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Sun Capital Partners Raw Materials Opportunity Analysis. Luis Pacheco: Director of Sourcing February 17 th 2011. Agenda. Executive Summary Approach Potential Savings Findings Risks and Opportunities Next steps. Executive Summary. The Current Situation - PowerPoint PPT Presentation
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Highly Confidential
Sun Capital Partners
Raw Materials Opportunity Analysis
Luis Pacheco: Director of Sourcing
February 17th 2011
1
Highly Confidential
Agenda
• Executive Summary• Approach• Potential Savings• Findings• Risks and Opportunities • Next steps
2
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The Current Situation• Split of resin/film spend is 50% Europe,47% America, and 3% Asia.• Many locations make it challenging to leverage global purchasing• The top 5 resin materials, PE, PS, PP, Nylon, and PET account for 93% of spend• Work on synergies has already started, typically “2” company projects• Different operational situations may dictate different priorities e.g. cash flow needs vs. cost• Current market conditions: volatile commodity market leading to increasing costs
The Opportunity• Potential savings of $8.6M to $13.7M identified with an additional $3.3M to $6.9M improvement in Working
Capital• Quick Wins by eliminating price inconsistencies, some supplier consolidation, and improved payment terms• Additional opportunity if we expand into other direct and indirect categories • Future review of technical cost reduction to be considered
Data Resins Film Total
Portfolio Companies 6 6 7
Countries 16 6 16
Resins/Films Classifications 104 22 126
Suppliers 59 79 133
Skus 490 427 917
Annual Volume (Tons) 225 K 43K + 268K +
Spend (USD) 414 million 167 million 581 million
Payment Terms Pay in advance → Net 150
Key Focus Unit price → Product breadth
Executive Summary
3
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Approach• Reviewed high level direct material spend from packaging companies buying
polymers… total spend of $922M
• Focused on resin and film which gave combined spend of $581M… 63% of direct material spend reviewed
• Inks, plastic components, and other items to be analyzed later• Collected, cleaned, and standardized detailed data to analyze resins and film• Completed calls to clarify doubts on data. Key feedback: “suppliers market today”
and “ability to buy regional”• Generated a first pass database that will be the basis for a broader project
4
Albea168.854531247303
18%Betts
66.90732385938987%
Exopack387.353871
42%Famosa7.29755
1%
Paccor90.1484011682265
10%
Reuther33.2348810298
4%
Veriplast168.521221808134
18%
Spend ($M) by Company
Resin414.253629911043
45%Film
166.76359635608418%Components
47.0295%
Inks, Dyes, Solvents $79 9%
Adhesives14.3085006915961
2%
Paper107.96
12% Misc92.8007076273215
10%
Spend ($M) by Category
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Database is Basis for Estimating Savings
• Does internal price benchmarking show opportunity for reductions?
• How much spend can be leveraged by supplier, item, and category?
• What are the contracted periods and exit restrictions?
• What are our payment terms?• What is the key focus when purchasing?• How much of the spend is customer
specified? What is required to qualify a new supplier?
• Are products purchased contractually or spot-buys?
Portfolio Companies
• How fragmented is the supply base?• Is there opportunity to leverage
purchasing scale? Regional or Global?
• What is the range of products offered vs. SCP needs?
• Are we buying from the right suppliers?
• What are we buying from distributors that we could buy from manufacturers?
• Should LCC suppliers be included?• What are the supply/demand
conditions for that product?
Supply Base
Savings Opportunity
5
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Potential Savings: $8.6M - $13.7M (1.5% -2.4%)
Under Contract?
Customer Specified?
Recently Addressed?
Resin and Film Spend
$581M Annual
$67M recently addressed
$2.5M saved in 2010
$514M not recently
addressed
Yes$172M
Yes$69M
No$103M
No$342M
Yes$188M
No$154M
$0.7M - $1.4M Long term savings
$1M -$2.1MMid term savings
$3.8M -$5.6M Long term savings Long approval on $75M
$2.5M -$3.7M Short term savings on $123M
$0.6 - $0.9 Long term savings Long approval on $31M
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Estimated savings of $8.6 -$13.7M on spend of $581M
• Low percentage savings applied to a large spend makes it an attractive opportunity• $2.5-$3.7M can be captured in the short term (less than 6 months)• Additional $3.3M - $6.9M improvement in working capital
1%-2%
1%-2%
2%-3%
2%-3%
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66897598.791
63%
38925136.222734137%
186400.450%
Spend ($) for Polystyrene
PS High ImpactPS General-PurposePS
LDPE; 61819845.63822; 37%
HDPE; 19175059.449; 11%
LLDPE/Octene; 16909000; 10%
LLDPE/Hexene16807000
10%
Spend ($) for Polyethylene
Closer Look At High Spend Items: Resin
7
• Polyethylene and polystyrene give 66% of resin spend. Multiple subgrades within each grade
• LDPE is the grade with the most spend (37%) within polyethylene
• PS-GP has 37% of the spend within Polystyrene
Polyethyle
ne (PE)
Polystyr
ene (
PS)
Polypro
pylene (
PP)Nylo
n
Copolymer
All Others
$0$20$40$60$80
$100$120$140$160$180$200
0%10%20%30%40%50%60%70%80%90%100%
167
106 82
15 8
37
Spend by Polymer
Spend
Cum Percent
$(M)
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• Low value outliers were due to purchase of discontinued LDPE grades
• High values outliers are grades specified by customer, which use specialty additives, and are currently bought from distributors
Albea Exopack Veriplast0
1,0002,0003,0004,0005,000
LDPE Price Range Across PortfolioUSD/ Ton • LDPE has 36 resin grades with
70% price spread• Removing 13 outliers gives a
price range of: Max $1,906/ton Min $1,698/ton 12% spread on price
Price Distribution Example: LDPE Resin
8
Price spread needs to be filtered before analyzing variation
1,000 1,500 2,000 2,500 3,000 3,500 4,000 4,5000
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
LDPE Price vs. Spend
AlbeaExopackVeriplast
Price (USD/Ton)
Spend (USD )
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Paccor Veriplast0
5001,0001,5002,0002,5003,000
PS-GP Price Range Across PortfolioUSD/ Ton
• PS-GP has 18 resins grades. • Removing 4 specialty outliers• Price range of:
Max $1,703/ton Min $1,619/ton 5% spread on price
• High values are grades which need to be approved by customers
• Terms may be an area we can leverage with volume where price can not
9
Price Distribution Example: PS-GP Resin Narrow non-typical price-volume curve for standard product
1,500 1,600 1,700 1,800 1,900 2,0000
2,000,0004,000,0006,000,0008,000,000
10,000,00012,000,00014,000,000
PS- GP Price vs. Spend
PaccorVeriplast
Price (USD/Ton)
Spend (USD )
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Note: Std days = Payments terms + Consignment inventory
Payment Terms Comparison
10
• Potential WC improvement for resin and film of $3.3M - $6.9M– Low improvement scenario factored with 5 days improvement for Albea, Betts,
and Exopack. Famosa improved to 15 days– High Improvement scenario factored with 10 days improvement for Albea, Betts,
and Exopack. Famosa improved to 30 days• Different expectations for payment terms in Europe vs. North America• Resin has better terms than films, except for Betts. Typically 10-20 days better.
Albea Betts Exopack Famosa Paccor Veriplast0
20
40
60
80
100
120
140
160
Payment Terms for Resin Purchases
MinNet Days
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Opportunity to Consolidate Supplier Base
11
Film Suppliers Spend USDTredegar 13,209,984Toray 8,713,810Treofan 7,937,776NEX AND BEMIS 7,606,162Berry Pliant 7,583,400Polyplex 7,551,749Huhtamaki 7,114,571DNP Indonesia 6,729,542All others 100,316,660
0 10 20 30 40 50 60 70 800
50100150200250300350400450
Distribution of Film Spend by Suppliers
Count of Suppliers
Annualized Cumulative Spend ($M)
$167M total spend with 79 suppliersTop 20 suppliers give 71% of spend15 suppliers < $200,000Bottom 30 suppliers give 4% of spend
0 10 20 30 40 50 60 70 800
50100150200250300350400450
Distribution of Resin Spend by Suppliers
Count of Suppliers
Annualized Cumulative Spend ($M) $414M total spend 59 suppliers
Top Ten suppliers give 82% of spend
• Potential to consolidate supplier base, particularly for films.
• More detailed understanding of technical specification will be needed for making final decisions
Resin Suppliers Spend ($)Total Petrochemical 71,099,724 Ineos Nova 45,063,248 LyondellBasell 33,257,629 Borealis 30,705,157 Chevron Phillips 29,688,800 Dow Chemical 28,709,150 Dupont 28,361,189 Synthos 26,269,183 All Others 204,439,072
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Opportunities
$2.5M-$3.7M Short Term < 6 months
• Do not slow down current projects• Reduce cost by internal benchmarking
– 3.8% achieved in 2010 by Exopack– Validated from data from 3% to 12% variation in
“narrowed” pricing distribution
• Improved terms– Variations across portfolio within same supplier
clearly shown– Famosa terms $300-$600K– Terms may be a bigger lever than cost in some
cases
• Supplier consolidation– How can we collaborate to make it a win/win?
• Bundling– Global suppliers but regional market conditions
likely to dictate format
$6.1M-$10M Medium to Long Term
• Expand to other categories– Inks, solvents, cap ex etc.
• Third Party Benchmarking– Do opportunities exist in non competing industries
or via third parties?• Low cost country sourcing
– Exopack has extensive experience in this area– Middle East?– Asia?
• Technical Cost Reduction– Grades?– Specifications?– Blend in house?
• Hedging indexes?• Support customer base expansion
overseas e.g. China
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Risks and Concerns
• Volatile Market Conditions– “It’s a nightmare”
• Suppliers Market– Some consolidation in progress
• Regional Markets– What ability do we have to work across continents?... Do suppliers serve all the markets where we are
purchasing?– Are the same expectations applicable on all locations?... Payment terms in Europe vs. North America– Inter Europe regional play
• Customers– Approval process could force us to expose cost reduction
• Historical Credit Issues– Lowest common denominator?
• Forecasting savings on categories that have been under continuous improvement– Historically we have seen cost reductions in resins and films– Some synergies between two portfolio companies already started
• Sun Capital Company Consolidation and Exits– Implications?
13
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Next Steps• Determine project approach
– Internal and/or consultants– Select team
• Determine project scope– Resin and film– Develop Supplier Strategy
• Agree buying process– Group process– Consortium buy
• Additional opportunities:• Plastic components• Inks, solvents, and dyes.• Printing plates
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Appendix
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Direct Spend Details ($M)
16
Category Albea Betts Exopack Famosa Paccor Reuther Veriplast Total
Resin 68 4 121 7 77 - 137 414
Film 10 28 103 - 2 12 13 167
Components 22 25 - - - - - 47
Inks, Dyes, Solvents 18 3 29 - 9 4 16 79
Adhesives - - 14 - 0 - 0 14
Paper - - 101 - - 7 - 108
Misc 51 7 21 - 1 10 3 93
Total 169 67 387 7 90 33 169 922
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Paccor Veriplast0
5001,0001,5002,0002,5003,000
PS HIPS Price Range Across PortfolioUSD/ Ton
• HIPS has 13 resins grades. • Removing 2 outliers gives a
price range of: Max $1,856/ton Min $1,749/ton 6% spread on price
1,600 1,800 2,000 2,200 2,400 2,600 2,8000
5,000,00010,000,00015,000,00020,000,00025,000,00030,000,00035,000,000
HIPS Price vs. Spend
PaccorVeriplast
Price (USD/Ton)
Spend (USD x1,000)
17
Price Distribution Example: PS HIPS Resin
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Resin Payment Terms Comparison by Company
18
Albea Betts Exopack Famosa Paccor Veriplast TotalSpend (Millions) $68.0 $3.8 $120.7 $7.3 $77.3 $137.0 $414.2
Average 52 31 52 0 72 78 New average net days low improvement 57 36 57 15 72 78 New average net days high improvement 62 41 62 30 72 78
Working capital current $9.8 $0.3 $17.2 $0.0 $15.3 $29.1 $71.8Working capital with low improvement $10.6 $0.4 $18.9 $0.3 $15.3 $29.1 $74.6 $2.8Working capital with high improvement $11.6 $0.4 $20.5 $0.6 $15.3 $29.1 $77.6 $5.7
• Used 2.5 and 5 days as the low and high improvement for film.• Low/High improvement for film of $0.5M-$1.2M• Total working capital improvement of $3.3-$6.9M
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Resin Payment Terms Comparison by Supplier
19
Supplier Albea Betts Exopack Paccor Veriplast
Borealis 73 70 92
LyondellBasell 66 30 30 39 84
Total Petrochemical 72 105 100 80
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Platts Resin Prices 2007-2010
20
Jan-
08
Feb-
08
Mar
-08
Apr-
08
May
-08
Jun-
08
Jul-0
8
Aug-
08
Sep-
08
Oct
-08
Nov
-08
Dec
-08
Jan-
09
Feb-
09
Mar
-09
Apr-
09
May
-09
Jun-
09
Jul-0
9
Aug-
09
Sep-
09
Oct
-09
Nov
-09
Dec
-09
Jan-
10
Feb-
10
Mar
-10
Apr-
10
May
-10
Jun-
10
Jul-1
0
Aug-
10
Sep-
10
Oct
-10
Nov
-10
Dec
-10
Jan-
11
Feb-
11
700
800
900
1,000
1,100
1,200
1,300
1,400
1,500
1,600
GPPS
PP
LDPE
PET
€/to
nne