Brian Purves
Analyst · KeyBanc
Thank you, and good morning, ladies and gentlemen. Welcome to the Luxfer conference call on third quarter of 2016.
Turning to Slide 4, the headlines for the quarter are, our earnings result was $0.01 better than our updated guidance, but it was a difficult quarter, because the FX styling is hindering us at the moment, but is expected to turn into a positive for us in the medium term. The difficulties affecting parts of our magnesium business are expected to reverse, but not until early 2017.
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The quarter 3 headwinds came from what it is normally a relatively predictable source, sales of our North American magnesium products, and in particular defense-related products. I will go into this in much more detail shortly.
Turning to Slide 6. Following 2015's rightsizing actions, results from the alternative fuel cylinder business stream remain much improved. European demand for composite medical cylinders, however, remains low, although sales of aluminum cylinders were up in the quarter.
Our Superform business is selling record levels of tooling associated with new contracts around the future supply of panels but is currently selling fewer than usual formed goods due to old contracts finishing in advance of the new contracts commencing.
Sales of high-performance magnesium alloys were again slightly improved, although towards the end of September, the largest sand customer that we supply entered Chapter 11 protection, citing the lower build rates on helicopters caused by reduced demand from the defense and oil and gas sectors, just as we ourselves have previously reported, but from within a much more diversified business.
The end customers are the helicopter and engine manufacturers that are specified the use of our materials. So we can have confidence that the castings are required and will be made, but we have to count in some disruption over the next few months.
In the catalyst sector, sales of automotive material were actually a little higher in the quarter, but there remains very significant potential for higher sales, particularly from our new G6 technology, on which we continue to get very positive feedback. We have further shipments of industrial material scheduled for quarter 4.
Major impact on the fourth quarter was the dearth of orders for several of our magnesium products in North America. On military powders, we have one customer still working towards a restock of the facility down east earlier this year, while another customer reported that they were short of orders from the military and would not require further atomized powder this year. In response to reduced costs, we have suspended operations at our magnesium atomizer in Pennsylvania for the balance of the year and laid off much of the direct workforce.
For each of the last 15 years, the U.S. military has come in with an add-on for Meals, Ready-to-Eat, or MREs, in the third quarter, adjusting the full-year requirement above the contracted minimum in order to rebalance stocks. In 2015, the add-on brought the year to about 25% above the base level and generated the need for additional flameless heaters from our Magtech business. This year, no add-on was forthcoming, which reinforces our focus on expanding the business into non-U.S. and nonmilitary areas. We did have expectations that we could, during the quarter, bring in one of the several large commercial tenders that we have underway to offset the military shortfall. But the timing of these tenders have slipped into 2017.
The U.S. military have also been very slow to issue expected orders for the chemical detection and decontamination products of Luxfer Magtech.
Accordingly, having scheduled production to a degree and expectation of an MRE add-on and additional decontamination business, our New York Magtech facility became short of work. Again, to reduce costs and avoid building stock, we have cut back on production and laid off several employees until year-end.
Finally, we have invested in improving the flexibility of our manufacturing processes at our Madison rolling plant, and this has given us the ability to offer a direct service to more of our North American customers for photo-engraving sheet. This will improve customer service, lower logistics costs and build customer loyalty. The downside is that the distributors to be bypassed had to be allowed to offload their stocks, and while this happens, our sales are reduced.
Turning to Slide 7, on addressing these matters. At the very end of September, we saw one large, new contract award for military flares placed by the DoD with one of our customers for 2017 through first quarter '18 production. With an expected resumption of production at the facility that had the outage, both major customers are expected to be back taking supplies from us early in the new year. I would remind you that we are only 2 years into the 5-year contracts for the core countermeasure flare requirements of the U.S. military and that we have 100% of the powder supply for the manufacture of these flares.
Three weeks ago, the new 5-year contracts for MRE supply were released by the U.S. military, split between 3 meal providers. We had already secured back-to-back contracts with all 3 for the supply of the flameless heaters, carrying over the 100% supply position that we inherited on purchasing Luxfer Magtech. The minimum annual quantity is carried over from the previous contract. And an informal indication was given that there would be an add-on in 2017, where there was none in 2016.
We've also received around $2 million worth of orders to date relating to stock replenishment, following usage of emergency supplies during the recent hurricane season, and we expect this to benefit quarter 1 2017. The castings made by the customer now in Chapter 11 will be required, so we should at most expect short-term disruption.
And as mentioned earlier, we have submitted tenders to several non-U.S. buyers of self-heating rations, and we are targeting incremental business in this area. The stock held by [indiscernible] photo-engraving distributors should be largely exhausted by the end of quarter 4, removing the current depression effect on sales.
Overall, while we still await some order cover, particularly for the decontamination products, we do expect a strong recovery in sales for these magnesium products early in 2017, albeit the quarter 1 may still be somewhat affected, as production is restarted at our customers.
Turning to slides on our update on the strategic growth projects, on Slide 8. BIOTRONIK have now launched their magnesium scaffold product, now branded Magmaris, in several countries, including in Europe, the Middle East and Australasia. Although for a small amount in this launch phase, it was a big moment for us when we received our first royalty statement during the quarter.
Slide 9. When we bought the business that we now call Luxfer Magtech 2 years ago, we said that one of our objectives would be to expand its geographic presence. Last year, we established new sales positions outside the USA, and in the second quarter of this year, we purchased a small European competitor in the field of flameless heaters and ready-to-eat meals, largely for their customer list. As stated earlier, we have now quoted for several millions of dollars' worth of business to a number of non-U.S. buyers of self-heating rations.
Slide 10. We now have 3 prototype components in testing for possible inclusion in new aircraft seat designs, and we remain confident of getting at least one of those parts into a production seat during 2017.
Slide 11. We continue to get good feedback from customers on the benefits from our next-generation automotive catalysis technology. The customer still needs to complete engine testing on catalysts made using the material, but we are already planning for how we can start making the material in commercial quantities.
Slide 12. The automotive industry increasingly demands a supply of assemblies rather than panels. We are currently investing in our Superform facility in the U.K., installing a restrike press to allow secondary operations to remain on superformed panels, and also on a henning cell [ph], where we fold the outer door panel over the inner panel and supply an assembled, unpainted door. These new facilities will be used on the new work for Ferrari and another high-end customer expected to start in the second half of 2017. Andy Beaden will now take you through some of the detail on the financial results.