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Page 1
Table of Contents
Page 2
Replay Plastics
The growing utilization of plastics in industrial and consumer applications, combined with
increased consumer awareness surrounding solid waste recycling, has led to an increased
demand for recycled plastic resins and products. One of the fastest growing types of collected
plastic materials for recycling is polyethylene terephthalate ("PET") from post-consumer
beverage and water bottles. Replay Plastics will capitalize on the opportunities in the recycled
resin and packaging markets through two main divisions: a Recycling Division and a
Packaging Division.
The Company will create a PET cleaning and refining plant located in the western United States
(all 16 major North American PET recycling plants are currently located in the eastern United
States or Canada). Its initial capacity will be 46 million pounds, and it will utilize post-consumer
bottle feed stock presently collected in California, Oregon and Washington States, which collect
over 200 million pounds per year. The Company will be vertically integrated, and use almost all
of its recycled material in its Packaging Division. Any surplus materials (clean flake) produced
will be sold to outside companies. The extruded sheet may then be sold to manufacturers, who
will thermoform it into high-visibility packaging or use it in other high value added
manufacturing operations. The strapping will be sold to companies who ship large packages or
pallets, such as the lumber milling industry. The Company currently has commitments
available from customers to purchase all of the product produced.
MANAGEMENT
Ben Braddock, President, has a 30-year history of experience encompassing all aspects of
Polymer Raw Material, Plastic Conversion Methods, and Venture Development. He has founded
successful ventures in the plastic converting industry, and assisted in the launch of five plastic
converting manufacturing plants. Sam McGuire, Executive VP and COO, is a graduate Engineer
with over 20 years experience in the post-consumer plastics recycling industry and is the
inventor of the primary cleaning & refining technology used in the process for this project. He
has received a patent for his technology and has been directly involved in over twenty-five
major post consumer plastics recycling projects. Carl R. Smith, CFO, has over 30 years
investment and merchant banking and management experience. He has assisted in raising over
$500 million and served as board member and/or officer in over 40 public and private
companies.
FINANCIAL SUMMARY
After a four month start-up period to build the recycling and packaging facilities, buy
equipment, and incorporate the business, Replay Plastics will begin a quick turnaround of
product. Sales will begin in May, and with over $15 Million in sales the first year, we will see a
first year net profit of $2.3 Million. The owners are investing $500,000 each, for a total of $1.5
Million, and are securing an $800K long-term loan.
The Company is also seeking an investment of $2,700,000 in order to begin operations. These
funds will be used for the purchase of one recycling line and one manufacturing line, for the set
up of the plant facilities and for working capital. An outside investor providing this amount
would receive 48% equity in Replay, and receive an IRR of 69% from simple dividends alone
over the next 5 years. At the end of that period, we will consider a public offering of stock or a
buy-out by a related business. Recent information on private sales of similar industry
companies has indicated that transactions under $25 million have averaged 5.3 times EBITDA,
while transactions in the range of $25-250 million have averaged over 7 times EBITDA. Further
details can be found in the Financial Plan, below.
Page 1
Replay Plastics
Chart: Highlights
1.1 Objectives
1. Sales passing $15 million in first year, $31 million in year 2, growing to $43 million.
2. Gross margin of 35% or more in first year, 45% in second year then 50% or more.
3. Net profit of 13% in year one, then exceeding 20% annually starting in year two.
1.2 Mission
Replay Plastics is a manufacturing company dedicated to converting waste plastic materials into
commercially viable products, utilizing environmentally friendly recycling and manufacturing
methods. We intend to make enough profit to generate a significant return for our investors
and to finance continued growth and continued development in quality products. We will also
maintain a friendly, fair, and creative work environment, which respects diversity, new ideas
and hard work.
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Replay Plastics
Replay is confident that it has secured good availability of low cost post-consumer PET
bottles (feed stock) derived from post-consumer beverage bottles from California based
recycling collectors, and has back up sources identified.
Replay will use a proven, patented technology that was developed by one of its principals
for the cleaning and recycling phase. The extrusion division will employ commercially proven
technology - the industry is employing unique recycled PET technology which is used by
prominent eastern U.S. manufacturers of PET extrusions.
The markets that have been identified are primarily in the western U.S., which will provide a
distinct advantage to the Company because of freight costs and delivery timing.
The Company has assembled a world class management team with proven ability and direct
experience in the Company's market segments.
The Company may not be able to sell all of its production capability
Through the Senior Management's industry-wide contacts, the Company has identified
potential customers and received commitments for all of the production potential of the
initial facility.
The Company will capitalize on the opportunities in the recycled resin and packaging markets
through two main divisions: a Recycling Division and a Packaging Division.
Recycling Division
Page 3
Replay Plastics
Using a patented process, the Company will create a PET cleaning and refining plant located in
the western United States; we have chosen this region because all 16 major North American
PET recycling plants are currently located in the eastern United States or Canada, despite
western states' favorable recycling attitudes among consumers. Its initial annual capacity will
be 46 million pounds and it will utilize bottle feed stock from California, Oregon and Washington
States, which collect over 200,000,000 pounds per year. The Company will become totally
vertically integrated, and use all or almost all of its recycled material in its Packaging Division.
Any surplus material produced will be sold to outside companies.
Packaging Division
We will create a plant (actual facilities to be shared with the Recycling Division) to manufacture
extruded plastic roll stock sheet or high-strength strapping, employing state-of-the-art
technology developed to utilize recycled PET resin.
The extruded sheet will be primarily sold to thermoformers who will convert it into high visibility
packaging, as well as laminators and fabricators. The strapping will be sold to commercial users
for use as package or pallet strapping.
The Company currently has commitments from customers to purchase all of the initial
production capacity. Excess flake will be sold to outside customers.
Replay Plastics is owned by the initial founders, B. Braddock, S. McGuire and C. Smith, who are
the proposed three executives of the operating entity. The plan was conceived and developed
by these individuals, with the intent to apply their extensive experience and contacts in the
industry to building a successful profitable corporation.
Our COO, Mr. Sam McGuire, the inventor and patent holder of the recycling process to be used
by the Company, is a principal in Company A of Chicago, IL. For many years, Company
has designed, manufactured and assembled plastic recycling equipment, and has given us
quotes on meeting our needs in this area.
After a thorough investigation, Replay has found that Company A is able to source or supply the
required equipment at considerably lower cost than any other company from which a quote was
available. Mr. McGuire has disclosed that Company A has included a smaller than normal
margin in their quote on goods they will manufacture, to cover overhead, contingency and
profit which might result in a small benefit to him. They have agreed to source all of the
equipment possible with no added margin.
Replay has concluded that the savings available outweigh any other consideration and that we
will purchase the cleaning and refining equipment from Company A.
Our start-up expenses are budgeted at $210,000, which is mostly for on-site contractor
services during facility preparation. $50,000 has been set aside for legal and accounting,
$25,000 for special consulting that may be required during start up and $50,000 each for local
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Replay Plastics
engineering and lab equipment and supplies. $30,000 has been set aside as a contingency for
the start up period.
Our largest Start-up Requirement is the building of the recycling and extrusion facility. Its final
value at completion is listed below as a long-term asset of $3,620,000 (excluding expensed
items like consultants and engineering listed above). Aside from the building itself, we need
$25,000 in machinery and fixtures, $500,000 of inventory (plastic bottle feed stock) and cash
to cover us through the initial year.
Start-up Funding
Start-up Expenses to Fund $210,000
Start-up Assets to Fund $4,790,000
Total Funding Required $5,000,000
Assets
Non-cash Assets from Start-up $4,145,000
Cash Requirements from Start-up $645,000
Additional Cash Raised $0
Cash Balance on Starting Date $645,000
Total Assets $4,790,000
Liabilities
Current Borrowing $0
Long-term Liabilities $800,000
Accounts Payable (Outstanding Bills) $0
Other Current Liabilities (interest-free) $0
Total Liabilities $800,000
Capital
Planned Investment
Founders $1,500,000
Investor $2,700,000
Additional Investment Requirement $0
Total Planned Investment $4,200,000
Page 5
Replay Plastics
Chart: Start-up
Table: Start-up
Start-up
Requirements
Start-up Expenses
Legal & Accounting $50,000
Stationery etc. $5,000
Consultants $25,000
Lab Equipment $50,000
Local Engineering $50,000
Misc Start up $30,000
Other $0
Total Start-up Expenses $210,000
Start-up Assets
Cash Required $645,000
Start-up Inventory $500,000
Other Current Assets $25,000
Long-term Assets $3,620,000
Total Assets $4,790,000
3.0 Products
Replay Plastics will utilize two processes in the same facility to produce:
Cleaned and recycled plastic PET flake (RPET), recovered from post-consumer beverage
bottles and manufacturing waste produced by its sheet customers
Extruded roll stock sheet PET.
Page 6
Replay Plastics
Extruded PET high-strength strapping for securing large packages or pallet loads; each
using 100% RPET produced in-house
Roll stock sheet will be sold to custom thermoformers primarily to be used to produce high-
visibility packaging. It will also be sold to manufacturers of laminates and fabricated plastic
products.
High strength PET packaging strapping is used to secure packages or pallets in such industries
as lumber milling and corrugated and other paper production.
Using a patented process, Replay will clean and refine the PET material from the post-consumer
bottle stock and post-industrial manufacturing waste. The PET flake resin produced will be
extruded into roll stock sheet or high-strength strapping.
Although the Company expects to convert all of its bottle feed stock into extruded products,
any surplus flake will be sold to outside manufacturers.
While quality and delivery are important factors to our potential clients, price is most often the
determining factor in a buying decision. Good-quality packaging products manufactured from
recycled (less expensive) resins, as close as practical to the end customer's operations, will be
most competitive and achieve a significant market share. These factors have helped to
determine the business parameters of Replay Plastics.
3.3 Sourcing
In excess of 200,000,000 pounds of post-consumer PET beverage bottles are collected and
available as feed stock for manufacturers who can re-process this material into commercial
products. The Company has excellent relations with the firms and associations that collect and
distribute these materials and has been assured that its requirements will be available for the
foreseeable future.
The Company has entered negotiations with a California based source of post-consumer bottles
and is confident that sufficient volumes are available on a contract basis from this source to
satisfy its requirements. In addition, the Company intends to purchase production waste from
its sheet customers and blend it into its feed stock.
Currently, the majority of the post-consumer PET bottles collected in California, Oregon and
Washington are exported to China. The Chinese have absorbed the amounts surplus to the use
in North America. Their interest has kept the industry in the position of being able to maintain a
steady price range for this bottle stock. A significant percentage of all sales of such bottle stock
are managed by Plastics Recycling Corporation of California (PRCC), an industry funded
marketing agency which operates similarly to a co-operative. They accept bids from potential
buyers on behalf of the firms which act as "consolidators," which accumulate stocks from the
Page 7
Replay Plastics
smaller, individual bottle-recycling depots. Some amount of the available stocks are regularly
bought by recyclers in eastern North America who focus on the carpet manufacturers who use
RPET resin in their process, but the high cost of transport from the western U.S. makes eastern
sources more desirable.
Replay has a good relationship with Company B, one of the larger consolidators in
California. Company B has indicated a desire to contract to supply Replay with all of its raw
material needs. They prefer to deal with a local consumer such as Replay, rather than the
uncertainty and extra preparation requirements of the export market.
There are other sources of post-consumer feed stock known to Replay, and we are confident
that we will have sufficient materials available for our production needs.
3.4 Technology
Sam McGuire, a key member of our Management team, is one of the original innovators of
cleaning and refining technology for post-consumer PET, and we will be utilizing his patented
process in our recycling facility. Sam has worked in the establishment and operation of facilities
employing similar technologies over the last several years.
On the manufacturing side, Management has been an integral part of the advancement of
industry practices over the last twenty years or so, and includes in their knowledge base most,
if not all, of the state-of-the-art available equipment and manufacturing techniques.
Strong demand for recycled plastics is working in the industry's favor. Major users of plastic
packaging, apparently responding to consumer desires, have begun incorporating at least some
recycled plastic content in their products as part of the growing interest in recycling. Recycled
resin demand is on the rise as prices for the two major recycled resins, PET and HDPE, continue
to hold value or appreciate against their virgin counterparts.
In volume, PET is currently the number one recycled resin. Supply of recycled PET is in excess
of 800 million pounds per year. This figure is expected to grow, reaching over 1 billion pounds
during the next few years. The plastics industry has developed new markets and applications
for recycled resins from both post-consumer and post-industrial sources.
PET leads the recycled recovered resins as the most visible and valuable, and its use is
increasing. Of the total 3.7 billion pounds of PET consumed in 1997, just 16% was from
recycled sources. Of the more than 90 billion pounds of plastics produced annually in the United
States, less than 5% is from recycled sources. Plastics, after aluminium, represent the second
highest value material in the waste stream and have the highest projected growth rate.
Markets and uses for recycled plastics are rapidly expanding. Plastic containers are being
collected at the curb for recycling in nearly 500 communities, representing more than 4 million
households. U.S. demand for recycled plastic will continue to expand and new markets will
develop as technologies permit the efficient segregation and reprocessing of high-purity resins.
Improved quality of resins, environmental issues and higher prices for virgin resin will
contribute to growth.
Packaging is expected to be the largest market segment for recycled plastics, with sheet and
lumber following. Surveys indicate that Americans are increasingly willing to collect and
Page 8
Replay Plastics
Increasingly, communities are refusing to consider incineration until every effort is made first to
recycle; public sentiment is strongly in favor of products that can be recycled or are made of
recycled materials. In recent years, the household recycling rate of PET bottles has more than
doubled to 30% of all PET soft drink bottles sold. In fact, PET's recycling rate is the fastest
growing among all beverage containers. The future of PET recycling is even brighter than it has
been in the past. PET intrinsic scrap value is second only to aluminium among container
materials. The plastics industry has launched a research and development program aimed at
increasing PET recycling. According to the U.S. Environmental Protection Agency (EPA), plastic
soft drink bottles account for approximately 2% of the solid waste discarded in America. The
EPA has set a national goal to recycle 25% of the municipal solid waste stream and the industry
is committed to achieving its share of that important goal.
The recycling industry intends to accelerate the rate of plastic recycling as part of its
commitment to develop solutions to the solid waste problem. Industry analysts have projected
that 50% of all PET containers will be recycled by the year 2007. More plastics will be recycled
annually than any other recyclable material. Replay believes a significant answer to America's
waste problem lies in creating high value, recycled thermoformable sheet and other extruded
products for the packaging market.
Although more than 200 million pounds of PET post-consumer materials are collected in the
western United States each year, there is presently no local cleaning and refining facility
converting the bottles into resins suitable for re-manufacturing. Originally, recycled PET (RPET)
was used primarily in the carpet fiber industry, which is located along the eastern seaboard.
The early development of the RPET industry was therefore focused in the eastern USA,
with eastern states adopting the first bottle deposit laws that resulted in collection of post-
consumer bottles that can be recycled. Recently, California, Oregon and Washington have
adopted bottle deposit programs, and accumulation of recyclable materials in those states has
begun. With all of the cleaning and recycling plants and the majority of consumers traditionally
located in the eastern part of the country, development of consumers of recycled flake and
down-line products, such as film and sheet, has been slow to develop in the West. A strong
demand for post-consumer bottles from Asia has prevented the buildup of inventories and
reduced the pressure for the collection industry to find or develop western markets.
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Replay Plastics
The Company has chosen its target markets because recycled PET (RPET) is in high demand as
flake resin by converters, as roll stock sheet used to produce high visibility packaging and as
high strength strapping for the lumber industry. Sales are price-sensitive, so that proximity to
markets and feed stock source provide a competitive edge. Replay Plastics identified an
opportunity to take advantage of both circumstances in the western United States.
RPET Flake
Total market demand is reported as 1.2 billion pounds per year. Since only 800 million pounds
are processed in the USA, consumers are forced to look at wide spec virgin PET (virgin resin
that is outside of spec but still usable) which is normally sold at a discount to virgin prices, but
still higher than recycled (RPET) pricing. Some manufacturers are also forced to import
materials from Mexico, India and South America. Some converters are being forced to use more
expensive virgin resin.
The current pricing for virgin resin is $0.65-0.73 per lb. and $0.42-.53 for RPET flake. The
spread between the two has traditionally been maintained at approximately $0.20 per lb.
The total reported market of extruded film and sheet is 872 million pounds, of which identified
industry usage of RPET is 160 million pounds.
The reported market demand (to replace virgin PS, PVC and PET) if RPET was available
is estimated at 1 billion pounds.
RPET Strapping
The total reported domestic plastic strapping market is 240 million pounds. Of this market,
industry usage of virgin polypropylene is 132 million pounds and of PET is 108 million pounds.
It is generally accepted in the industry that less expensive strapping made from RPET could not
only take over the polypropylene strapping market, but convert as much of the much larger and
more expensive steel strapping market as RPET strapping was available.
California: 62
Oregon: 8
Washington: 9
Page 10
Replay Plastics
California: 73
Oregon: 10
Washington: 12
All information is based on industry research,and data provided by the American Plastics
Council.
Market Analysis
Year 1 Year 2 Year 3 Year 4 Year 5
Potential Customers Growth CAGR
Western PET Buyers 1% 79 80 81 82 83 1.24%
Western HDPE Buyers 1% 95 95 95 95 95 0.00%
Total 0.57% 174 175 176 177 178 0.57%
Currently there is no direct competition in the western United States for either of the two
divisions of the Company. Any production in the trading area remains captive and not available
to our target market.
The ability of the Company to obtain a source of post-consumer bottle stock is an integral
component of the strategy to vertically integrate operations and manufacture products in
demand by western consuming industries. Without the cleaning and refining division, it
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Replay Plastics
would be difficult to source sufficient RPET flake resin at costs that would allow the Company to
be competitive.
Equipment costs are high and industry specific, resulting in a high exit cost.
Because of the scarcity of RPET flake, entrants may be forced to establish cleaning and refining
facilities for post-consumer bottles. The equipment required is costly and very industry specific.
It would not easily be re-sold as a system.
There is a market for used extrusion equipment, which normally sees 60-70% of new value
being realized.
There has been a strong demand (sellers' market) for our products for several years.
Traditional buying patterns in this industry are based on quality, price, reputation of
manufacturer, freight costs, delivery times and proximity to markets. During such a sellers'
market, buying patterns are often more influenced by availability.
Currently in the western United States, there is no direct competition for cleaning and refining
post-consumer or post-industrial PET. Nor is there any non-captive extrusion of roll stock sheet.
Page 12
Replay Plastics
In a news release dated September 10, 2004, Itec Environmental Group, Inc. announced their
intention to open a PET and High Density Polyethelene (HDPE) recycling operation in Riverbank,
CA (east of San Francisco). The news release states that the Company's new and yet
unproven technology lets it work with bottle streams that others have to reject as too dirty.
This Company is familiar to our Management, and is not considered a significant factor in any of
our markets.
Replay Plastics will utilize its strong industry-wide relationships to obtain significant contracts
for its production. Some business will be obtained directly by Management, while some amount
of product will be sold by sales agents well known to the Company who have proven their
effectiveness.
These industry-wide relationships will also provide the Company the ability to secure contracts
for the supply of its raw material at competitive pricing.
In a vertically integrated environment, Replay will apply state-of-the-art recycling and extrusion
technology managed by decades of industry specific expertise to create a competitive
advantage for its clients. These processes will produce clean, cost-efficient, recycled raw
material for manufacturers of thermoform, laminate and other high value-added products, and
high strength packaging strapping for shippers of large products and pallets, thereby reducing
costs and creating a clear pricing edge among their competitors.
Replay Plastics' competitive edge rests with its proximity to its target markets, as well as the
industry knowledge, reputation and contacts of its senior management. Their many years of
direct experience have led them to identify this unique opportunity and put together the
technology and sources to take advantage of it. Their reputation in the specific market segment
will result in the achievement of long-term commitments for our production.
The Company has chosen to focus on the production of plastic packaging materials from
recycled post-consumer beverage bottles. Because of the industry experience and expertise of
the management, we have identified a significant available market in the western United
States. All of our initial marketing strategy will be to secure contracts in that segment, and
after reaching full planned capacity, look to grow in concert with that segment and related
markets. We see little need at present for further market research and development, and will
focus on continually updating our production technology in an effort to remain in the forefront
of our chosen marketplace.
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Replay Plastics
Because of the unique extensive experience and reputation of our Management in the
Company's chosen industry segment, we are able to identify all of the potential customers for
each of the products we will produce in our facility. While most of the production of flake is
ultimately intended to be used internally, we are confident that any developed surplus will be
sold immediately.
All of the production of the initial facility is committed for, and should there be any capacity not
consumed by these commitments, once again we are confident that the contacts of our senior
management will allow for the rapid sale of any such capacity.
If the Company grows faster than its prime customer base, additional capacity may be
developed. Mr. Braddock's many years of sales and sales development will be utilized to identify
additional customers and/or sales agents currently servicing the Company's target markets.
To market the products, the Company will use a number of sales agents/brokers well known to
the founders from business transactions over more than 10 years. All of these seasoned
veterans have a customer base of their own, having developed successful relationships with
their clientele over the years. Their customer base is currently demanding product so they can
expand upon their current base. Of course, they will expand that to new customers when
product is available from Replay. Those agents are located in:
Jacksonville, Florida
Houston, Texas
Chicago, Illinois
Louisville, Kentucky
Los Angeles, California
Vancouver, British Columbia
As stated, Ben Braddock, himself, is a strong marketing individual. Over his 30 years of
experience in the packaging and converting industry he has developed relationships with a
number of clients that are buyers of packaging materials. He has consulted to many and has
been personally responsible for sourcing raw materials and converted sheet for customers in
this industry.
Custom formers, extruders, laminators, and end user markets will be called upon by Ben and
the sales agent team to promote and generate demand from those that buy and use RPET
packaging materials.
The sales forecast is based on the assumption that we will sell all of the highest value extruded
products that we can produce. In addition, it is expected that there will be amounts of refined
flake surplus to our extrusion capacity. This flake will be sold to other manufacturing
companies. There is a continuing strong demand for flake and extruded products made from
recycled PET.
Cost of raw materials includes 24% allowance for price variation and 15% non-recoverable
waste.
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Replay Plastics
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Replay Plastics
Sales Forecast
Year 1 Year 2 Year 3 Year 4 Year 5
Unit Sales
Recycled Flake PET 20,533,600 12,833,900 0 0 0
Extruded Roll Stock Sheet 8,341,400 28,874,600 30,800,000 30,800,000 30,800,000
Extruded Strapping 0 4,491,500 15,400,000 15,400,000 15,400,000
Total Unit Sales 28,875,000 46,200,000 46,200,000 46,200,000 46,200,000
Sales
Recycled Flake PET $9,240,120 $6,064,018 $0 $0 $0
Extruded Roll Stock Sheet $5,838,980 $21,222,831 $23,769,900 $24,958,395 $26,206,315
Extruded Strapping $0 $4,266,925 $15,400,000 $16,170,000 $16,940,000
Total Sales $15,079,100 $31,553,774 $39,169,900 $41,128,395 $43,146,315
5.5 Milestones
Because the Company is a start-up, our milestones will surround the establishment of
continuing facilities, confirmation of sourcing and sales contracts, equipment acquisition and
installation, staffing and training, and initiating production.
Table: Milestones
Milestones
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Replay Plastics
Chart: Milestones
The three founders form the senior management group. Several qualified candidates have been
identified for the position of plant manager. The balance of the employees will be hired and
trained during the equipment purchase and installation phase (first five months after funding).
Because the sales management function will be the responsibility of Ben Braddock, with
projected use of familiar sales agents, there are no plans for additional inside sales people or
managers.
Ben Braddock and Sam McGuire have agreed to remain with the Company for the foreseeable
future. In addition to their respective duties, they will each become totally familiar with all
aspects of Senior Management, and be in a position to take over for each other should the need
arise.
Carl Smith has agreed to remain with the Company for a minimum of two years, and will
assume the responsibility of locating and training a replacement before the end of his
employment.
The Organizational Structure of Replay Plastics is planned to be a simple and traditional one. All
recycling and manufacturing operations will report to the COO. All administrative and finance
functions will report to the CFO. Both the COO and CFO will report to the CEO, who will also
have the responsibility for Sales and Marketing.
Ben Braddock, President and CEO, has a 30-year history of experience encompassing all
aspects of Polymer Raw Material, Plastic Conversion Methods, and Venture Development. He
founded Company C, a multi-cavity plastic injection molder container facility, and Company
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Replay Plastics
D, a solid phase pressure forming polypropylene (PP) food container facility. He also assisted in
the launch of five plastic converting manufacturing plants.
For the last fifteen years Ben has been an independent consultant in the plastics industry. His
clients have included [proprietary and confidential information removed].
Sam McGuire, Executive VP and COO, is a graduate engineer with over 20 years experience in
the post-consumer plastics recycling industry and is the inventor of the primary recycling
technology used in the process for this project. He has received a patent for his recycling
technologies and has been directly involved in over twenty-five major post consumer plastics
recycling projects. Sam has played a major role in the design and manufacture of
specific recycling equipment as well as playing a key management role in the design,
construction, installation, commissioning and operation of several independent recycling
businesses.
In 1998, Sam sold his interests in a medical waste treatment and plastics recycling business to
a public company (Company A) based in Chicago. Since that time he has served as Vice
President, International Business Development and Engineering for this Company. His primary
responsibilities over the past five years have included: the rollout of the corporate business
model to international countries; the licensing of intellectual property to joint venture
companies; managing the design and construction of medical waste treatment and plastics
recycling facilities and continuing business and technical support to the resulting joint venture
businesses throughout the world.
In the past five years, Sam has successfully completed projects in Brazil, Argentina, South
Africa, Japan and Australia totaling over $100 Million in investment.
Carl R. Smith, CFO, has over 30 years of investment, merchant banking and management
experience. He has assisted in raising over $500 million and served as board member and/or
officer in over 40 public and private companies.
Carl is the former CEO of E Corporation, Ltd., a company manufacturing plastic injection
molded products. Prior to 1993 he was a partner in two independent investment banking firms,
Company F and Company G. During his time at Company G, more than $450 million was raised
for client companies, and the assets grew to $50 million. Prior to forming Company G, Carl was
a principal and manager of several operating companies in industries such as plastics, mining
and oil and gas exploration.
The Company expects to have a head count of 53 (6 part-time) by the end of year one, 59 (9
part-time) in year two, and 73 (15 part-time) in year three through five at full capacity. We
have budgeted for labor rates ranging from $10 per hour for unskilled labor to $18 per hour for
machine operators and Maintenance Technicians. We expect to pay $20 per hour to
supervisors. We have also included 30% burden for benefits and employee costs, as well as a
25% bonus potential for all plant employees.
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Replay Plastics
Table: Personnel
Personnel Plan
Year 1 Year 2 Year 3 Year 4 Year 5
Production Personnel
Shift Supervisor $129,169 $210,000 $220,500 $231,525 $243,101
Maintainence Techs $116,664 $183,750 $192,938 $202,585 $212,714
Skilled Recycle Plant Labor $350,000 $551,250 $578,813 $607,754 $638,141
Unskilled Recycle Plant Labor $164,066 $295,513 $310,078 $325,582 $341,861
Extruder Operator (full time) $87,504 $206,719 $289,406 $303,876 $319,070
Extruder Operator (part time) $25,522 $68,906 $96,469 $101,292 $106,357
Production Assistant (full time) $62,504 $147,656 $206,719 $217,055 $227,908
Production Assistant (part time) $18,228 $49,219 $68,906 $72,351 $75,969
Name or Title or Group $0 $0 $0 $0 $0
Subtotal $953,657 $1,713,013 $1,963,829 $2,062,020 $2,165,121
Other Personnel
Name or title $0 $0 $0 $0 $0
Name or title $0 $0 $0 $0 $0
Subtotal $0 $0 $0 $0 $0
Total People 51 57 69 69 69
Once the equipment is installed, production ramps up quickly, with sales beginning in the sixth
month after funding. Positive cash flow and net profit are achieved within the first year.
Replay has allowed for 30 days to collect receivables due to knowledge and experience with
customers in the industry.
Inventory turnover is predicted at 12 times, which is extremely conservative.
The personnel burden includes contribution by the Company to employee health care.
We have allowed for Accounts Receivable financing of 70% at interest of 12% per annum.
It is assumed that additional extrusion lines will be added in the second year, with down
payments of 33% at time of order and balance paid at time of shipment (see Cash Flow for
details). These will be purchased as long-term assets out of the cash flows of the business.
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Replay Plastics
General annual growth rates of 5% have been assumed on all sales prices and material and
labor costs.
General Assumptions
Year 1 Year 2 Year 3 Year 4 Year 5
Plan Month 1 2 3 4 5
Current Interest Rate 12.00% 12.00% 12.00% 12.00% 12.00%
Long-term Interest Rate 8.00% 8.00% 8.00% 8.00% 8.00%
Tax Rate 30.00% 30.00% 30.00% 30.00% 30.00%
Other 0 0 0 0 0
With fixed costs of about $184,000 per month in the first year, and variable unit costs at
roughly 52% of prices, we need to produce and sell 715,963 units per month to break even. We
will far exceed the break-even point in our first full month of sales.
Break-even Analysis
Assumptions:
Average Per-Unit Revenue $0.52
Average Per-Unit Variable Cost $0.27
Estimated Monthly Fixed Cost $184,160
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Replay Plastics
The rapid growth of sales in year one and two is due primarily to increase in capacity over that
period, as we add new extrusion equipment. The plan assumes the sale of all production
capacity as it is added. The favorable gross margin projections are in part due to the vertical
integration of the two processes. Our Managements' ability to handle all initial sales and
marketing allows us to predict virtually no sales or marketing expense.
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Replay Plastics
Operating Expenses
Other Expenses:
Other Payroll $0 $0 $0 $0 $0
Misc (contingency) $90,661 $163,239 $195,905 $205,481 $215,542
Prof Fees ( Includ legal & accounting) $300,000 $330,000 $363,000 $399,300 $439,230
Total Other Expenses $390,661 $493,239 $558,905 $604,781 $654,772
Other % 2.59% 1.56% 1.43% 1.47% 1.52%
Profit Before Interest and Taxes $3,379,758 $11,352,223 $16,747,087 $17,602,893 $18,317,641
EBITDA $3,621,498 $11,758,215 $17,309,995 $18,165,801 $18,880,549
Interest Expense $60,568 $54,464 $48,064 $41,664 $35,264
Taxes Incurred $995,757 $3,389,328 $5,009,707 $5,268,369 $5,484,713
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Cash flow is predicted to turn positive in the sixth month of operations, which is the tenth
month after funding. The Cash Flow table shows our planned repayment of the long-term loan,
as well as the purchase of new extrusion equipment in the first two year of the plan. Dividends
to founders and the outside investor are shown near the bottom of the table.
Chart: Cash
Page 25
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Current Assets
Cash $990,213 $312,002 $4,108,444 $6,737,976 $9,805,562
Accounts Receivable $1,984,881 $4,153,463 $5,155,983 $5,413,782 $5,679,403
Inventory $510,125 $1,371,937 $914,828 $942,406 $1,004,139
Other Current Assets $25,000 $25,000 $25,000 $25,000 $25,000
Total Current Assets $3,510,219 $5,862,402 $10,204,254 $13,119,164 $16,514,104
Long-term Assets
Long-term Assets $5,211,000 $8,440,000 $8,440,000 $8,440,000 $8,440,000
Accumulated Depreciation $241,740 $647,732 $1,210,640 $1,773,548 $2,336,456
Total Long-term Assets $4,969,260 $7,792,268 $7,229,360 $6,666,452 $6,103,544
Total Assets $8,479,479 $13,654,670 $17,433,614 $19,785,616 $22,617,648
Current Liabilities
Accounts Payable $1,445,246 $1,792,005 $1,961,634 $2,100,776 $2,215,144
Current Borrowing $0 $0 $0 $0 $0
Other Current Liabilities $0 $0 $0 $0 $0
Subtotal Current Liabilities $1,445,246 $1,792,005 $1,961,634 $2,100,776 $2,215,144
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Replay Plastics
Table: Ratios
Ratio Analysis
Year 1 Year 2 Year 3 Year 4 Year 5 Industry
Profile
Sales Growth n.a. 109.26% 24.14% 5.00% 4.91% 9.27%
Percent of Sales
Sales 100.00% 100.00% 100.00% 100.00% 100.00% 100.00%
Gross Margin 37.07% 48.05% 54.44% 54.63% 54.43% 28.02%
Selling, General & Administrative 22.36% 22.63% 24.36% 24.16% 24.37% 15.89%
Expenses
Advertising Expenses 0.04% 0.17% 0.27% 0.38% 0.48% 0.17%
Profit Before Interest and Taxes 22.41% 35.98% 42.75% 42.80% 42.45% 2.46%
Main Ratios
Current 2.43 3.27 5.20 6.24 7.46 1.79
Quick 2.08 2.51 4.74 5.80 7.00 1.22
Total Debt to Total Assets 25.54% 17.82% 14.47% 13.05% 11.57% 57.88%
Pre-tax Return on Net Worth 52.57% 100.68% 111.99% 102.08% 91.40% 2.22%
Pre-tax Return on Assets 39.14% 82.74% 95.79% 88.76% 80.83% 5.28%
Activity Ratios
Accounts Receivable Turnover 7.60 7.60 7.60 7.60 7.60 n.a
Collection Days 29 36 43 47 47 n.a
Inventory Turnover 15.76 13.67 11.91 15.32 15.41 n.a
Accounts Payable Turnover 7.76 12.17 12.17 12.17 12.17 n.a
Payment Days 27 27 29 29 29 n.a
Total Asset Turnover 1.78 2.31 2.25 2.08 1.91 n.a
Debt Ratios
Debt to Net Worth 0.34 0.22 0.17 0.15 0.13 n.a
Current Liab. to Liab. 0.67 0.74 0.78 0.81 0.85 n.a
Liquidity Ratios
Net Working Capital $2,064,973 $4,070,396 $8,242,620 $11,018,388 $14,298,960 n.a
Interest Coverage 55.80 208.44 348.43 422.50 519.44 n.a
Additional Ratios
Assets to Sales 0.56 0.43 0.45 0.48 0.52 n.a
Current Debt/Total Assets 17% 13% 11% 11% 10% n.a
Acid Test 0.70 0.19 2.11 3.22 4.44 n.a
Sales/Net Worth 2.39 2.81 2.63 2.39 2.16 n.a
Dividend Payout 0.00 0.38 0.68 0.81 0.78 n.a
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Replay Plastics
The plan calls for maximum production rate for flake in the sixth month from funding.
Approximately one third of that production will be converted into extruded sheet beginning
approximately at the same time. A second sheet extruder, which will also consume one third of
the flake produced, is planned to be added at the end of year one, coming on line mid year two.
A third extruder, which is planned to produce high-strength strapping, is expected to come on
line late in year two. By the beginning of year three, it is expected that all of the 46,200,000
lbs. of RPET cleaned & recycled annually will be converted into extruded products. Up until this
time, excess flake produced will be sold to other extruder companies.
The plan assumes a 5% increase in the sales price of all products and a 5% increase in the cost
of raw materials and labor in each of years 2 through 5.
The result of the above is rapid growth in revenue and profit through year three, and moderate
growth in years four and five, assuming no expansion of capacity during that time.
Management is indifferent as to the question of looking to sell the Company after 4-5 years or
retaining ownership and the resulting annual cash flow. They will look to the investors for their
direction and will generally support their wishes.
Recent information on private sales of similar industry companies has indicated that
transactions under $25 million have averaged 5.3 times EBITDA, while transactions in the range
of $25-250 million have averaged over 7 times EBITDA.
Such multiples would put the potential sales price of Replay, after 4-5 years of operation, in
excess of $100 million based on current projections.
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Appendix
Sales Forecast
Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Unit Sales
Recycled Flake PET 0% 0 0 0 0 1,925,000 3,208,400 2,566,700 2,566,700 2,566,700 2,566,700 2,566,700 2,566,700
Extruded Roll Stock Sheet 0% 0 0 0 0 0 641,600 1,283,300 1,283,300 1,283,300 1,283,300 1,283,300 1,283,300
Extruded Strapping 0% 0 0 0 0 0 0 0 0 0 0 0 0
Total Unit Sales 0 0 0 0 1,925,000 3,850,000 3,850,000 3,850,000 3,850,000 3,850,000 3,850,000 3,850,000
Unit Prices Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Recycled Flake PET $0.45 $0.00 $0.00 $0.00 $0.45 $0.45 $0.45 $0.45 $0.45 $0.45 $0.45 $0.45
Extruded Roll Stock Sheet $0.70 $0.70 $0.70 $0.70 $0.70 $0.70 $0.70 $0.70 $0.70 $0.70 $0.70 $0.70
Extruded Strapping $0.95 $0.95 $0.95 $0.95 $0.95 $0.95 $0.95 $0.95 $0.95 $0.95 $0.95 $0.95
Sales
Recycled Flake PET $0 $0 $0 $0 $866,250 $1,443,780 $1,155,015 $1,155,015 $1,155,015 $1,155,015 $1,155,015 $1,155,015
Extruded Roll Stock Sheet $0 $0 $0 $0 $0 $449,120 $898,310 $898,310 $898,310 $898,310 $898,310 $898,310
Extruded Strapping $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Total Sales $0 $0 $0 $0 $866,250 $1,892,900 $2,053,325 $2,053,325 $2,053,325 $2,053,325 $2,053,325 $2,053,325
Direct Unit Costs Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Recycled Flake PET 0.00% $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27
Extruded Roll Stock Sheet 0.00% $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27
Extruded Strapping 0.00% $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27 $0.27
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Appendix
Table: Personnel
Personnel Plan
Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Production Personnel
Shift Supervisor $0 $0 $0 $0 $12,500 $16,667 $16,667 $16,667 $16,667 $16,667 $16,667 $16,667
Maintainence Techs $0 $0 $0 $0 $14,583 $14,583 $14,583 $14,583 $14,583 $14,583 $14,583 $14,583
Skilled Recycle Plant Labor $0 $0 $0 $0 $43,750 $43,750 $43,750 $43,750 $43,750 $43,750 $43,750 $43,750
Unskilled Recycle Plant Labor $0 $0 $0 $0 $0 $23,438 $23,438 $23,438 $23,438 $23,438 $23,438 $23,438
Extruder Operator (full time) $0 $0 $0 $0 $10,938 $10,938 $10,938 $10,938 $10,938 $10,938 $10,938 $10,938
Extruder Operator (part time) $0 $0 $0 $0 $0 $3,646 $3,646 $3,646 $3,646 $3,646 $3,646 $3,646
Production Assistant (full time) $0 $0 $0 $0 $7,813 $7,813 $7,813 $7,813 $7,813 $7,813 $7,813 $7,813
Production Assistant (part time) $0 $0 $0 $0 $0 $2,604 $2,604 $2,604 $2,604 $2,604 $2,604 $2,604
Name or Title or Group $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Subtotal $0 $0 $0 $0 $89,584 $123,439 $123,439 $123,439 $123,439 $123,439 $123,439 $123,439
Other Personnel
Name or title $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Name or title $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Subtotal $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Total People 3 3 3 4 50 50 51 51 51 51 51 51
Total Payroll $5,600 $5,600 $5,600 $12,600 $129,234 $163,089 $165,689 $165,689 $165,689 $165,689 $165,689 $165,689
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Appendix
Page 3
Appendix
General Assumptions
Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Plan Month 1 2 3 4 5 6 7 8 9 10 11 12
Current Interest Rate 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00% 12.00%
Long-term Interest Rate 8.00% 8.00% 8.00% 8.00% 8.00% 8.00% 8.00% 8.00% 8.00% 8.00% 8.00% 8.00%
Tax Rate 30.00% 30.00% 30.00% 30.00% 30.00% 30.00% 30.00% 30.00% 30.00% 30.00% 30.00% 30.00%
Other 0 0 0 0 0 0 0 0 0 0 0 0
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Appendix
Gross Margin $0 $0 $0 $0 $214,566 $637,241 $789,645 $789,645 $789,645 $789,645 $789,645 $789,645
Gross Margin % 0.00% 0.00% 0.00% 0.00% 24.77% 33.66% 38.46% 38.46% 38.46% 38.46% 38.46% 38.46%
Operating Expenses
Page 5
Appendix
General and Administrative % 0.00% 0.00% 0.00% 0.00% 17.26% 10.88% 10.54% 10.54% 10.54% 10.54% 10.54% 10.54%
Other Expenses:
Other Payroll $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Misc (contingency) $1,871 $1,871 $1,871 $2,326 $7,477 $10,295 $10,825 $10,825 $10,825 $10,825 $10,825 $10,825
Prof Fees ( Includ legal & $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000
accounting)
Total Other Expenses $26,871 $26,871 $26,871 $27,326 $32,477 $35,295 $35,825 $35,825 $35,825 $35,825 $35,825 $35,825
Other % 0.00% 0.00% 0.00% 0.00% 3.75% 1.86% 1.74% 1.74% 1.74% 1.74% 1.74% 1.74%
Total Operating Expenses $64,796 $64,796 $64,796 $74,351 $182,523 $241,697 $252,826 $252,826 $252,826 $252,826 $252,826 $252,826
Profit Before Interest and Taxes ($64,796) ($64,796) ($64,796) ($74,351) $32,043 $395,544 $536,818 $536,818 $536,818 $536,818 $536,818 $536,818
EBITDA ($44,651) ($44,651) ($44,651) ($54,206) $52,188 $415,689 $556,963 $556,963 $556,963 $556,963 $556,963 $556,963
Interest Expense $5,289 $5,245 $5,201 $5,157 $5,113 $5,069 $5,025 $4,981 $4,937 $4,893 $4,849 $4,805
Taxes Incurred ($21,026) ($21,012) ($20,999) ($23,852) $8,079 $117,142 $159,538 $159,551 $159,564 $159,578 $159,591 $159,604
Net Profit ($49,060) ($49,029) ($48,998) ($55,656) $18,850 $273,332 $372,255 $372,286 $372,317 $372,348 $372,378 $372,409
Net Profit/Sales 0.00% 0.00% 0.00% 0.00% 2.18% 14.44% 18.13% 18.13% 18.13% 18.13% 18.14% 18.14%
Page 6
Appendix
Expenditures Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Net Cash Flow ($12,977) ($35,514) ($35,483) ($42,442) ($144,209) $236,423 $41,101 $385,801 $385,832 ($182,137) $385,894 ($637,076)
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Appendix
Cash Balance $632,023 $596,509 $561,026 $518,585 $374,376 $610,798 $651,899 $1,037,700 $1,423,532 $1,241,395 $1,627,288 $990,213
Current Assets
Cash $645,000 $632,023 $596,509 $561,026 $518,585 $374,376 $610,798 $651,899 $1,037,700 $1,423,532 $1,241,395 $1,627,288 $990,213
Accounts Receivable $0 $0 $0 $0 $0 $837,375 $1,829,803 $1,984,881 $1,984,881 $1,984,881 $1,984,881 $1,984,881 $1,984,881
Inventory $500,000 $500,000 $500,000 $500,000 $500,000 $255,063 $510,125 $510,125 $510,125 $510,125 $510,125 $510,125 $510,125
Other Current Assets $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000 $25,000
Total Current Assets $1,170,000 $1,157,023 $1,121,509 $1,086,026 $1,043,585 $1,491,813 $2,975,726 $3,171,905 $3,557,706 $3,943,538 $3,761,401 $4,147,294 $3,510,219
Long-term Assets
Long-term Assets $3,620,000 $3,620,000 $3,620,000 $3,620,000 $3,620,000 $3,620,000 $3,620,000 $3,620,000 $3,620,000 $3,620,000 $4,188,000 $4,188,000 $5,211,000
Accumulated Depreciation $0 $20,145 $40,290 $60,435 $80,580 $100,725 $120,870 $141,015 $161,160 $181,305 $201,450 $221,595 $241,740
Total Long-term Assets $3,620,000 $3,599,855 $3,579,710 $3,559,565 $3,539,420 $3,519,275 $3,499,130 $3,478,985 $3,458,840 $3,438,695 $3,986,550 $3,966,405 $4,969,260
Total Assets $4,790,000 $4,756,878 $4,701,219 $4,645,591 $4,583,005 $5,011,088 $6,474,856 $6,650,890 $7,016,546 $7,382,233 $7,747,951 $8,113,699 $8,479,479
Liabilities and Capital Month 1 Month 2 Month 3 Month 4 Month 5 Month 6 Month 7 Month 8 Month 9 Month 10 Month 11 Month 12
Current Liabilities
Accounts Payable $0 $22,538 $22,508 $22,478 $22,147 $437,980 $1,635,016 $1,445,395 $1,445,365 $1,445,335 $1,445,305 $1,445,276 $1,445,246
Current Borrowing $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Other Current Liabilities $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0 $0
Subtotal Current Liabilities $0 $22,538 $22,508 $22,478 $22,147 $437,980 $1,635,016 $1,445,395 $1,445,365 $1,445,335 $1,445,305 $1,445,276 $1,445,246
Long-term Liabilities $800,000 $793,400 $786,800 $780,200 $773,600 $767,000 $760,400 $753,800 $747,200 $740,600 $734,000 $727,400 $720,800
Total Liabilities $800,000 $815,938 $809,308 $802,678 $795,747 $1,204,980 $2,395,416 $2,199,195 $2,192,565 $2,185,935 $2,179,305 $2,172,676 $2,166,046
Paid-in Capital $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000 $4,200,000
Retained Earnings ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000) ($210,000)
Earnings $0 ($49,060) ($98,089) ($147,087) ($202,743) ($183,892) $89,440 $461,695 $833,981 $1,206,298 $1,578,645 $1,951,024 $2,323,433
Total Capital $3,990,000 $3,940,940 $3,891,911 $3,842,913 $3,787,257 $3,806,108 $4,079,440 $4,451,695 $4,823,981 $5,196,298 $5,568,645 $5,941,024 $6,313,433
Total Liabilities and Capital $4,790,000 $4,756,878 $4,701,219 $4,645,591 $4,583,005 $5,011,088 $6,474,856 $6,650,890 $7,016,546 $7,382,233 $7,747,951 $8,113,699 $8,479,479
Net Worth $3,990,000 $3,940,940 $3,891,911 $3,842,913 $3,787,257 $3,806,108 $4,079,440 $4,451,695 $4,823,981 $5,196,298 $5,568,645 $5,941,024 $6,313,433
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