Douglas Dietrich
Analyst · Jeff Zekauskas from JPMorgan
Thanks, Joe. Good morning, everyone. I'll take you through our consolidated and business segment results for the third 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 third quarter 2011 and sequentially, to the second quarter of 2012.
As Joe mentioned, we reported earnings per share of $1.05, which represents an 11% increase from the $0.95 per share recorded in the third quarter of 2011, excluding special items. Our reported earnings last year were $0.87 per share as the company recorded a noncash special currency translation charge related to the sale of our majority ownership in the company's refractory operations in Korea.
Our solid performance this quarter was achieved due to record quarterly earnings from our Specialty Minerals segment. The Performance Minerals business continues to operate on a very strong track, and profits also improved in Paper PCC. These strong earnings were accomplished despite weaker-than-expected results in the Refractories segment and the continued weak market conditions in Europe, where total company sales and operating income were down 14% and 37%, respectively.
Our consolidated sales decreased 5% or about $12 million from the prior year. This decline was primarily due to foreign exchange, which had an unfavorable impact of $11.6 million. In addition, sales were affected by the permanent and temporary mill shutdowns in Finland and France in the fourth quarter of last year.
Excluding foreign exchange and these closures, our underlying sales are up 2%. Though our sales are down 5%, our cost of sales decreased 7%, resulting in a 4% increase in gross margin. The margin improvement occurred in all business units, but most significantly in Performance Minerals. Expenses were slightly below last year and represented 10.8% of sales. This resulted in operating income of $27.8 million, an increase of 9%, and represented 11.1% of sales versus the 9.8% last year. The improvement on operating income was due to increased pricing, which more than offset higher materials costs in Specialty Minerals, continued productivity gains in all business units, lower energy costs and good expense and cost control.
Our return on capital for the quarter was 8.8% on an annualized basis, which is higher than the 8.3% we achieved last year. In the quarter, we generated $40 million in cash from operations, of which $14 million was used for capital expenditures. Cash and short-term investments were approximately $462 million at the end of the third quarter.
Sequentially, our consolidated sales decreased 1% and our operating income performance was better than expected. As we indicated on the last call, we expected Paper PCC profits to be similar to second quarter levels. However, profits improved by approximately 10% due to better-than-expected performance in Europe.
Our Performance Minerals business was in line with our expectations and continues to operate at a high level. The Refractories segment performance was lower than expected as its operating income declined 17%, which was more than the 10% to 15% decline we'd anticipated on our last call. In total, our third quarter results were better than expected and reflect continued strong financial performance with earnings in excess of $1 per share for the fourth consecutive quarter.
This chart shows where the margin improvement is coming from. Margins have increased over last year in both Paper PCC and Performance Minerals. However, they've decreased slightly in the Refractories segment. The increase in Paper PCC was primarily due to higher profitability in North America and Latin America due to productivity improvements, lower operating costs and overhead expenses, which helped to offset the effects of lower European volumes. The improvement in Performance Minerals was due to lower utility costs, higher pricing and continued productivity gains being driven by our operational excellence program.
In Refractories, lower raw material costs and continued cost and expense control programs were more than offset by the declines in refractory product, equipment and metallurgical wire sales resulting from the weakening steel market conditions in both North America and Europe.
This chart shows the changes in North America and Europe over the prior year in our main market segments. Uncoated wood-free paper production was down about 1.6% in North America and around 2.8% in Europe. The construction market in the U.S., which includes both residential and commercial markets, was up over 7% in the third quarter versus the prior year.
Automotive unit production in North America also continues to be strong with production rates up nearly 16%, but dropped significantly in September from August levels. Steel production in North America decreased slightly from last year as third quarter average steel capacity utilization rates in the U.S. declined 1% over last year to approximately 75%.
Sequentially, however, steel capacity utilization rates declined 5% from the second quarter, with the majority of this decline occurring in September. Rates have declined even further through October and are currently around 68%, which is the lowest level in approximately 2 years.
In Europe, you can see that the construction, automotive and steel markets continue to reflect the soft economic conditions as each are down between 3% and 9%. Here's a table of our regional revenue and operating income changes over last year. Let me highlight a few areas. The figures on the lower right corners on this chart are shown excluding the effect of foreign exchange. You can see the impact that Europe and weaker foreign currencies are having on our overall sales and operating income. In North America, we've exhibited strong operating income performance despite flat sales. 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 material and utility costs.
You can also see the significant underlying growth that's developing in Asia and Latin America. And in total, we've managed to improve our operating income by almost 10%, despite a 37% operating income decline in Europe.
Let me give you some perspectives on the specific factors that are affecting our year-over-year revenue. As you can see, the paper mill closures in Europe had a significant impact on our sales over last year. In addition, several recent steel mill closures and lower equipment sales have also put downward pressure on our top line. However, we've been able to offset these declines with new satellite startups, price increases, base volume growth and share gain in our Specialty PCC and talc product line, as well as increased volumes from our existing Paper PCC sites. In total, these initiatives have generated over $9 million in revenue growth this quarter.
You can also see the significant impact that currency is having on our top line, and on its own accounts for almost all of the year-over-year sales decline. I thought I'd show this chart to provide some insight into our true underlying sales growth, which may not be readily apparent.
On this slide, I break out our profitability improvements by region. As I mentioned earlier, our operating income ratio remained above 11% this quarter, approaching the 12% operating income target we set for ourselves to achieve by 2015. The company continues to overcome the weak economic conditions in Europe and improve operating margins over last year. North America drove about 2 percentage points of the improvement due to strong earnings in Performance Minerals and increased profitability in Paper PCC.
Europe was affected by lower PCC volumes and wire sales, as well as fewer equipment installations. In addition, foreign exchange affected Europe's profitability. Asia increased primarily due to improved profits in our Japan Refractories business, as a result of lower raw material costs in the region. These increases were offset by startup costs associated with our new PCC satellite operation in India.
Let's go over the financial results within the Specialty Mineral segment. The $22.6 million of operating income is the highest level in the segment's history, exceeding the previous record set last quarter. Segment sales decreased $5.5 million or about 3% from the prior year to approximately $166 million. Foreign exchange had a $7.4 million unfavorable impact on sales or 4%, and the paper mill closures in Europe affected sales by an additional 4%.
Excluding foreign exchange and these shutdowns in Europe, segment's underlying sales grew 5%. Within the segment, Paper PCC sales, excluding the shutdowns and foreign exchange, grew 7%. Volume declines in Europe were partially offset by new volumes from 3 satellite facilities that came online over the past year, 1 in Superior, Wisconsin, and 2 in India, and we expect to have 3 additional satellites operational, 2 in India and 1 in Thailand, by the first quarter of next year.
In other segment product lines, Specialty PCC sales were up 2%, talc sales increased 5% and GCC sales were down 3%. Segment operating income in the third quarter increased 17% over the prior year, driven by a 27% increase in Performance Minerals, the 10% increase in Paper. As I mentioned earlier, the improvement in Performance Minerals was due to lower utility costs, higher prices, improved talc volumes and continued productivity gains, the increase in Paper PCC activity and good expense control. In addition, we're generating profit contribution from our new satellite facilities and the FulFill E-325 program. Overall, segment operating income represented 13.6% of sales in the third quarter compared to 11.3% last year.
Sequentially, segment sales were 1% below second quarter levels. Despite the decline in sales, operating income increased to 2% and was higher than we had anticipated in the last call. Paper PCC profits increased approximately 10%, while we anticipated similar performance levels through the second quarter. This was driven primarily by better-than-expected performance in Europe. The Performance Minerals business results were in line with our expectations.
Looking forward, fourth quarter North America paper production is projected to be down 4% compared to the third quarter, and European paper demand is expected to be down about 2%. Current indications are that fourth quarter volumes and profits in our Paper PCC product line will be down from the third quarter level in both regions. In addition, lime cost increases, that we will absorb in North America in the fourth quarter, will not be recovered until the first quarter of next year.
In Performance Minerals, we expect profits to decrease from the third quarter as the normal seasonal drop in construction activity will reduce volumes in all product lines. Overall, we expect that fourth quarter operating income for Specialty Minerals to be about 10% lower than the third quarter. This decrease is consistent with the typical drop we see given the seasonality of our end markets going into the fourth quarter.
Here are the components of the improvement in the Specialty Minerals operating margin over last year. As I mentioned earlier, segment operating margins increased to 13.6% from 11.3% last year. Volume declines in Europe associated with paper mill and machine closures impacted segment margins by slightly more than 1 percentage point. Currency also had a negative impact of more than 0.5 percentage point. Sales from our new satellite facilities, FulFill deployment, improved product mix in Performance Minerals and price increases improved margins by 2 percentage points.
Finally, productivity improvements in both Paper PCC and Performance Minerals, lower utility costs and good expense control also added another 2 percentage points to the margin improvement.
Now let's go through the results within the Refractories segment. Sales in the third quarter were 7% lower than the prior year. Foreign exchange accounted for about 5 percentage points of this decline. Refractory product sales were down 9% in North America due to the closure of RG Steel's Sparrows Point and Warren mills in early June, and to lower volumes from our non-steel refractory product line.
Europe refractory sales declined 10% from last year as a result of 3 steel mills shutdowns, 2 at ArcellorMittal and 1 at Synsil, significantly lower equipment sales and the impact of foreign exchange. Metallurgical wire sales decreased 7%, primarily in North America, due to product mix.
Operating income for the segment decreased 6% in the quarter, $7.2 million from $7.7 million in the prior year. The profit decline was due to the combined effect of lower refractory, equipment and metallurgical wire sales, and to the impact of foreign exchange, which more than offset the benefits derived from our lower NGL [ph] cost and improved productivities.
The segment operating income ratio was 8.5% of sales, which was the same as last year. Sequentially, Refractories segments -- the Refractories segment was impacted by the weakening global steel market. Steel production in the third quarter was down 4% in North America and 11% in Europe from second quarter levels.
Segment operating income decreased 17% in the second quarter, which was more than the 10% to 15% we had expected on the last call. The decline from the second quarter occurred primarily in our North America Refractories operations due to reduced volumes and an unfavorable product mix. In addition, our metallurgical wire product line had reduced profitability in both North America and Europe.
Looking forward, we anticipate continued lower refractory volumes in North America due to the continued decline in U.S. steel utilization rates through October. In addition, a number of customers have delayed equipment orders as their capital spending has been severely curtailed. Equipment products are some of our highest margin sales and the fourth quarter is usually the strongest sales period for this product line.
Given the lack of orders from our customers this year, profits from equipment sales will be over $2 million lower than the fourth quarter of last year. As a result, we expect that our fourth quarter operating income for the full segment to be 15% lower than the third quarter and 40% lower than last year.
This chart shows the changes in the Refractories segment operating margin, and the third quarter ratio, as I mentioned, was 8.5%, which was the same as last year. Refractory volume declines, significantly lower equipment sales and the weaker euro negatively impacted margins by over 3 percentage points. These factors were offset by lower raw material costs, primarily magnesium oxide, improved productivity levels and cost and expense control programs. These items contributed over 3 percentage points to the margin growth.
These charts illustrate our working capital and cash flow trends. Our total days of working capital increased slightly to 58 days. This increase was mainly due to higher inventory levels in the Refractories segment. Our cash flow from operations is approximately $40 million in the third quarter as compared to $36 million last year, and our capital investment for the quarter was $14 million.
Let's take a look at where we are so far this year compared to 2011. Sales were off for about 4% from last year, primarily due to foreign exchange. We've also faced weak market conditions in Europe, which has reduced sales volumes and resulted in various paper mill and steel mill closures that have put pressure on our top line. Despite these challenges to our topline growth, we've continued our focus on executing our major strategic initiatives and have improved the performance of all of our businesses.
New satellite contracts, new product launches, productivity improvements, cost control and solid supply chain sourcing decisions around raw materials and energy have led to this improvement. We continue to treat capital as a scarce resource, and we remain focused on improving working capital efficiency. As a result, thus far, we've generated record operating income and earnings per share, and also improved our return on capital and cash flow from operations. In total, our performance resulted in the strongest 9 months in the company's history.
As I mentioned earlier, we had a strong financial performance in the third quarter with earnings of $1.05 per share. This represented the fourth consecutive quarter of earnings in excess of $1 per share and is highlighted by the record earnings in the Specialty Minerals segment.
Looking to the fourth quarter, we expect Specialty Minerals segment operating income to be about 10% lower than the third quarter levels, which is a typical seasonal drop. Profits in our Paper PCC product line will be down from third quarter due to lower product demand in North America and Europe. We'll also absorb higher lime costs in North America in the fourth quarter, which cannot be passed through to customers till the first quarter due to contractual limitations.
In Performance Minerals, we expect a typical seasonal volume decrease as the fourth quarter is the low point of demand in the year for our end markets. In our Refractories segment, we expect profits to be 15% lower than the third quarter and 40% below last year, due primarily to the significant drop in our high-margin equipment sales. We also anticipate a decline in both refractory volumes and metallurgical wire sales given the recent drop in U.S. steel capacity utilization rate to below 70%.
In Europe, the steel market remains soft, which will continue to impact our Refractory business there. Further deterioration in global steel market conditions remains a concern through the fourth quarter and could add further downward pressure on our Refractories segment sales. Overall, we expect total company earnings for the fourth quarter to be 10% to 15% lower than the third, between $0.90 and $0.95 per share. Now let's open up to questions.