R. Berrier
Analyst · Sidoti & Company
Thanks, Ron and good morning, everyone. After year-over-year total retail sales in the U.S. dropped by 0.3% in October, U.S. retail sales rose 0.4% in November and 0.5% in December. And although these are weaker sales gains compared to previous holiday periods, they were encouraging results nonetheless. The economy appears to have some underlying momentum to it and many experts believe the momentum will continue into 2013. So I'll start my comments today with the automotive and housings segments, which have been leading the way in terms of the overall economy recovery. These 2 segments represent approximately 20% of the company's volume. The U.S. automotive market has been a bright spot as Americans continue to replace older vehicles and ones damaged by super storm Sandy. A strong December helped push 2012 U.S. light vehicle sales to their highest volume levels in 5 years. After bottoming out at 10.4 million units in 2009, sales rose 11% in 2010, 10% in 2011 and 13% in 2012, which was the biggest 1-year jump in decades. The seasonally adjusted annual sales rate in December was 15.4 million units, marking the second straight month that the annualized sales rate was above 15 million and a performance status created considerable momentum for 2013.
In the housing market, 2012 finished as the best year for residential construction since the housing crisis began, with an increase of 28% more new homes starts in 2012 compared to 2011. The resurgence in the housing market has helped drive a 7.5% increase in retail furnishing sales in 2012 compared to 2011. Although volumes in our furnishings segment have only increased slightly, we remain encouraged by these trends in the housing market and retail furnishings segment.
Retail sales of apparel in the U.S. increased 5.5% for the 2012 calendar year but the consumption on a square meter fabric basis declined by an estimated 1.6%, indicating that the sales dollar gains are primarily due to the impact of raw materials, inflation and retail pricing strategies rather than actual increases in units purchased. The rate of decline in the square meter fabric equivalent volumes improved during the second half of the calendar year, which is better for the company since yarn consumption is closely aligned with the square meter fabric equivalent. Trends for synthetic apparel in the Americas region have been positive over the past several years, which is still projected to hold share at approximately 18% of the synthetic apparel supply to the United States. The share of synthetic apparel versus cotton has been increasing steadily since 2009 and this has provided growth for synthetic yarn consumption during the past 2 years.
What we're seeing in our domestic business for the first 6 months of fiscal 2013 is steady volume with some incremental growth that is paralleling the improvement in the overall economy. The improvements in our domestic financial performance are a result of growth in our PVA products, recapturing lost margin from past raw material increases and our relentless efforts in operations to minimize costs with our process improvement and lean manufacturing initiatives.
I will now make a few comments on raw materials before I get to our international operations and an update on our premier value added products. Polyester raw material prices have been steadily increasing since the start of fiscal year 2013. Polyester raw materials were, on average, approximately 10% higher in the December 2012 quarter compared to the September 2012 quarter, and we expect them to increase slightly in the March 2013 quarter. We have been adjusting our sales prices accordingly and if the current trend continues, we will be adjusting our sales prices in the coming months. The gap in polyester polymer pricing between the U.S. and Asia has averaged approximately $0.12 per pound for the first 6 months of fiscal 2013. This is approximately equal to the gap in the December 2011 quarter. The raw material gap along with cheap import pricing in polyester DTY continues to put pressure on the low end of our product offering, although our mix enrichment strategy has dampened the impact of such pressures over the last several years.
Turning to our global business. Imports of fiber, fabric and finished goods continue to put pressure on the domestic supply chain in Brazil and that made it increasingly difficult for us to remain competitive at the lower end of our textured yarn products. The inflation rate in Brazil, which has been running in the 5% to nearly 7% range for the past 3 years, has negatively impacted our converting costs and has made it extremely difficult to raise prices to recoup lost margin while competing against the influx of low end imports. Although our quarter-over-quarter volume improved in Brazil, our adjusted EBITDA there only increased slightly due to the negative impact from imports and inflation.
For the first 6 months of fiscal 2013, net sales for Brazil are 10% below our forecast, while gross profit is 26% below forecast, further indicating the negative impact that imports and inflation have had on the company's business. The exchange rate for the Brazilian real continued to remain slightly above BRL 2.0 to the U.S. dollar in the December quarter. The exchange rate has helped mitigate some of the issues with imports and inflation, but the exchange rate alone is not enough to offset the impact of cheap imports into Brazil. Our focus in Brazil continues to be on implementing process improvement and manufacturing efficiency gains to lower our per unit cost, to counter the pressure at the low end of the product mix with an aggressive mix enrichment strategy, leading to a more defensible product mix.
Turning to China, our fiscal year-to-date volume in China is below our forecast, along with our expectations for gross profit. Our operation in China is still impacted by one of the larger customers working through significant inventory in their overall supply chain. We do expect this customer to return to the market and remain a key customer of the company. We continue to capture new programs in China and have several new developments underway with key brands, some that will be coming online later in 2013. This positive momentum and contribution continues to reinforce our global PVA strategy and partnership with brands and retailers that we support. We expect our business to be more in line with forecasted expectations during the second half of the fiscal year.
We continue to be confident that we're on the path to double our global sales of premier value added yarn by 2014. We got back on our 20% growth rate domestically after the recession but conditions in China and Brazil offset much of this growth in the past year. We expect our consolidated PVA portfolio to be back on the 20% global growth rate in 2013, based on current volume trends and recent program adoptions.
Newly announced programs include cold-proofed base-layer apparel, casual pants from Eddie Bauer and Dockers, a graphic T-shirt program from Qualcomm [ph] and band uniforms for DeMoulin, which is the oldest and largest manufacturer of music performance group apparel in the world. These programs join high-profile REPREVE-based programs from Lee, Savan [ph], Dickies, Haggar, Ford, IZOD and others. The company has taken a more active role in marketing REPREVE, which is our umbrella brand for our recycled products, directly to consumers. Not only will this create awareness for REPREVE among target consumers, it will also raise the visibility and credibility for REPREVE among brands and retailers. We believe that the best approach to marketing REPREVE is to educate consumers about the importance of recycling and choosing products made with recycled material. And because REPREVE is in many well-known and respected winter sports related brands including Patagonia, The North Face and Polartec, we believe the X Games in Aspen will be an ideal venue for us to help consumers understand the range of products made with REPREVE recycled fibers. Recently, we announced that REPREVE will be the official recycling partner at the X Games Aspen, which will air on ESPN from January 24 through the 27.
To help drive awareness for REPREVE, we have teamed up with Elena Hight, who is a decorated X Games women's snowboard SuperPipe medalist and is best known for her progressive riding style. Hight will be featured in a REPREVE TV commercial that will air 15 times during the broadcast on ESPN. We also recently launched a new consumer-focused website, which is repreve.com and will be supporting our X Games sponsorship with radio advertising, on-site promotions, public relations and social media initiatives. We believe that many consumers think that recycled polyester doesn't wind up in any cool or innovative products. Our presence at the X Games and our partnership with Elena Hight will help raise positive awareness for recycled polyester and establish REPREVE as a leading ingredient in sustainable products. I'd like to encourage you to see what we're doing to promote REPREVE to consumers by visiting the new repreve.com website. On the site, you'll find links to our X Games content, including our TV commercial, as well as information on many of the great products that we're in. With that as a backdrop, I will turn the call back over to Ron.