Jeff MacDonald
Analyst · Stonehouse Capital
Thank you. Good morning. We issued our 2023 second quarter results yesterday afternoon. As we move into the second half of 2023, we are beginning to see emerging signs that make us optimistic the business is turning a corner with a return to a growth trajectory. The second quarter, which is now behind us, was certainly a continuation of the macro challenges we experienced in Q1 as we expected and mentioned at the time of our Q1 call in May. Sales were flat sequentially at $3 million and down 29% from the prior year period. This change was due to lower volumes.
The reason for our optimism today is twofold. Number one, we are seeing positive signs on the opportunity side, specifically in terms of an expansion of our pipeline in the wood composites, tissue, paperboard and pulp end markets. And number two, we're seeing positive indicators on starch availability and pricing earlier than we had originally anticipated, which should support margins and pricing to win new business.
On the wood composites front, the movement toward bio-based glues is gathering momentum. IKEA published its sustainability and climate reports earlier this year, which we've highlighted previously. In those reports, they've highlighted glues for wood panels as one of the critical drivers to reduce their carbon footprint and achieve their climate goals. Wood glues represent 5% of their total carbon footprint. They've set a goal of reducing that impact by 40% by 2030 through the use of bio-based glues, which they are implementing at one of their facilities.
In June, CNN did a feature report on IKEA's development journey on its use of bio-based glues from cornstarch in the production of wood panels like particleboard. As one of the largest consumers of wood panels in the industry, IKEA's influence on their supply chain and manufacturing base is significant. When retailers and manufacturers like IKEA move to bio-based glues, other suppliers follow.
We have long said the market is moving toward our solutions, and we appreciate the patience our shareholders have shown as the impact on our sales has been slow to materialize. We believe this new level of awareness in the market is having an effect. Let me explain.
In May, we attended the Ligna Trade Show, where the whole wood processing market comes together every few years for 5 days. There were 2 issues that were front and center. Number one, like most industries was artificial intelligence; but number two was bio-based glues for wood panels. We are the clear incumbent in the bio-based glue market. We have seen trial activity pick up year-to-date, with new prospects requesting material and support for trials and prospects that have trialed with us before reengaging. They see the movement in the market and they do not want to be left behind. The industry clearly recognizes that we are the leading bio-based offering that is being used commercially and technically successfully today.
With the thought leaders in the market leading the way toward greater use of bio-based glues, others in the market see this as a catalyst that the change is real. This movement gives us confidence that the second half of 2023 and into 2024 can be stronger than the market conditions we've just endured.
In the tissue, paperboard and pulp end market, we continue to engage with manufacturers, advancing trials with existing prospects and broadening our pipeline with new prospects and applications. The tissue, paperboard and pulp market has been dealing with the same macroeconomic challenges that we've faced. The sector was dealing with excess inventory as strong sales of paper-based products through 2022 dropped sharply heading into 2023. These manufacturers have been downsizing staff through layoffs and restructuring production with temporary or permanent mill closures. The purpose in mentioning these conditions is that despite these challenges, customers have continued to engage with us to advance SurfLock trial programs. This engagement demonstrates that they recognize what we have is valuable and important enough to them that they're prioritizing it among some really challenging conditions.
It's a cost-saving solution. With that in mind, we wanted to provide a flavor of what we offer manufacturers. We recently published performance results from a successful program implemented at one of our tissue paper wins. This manufacturer produces toilet tissue from 100% virgin fiber and our SurfLock. Their objective in adding SurfLock was to improve the tensile strength with no negative impact on softness or dusting. The manufacturer used a mix of short and long fiber, and, in our trials, they added 2 to 2.5 kilograms of SurfLock per ton of fiber. The results of the study speak for themselves. The manufacturer proceeded to commercial volumes due to a 30% increase in tensile strength, a 40% reduction in base weight, reduced line breaks, which resulted in increased line speed, increased productivity, no negative impact on softness and a 50% reduction in dusting. It's results like these that make us excited about the opportunity that's in front of us in this end market.
This performance resulted in this manufacturer converting to commercial production at this line, and it is now trialing SurfLock at a second line at a separate location. And that's typical of our go-to-market strategy, successfully deploy the technology on one line at a first location and then within the same account move to a second and third location once they've seen the benefits of the first line. That's the same playbook we are using with another account where we are commercial today and now expanding to a second line with new trials.
At the same time, we're broadening our pipeline of opportunities through new geographies and new applications.
One important characteristic of the value chain in this market is that many paper product manufacturers outsource the management of their wet-end chemicals to distributor service providers. In addition to generally being an important channel to market, we've identified several of these players who are located in geographies where we do not have a strong presence. We've now cultivated several of these relationships and some of these new partners have now received trial product from us to begin new programs. We believe this will be an important channel to market for SurfLock going forward.
On the new applications front, we are working with one manufacturer that has an interest in developing SurfLock as a strength to aid an upstream from the mill process, modifying the pulp at source to make it more valuable for their customers. This manufacturer has already conducted successful initial trials and has now ordered more material to run larger-scale trials later this summer to advance the program.
It's another opportunity that expands our addressable market, and it's a concentrated one, think tens of millions of opportunity per line, but with fewer targets. It's a development program at this stage, so it's not a slam dunk will be successful, but it demonstrates the flexibility of the platform, and it's another reason for our optimism in the long-term outlook of the business.
On the personal care front, our marketing and development partner, Dow, continues to be highly engaged with its prospect base on the Mazecare opportunity. At this point, there's no doubt that the pandemic really set the product launch back significantly. But where are we today? Dow has successfully won some smaller players, and they're seeing signs in the market that larger players are engaged in advancing their development programs. Dow has consistently told us they entered the $460 million hair fixative space with an all-natural product because they believe they can take a meaningful share. The engagement they're seeing today with some of the larger players has them excited that bigger opportunity is near at hand. We follow their lead in this end market and when they're excited, we get excited, too.
On the legacy graphic paper front, the macro challenges are worsening, both from an overall demand perspective as well as the pricing dynamics of the petroleum binders our chemistry replaces. Coated freesheet is the primary market we monitor as the opportunity for our EcoSphere binder. In Q2, the coated freesheet graphic paper industry experienced significant challenges, a 36% year-over-year decline in demand, a 46% year-over-year decline in production and current mill operating rates are at 62%. These declines are relative to the 2022 comparison periods where the market had already endured significant declines.
On the pricing dynamics, oil remains below $80 a barrel and the price of SB latex, which our product replaces, remains well below historical levels with abundant supply. The price of SB latex, together with the high raw material pricing we experienced in the first half of 2023 eroded the cost savings EcoSphere offered manufacturers historically.
With some early improvements that we're recently seeing in cornstarch pricing, we'll be able to recover some share in this market, but we do not expect it to recover fully based on the macro demand dynamics I mentioned earlier.
The vast majority of the volume decline we experienced in the first half of this year was a result of the legacy graphic paper market. We'll continue to deliver for our customers in this space, but it's not a growth driver of the business, and that's where our focus lies, in wood composites, tissue, paperboard and pulp, and with our partner, Dow in personal care.
On the supply side, we've seen emerging signs of improvement in both availability and pricing of cornstarch. Earlier in the year, we were told to expect no relief on pricing until the new harvest in the fall. Instead, we're seeing modest early improvements. And while it's definitely not back to normalized levels, indicators suggest a better outlook.
On the availability front, we're also seeing an improvement. We're expanding our supplier base in Europe, qualifying alternative suppliers of cornstarch to give us greater optionality in the future. Between the new suppliers and the new harvest coming up, we're in a much better position. It was a tough first 6 months of the year. We managed through it effectively, maintaining our cash position, and we see greater opportunity in the second half of 2023 and into 2024.
As a result, during the quarter, we doubled our use of the normal course issuer bid compared to Q1 2023. It demonstrates our confidence in the long-term outlook of the business. While we recognize some stakeholders believe we should be even more aggressive on this front, we believe doubling the program, while at the same time, preserving a strong cash position is an effective and balanced strategy. Our strong cash position is critical to our key strategic wood composites account and our other large customers. It gives them confidence that they can rely on us regardless of the market cycle as a dependable supplier of a key ingredient on their path to greater use of bio-based glues and resins.
With that, I'll turn it over to Rob to review the financials. Rob?