R. Berrier
Analyst · Sidoti & Company
Thanks, James, and good morning, everyone. I'll start this morning with a few brief comments regarding the retail market.
Freezing temperatures and heavy snow across much of the U.S. cut many shoppers indoors during the start of 2014, and forced some stores to close for a couple of days in January and February, causing retail sales to drop. Retail sales began to rebound in the month of March, however. The results for the 3 months of the March quarter, retail sales of apparel declined 1.2% when compared to the December quarter, while retail sales of furnishings declined 2.4% and other sales were down 1.8%. However, when compared to the prior year March quarter, retail sales of apparel, furnishings and autos were flat to slightly up in each segment for the March 2014 quarter. As a result, we continue to see positive year-over-year growth in our key segments, despite the impacts of the unusually cold and snowy weather in the March quarter.
We remain very encouraged by the stability of synthetic apparel produced in the NAFTA-CAFTA region, which has held steady at approximately 18% of the total U.S. apparel consumption for the last 4 years. During January and February, synthetic production from this region increased by more than 10% versus the same period last year, giving more indication that brands and retailers are looking to source more products from the region. Our production volumes and sales volumes remain strong, particularly in our polyester segment which includes both our value-added products and commodities, and our future orders look strong for our fiscal fourth quarter. We anticipate expanding our texturing capacity over the next 6 to 9 months to take advantage of this incremental growth that Bill will touch on later.
In terms of polyester raw materials, prices have remained relatively stable over the past 12 months, which has led to pricing stability for our customers throughout the supply chain. Polyester raw material prices declined by 5% in the March 2014 quarter compared to the December quarter, and our overall margins have improved from the lower cost raw materials. However, we do expect a corresponding increase in raw materials over the next several months.
The gap in polymer pricing between the U.S. and Asia remained at approximately $0.14 per pound, which continues to put pressure on the lower end of our commodity business, and makes it difficult to compete with imported yarn in market segments that do not require compliant yarn. While the timing of the holiday shutdown period negatively impacted our year-over-year domestic volume comparison in the December quarter, that timing led to an improvement in the March 2014 quarter compared to the prior year quarter. Sales of our premier value-added yarns and other value-added products also contributed to overall improvements in sales and margins in our domestic polyester and nylon businesses, which James will explain in more detail in a few minutes.
Looking at Brazil, our volumes and sales revenue, based on local currency, are close to our targeted goals. However, our margins continue to be negatively impacted by price pressures from imported DTY, which we have discussed during the last 2 quarters. With capacity utilization rates for polyester filament in Asia at about 65%, imported DTY from Asia continues to flood into the Brazilian market, and our gross margin has suffered as are have forced to match import pricing in order to hold onto market share. Changes in currency translation of the real into U.S. dollar have also impacted our results, which James will detail in the financial review.
We remain focused on mix enrichment in Brazil and are encouraged by the level of interest in value-added products, such as solution dyed and hair-covered yarns, as well as REPREVE. However, we expect that the shift to higher margin products will be a slow and gradual process, given the pricing pressures from imports and the challenging economic conditions in Brazil, which is facing slow growth as a result of high inflation and interest rates. We expect gradual improvement in Brazil as these initiatives are implemented.
Turning to China, our volume was slightly higher in the March 2014 quarter compared to the prior year. However, our gross margin declined based on pricing pressures in the market, due to the low operating rates and over capacity. However, we continue to expect financial improvement in China in our 2015 fiscal year based on the pipeline of projects, that we are working on, that utilize REPREVE and other value-added products.
Looking at our global performance in growth of our premier value-added products. We set a goal, 4 years ago, to double the sales in this segment over 4 years. While the challenges in Brazil and China have made it difficult to meet this goal, we are extremely excited about the growth in our domestic business, especially with REPREVE-based products.
We continue to service our domestic customers with high-quality commodity products, as well as differentiated products such as solution dying cationic dye yarns that add value to their programs, in addition to our premier value-added yarns. We are also very excited that the expanded capacity at our REPREVE Recycling Center will come online in May, which will increase our capacity for REPREVE from 42 million pounds annually to around 72 million pounds. We continue to explore opportunities to sell REPREVE polymer and chip to customers outside our traditional textile base, and we are investigating adding additional expansions to support REPREVE in the future. We will provide additional updates and details on these opportunities as we evaluate them further.
We continue to be committed to driving demand for REPREVE by increasing consumer awareness for the brand. We were, once again, the official recycling sponsor of ESPN's X Games Aspen, which took place in January. Our sponsorship and the launch of our #TurnItGreen campaign resulted in over 50 million consumer impressions through on-site activations, social media and advertising. The exposure that we generated for REPREVE, through the X Games, has also opened the door to other exciting and new opportunities, including a sponsorship at Marvel Universe LIVE!, an exciting live entertainment experience that will take place in multiple cities across the country; and potential activation programs with the Detroit Lions of the NFL, and the Portland Trail Blazers of the NBA. We will provide additional details of these programs once they have been finalized.
We also continue to be a branding partner on several new programs that utilize our PVA products, particularly our flagship REPREVE product. One element that is catching on in our co-branding efforts is the inclusion of the number of bottles used in the production of each item. We think that communicating the bottle count information to the end consumer will help reinforce that many cool and desirable products are made with recycled polyester, and will aid in creating awareness for the need to recycle more plastic bottles in the future. A partial list of new programs and their associated bottle counts includes: The Ford 2015 F Truck series, which will incorporate approximately 28 bottles per truck; Dockers Smart Shield pant, which uses approximately 6 bottles per pant, and also includes our Sorbtek moisture management yarn; Quiksilver youth and men's board shorts, which use approximately 10 to 12 bottles each. Brooks Brothers 50-50 Rethink T-shirts, which use about 2 bottles per shirt; and Volcom T-shirts, which use about 2 bottles per shirt. We were also featured in a national ad for the Hagger Performance Cotton Khaki program, utilizing our SORBTEK moisture management technology, which we're in, in a recent addition of Men's Health magazine.
As we build consumer awareness for REPREVE and explore other non-textile-related opportunities for REPREVE, we see ourselves evolving more and more interest sustainable solutions, generally, across a broad spectrum, not just sustainable solutions in textiles. We are finding that more opportunities exist for our high-quality REPREVE polymer product outside our normal textile customer base.
With that as a backdrop, I'll turn the call back over to James.