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Special Charges, Net
12 Months Ended
Dec. 28, 2013
Special Charges, Net [Abstract]  
Special Charges, Net
Special Charges, Net
As part of our business strategy, the Company incurs amounts related to corporate-level decisions or Board of Director actions. These actions are primarily associated with initiatives attributable to restructuring and realignment of manufacturing operations and management structures as well as the pursuit of certain transaction opportunities when applicable. In addition, the Company evaluates its long-lived assets for impairment whenever events or changes in circumstances including the aforementioned, indicate that the carrying amounts may not be recoverable. These amounts are included in Special charges, net in the Consolidated Statement of Operations. A summary for each respective period is as follows:
 
 
Successor
 
 
Predecessor
In thousands
Fiscal Year Ended
December 28,
2013
 
Fiscal Year
Ended
December 29,
2012
 
Eleven Months
Ended
December 31,
2011
 
 
One Month
Ended
January 28,
2011
Restructuring and plant realignment costs
 
 
 
 
 
 
 
 
Internal redesign and restructure of global operations
$
2,291

 
$
12,403

 
$

 
 
$

Plant realignment costs
8,395

 
4,096

 
1,515

 
 
194

IS support initiative
25

 
867

 

 
 

Other restructure initiatives
42

 
511

 

 
 

Total restructuring and plant realignment costs
10,753

 
17,877

 
1,515

 
 
194

Acquisition and merger related costs
 
 
 
 
 
 
 
 
Blackstone acquisition costs
37

 
452

 
27,919

 
 
6,137

Fiberweb acquisition costs
18,306

 

 

 
 

Accelerated vesting of share-based awards

 

 

 
 
12,694

Total acquisition and merger related costs
18,343

 
452

 
27,919

 
 
18,831

Other special charges
 
 
 
 
 
 
 
 
Colombia flood

 
57

 
1,037

 
 
1,685

Goodwill impairment

 

 
7,647

 
 

Asset impairment charges
2,259

 

 
1,620

 
 

Other charges
1,833

 
1,206

 
1,607

 
 
114

Total other special charges
4,092

 
1,263

 
11,911

 
 
1,799

Total
$
33,188

 
$
19,592

 
$
41,345

 
 
$
20,824


Restructuring and Plant Realignment Costs
Internal redesign and restructuring of global operations
During 2012, the Company initiated the internal redesign and restructuring of its global operations for the purposes of realigning and repositioning the Company to consolidate the benefits of its global footprint, align resources and capabilities with future growth opportunities and provide for a more efficient structure to serve existing markets.
Costs incurred for the respective periods presented consisted of the following:
 
Successor
 
 
Predecessor
In thousands
Fiscal Year Ended
December 28,
2013
 
Fiscal Year
Ended
December 29,
2012
 
Eleven Months
Ended
December 31,
2011
 
 
One Month
Ended
January 28,
2011
Employee separation
$
171

 
$
8,788

 
$

 
 
$

Professional consulting fees
1,603

 
1,589

 

 
 

Relocation, recruitment and other
517

 
2,026

 

 
 

Total
$
2,291

 
$
12,403

 
$

 
 
$

Plant Realignment Costs
The Company incurs costs associated with ongoing restructuring initiatives intended to result in lower working capital levels and improve operating performance and profitability. Costs associated with these initiatives include improving manufacturing productivity, reducing headcount, realignment of management structures, reducing corporate costs and rationalizing certain assets, businesses and employee benefit programs. Costs incurred for the respective periods presented primarily consisted of plant realignment initiatives in the Americas and Europe regions. However, amounts recorded in the current period primarily relate to costs incurred in association with our acquisition of Fiberweb.
IS Support Initiative
During 2012, the Company launched an initiative to utilize a third-party service provider for its Information Systems support tactical functions, including: service desk; desktop/end-user computing; server administration; network services; data center operations; database and applications development; and maintenance. Cost incurred for the respective periods presented primarily consisted of employee separation and severance expenses.
Other Restructuring Initiatives
The Company incurs costs associated with less significant ongoing restructuring initiatives resulting from the continuous evaluation of opportunities to optimize manufacturing facilities and the manufacturing process. Costs associated with these initiatives primarily relate to professional consulting fees.
Amounts accrued for Restructuring and Plant Realignment costs are included in Accounts payable and accrued expenses in the Consolidated Balance Sheets. Changes in the Company's reserves for the respective periods presented were as follows:
 
Successor
 
 
Predecessor
In thousands
Fiscal Year Ended
December 28,
2013
 
Fiscal Year
Ended
December 29,
2012
 
Eleven Months
Ended
December 31,
2011
 
 
One Month
Ended
January 28,
2011
Beginning balance
$
6,278

 
$
1,100

 
$
1,694

 
 
$
1,726

Additions
8,634

 
15,074

 
1,515

 
 
194

Acquisitions
2,010

 

 

 
 

Cash payments
(8,343
)
 
(9,930
)
 
(2,022
)
 
 
(220
)
Adjustments
(119
)
 
34

 
(87
)
 
 
(6
)
Ending balance
$
8,460

 
$
6,278

 
$
1,100

 
 
$
1,694


The Company accounts for its restructuring programs in accordance with ASC 712, "Compensation - Non-retirement Postemployment Benefits" ("ASC 712"). Programs in existence prior to the acquisition of Fiberweb are substantially complete with any year-end accrued liability remaining to be paid in early 2014. As a result of the acquisition of Fiberweb, the Company has initiated several restructuring programs to integrate and optimize the combined footprint. Projected costs for these programs are expected to range between $16.0 million and $23.0 million.
Acquisition and Merger Related Costs
Blackstone Acquisition Costs
As a result of the Merger on January 28, 2011, the Company incurred direct acquisition costs associated with the transaction including investment banking, legal, accounting and other fees for professional services. Other expenses included direct financing costs associated with the issuance of the Senior Secured Notes as well as the fee to enter into the ABL Facility, both of which have been capitalized as intangible assets on the Consolidated Balance Sheet as of the date of the Merger.
Fiberweb Acquisition Costs
As a result of the Acquisition on November 15, 2013, the Company incurred direct acquisition costs associated with the transaction including investment banking, legal, accounting and other fees for professional services. Other expenses included direct financing costs associated with both the Secured Bridge Facility and the Unsecured Bridge Facility, as well as with the Term Loans. These costs have been capitalized as intangible assets on the Consolidated Balance Sheet as of the date of the Acquisition.
Accelerated Vesting of Share-Based Awards
Due to the change in control associated with the Merger, the Company's Predecessor stock options as well as the restricted shares and restricted share units underlying the Restricted Stock Plans vested, if unvested, were canceled and converted into the right to receive on January 28, 2011, (i) an amount in cash equal to the per share closing payment and (ii) on each escrow release date, an amount equal to the per share escrow payment, in each case, less any applicable withholding taxes. With respect to the Company's stock options, the amount in cash was adjusted by the exercise price of $6.00 per share.
Other Special Charges
Colombia Flood
In December 2010, a severe rainy season impacted many parts of Colombia and caused the Company to temporarily cease manufacturing at its Cali, Colombia facility due to a breach of a levy and flooding at the industrial park where its manufacturing facility is located. The Company established temporary offices away from the flooded area and worked with customers to meet their critical needs through the use of our global manufacturing base. The facility re-established manufacturing operations on April 4, 2011 and operations reached full run rates in third quarter of 2011. The costs related to restoration of the facility were net of insurance proceeds. In addition, the Company capitalized $8.0 million of costs that were incurred to bring the manufacturing equipment to a functional state during 2011.
Goodwill Impairment
Goodwill is tested and reviewed annually for impairment during the fourth quarter or whenever there is a significant change in events or circumstances that indicate that the fair value of the asset may be less than the carrying amount of the asset. In the fourth quarter of 2011, the Company performed its annual impairment test of goodwill in accordance with current accounting standards. As a result, the Company recorded a $7.6 million non-cash impairment charge attributable to reporting units in Asia and the Americas.
Asset Impairment
The Company reviews long-lived assets for impairment whenever events or changes in circumstances indicate that the carrying value of an asset may not be recoverable. In the fourth quarter of 2013, the Company performed an impairment test on long-lived assets in Argentina. Based on third-party valuations, the Company determined the fair value of the long-lived assets to be $14.4 million fair value. As a result, the Company recorded an non-cash impairment charge of $2.2 million to adjust the carrying value to its fair value. In addition, a $1.6 million non-cash impairment charge was recorded during the fourth quarter of 2011. The charge related to the fair value adjustment of a former manufacturing facility in North Little Rock, Arkansas.
Other Charges
Other charges consist primarily of expenses related to the Company’s pursuit of other business opportunities. The Company reviews its business operations on an ongoing basis in light of current and anticipated market conditions and other factors and, from time to time, may undertake certain actions in order to optimize overall business, performance or competitive position. To the extent any such decisions are made, the Company would likely incur costs associated with such actions, which could be material. Other costs may include various corporate-level initiatives.