Douglas Dietrich
Analyst · Gabelli
Thanks, Joe. Good morning, everyone. I'd like to review with you our consolidated business segment results for the fourth quarter. I'll highlight the key market and operational elements. For the financial results before specialized items in each major product line, comment on comparisons to both fourth quarter 2010 and sequentially to the third quarter 2011.
As Joe mentioned, we reported earnings per share of $1.05 excluding special items, which represents a 24% increase from the $0.85 per share reported in the fourth quarter 2010.
We recorded a tax settlement benefit of $1 million or $0.06 per share in the quarter, with our reported earnings to $1.11. Consolidated sales increased 3% or about $8.4 million from the prior year. Sales increased in both the Specialty Minerals and Refractories segments, with the most significant growth occurring in our Refractories segment were sales grew 8%.
Sales in Specialty Minerals grew 1% with Paper PCC sales down 3%. Specialty PCC, up 16% and Processed Minerals product sales up 11%.
Operating income increased 11% to $25.2 million and represented 10% of sales versus 9.4% in the prior year. Specialty Minerals segment operating income declined 6% due to European paper mill shutdowns and curtailments affecting paper PCC volumes. Refractory segment operating income increased 58% due to improved refractory margins, as well as increased metallurgical volumes. Both segments were affected higher raw material and energy costs, which were partially offset by price increases.
For the company, total expenses including plant overhead cost represented 14.7% of sales in the fourth quarter, below last year's ratio of 15.7% reflecting our ongoing efforts to keep expenses tightly in control.
Our sequential performance was above expectations, as earnings per share were $0.10 higher than in the third quarter driven primarily by higher operating income in refractories. In addition, we also benefited from a favorable swing in other income primarily due to foreign exchange and a lower tax rate.
Our full-year effective tax rate was 28.8%, which resulted in a fourth quarter rate of 26.3%, excluding special items.
Our consolidated sales decreased 4% and operating income decreased 2% from the third quarter. The decrease in sales was in Specialty Minerals due to lower Paper PCC volumes in Europe and to the normal seasonal declines in our Processed Minerals product line. The decrease in operating income was also in Specialty Minerals segment due to these volume declines combined with higher-line cost in North America which we cannot pass through contractually until the first quarter 2012.
The Refractories segment operating income performance was higher than expected due to an increase in sales and higher refractory and wire volumes. Our return on capital for the quarter was 9.5% on an annualized basis, and 8.5% for the year, which is above our weighted average cost of capital of 8.4%.
Our balance sheet remains strong. We have nearly $415 million in cash and just under $100 million of debt. And in the fourth quarter, we generated $41 million in cash flow from operations, of which $15 million was used for capital expenditures.
In summary, our fourth quarter results reflect strong financial performance and our continuous focus on profitable growth and maintaining strong cash flows.
This chart illustrates our quarterly earnings per share over the past 5 years. We're now performing in the range of EPS that we recorded in early 2008 before the recession, despite 16% lower revenue.
This slide shows the financial results within the Specialty Minerals segment. In total, sales in Specialty Minerals grew 1% from the prior year. Paper PCC sales were down 3%, primarily due to a 13% decline in European Paper PCC volumes. The declines in Europe are the result of permanent mill shutdowns in Finland, a temporary mill shutdowns in France, and general weakness across Europe.
These declines in Europe were partially offset by volumes from our 3 new satellite facilities in Superior, Wisconsin and in India, reflecting the benefits that our growth strategies beginning to have on our business.
In the other segment product lines, Specialty PCC sales were up 16% and Processed Minerals products rose 11%. Within Processed Minerals, talc sales increased 17% and GCC sales were up 6%.
Segment operating income in the fourth quarter decreased 6% from the prior year to $16.2 million. This decrease was a result of higher raw material and energy costs, and lower paper PCC volumes in Europe, which was partially offset by the contribution our new PCC satellite facility and volume growth and price increases at our talc and specialty PCC product line. In addition, we benefited from continued productivity improvements on our Performance Minerals facilities and overall, segment operating income represented 10% of sales in the fourth quarter compared to 10.9% the prior year excluding special items.
Sequentially, fourth quarter segment sales declined 6% and operating income decreased 17% from the third quarter. Decline in profits was more than the 10% we had anticipated in our last call and occurred primarily in the Paper PCC product line. The European economy and subsequent impact on the paper market was more severe than expected, and as I mentioned earlier, many European paper mills curtailed production in the quarter. This decline was also due to higher lime costs in North America, which cannot be passed through contractually PCC prices until the first quarter this year and lower volumes in Performance Minerals due to the normal seasonal declines in our end markets.
Looking forward, North America PCC demand is projected to be down about 2% in 2012. I mentioned the concerns we have about the European paper market as sequential demand was down 2% in the fourth quarter, and the forecast for 2012 was to be 5% lower than 2011.
Our indications are that first-quarter profits in our PCC product line will increase slightly from fourth quarter levels due mainly to the contractual price recovery of lime costs in North America. In Processed Minerals, we're expecting similar levels of profitability to the fourth quarter. Overall, we expect first quarter operating income for this segment to be up slightly.
Each call I show these 2 charts to illustrate the current market trends in the uncoated freesheet segment in North America and Europe. As you can see, North American production levels have been relatively stable in the past 2 years, but they remain roughly more than 20% below average prerecession levels. European printing and writing paper production, of which uncoated freesheet is a part, were down 3% versus 2010 and 2% lower than the third quarter.
Economic conditions in Europe continue to be unstable and our first quarter Paper PCC volumes will continue to be affected by these conditions. As I mentioned in the last 2 calls, M-real Corporation announced plans to divest its Alizay paper mill in France. For the past several months, we've been in negotiation with a number of paper producers. Although the paper mill is presently not operating, we believe discussions for the sale of the mill continue.
In addition, our Myllykoski paper facilities, our associated satellite operation has been closed in our production at the Anacostia [ph] mill has been substantially reduced due to lower demand of both M-real and UPM. The effect of these shutdowns and demand changes have in our volumes are on average about 40,000 tons per quarter.
Our growth in Paper PCC though remains on-track with the projections we communicated to you approximately a year ago. To give you some dimensioning of the volume growth associated with our new satellite PCC facility, this chart shows the announced the PCC capacity that we have been deploying and will continue to deploy over the next 2 years.
In 2011, we began operations at 3 new facilities. One in the U.S. and 2 in India, and 3 satellite expansions with a combined annual capacity of 160,000 tons. In 2012, we'll begin operations at 3 more facilities with a combined annual capacity of another 150,000 tons.
It should be noted that volumes at these new facilities tend to ramp up slowly as the paper mill comes online. We also expect some small additional volume growth at our existing facilities as the deployment of the Fulfill program gains traction. And in total, this new satellites should contribute an incremental 140,000 to 150,000 tons in 2012. I highlight this because given the current situation in Europe, this goal may not be clearly visible until the latter part of this year.
As Joe mentioned earlier, the Refractory segment had a record year. Its highlights the turnaround we've achieved in this business from where it was only 2 years ago. In total, sales in the fourth quarter grew 8% over the prior year. Refractory products sales were up 4% to $71.3 million, Metallurgical Wire sales grew 24% to $20.5 million. This growth was attributable to higher refractory volumes and prices in both North America and Europe and to improve metallurgical wire volumes.
Operating income increased 58% in the fourth quarter to $10.4 million from $6.6 million in the prior year. This was due to improved margin in refractory product-line particularly in Europe, higher metallurgical wire volumes and lower expenses.
Expense levels including plant fixed costs improved significantly in the fourth quarter and were 14.7% of sales as compared to 17% last year.
Segment operating income ratio improved to 11.3% of sales compared to with 7.8% in the prior year. Sequentially, segment sales increased 1% and operating income increased 35% from the third quarter, which was better than expected.
This improved profitability was driven by an increase in higher-margin equipment sales, which contributed half of the profit growth. A couple of units that we expected to be qualified by our customers in the first quarter were completed in the fourth. The remainder of this increase was the result of higher refractory volumes due to the delay of a number of steel mill furnace re-aligns [ph] to the first quarter.
Improved productivity and overhead expansion -- overhead expenses control -- contributed to the increase. Looking forward, we expected our first quarter operating income for the full segment to be lower. Segment sales will be down -- equipment sales will we down significantly from fourth quarter levels and we remain concerned that steel production levels in Europe will continue to soften.
As I just mentioned, several steel mills in the U.S. and Europe postponed their vessel re-aligns [ph] of the first quarter, which will lower refractory product volumes. This chart illustrates North America and European steel production over the past 2 years. As you can see, North America steel production has remained relatively stable during 2011. Production in the fourth quarter increased 7% from 2010, but decreased 2% from the third quarter.
In Europe, monthly steel production levels have been much more volatile. During the fourth quarter, steel production decreased 3% from 2010, was down 1% from the third quarter. However, production level -- production and several the major markets which is Germany, Italy and France have acquired 12%, 17% and 13%, respectively over the months of November and December.
These charts illustrate our working capital and cash flow trends. As you can see, total days of working capital remained at 55 days over the past 2 quarters. Last, the company has made significant improvements in this area since 2009 and we've been able to sustain this low level over the past 2 years. This reflects the constant focus we give to working capital management within all our business units. Our cash flow from operations was approximately $41 million in the fourth quarter and was $134 million for the full year.
Capital investment for the quarter increased to $15 million. Total capital expenditures for the year were $52 million. Capital spending is primarily supporting our new PCC satellite construction projects.
As I mentioned earlier, our earnings performance of $1.05 per share this quarter was above our expectations primarily due to stronger-than-expected performance in the Refractories segment and favorability below the operating income line.
Looking to first quarter, Specialty Minerals segment profits will increase slightly from the fourth quarter as Paper PCC product line will recover higher lime cost absorbed in the fourth quarter. However, European paper demand will continue to be lower.
In Processed Minerals, we expect profits to be similar to the fourth quarter. In our Refractory segment, we expect lower profitability in the first quarter as sequential equipment sales will be significantly lower. Our biggest area of concern remains the uncertainties in Europe and the potential effect on our end markets.
We expect the company's first quarter profits to be 10% to 15% lower than the fourth quarter driven primarily by lower sequential refractory profits. The items below the operating income line that will not reoccur and higher tax rate. Keep in mind however, that even with this projected decline, our first quarter profit should be 5% higher than the first quarter last year.
Now let's go to D.J. Monagle, and will provide an update on the deployment of our Fulfill program. DJ?