt	(4,011)	9,592	(16,917)
Other (income) expense, net	9,074	2,327	(1,367)
Income (loss) from continuing operations before income taxes	8,449	(250,900)	(70,629)
Income tax expense (benefit)	9,477	(53,202)	(21,593)
Income (loss) from continuing operations	(1,028)	(197,698)	(49,036)
Income (loss) from discontinued operations, net of taxes	(7,537)	11,321	18,097
Net income (loss)	$ (8,565)	$ (186,377)	$ (30,939)
Income (loss) per share - basic: [Abstract]
Continuing operations per share - basic	$ (0.02)	$ (3.17)	$ (0.86)
Discontinued operations per share - basic	$ (0.12)	$ 0.18	$ 0.32
Net income (loss) per share - basic	$ (0.14)	$ (2.99)	$ (0.54)
Income (loss) per share - diluted: [Abstract]
Continuing operations per share - diluted	$ (0.02)	$ (3.17)	$ (0.86)
Discontinued operations per share - diluted	$ (0.12)	$ 0.18	$ 0.32
Net income (loss) per share - diluted	$ (0.14)	$ (2.99)	$ (0.54)
Weighted average shares: [Abstract]
Basic shares	62,983	62,382	56,787
Diluted shares	62,983	62,382	56,787