James Cline
Analyst · Stephens
Thank you, Ron. Good morning, everyone. As you know, the press release with Trex's fourth quarter and full year financial results was issued this morning. First, I would like to review our fourth quarter results.
The company recognized net sales of $51.5 million in the fourth quarter of 2011, a 32% decrease compared to 2010. As Ron noted, the December contribution to our early-buy sales program was much lower this year due to a change in our pricing strategy. We informed our distributors in the fourth quarter of 2011 that we would not be increasing prices. The very strong fourth quarter 2010 sales were heavily influenced by the announced January 1, 2011, price increase of 12% on Transcend.
The company recorded a net loss of $18.3 million or $1.18 per share in the fourth quarter of 2011, compared to a net loss of $500,000 or $0.03 per share in 2010. The company's results for the fourth quarter of 2011 include a $10 million charge related to an increase in our warranty reserve. The company's results for the fourth quarter of 2010 included $4.1 million of charges. Before giving effect to these charges, our fourth quarter 2011 net loss was $8.3 million or $0.54 per share. And our fourth quarter 2010 net income was $3.6 million or $0.23 per share.
We recognized loss at gross profit of $1.1 million in the fourth quarter of 2011. Gross profit on an underlying basis was $8.9 million. Our underlying gross margin was 17.3% compared to an underlying gross margin of 30.1% in 2010. The decline in underlying gross margin was driven by lower sales volume and reduced capacity utilization, which negatively impacted margins by 11.6% and 4.6%, respectively. In addition, the company recognized an unfavorable inventory valuation adjustment compared to the prior year of 4.9%. The 2011 negative impact of reduced sales and capacity utilization was partially offset by the elimination of the 2010 Transcend start-up earnings drag of 7.8%.
SG&A for the fourth quarter was $13.6 million compared to $15.5 million in 2010. The decrease of $1.9 million was primarily related to lower incentive compensation.
Net interest in the quarter was $3.6 million in 2011, a $100,000 decrease from 2010. The company's results for the fourth quarters of 2011 and 2010 included $3.4 million and $2.1 million of noncash interest expense, respectively, related to our convertible bonds.
The fourth quarter of 2011 effective income tax rate remains low as a result of the valuation allowance against the deferred tax asset.
Turning to our full year 2011 results. Net sales were $266.8 million compared to net sales of $317.7 million for 2010, a decrease of 16%. The decrease in net sales was attributable to a 22% decrease in sales volume, which was partially offset by an 8% increase in the average price per unit. The increase in average price per unit was driven by the 2011 price increase for Transcend decking products and a shift in sales mix towards higher-priced products. We believe the decrease in sales volume was a result of poor weather conditions during the deck building season in the northern regions of the United States, reduced consumer spending due to lower consumer confidence and the shift of Transcend sales from early 2011 into late 2010 as customers purchased Transcend ahead of the announced 2011 price increase.
The company recorded a net loss of $11.6 million or 75% -- $0.75 per share for 2011 compared to a net loss of $10.1 million or $0.66 per share for 2010. The 2011 results include unusual charges of $7.7 million, including the $10 million increase in warranty reserve and a $300,000 noncash charge for the extinguishment of $5.6 million of our convertible notes in the third quarter. These noncash charges were partially offset by a favorable resolution of uncertain tax positions in the first quarter that positively impacted income taxes by $2.6 million. Before giving effect to these adjustments, the net loss for 2011 was $3.9 million or $0.25 per share. The company's results in 2010 included $21.3 million of charges. Before giving effect to these charges, our net income for 2010 was $11.3 million or $0.72 per share.
Gross profit as a percentage of net sales increased to 23.5% in 2011 from 22.9% in 2010. The gross profit in 2011 was adversely affected by the $10 million increase to the warranty reserve. Gross profit in 2010 was adversely affected by $18.9 million worth of charges, including a $15 million increase to the warranty reserve and $3.9 million for minimum purchase penalties.
Underlying gross margin in 2011 was 27.3%, a 1.6% decrease compared to the underlying gross margin in 2010 of 28.9%. The company recognized a combined 8.5% of margin improvement from the elimination of the Transcend start-up earnings drag from 2010 and improved manufacturing efficiencies. This 8.5% margin improvement was fully offset by the impact of reduced sales, which decreased margins by 5%, operating at reduced level of capacity utilization, which resulted in a 3.6% lower margin and an unfavorable inventory valuation adjustment of 1.3% compared to the prior year.
SG&A for the full year of 2011 was $60.6 million compared to $67.8 million in 2010. SG&A in 2010 included a nonrecurring $2.4 million noncash charge related to our joint venture in Spain. The remaining decrease of $4.7 million was primarily related to lower incentive compensation.
Net interest was $16.4 million for the full year of 2011, a $1.1 million increase from 2010. The company's results for full year 2011 and 2010 included $10.5 million and $8.1 million of noncash interest expense related to our convertible bonds. As a reminder, the convertible bonds will be paid off in July and we expect 2012 interest expense to decrease by approximately $7 million year-over-year.
The effective income tax rate for the full year of 2011 remained low as a result of the valuation allowance against the deferred tax assets. In addition, earlier this year, we recorded a $2.6 million favorable noncash adjustment to taxes related to the resolution of uncertain tax positions. We expect the effective tax rate to continue to be low through 2012.
In addition, our loss carryforward at the end of 2011 was $65.3 million. At December 31, 2011, the company had $41.5 million of cash on hand and no borrowing on the revolving line of credit. Our only borrowing was the remaining $92 million of convertible notes.
Net debt to total capitalization at December 31, 2011, was 33% compared to 36% at December 31, 2010. Inventory was $29 million at December 31, 2011, which is slightly below the balance of the prior year.
The company had free cash flow of $24.5 million for the full year of 2011, a $15.3 million year-over-year increase. Free cash flow during the full year of 2010 benefited from a $7.5 million one-time tax refund. Cash flow from operations in 2011 was positively impacted by the change in accounts receivable, as we ended the year with a significantly lower accounts receivable compared to 2010.
The cash used in investing activities was $9.4 million, a $400,000 decrease versus the prior year. In this morning's press release, we communicated that we recorded a $10 million addition to our warranty reserve related to certain production at its Nevada facility that occurred prior to 2007. Since 2007, we have seen a decline in the number of warranty claims in every year with the exception of 2009 when we published the national settlement notice. The settlement of the class-action suit and a related publication of the national settlement notice had a significant impact on the warranty reserve.
However, since 2007, cash payments for claims declined from $18 million in 2008 to $8 million in 2011. The 2011 year-over-year decline was over 20% for both the number of claims and cash paid for claims. While we expect these claims and related payments will continue to decline significantly over the next few years, we also expect a longer tail claims than previously anticipated. Due to this longer tail claims and our estimate that the cost per claim will be approximately 10% higher, we increased the warranty reserve.
I would like to summarize several significant achievements that we've accomplished during 2011. We have eliminated the earnings drag related to the 2010 Transcend start-up. Our continued focus on generating free cash flow resulted in paying down $8.1 million in debt this year, while ending the year with $41.5 million of cash to support ongoing operations and to pay off the convertible debt in July.
We replaced our $55 million line of credit with a $100 million credit agreement in early 2012 that provides us with greater borrowing capacity at lower costs. This facility, coupled with our continued free cash flow generation, provides more than adequate liquidity to handle the mid-2012 maturity of our convertible notes.
Finally, turning to our guidance. I would like to reiterate first quarter sales forecast of $90 million, a 30% increase over 2011. Second, we believe that our capacity utilization for the first quarter will be approximately 35% compared to 18% in the fourth quarter of 2011. Finally, I want to remind everyone the face value of the convertible debt of $92 million will be paid off in cash in early July this year, significantly reducing interest expense in the second half of 2012.
Operator, we'd now like to open the call up for questions, after which Ron will provide his closing statement.