Douglas Dietrich
Analyst · Silke Kueck with JPMorgan
Thanks, Joe. Good morning, everyone. I'll take you through our consolidated and business segment results for the fourth quarter and the full year. I'll highlight the key market and operational elements of our financial results in each major product line and comments on comparisons to both the fourth quarter of 2011 and sequentially to the third quarter of 2012.
As Joe mentioned, we reported earnings per share of $0.50 versus the $0.52 per share recorded in the fourth quarter of last year, excluding special items. Our solid performance this quarter was due to better-than-expected earnings from our Refractories segment offsetting the Specialty Minerals segment performance, which was slightly below our forecast. In addition, our fourth quarter tax rate was 26.3%, which was lower than expected and improved our fourth quarter earnings by $0.02 per share. Our consolidated sales this quarter decreased 3% or about $8 million from the prior year. Foreign exchange had an unfavorable impact of $3 million or about 1% and the permanent and temporary paper mill shutdowns in Finland and France last year, as well as several steel mill shutdowns this year account for the remainder of the decrease.
We continue to be affected by the weak market conditions in Europe. Our total company sales and operating income were down 8% and 18%, respectively. The company's cost to sales this quarter were 4% lower, resulting in a 1% improvement in gross margin. Specialty Minerals segment margins improved significantly over last year due to increased pricing, continued productivity gains and lower energy costs, while partially offset by the Refractories segment margins, which contracted from lower equipment profits this year. In addition, total expenses for the company were slightly lower than last year.
Operating income increased 2% to $25.7 million and represented 10.5% of sales compared with 10% last year. Our return on capital for the quarter was 8.5% on an annualized basis. In the quarter, we generated $35 million in cash from operations, of which $14 million was used for capital expenditures. We repurchased $19 million of our shares in the quarter, and cash and short-term investments ended at $468 million. Sequentially, our consolidated sales decreased 2% and our operating income declined 8%, which was slightly better than our expectations. In total, our fourth quarter results reflect continued strong financial performance.
As you can see from this chart, our earnings for the last 5 quarters are on a strong track of more than $0.50 per share. We have successfully managed to overcome the lost income from several steel mill shutdowns this year and the 2 paper mill closures in the fourth quarter of last year through new satellite PCC volume, new product sales, productivity gains and overhead expense savings.
Looking at free cash flow and cash flow from operations, you can see the improvement in 2012 over 2011. Free cash flow at $88 million is 7% higher than the previous year, and cash flow from operations at $140 million is 5% better.
This chart outlines the improvement in our operating margin over last year. Margins have increased in both Paper PCC and Performance Minerals, but decreased in the Refractories segment. The increase in Paper PCC was primarily due to higher profitability in North America and Europe as a result of productivity improvements, reduced operating costs and lower overhead expenses, which offset the effect of lower European volumes. Some of the European overhead reductions were the result of shifting R&D resources to Asia to support our growth initiatives there. The improvement in Performance Minerals was due to higher pricing, continued productivity gains and lower utility costs.
In Refractories' lower raw material costs were more than offset by the declines in refractory product sales resulting from the weak steel market conditions in both North America and Europe. In addition, as we anticipated, this segment was impacted by significantly lower profits from equipment sales as several steel mill customers curtailed capital spending for the fourth quarter.
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 0.5% in North America and 1.5% in Europe. The construction market in the U.S., which includes both residential and commercial markets, was up over 6% from the fourth quarter versus the prior year. Automotive unit production in North America also continues to be strong with production rates up nearly 9%, but has leveled off somewhat as the fourth quarter was only 2% higher from third quarter levels. Steel production in North America was 2% lower than the fourth quarter of last year and 3% lower sequentially. The United States production decreased 4% both year-over-year and sequentially as steel capacity utilization rates went from 75% to approximately 72%. In Europe, you can see that the construction, automotive and steel markets are each down between 5% and 9%.
On this slide, I'd break out our profitability improvement by region. North America drove about 1.2 percentage points of the margin improvement due to strong earnings in Performance Minerals and increased profitability in Paper PCC. Europe was affected by lower refractory product and metallurgical wire volumes, as well as lower equipment sales. Foreign exchange also affected Europe's profitability. Asia was affected primarily by lower equipment sales, which profits decreased approximately $1 million from the prior year.
Let's go over the financial results within the Specialty Minerals segment. $19.6 million of operating income is 21% higher than the fourth quarter of 2011 despite a similar level of sales. Foreign exchange had an unfavorable impact on sales of $2 million or 1%, and the paper mill closures in Europe affected sales by an additional 2%. Excluding foreign exchange and the shutdowns in Europe, segments underlying sales grew 3%. Within this segment, Paper PCC sales, excluding the shutdowns and foreign exchange, grew 4%.
The European PCC volume declines experienced last year were offset by the ramp-up of volumes from several new satellite facilities that began operations over the last 2 years. We will see additional volume growth from 2 new satellites we commissioned in the fourth quarter, 1 in India and 1 in Thailand, and from our 5th Indian satellite, which we expect to start up in March. I'll go into more detail and outline further our capacity additions in a minute.
In other segment product lines, Specialty PCC sales were up 5%, talc sales decreased 4% and GCC sales were down 3%. Segment operating income in the fourth quarter increased 21% over the prior year driven by a 25% increase in Paper PCC and a 13% increase in Performance Minerals. The increase in Paper PCC was primarily due to operating -- lower operating costs and 9% improvement in productivity and good expense control. In addition, we're generating profit contribution from our new satellite facilities in the FulFill E-325 program. FulFill, for the full year, generated approximately $1.4 million in operating income. The improvement in Performance Minerals was due to higher prices, improved Specialty PCC volumes, continued productivity gains and lower utility costs.
Overall, segment operating income represented 12.2% of sales in the fourth quarter compared to 10.1% last year, an increase of 21%. Sequentially, segment sales were 3% below third quarter levels. Sales in Paper PCC were 1% lower while sales in Performance Minerals were down 7% due to the typical seasonal decline in the construction market. Operating income increased 13%, which was more than the 10% decline -- I'm sorry, decreased 13%, which was more than the 10% decline we anticipated on our last call, primarily due to lower-than-expected talc and GCC sales.
Looking forward, current indications are that first quarter sales and profits in our Paper PCC product line will be slightly better than the fourth quarter due to volume growth in Asia. But I'd also like to mention that given the continued weakness in the European paper market, as highlighted by the recent announcements by UPM to close or sell several of their paper mills, we may need to make further adjustments to our overhead in the region. However, there's been some positive news for us that the Alizay paper mill in France have been purchased by Double A Paper. Our satellite there remains in operating condition and we expect to begin supplying PCC to the mill when it comes online, most likely sometime in the second half of this year.
In Performance Minerals, we expect profits to be down slightly from the fourth quarter as the first quarter is normally a seasonally low period of the year, and we are currently seeing an increase in energy costs. Overall, we expect the first quarter operating income for Specialty Minerals to be similar to the fourth quarter.
This chart highlights the components of the 21% improvement in Specialty Minerals operating margin over last year. As I mentioned earlier, segment operating margins increased 12.2% from 10.1%. Volume declines in Europe associated with the paper mill closures impacted segment margins by approximately 1 percentage point. Currency also had a slight negative impact. Sales from our new satellite facilities, FulFill deployment, improved product mix in Performance Minerals and price increases improve margins by about 2.5 percentage points. Productivity improvements in both Paper PCC and Performance Minerals, lower utility costs and good expense control have also added nearly another percentage point to the margin improvement.
Now let's go through the results within the Refractories segment. Sales in the fourth quarter were lower in both North America and Europe, and in total, were 9% lower than the prior year. Foreign exchange accounted for about 1 percentage point in this decline. The decline in North America was driven primarily by the closure of RG Steel's, Sparrows Point and Warren mill's last June. In Europe, it was driven by lower refractory volumes resulting from a 6% drop in steel production, significantly lower equipment sales and the impact of foreign exchange.
Operating income for the segment decreased $2.9 million in the quarter to $7.5 million. $2.3 million of this decline was due to significantly lower equipment sales in the RG Steel mill closures. The remainder was due to lower refractory and wire volumes in Europe and the impact of foreign exchange. These factors more than offset the benefits derived from lower magnesium oxide costs. The segment operating income ratio was 9% of sales in the quarter. Sequentially, refractory sales were down 4% from the third quarter but were better than we expected due to higher refractory and wire volumes in North America.
Segment operating income increased 4% from the third quarter, which was considerably better than we had expected on the last call. Our North America income came in better than expected due to favorable refractory product mix, overall higher refractory volumes and increased profits from our small non-steel pyrogenic product line, which benefited from onetime sales. In addition, our metallurgical wire product line improved due to favorable product mix in both North America and Europe.
Looking forward, we remain concerned about steel production levels in North America and particularly in Europe, as production in both regions has been inconsistent. The recent announcements by ArcelorMittal regarding production curtailments in Belgium reflect the steel market uncertainty in Europe, and as a result, our refractory volumes will be affected in the region. Also the current low level of equipment sales continues to carry through into the first quarter, and profits will be lower in our non-steel product lines. As a result, we expect that our first quarter operating income for the full segment will be slightly lower than the fourth quarter.
This chart shows the changes in the Refractories segment operating margin. The fourth quarter ratio was 9%, well below the 11.3% achieved last year. Refractory volume declines, significantly lower equipment sales and the weaker euro negatively impacted margins by nearly 5 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 2 percentage points to margin growth.
These charts illustrate our working capital and cash flow trends. Total days of working capital increased slightly to 59 days. This increase was mainly due to higher receivables and lower payables in the Refractories segment. Our cash flow from operations was $35 million in the fourth quarter, and capital spending for the quarter was $14 million and $52 million for the full year.
Let's take a quick look at the full year. We had another strong performance, and our earnings of $2.09 is an 11% increase from the $1.89 per share recorded in 2012. This represents the third consecutive year of record earnings for the company. Our consolidated sales decreased 4% or about $40 million from the prior year; foreign exchange accounted for 3% of this decline. Excluding FX and the various paper mill and steel mill shutdowns we experienced over the past year, our underlying sales grew just over 1%. Our cost of sales decreased 6% driven by productivity improvements and good cost control, which resulted in a 3% increase in gross margin. We did a good job again managing total overhead expenses this year, which declined 3%. Operating income increased 9% to $110 million, and represented 10.9% of sales compared with 9.6% last year, a 13.5% improvement. Return on capital for the year was 8.9%, higher than the 8.5% achieved last year.
We generated approximately $140 million in cash from operations compared with $134 million last year and we repurchased $28 million in our share buyback program, of which $19 million was repurchased in the fourth quarter. In total, we had the strongest performance in the company's history.
Let me take a minute to review where we are with our Paper PCC geographic growth strategy. We're on track with the projections we communicated to you approximately 2 years ago, and I thought a summary would be helpful to outline the progress we have made, primarily in Asia. To give you some dimensioning of the volume growth associated with our new Paper PCC facilities, this chart shows the announced Paper PCC capacity that we have been deploying and will continue to deploy over the next 2 years. In total, these new satellites and expansions should add an incremental 525,000 to 625,000 tons of capacity by the end of 2014 and into the beginning of 2015.
In 2012, we began operations at 2 new facilities, 1 in Thailand and 1 in India, with a combined annual capacity around 10,000 -- 100,000 tons. In 2013, we'll begin operations at our 5th facility in India and we'll complete 4 expansions in the U.S. with a combined annual capacity of another 120,000 tons. In 2014, we'll commence operations at 3 additional satellites, 2 in China and 1 in Bangladesh, with a combined annual capacity of 150,000 tons. These 2 satellites in China are our first new operations there in 7 years and brings our total satellites in China to 5.
As Joe mentioned earlier, we're in discussions with a number of papermakers in China and India, which, if we're successful securing this business, could add an additional 150,000 to 250,000 tons in the 2014, 2015 period. It should be noted that PCC volumes in each satellite we build tend to ramp up gradually as new paper machines come on slowly. We also expect additional volume growth through 2014 from the new satellite opportunities we're pursuing this year and as well from the FulFill program as it gains traction. In total, over the next 2 years, we expect 500,000 to 600,000 tons of PCC volume growth from these initiatives, which represents a 15% to 18% increase in volumes from where we stand today.
As I mentioned earlier, our fourth quarter earnings performance of $0.50 per share was above our expectations, primarily due to better-than-expected performance in the Refractories segment. Looking to the first quarter, we expect the Specialty Minerals segment profits to be similar to the fourth quarter, as improved PCC volumes in Asia will be offset by increased energy costs in Performance Minerals. In our Refractory segment, we expect profits to be slightly lower than the fourth quarter, as our volumes will be affected by the continued weakness in North America and European steel markets. Overall, we expect the total operating income to be of similar levels to the fourth quarter. However, net income will be slightly lower due to our projected higher effective tax rate.
Now let's go to questions.