R. Berrier
Analyst · Sidoti & Company
Thanks, Ron. There were signs that the economy is continuing to gain strength as rising consumer confidence translated to stronger than expected consumer spending in the September quarter.
According to recent figures released by the Commerce Department, all retail sales increased by 1.1% in September, and this comes on the heels of a 1.2% increase in August, which marks a strong back-to-school performance.
Core retail sales, which exclude automobiles, gasoline and building materials, rose 0.9% in September, which was well above the 0.3% that analysts expected.
Looking specifically at apparel, retail sales in the U.S. increased 5.5% in the September quarter compared to the prior year quarter and are up 1.9% compared to the June quarter.
Inventory levels at retail for apparel continued to hold at approximately 72 days while total supply chain inventory decreased to 64 days in the September quarter, compared to 67 days for the year-ago quarter.
Inventory days at apparel producers, which had been growing from 50 days in the March 2011 quarter to 56 days in the June 2012 quarter, decreased to 54 days in the September quarter.
Therefore, we see that inventory in the total supply chain has been stable for the last 3 to 4 months, which indicates current production rates are staying closely aligned to retail sales rates.
On a square meter fabric equivalent basis, total apparel input or -- excuse me, total apparel imports into the U.S. are expected to climb by approximately 2.7% for calendar year 2012, compared to the previous calendar year.
This would indicate that the projected annual improvement in retail sales of apparel mentioned earlier will be largely due to inflationary prices at retail and not by actual increases in units purchased.
Since total volume of actual yarn consumption is closely aligned with square meter fabric equivalents, we will project an equivalent year-over-year decline of 2.7% in yarn consumption associated with apparel.
Looking at a few other market segment trends that impact the company's volumes. Building permits and housing starts grew in the September quarter compared to the June quarter and are significantly higher compared to year-ago levels.
Retail sales for home furnishings increased 9% in the current September quarter, compared to the year-ago September quarter and rose 2% compared to the June quarter.
Retail inventory days in the home furnishings segment were at 102 days at the end of September quarter, and this marks their lowest level in our rolling 5 years of tracking.
The automotive market in the U.S. continued its strong year-over-year performance with sales increasing 14% and production increasing 15% in the September quarter, compared to the prior year quarter.
However, compared to the June quarter, August sales declined 4.6% and production was down 8%, which reflects the normal seasonality trends typically seen in this segment.
Turning to our global business. The exchange rate for the Brazilian real was slightly above BRL 2.0 to the U.S. dollar for the September quarter, which compares to a 1.63 average in the year-ago quarter.
The stabilization of the real, which has been near or above BRL 2.0 to the U.S. dollar since May, has helped stabilize our volume in Brazil.
Although the currency rate favors domestically produced goods, we are still facing stiff competition from imported fibers, fabrics and finished garments in Brazil.
We continue to see slow growth of retail sales of apparel in Brazil, which is projected at 1.8% for calendar 2012. However, domestically produced garments in Brazil are projected to decline by 11.5% in 2012.
Imports of not only finished garments but polyester yarns as well continue to put pressure on our volumes and margins in Brazil. We are countering these trends with an aggressive mix enrichment strategy along with continuous process improvement in manufacturing efficiency gains to lower our costs and remain competitive with these increasing commodity imports, especially the textured yarn imports.
Turning to the North American region. Our customers remain committed to their sourcing strategies in the region, and we continue to see indications that CAFTA will remain a key supply base for U.S. apparel with more opportunities for growth.
In calendar 2012, the North American region is projected to hold share for the fourth consecutive year at approximately 18%.
Turning to China. We had expected 2 of our larger customers to return to the market in the September quarter. One customer did return while the second customer did not as they continue to work through inventory issues throughout their supply chain. Fortunately, some of our development projects came online during the September quarter, which made up the volume shortfall attributed to this customer.
The new volume that we picked up from these new programs was at a lower average price, which also has a lower margin and, therefore, negatively impacted our overall margins.
Our outlook for China remains positive, particularly since we expect the other large customer to return to the market. We anticipate that we'll be running close to budget expectations in China in the second half of the 2013 fiscal year, and we remain encouraged by the projected growth in the region, especially for our PVA products.
Our PVA strategy in Asia continues to be an important factor in our downstream efforts with brands and retailers as we work with them to develop programs that incorporate our premier value-added yarns.
Looking at Central America. We continue to be satisfied with the performance of our operations there. We recently completed the installation of the additional texturing capacity at UCA, and we are currently running our DTY capacity near full utilization.
In addition, a bill was passed in Congress on August 3 that provides a technical correction to the sewing thread provision in the United States-Dominican Republic-Central America Free Trade Agreement. The amended legislation, which took effect on October 13, will close a loophole that allowed for the use of non-originating sewing thread in the assembly of textiles and apparel under the DR CAFTA agreement.
The technical modification clarifies that single or -- that single-ply synthetic sewing thread is required to be produced in the United States or the CAFTA-DR region in order for goods to qualify for preferential tariff treatment.
All other sewing threads already enjoy the benefits of yarn forward rules of origin under the free trade agreement.
The passage of this bill is important to Unifi and our operations in Central America as it will likely result in improvements to our twisted and sewing thread volume and business in UCA.
As you know, 2 years ago we set a goal to double our global PVA sales within 3 years, but we projected on our quarterly earnings call in July that it would likely take 3.5 to 4 years based on the economic conditions in China and Brazil. We remain on the path to meet that goal, which translates to a 20% average annual growth rate for our PVA products.
Once we achieve this goal of doubling our PVA volume, we will continue our focus toward improving the total share of PVA sales within our complete portfolio of products, which currently stands at approximately 20% of consolidated revenue. We feel confident that we can continue our growth, our global PVA sales 15% to 20% annually, and that this growth will drive overall product mix enrichments for the company, which will result in PVA products representing a larger share of our overall sales volume.
Raising the visibility of REPREVE continues to put us in a position to develop programs with many of the world's leading apparel brands. For example, we are very excited by programs being developed for 2013 by Lee, Dockers, Savan [ph], Dickies, Eddie Bauer and IZOD. We are also looking to build more consumer awareness for REPREVE, and we are in final negotiations with ESPN to be a major sponsor of the Winter X Games, which targets the lucrative 18- to 34-year old consumer base.
The X Games will take place in Aspen, Colorado, from January 24 through the 27, 2013, and this REPREVE brand sponsorship has the potential to reach over 57 million consumers.
Finally, polyester raw material pricing in the September quarter continued to moderate from a year-ago levels, coming down from their highest levels in more than 30 years over the 9 months ending June 2012.
As this moderation in polyester raw materials costs worked through our inventory, we realized a quarter-over-prior-year-quarter improvement in the company's gross profit, up 350 basis points as we recovered lost margins.
We did, however, see polyester raw material prices begin to move upward again in August and September, and we expect this upward movement to continue as demand for PX and PTA improves as capacity tightens for PX and MEG around the globe.
Our adjusted EBITDA results in the December quarter will likely be impacted as we implement price increases and recover margin in this rising raw material environment over the next 1 to 2 quarters, and Bill will comment more on this in a few minutes.
One additional challenge that we continue to face is the gap in polymer pricing between the U.S. and Asia, which has actually increased to $0.11 per pound in the September quarter from $0.09 per pound in the prior year September quarter, even as raw material prices have moderated.
This anomaly can occur based on the fact that Asia's PTA pricing is market-driven, while it is formula driven in the U.S.
This gap, which was only $0.05 per pound in the September 2010 quarter, puts additional pressure on our volumes and margins, particularly at the lower end of our product line as we compete with DTY imports at low prices. We are seeing added pressure on this segment for ourselves and volume projections for the second quarter.
With that as a backdrop, I will turn the call back over to Ron.