Douglas Dietrich
Analyst · Gabelli & Company
Thanks, D.J. Good morning, everyone. I'll now take you through our consolidated and business segments results for the second quarter. I'll highlight key market and operational elements of our financial results in each major product line and comment on comparisons to the second quarter of 2011 and sequentially to the first quarter of this year.
As Joe mentioned, we reported record quarter earnings per share of $1.11, which represents a 23% increase from the $0.90 per share recorded in the second quarter of 2011. Another quarter of record earnings from our Performance Minerals business, a solid performance from our refractory segment, higher profitability in our Paper PCC business and continued productivity improvements were the primary drivers of the earnings growth.
We're able to achieve this level of income despite the continued weakening of our European end markets, where sales and operating income were down 17% and 27% respectively. Our consolidated sales decreased 5% or about $14.4 million from the prior year. However, excluding foreign exchange, the permanent and temporary paper mill shutdowns in Finland and France and the deconsolidation of our Korea Refractory business last year, our underlying sales were up slightly at 1%.
Our cost of sales decreased 8%, which had a favorable leveraging impact on sales, resulting in a 5% increase in gross margin. A favorable leveraging occurred in all business units, but most significantly in Performance Minerals. Expenses declined 6% from last year and represented 10.6% of sales in the second quarter versus 10.7% last year. This resulted in operating income of $29.5 million, an increase of 18% over last year and represented 11.6% of sales versus 9.3% in the second quarter of last year, a 25% improvement.
Our return on capital for the quarter was 9.4% on an annualized basis, which is above our weighted average cost of capital of 8.3% and higher than the 7.9% achieved last year. In the quarter, we generated $40 million in cash from operations of which $15 million was used for capital expenditures. Sequentially, our consolidated sales decreased 1% and our sequential operating income performance was above expectations, increasing 9%. This was primarily due to stronger results in the performance minerals product line due to lower utility costs, good cost control and higher volumes in our talc business.
As we indicated on the last call, we expected Paper PCC profits to decline in the range of 7% to 10% from the first quarter levels due to annual paper mill maintenance shutdowns. Paper actually came in slightly better at 6% lower. The Refractories segment performance was lower than expected as its operating income declined 4%. However, this was more than offset by strong results in our Performance Minerals business. In total, our performance resulted in the highest quarterly earnings per share in the company's history.
Each of the 3 product lines contributed to the increase in operating margin. The improvement in Paper PCC was primarily due to higher volumes in all regions with the exception in Europe and price recovery of higher raw material costs. In addition, productivity improvements, lower operating cost and overhead expenses helped to offset the effects of lower European volumes. The improvement of Performance Minerals was due to lower utility costs, higher pricing, improved volumes in most product lines and continued productivity gains being driven by our operational excellence program. In Refractories, lower raw material costs, higher metallurgical wire volumes and continued cost and expense control programs drove this improvement.
Today's volume growth in our business is primarily driven by the economic conditions in uncoated wood-free paper, construction, automotive and steel markets. This chart shows the changes in these markets over the prior year in our 2 main regions, North America and Europe. Uncoated wood-free paper production was down about 3% in North America and about 5% in Europe. For the full-year, North America uncoated wood-free paper production is forecasted to decline 2% and then Europe is forecasted to decline over 5%.
I'd like to note that as of today, there's still no new information regarding the status of the Mesta Board Corporation's Alizay paper mill in France. The paper mill is presently not operating. We believe discussions for the sale of the mill continue. The construction market in the U.S., which includes both residential and commercial markets, was up nearly 7% in the second quarter versus the prior year. Automotive unit production in North America also continues to be strong, with production rates up 26% and steel production in North America has improved by more than 6%. Average steel capacity utilization rates in the U.S. increased to 78% in the second quarter from 75% last year. However, rates dropped approximately 6% in June to 76% from up high of around 81% in April. This raises some concern for us as operating rates have declined further in July. In Europe, you can see that the construction, automotive and steel markets reflect the current soft economic conditions as each are down more than 6%.
I'd like to highlight our regional sales and operating income changes over last year. I think this will give you a perspective of the impact that Europe and weaker foreign exchange rates were having on us. Figures in the lower right corners of this chart are shown excluding the effect of currency and for Asia, also reflect the deconsolidation of the Korea refractories business.
Excluding foreign exchange, sales in all regions are higher than 2011 levels, except for Europe, which has been affected by the weak economic conditions and the closure or idling of several paper and steel mills. You can see the impact that Europe and the weaker euro is having on our overall sales and operating income. We've been able to overcome this with strong performances in all other regions, which has helped improve our operating income by almost 20%. This improvement is a direct result of our operational excellence program, diligent cost control, price increases and solid supply-chain sourcing decisions related to raw materials and utility costs.
This gives you a view of our profitability improvement by region. As I mentioned earlier, our operating income ratio increased to 11.6% this quarter, approaching to 12% operating income target we set for ourselves in 2010. The company was able to overcome the weak conditions in Europe, improved operating margins over last year. North America drove 2 percentage points of improvement due to record earnings in Performance Minerals and increased profitability in both Paper PCC and Refractories. Europe was affected by lower paper PCC volumes, including the temporary and permanent paper mill shutdowns and by lower volumes across the refractory segment product lines. Asia increased primarily due to improved profits in our Japanese -- in our Japan Refractories business. Our raw material costs are lower in the region and if you recall, our Japan refractory business was affected by the tsunami that occurred in March of last year. These increases were offset by startup costs associated with our new PCC satellite operations in India. Latin America also demonstrated an improvement.
This slide illustrates the financial results within the Specialty Minerals segment. The $22.1 million of operating income is an all-time best for the segment. In total, segment sales decreased 2% from the prior year to $168 million. However, excluding foreign exchange and the permanent and temporary paper mill shutdowns in Europe, the segment's underlying sales grew 5%. Paper PCC sales, excluding the shutdowns in foreign exchange, grew 6%. The volume declines in Europe were partially offset by new volumes from the 3 satellite facilities that came online over the past year, 1 in Superior, Wisconsin and 2 in India.
In the other segment product lines, Specialty PCC sales were up 2%. Talc sales increased 3% and GCC sales were down slightly 1%. Segment operating income in the second quarter increased 19% over the prior year driven by a 27% increase in Performance Minerals operating income and an 11% increase in Paper PCC. As I mentioned earlier, the improvement of Performance Minerals was due to lower utility costs, higher prices, improved Specialty PCC and talc volumes and continued productivity gains. The increase in Paper PCC is primarily due to higher pricing in North America and Latin America, lower operating costs and an 8% improvement in productivity.
In addition, we're starting to see profit contributions from our growth initiatives related to our new satellite facilities and the FulFill E-325 program. Overall, segment operating income represented 13.1% of sales in the second quarter, compared to 10.8% in the prior year. This operating income level is the highest for the segment since the third quarter of 2002 or nearly 10 years. Sequentially, segment sales were the same as the first quarter levels. Despite the flat sales, operating income increased 11%, is higher than we had anticipated on our last call. Performance Minerals benefited from lower utility and operating costs, slightly higher volumes in the talc product line and a favorable mix in the GCC East product line. Paper PCC profits decreased 6%, just slightly better than the 7% to 10% decline we had indicated on our last call.
Looking forward, third quarter North America paper production is projected to be up slightly at 1.5% compared to the second quarter. However, European paper demand is expected to be down about 5%. Current indications are the third quarter profits and our Paper PCC product line will be similar to the second quarter levels as the expected volume increases in North America will be offset by lower volumes in Europe. In Performance Minerals, we expect profits to decrease between 5% and 10% from the second quarter as the construction sector will seemingly drop off late in the third quarter. Overall, we expect the third quarter operating income for the segment to be down 5%.
As I mentioned on the last chart, Specialty Minerals' operating margin increased to 13.1% from 10.8% last year as the segment overcame some significant factors 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 slightly more than 1 percentage points. Currency had a negative impact of 0.5 percentage point and PCC price increases, including contractual pass-through of higher lime and raw material costs, increased our rate by 1.5 percentage points. Price increases and favorable mix in the Performance Minerals improved margins by over 1%. Finally, productivity improvements in both Paper PCC and Performance Minerals and good expense control have also added another percent to the margin improvement.
This slide shows the financial results within the refractory segment. In total, sales in the second quarter were 11% lower than the prior year, excluding foreign exchange and the deconsolidation of our Korea Refractories business, which occurred in the third quarter of last year. Underlying sales declined 6%. Refractory product sales were down 13% to $65.4 million.
In North America, refractory product sales decreased 9% due to the closure of RG Steels, Sparrows Point and Warren mills in early June and to lower volumes from our non-steel Refractories product line. Europe refractory sales declined 14% as a result of 3 steel mill shutdowns, 2 at ArcellorMittal and 1 at Ten [ph] Steel, weak refractory demand from other steel customers and the impact of foreign exchange. Metallurgical wire sales decreased 4% to $20.5 million as sales in Europe were down 13%.
Operating income for this segment increased 12% in the second quarter to $8.7 million from $7.8 million in the prior year. The improvement was due to a number of factors, including lower raw material costs, slightly higher pricing, higher margins in our metallurgical wire business, productivity gains, and reduced overhead expenses. The segment operating income ratio improved significantly to 10.1% of sales compared with 8.1% in the prior year. Sequentially, both refractory segment sales and operating income decreased 4% from the first quarter, both larger decreases than we had indicated on our last call. Steel capacity utilization in U.S. reached 81% in April, but then dropped to around 76% in June, a 6% decline. Two steel furnace reliance that were postponed from the first to the second quarter, combined with 4 other vessel relines and the closure of the 2 steel mills in June, drove lower demand for our refractory products. Overall, our volumes in North America were down 6%. The region was able to offset most of the impact from the lower volumes with good cost and expense control.
Looking forward, we anticipate lower refractory volumes in North America as the decline in U.S. steel utilization rates through June has continued further through the first few weeks of July. We will also see a full quarter of sales and income impacts from the closure of the Sparrows point and Warren mills. In Europe, steel production levels continue to soften. We expect that a number of European steel customers will delay equipment orders as they curtail their capital spending. Equipment products are some of our higher-margin sales. Therefore, we expect that our third quarter operating income for the full segment to be 10% to 15% lower than the second.
The refractory segment operating margin ratio increased significantly to 10.1% of sales this quarter. Refractory volume declines, lower equipment sales and the weaker euro impacted margins by about 2.5 percentage points. It was offset by lower raw material costs, primarily magnesium oxide, and higher margins in our North America metallurgical wire business. In addition, the business has improved productivity levels and has continued with its cost and expense control programs. These items contributed over 2 percentage points to the margin growth.
These charts illustrates our working capital and cash flow trends. Total days of working capital decreased slightly to 56 days, which is 1 day lower than both the first quarter of 2012 and the second quarter of last year. Our cash flow from operations was approximately $40 million in the second quarter as compared to $38 million in the second quarter of 2011, and our capital investment for the quarter was $15 million.
As Joe mentioned, we recorded record first-half earnings per share of $2.12, which represents the 20% increase from the $1.76 per share recorded in the first half of 2011. Our consolidated sales decreased 4% or about $20 million from the prior year. However, excluding foreign exchange, the paper mill shutdowns in Europe and the deconsolidation of Korea, our underlying sales grew 2%. Our cost of sales decreased 6%, which had a favorable leveraging impact on sales, resulting in a 4% increase in gross margin. Expenses declined 3% and represented 10.7% of sales in the first half, about the same ratio as last year. This resulted in an operating income of $56.5 million, an increase of 13% and represented 11.1% of sales versus 9.4% last year.
Our return on capital for the half was 9.1% on an annualized basis, higher than the 7.8% achieved last year. We generated $65 million in cash from operations this half versus $57 million last year. In total, our performance resulted in the strongest first half performance in the company's history.
As I mentioned earlier, our earnings of $1.11 per share was a record second quarter performance for the company and was above our expectations, primarily due to stronger-than-expected results in the Performance Minerals business. Looking forward, weaker foreign exchange rates both sequentially and year-over-year will have a negative impact on both segments' results. In Specialty Minerals, we expect segment operating income to decline by 5% from the second quarter. Profits in our Paper PCC product line will be similar to second quarter levels and in Performance Minerals, we expect profits to decrease, as sales for the construction sector will begin the normal seasonal decline late in the third quarter. In our Refractories segment, we expect that the third quarter operating income will be 10% to 15% lower than the second quarter. The drop in U.S. steel capacity utilization rate is a concern and we anticipate a decline in refractory volumes as a result. In addition, we'll see the impact of the closure of the Sparrows Point and Warren Mills for the full third quarter.
In Europe, the steel market continues to soften, which will impact our refractory volumes and equipment sales. And overall, we expect total company profits for the third quarter to be around 10% lower than the second. However, further deterioration in the market conditions in Europe remains a concern and could have an additional negative impact on us. Even though we face these market challenges in Europe, we'll build upon our strong first-half performance and continue to focus on driving the growth initiatives in each of our businesses. Now let's open up to questions.