Gordon Jones
Analyst · TD Securities
Thanks, John, and by the way, welcome to your first earnings call as Chief Financial Officer at Clearwater Paper. We are absolutely delighted that you are here. Consumer products net sales were $293 million for the third quarter of 2012, up 2.7% versus the third quarter of 2011, due to record shipment volumes.
Compared to the second quarter of 2012, net sales increased $9.8 million, primarily due to a 4.4% increase in product volumes to 138,848 tons, our highest ever. The record tonnage was the result of increased non-retail demand that we met via a strong production quarter as well as by drawing down inventory. Partially offsetting the increased shipment volume was a slight decline in average net selling price per ton to $2,110 a ton, which was a result of price decline within non-retail. As a reminder, these volumes and pricing figures are available on our website as supplemental materials in the events and presentations section of the investor relations page.
Consumer products operating income for the third quarter of 2012 more than doubled, to $18.5 million as compared with the third quarter of 2011, primarily due to higher net sales and lower operating costs, particularly pulp costs. Compared to the second quarter of 2012, operating income declined $7.2 million. Of this amount, $2.6 million was due to the lower pricing within the non-retail shipments, while approximately $5 million was due to incremental maintenance and transportation costs. Inventories were of course tight, as well as training and start up expenses for Shelby.
Net cost savings synergies associated with the acquisition of Cellu Tissue were $8.6 million for the quarter. Pulp and paperboard net sales of $187.3 million for the third quarter of 2012 were down 13.3% compared to the third quarter of 2011 net sales of $215.9 million. The decrease was primarily due to the divestiture of the company's sawmill last November and the reduction in the sale of external pulp due to increased internal usage. Standalone and paperboard net sales increased 3%, to $184.9 million, due to higher volumes that more than offset lower net selling prices per ton.
Now, compared to the second quarter of 2012 standalone paperboard net sales decreased 1.9% due to a 2.8% decline in paperboard average net selling price, to $948 per ton. The decrease in average paperboard pricing was caused by a mixed shift away from extruded product, which has a higher sales price, and was partially offset by a 0.9% increase in shipping volumes to 195,097 tons.
Compared to the second quarter in 2012, pulp volumes rose by 500 tons to 4,593 tons, while net selling price per ton was essentially flat. We continue to sell very little pulp externally due to increased internal usage to make tissue and paperboard. Pulp and paperboard operating income for the quarter increased 31.2%, to $34.4 million, compared to $26.3 million for the third quarter of 2011. The improvement was primarily due to lower operating cost, including no major maintenance this quarter versus major maintenance expense of $3.1 million in the third quarter of 2011.
Compared to the second quarter of 2012, operating income increased 7.6%, primarily due to lower wood fiber chemicals and maintenance cost. Regarding our outlook, we expect tissue volumes to be 128,000 to 135,000 tons for the fourth quarter. Further, we believe that retail and non-retail pricing will remain consistent with the third quarter. We expect annual run rate, net cost of saving synergies from our Cellu Tissue acquisition to be in the $35 million to $40 million by the end of the year, with $8.6 million in the fourth quarter and $29 million achieved in 2012.
We also expect fourth quarter Shelby start-up cost to be in the range of $3 million to $4 million. Regarding the new paper machine at Shelby, the project remains on time and on budget with tissue expected to be produced by the end of this year. For 2013, we expect the new paper machine to produce between 50,000 to 55,000 tons of tissue, with a full annual run rate of 70,000 in 2014. We also expect to finish the improvements to our Las Vegas TAD machine in the fourth quarter, which will entail 16 to 18 days of paper machine downtime at that facility.
We remain excited about Shelby and Las Vegas projects, which will allows us to supply a full range of TAD products, including paper towels and bath tissue to customers across the entire United States. As for our pulp and paperboard segment, we expect paperboard volumes to be 185,000 to 190,000 tons in the fourth quarter of 2012.
Our paperboard mix shifted in the third quarter to more normalized levels of extruded product and we expect that mix to continue next quarter. External pulp sales will continue to be minimal, as we anticipate utilizing almost all of our pulp internally. A portion of our scheduled major maintenance in the pulp and paperboard segment has been deferred to the first quarter of next year. We now expect to spend $2 million in our fourth quarter compared to the previously reported $4.3 million and will not take any associated down time, the remainder will be spent in the first quarter of 2013.
Regarding total company costs of sales we believe the cost structure will not change significantly during the remainder of 2012. We see minor changes in pulp prices, as some price increases have been announced; slightly higher natural gas prices; lower major maintenance costs, due to the deferral of pulp and paperboard maintenance in the first quarter of 2013; and, of course, the 3 million to 4 million in start up cost for Shelby. Further out, assuming commodity cost remain stable we are on track to deliver on our 300 million EBITDA target which includes $50 million to $60 million from Shelby.
Lastly, as you know I will be retiring from Clearwater Paper at the end of this year. It’s been a pleasure working with our employees, customers, investors and analysts and I am very pleased with the results we have achieved. Although, I will no longer be CEO of this great company, I look forward to remaining a member of the Board and a stockholder. I would also like to congratulate Linda Massman on her appointment as Clearwater Paper’s new CEO effective January 1, 2013. Linda has the perfect blend of broad financial expertise, operations background, leadership capabilities and drive to take Clearwater Paper to the next level. And I look forward to working with her to generate additional value for all stockholders.
I will now turn the call over to Linda, to make some closing remarks.