Douglas Dietrich
Analyst · JPMorgan
Thanks, Joe. Good morning, everyone. I'd like to review with you our consolidated and business segment results for the first quarter. I'll highlight the key market and operational elements of our financial results in each major product line and comment on comparisons to both the first quarter of 2011 and sequentially to the fourth quarter of 2011.
As Joe mentioned, we reported record first quarter earnings per share of $1.01. It represents a 16% increase from the $0.87 per share recorded in the first quarter of 2011. Strong performances from our Refractory and Performance Minerals businesses were the primary drivers of the growth over last year. Our consolidated sales of $257 million decreased 2% or about $5.4 million from the prior year. However, excluding foreign exchange, the permanent and temporary mill shutdowns in Finland and France and the deconsolidation of our Minteq Korea business last year, our underlying sales grew 3%.
Our cost of sales decreased 4%, which had a favorable leveraging impact on sales resulting in a 4% increase in gross margin. Again, this occurred primarily in the Performance Minerals and Refractories business. Total expenses, including plant overhead costs, represented 14.8% of sales in the first quarter, below last year's ratio of 14.9%. This resulted in an operating income of $27 million, an increase of 8% over last year, and represented 10.5% of sales versus 9.5% in the first quarter of last year.
Our return on capital for the quarter was 8.7% on an annualized basis, which is above our weighted average cost of capital of 8.3% and higher than the 7.8% achieved in the first quarter of 2011. In the first quarter, we generated $25 million in cash from operations, of which $9 million was used for capital expenditures. We have nearly $35 million in cash on hand and continue with just under $100 million of debt.
Sequentially, our consolidated sales increased 2% in the fourth quarter, and our sequential operating income performance was above expectations, increasing 8% primarily due to the strong performances in the Refractories and Performance Minerals product line. Paper PCC also improved from fourth quarter levels, as expected, due to increased pricing associated with lime costs, which were contractually passed through to customers in the first quarter. In total, our performance resulted in the highest first quarter earnings per share in the company's history despite sales that were 10% to 15% below pre-recession levels.
The improvement in operating margin from 9.5% of sales in the first quarter of 2011 to 10.5% this quarter was attributable to the improved results in the Performance Minerals and Refractories businesses, which more than offset the margin decline in PCC. The decrease in Paper PCC was due primarily to lower volumes associated with the permanent and temporary paper mill shutdowns in Europe, as well as the general lower paper demand in that region. The improvement of Performance Minerals was due to higher pricing, improved volumes and lower costs from the favorable weather conditions in the northeast and continued productivity gains offset by higher energy costs. In refractories, lower raw material costs, higher metallurgical wire volumes and continued costs and expense control programs contributed to this increase.
Base volume growth in our business is primarily driven by the economic conditions in the uncoated woodfree paper, construction, automotive and steel markets. This chart shows the change in these markets over the prior year in our 2 main regions, North America and Europe. As you can see, uncoated woodfree paper production was down 3.3% in North America and 6.3% in Europe. As I mentioned in previous calls, Metsa Board Corporation announced plans last year to divest its Alizay paper mill in France. Although the paper mill is presently not operating, we believe discussions for the sale of mill continue. In addition, the Myllykoski paper facility and our associated satellite operation has been closed, and our production at the Aanekoski mill has been substantially reduced due to lower demand both by Metsa Board and UPM. The combined effect of these items reduced European PCC volumes by about 45,000 tons this quarter compared to last year.
For the full year, the uncoated woodfree paper production forecast for 2012 for North America is a decline of 3%; and in Europe, a decline of over 5%. The construction market in the U.S., as measured by residential fixed investment, was up nearly 11% in the first quarter versus the prior year. Automotive unit production in North America also continues to be strong, with production rates up 18% and steel production in North America has improved by almost 7%. Steel capacity utilization rates in the U.S. have increased to 78% in the first quarter from 74% last year. However, in Europe, our end markets reflect the current soft economic conditions there. Construction output was down over 7% versus the prior year, automotive production rates have declined almost 5%, and steel production has also declined almost 4%.
This slide illustrates the financial results within the Specialty Minerals segment. In total, sales in Specialty Minerals decreased 3% from the prior year. However, excluding foreign exchange and the permanent and temporary paper mill shutdowns in Europe, the segments underlying sales grew 4%. Paper PCC sales, excluding the shutdowns, grew 3%. The volume declines in Europe were partially offset by new volumes from the 3 satellite facilities that came online over the past year, one in Superior, Wisconsin and 2 in India.
As we indicated on the fourth quarter call, we expected that the volume declines in Europe would exceed the volume increases from our new satellites until they fully ramp up and until the other 3 satellites currently under construction, 2 in India and 1 in Thailand, come online later this year.
In other segment product lines, Specialty PCC sales were up 5%, talc sales increased 6% and GCC sales were up 2%. Segment operating income for the first quarter increased 1% over the prior year to $19.9 million due to a 26% increase in Performance Minerals' operating income, which more than offset the lower volumes in PCC. It's worth highlighting that Performance Minerals' operating income margins have increased 20% over the prior year. This improvement in Performance Minerals was due to higher prices, improved Specialty PCC and talc volumes and overhead cost reductions. In addition, each of the Performance Minerals facilities made gains in productivity over the last year. The decline in PCC was primarily due to the lower Paper PCC volume in Europe associated with the mill closures I mentioned earlier.
Overall, segment operating income represented 11.9% of sales in the first quarter compared to 11.4% in the prior year. Sequentially, first quarter segment sales increased 5%, operating income increased 23% and was higher than we had anticipated on our last call. Performance Minerals benefited from lower operating costs due to the unexpectedly mild winter weather and a favorable mix in the talc product line. Paper PCC profits increased in line with our expectations as we recovered the higher lime costs that were absorbed in the fourth quarter.
Looking forward, second quarter North America paper production is projected to be down about 3% compared to the first quarter, as a number of paper mills will perform their annual maintenance outages. If you recall, this occurred last year, as North America PCC volumes were down 7% in the second quarter versus the first quarter of 2011. European paper demand is also expected to be down sequentially, about 2% in the second quarter. Current indications are that the second quarter profits in our PCC product line will decrease by approximately 7% to 10% from first quarter levels. In Performance Minerals, we expect profits to increase from first quarter as the second quarter is typically the strongest period for that business as construction activity ramps up. Overall, we expect the second quarter operating income for this segment to be similar to first quarter levels.
As I mentioned, Specialty Minerals operating income margin ratio increased from 11.4% of sales in 2011 to 11.9% in the first quarter of this year. As you can see from the chart, this segment overcame some significant factors and was able to improve profitability. Volume declines in Europe, associated with the closure of Myllykoski, paper machine curtailments at Aanekoski and the temporary closure of the Alizay paper mill impacted segment margins by over 2 percentage points. Paper PCC contractual price increases and lime recovery improved margins by about 1.5%. Energy costs continued to be higher relative to last year as the price of fuel oil, used in the Performance Minerals business, escalated over last year. Price increases in Specialty PCC and talc, productivity improvements and expense control have also contributed almost 2 percentage points of margin improvement.
This slide shows the financial results within the Refractories segment. In total, sales in the first quarter were flat with the prior year. However, excluding foreign exchange and the deconsolidation of our Korea Refractories business, which occurred in the third quarter of last year, underlying sales grew 3%. Refractory product sales were down 1% to $69.1 million, but increased 2% excluding Korea. In North America, refractory product sales increased 5% benefiting from the higher capacity utilization rates in the U.S. Europe refractory sales declined 7% as a result of steel mill shutdowns and general weakness in the European steel market. Metallurgical wire sales grew 4% to $20.3 million. North America wire sales grew 7% as a result of both market share gains and improved steel industry conditions. In Europe, wire sales declined 6%. Expense levels, including plant fixed costs, were 15.4% of sales as compared to 16.5% last year.
Operating income increased 36% in the first quarter to $9.1 million from $6.7 million in the prior year. The improvement was due to a number of factors including pricing improvements, lower raw material costs, higher productivity and reduced overhead expenses. Profit improvements were most notable in our Japan and Turkey operations. The segment operating income ratio improved significantly to 10.2% of sales compared to 7.5% in the prior year. Sequentially, refractory segment sales decreased 3%, and operating income decreased 13% from the fourth quarter. As expected, the decline in both sales and operating income was due to lower high-margin equipment sales.
Segment results were slightly better than forecast as steel production in the U.S. was stronger than we anticipated, growing almost 7% sequentially, resulting in higher refractory and metallurgical wire volumes. In addition, 2 steel furnace re-lines were postponed to the second quarter, which helped refractory volumes.
Looking forward, we expect that our second quarter operating income for the full segment to be similar to the first quarter. We remain concerned that steel production levels in Europe will continue to soften, and there are some indications that magnesium oxide prices have begun to rise. In addition, the 2 vessel re-lines that were moved to the second quarter were lower refractory product demand.
As I mentioned on the previous slide, the Refractory segment operating margin ratio increased significantly to 10.2% of sales this quarter from 7.5% in the first quarter of last year. As you can see from the chart, refractory and metallurgical wire volume declines in Europe, net of the increases we saw in North America, impacted operating margins by over 2 percentage points. This is fully offset by improved refractory and wire pricing and product mix over the first quarter of last year.
We began to realize the benefits of lower magnesium oxide costs in the quarter compared to last year. However, magnesium oxide prices are beginning to increase, which could have a dampening effect on these segments' margins going forward. In addition, this business has improved productivity levels and has continued with its cost and expense control programs. These items contributed almost 1 percentage point to the margin growth.
These charts illustrate our working capital, cash flow trends. As you can see, the total days of working capital increased slightly to 57 days, but were 3 days below the first quarter of 2011. Working capital management remained the key area of focus for the company, and we're constantly looking for ways to improve our efficiency further. Our cash flow from operations was approximately $25 million in the first quarter, as compared to $19 million in the first quarter of 2011, and our capital investment for the quarter was $9 million.
As I mentioned earlier, our earnings of $1.01 per share was a record first quarter performance for the company, and was above our expectations, primarily due to stronger-than-expected performance in the Refractories and Performance Minerals businesses. Looking to the second quarter, we expect the Specialty Minerals segment operating income to be similar to the first quarter. Profits in our PCC product line will decrease by approximately 7% to 10% from first quarter levels due to the annual maintenance outages in North America.
In Performance Minerals, we expect profits to increase from the first quarter as the second quarter is typically the strongest period for that business. In our Refractory segment, we expect that our second quarter operating income for the full segment will also be similar to the first quarter. We should continue to benefit from the higher capacity utilization rates in the U.S., however, we remain concerned that steel production levels in Europe will continue to soften. As I mentioned earlier, 2 vessel reliance in the U.S. were postponed to the second quarter, which were lower refractory demand. Overall, we expect total company profits for the second quarter to be similar to the first.
Let's go to questions.