David Petratis
Analyst · Imperial Capital
Happy holidays and thank you for joining us for our fourth quarter and year end conference call. On the call with me today is Brent Korb, our Chief Financial Officer; and Martin Ketelaar, our Vice President of Investor Relations and Corporate Communications.
Today's call will include a brief recap of fourth quarter results and our annual results, a final update of the consolidated results of our insulating glass spacer facility and a progress report on Nichols Aluminum. We will give a general outlook for demand in fiscal 2013 and a recap of what we believe our earnings prospects will be once our end markets return to more normal levels, including our definition of normal market conditions. We'll also provide you with some additional clarity on some of our recent initiatives and how we expect them to impact our financial results.
Before I begin, let me give you a brief update on the Aluminite acquisition we announced Monday evening. We're very pleased to welcome Aluminite to the Quanex family. Aluminite is a strategic acquisition that expands our windows screen product offerings into the vinyl market in addition to increasing our geographical footprint from which we can better serve window and door OEM. The window and door screen market in total is estimated to be a $450 million market, dominated by vertically integrated OEMs who make their own screens. With the addition of Aluminite, the range of screen products and price points positions us better to serve these OEMs. The transaction is expected to close by December 31, 2012, and will be funded from cash on hand.
Turning to our quarterly results, Engineered Products finished the year strongly with fourth quarter net sales up 5.2%, but operating income was down $1.3 million over the year ago quarter. Our operating margin was 9.9% compared to 11.5% in the fourth quarter of 2011, driven largely by continued investments in our sales and marketing efforts that will position the company for future growth. For fiscal 2012, comparable sales at EPG increased 6%, primarily driven by higher vinyl extrusion sales to one of our large OEM customers.
Operating income and margins for the year were burdened by the consolidation cost at our IG operations. The good news is that the consolidations were successfully completed on time and on schedule, and we have begun to see the financial and the operational benefits of that consolidation in our first quarter. The total cost of the consolidation was $16 million, $9 million of expense and $7 million of capitalized items. We expect to achieve an estimated annual savings of $8 million, so EPG results will clearly benefit from this consolidation.
According to Ducker Worldwide, the market intelligence firm we use to benchmark EPG's performance against the industry, total estimated U.S. window shipments increased approximately 1.5% for the 12-month period ended September 2012, with increases in new construction more than offsetting the 6.6% decline in the repair and remodel window market. 2012 sales at EPG increased nearly 14% on an absolute basis, or 6% on a comparable basis when adjusted for Edgetech, and we are very pleased with these results.
EPG's combined sales and marketing team continues to show modest yet steady progress. You'll recall that the objective of this project was to provide a resource for customers as well as to partner with and be the provider of choice to the window and door OEMs. We are a couple of years into this initiative, and we are seeing some tangible results as our customers look to develop new, more energy-efficient systems with the features and benefits that their customers seek. We believe we have the products and level of service to meet those needs.
Our belief was confirmed based on the responses and attendance at our booth at the 2012 GlassBuild show in Las Vegas this last September. Quanex had a significant presence at this year's event. And it was clearly a success as we won Best in Show, and our ScreenItAgain.com website won a Crystal Achievement Award for the Best Industry Website.
More importantly, we invested quality time with many wide-ranging customers to gain valuable feedback on what we can do to help them succeed. We also generated numerous leads that our sales team is actually working into turning into new business.
Now let me turn to Nichols Aluminum. 2012 was one of the most difficult years in Nichols' history. We started up the year poorly with quality issues at our Alabama paint facility and weak demand as our customers operated in a destocking mode. The second quarter brought us a 12-week strike that directly cost us slightly more than $11 million in higher costs and lost volume, not to mention the inefficiencies that continued after the strike ended.
Additionally, we changed the management team, including the Vice President -- including the President, Vice President of Operations and the General Manager of the casting facility. That's a lot of change. Our new management team, led by Russ Brown, who came on board in July, has already made significant improvements. Russ is not from the aluminum industry, and that is intentional. Russ has a great deal of experience with operations, particularly in Lean Six Sigma and standard work processes, and we are already beginning to see visible results as the program and programs gain momentum.
In late September the union at Davenport, Iowa casting and finishing facilities ratified a new 5-year contract. This contract has provisions for 2-tier wage systems, more equitable sharing of health care costs and allows us to have a more flexible set of work rules.
Part of the quality problems experienced at Nichols is due to aging equipment. The new operating philosophy at Nichols will focus on preventative maintenance, improving quality and on-time delivery.
As I stated last quarter, this will require some additional investment in Nichols. During the fourth quarter, we spent $1.5 million to complete the installation of a new annealing furnace that will help improve the throughput at our Lincolnshire finishing facility. And in April, we expect to replace the paint oven at our Decatur, Alabama facility. The ability to produce and ship consistent high-quality painted aluminum sheet will make a positive impact on Nichols' profitability. Over the last 5 years, Nichols' averaged capital expenditure has been approximately $7 million. We expect Nichols' capital expenditures to increase to the range of $10 million to $13 million over the next few years. We believe these investments will make a significant improvement in quality, on-time delivery, reliability and, therefore, profitability.
During the fourth quarter, Nichols shipped 73 million pounds, 11% better than the 66 million pounds shipped in the year ago fourth quarter. But it did not meet our expectations. Operational issues at the casting facility included an inductor [indiscernible] and a melter going down, causing us to miss our target of 80 million pounds. Many of these operational issues will be addressed through the preventative maintenance programs we now have in place and as I mentioned.
We are encouraged by the positive results we're seeing at Nichols. The Aluminum Association which tracks industry shipment of sheet products reported industry volumes for the 12 months ended October 31, 2012, up 8.6%, while Nichols' shipments declined by 8.9%. Our performance can be attributed to the impact of a strike, the operational issues I just mentioned and weaker repair and remodeling demand.
Nichols' fourth quarter operating income was also disappointing, coming in at a loss of nearly $1 million compared to operating income of $3.1 million a year ago. Although demand remains strong in the quarter, spreads declined by 18% or 9% per pound to $0.41 per pound. The result, a larger decline in aluminum prices compared to scrap material.
Let me now turn the call over to Brent, who will take you through some additional financial highlights.