Mark W. Kowlzan
Chief Executive Officer at Packaging Co. of America
Thank you, Josh. Good morning everyone and again thank you for participating in Packaging Corporation of America's third quarter 2021 earnings release conference call. I'm Mark Kowlzan, Chairman and CEO of PCA and with me on the call today is Tom Hassfurther, the Executive Vice President, who runs the Packaging business and Bob Mundy, our Chief Financial Officer.
I'll begin the call with an overview of the third quarter results and then I'll be turn the call over to Tom and Bob, who will provide more details. After that, I'll then wrap things up and then would be glad to take questions. Yesterday, we reported third quarter net income of $251 million or $2.63 per share, excluding the special items, third quarter 2021 net income was $257 million or $2.69 per share compared to third quarter 2020 net income of $149 million or $1.57 per share. Third quarter net sales were $2 billion in 2021 and $1.7 billion in 2020. Total company EBITDA for the third quarter excluding the special items was $464 million in 2021 and $323 million in 2020.
Third quarter net income included special items expenses of $0.06 per share primarily for certain costs at the Jackson Alabama mill for paper to containerboard conversion related activities while last year's third quarter net income included special items expenses of $0.11 per share that were related primarily to the impact of Hurricane Laura on the DeRidder, Louisiana mill.
Details of all special items for the third quarter of 2021 were included in the schedules that accompanied the earnings press release. Excluding the special items, the $1.12 per share increase in third quarter 2021 earnings compared to the third quarter of 2020 was driven primarily by higher prices in mix of $1.58 and volume $0.62 in our Packaging segment. Higher production volume of $0.06 in prices in mix of $0.05 in our Paper segment and lower non-operating pension expense $0.03 and lower interest expense $0.01.
The items were partially offset by operating costs, which were $0.84 per share higher, primarily due to inflation-related increases, particularly in the areas of labor and benefits expenses, recycled fiber costs, energy, repairs, materials and supplies, as well as several other indirect and fixed cost areas. We also had inflation-related increases in our converting costs, which were $0.10 per share higher.
For the last several quarters, freight and logistics costs have risen, and were $0.23 per share higher compared to last year, driven by significant increases in fuel costs, tight truck supply, driver shortages, and the higher mix of spot pricing to keep up with box demand. And finally, scheduled outage expenses were $0.04 per share higher than last year. And sales volume in our Paper segment was lower by $0.02 per share.
Looking at the packaging business. EBITDA excluding special items in the third quarter of 2021 of $467 million with sales of $1.8 billion, resulted in a margin of 26% versus last year's EBITDA of $324 million with sales of $1.5 billion and a 22% margin.
Packaging segment demand remained strong and the teams did a tremendous job of implementing their previously announced containerboard and corrugated products price increases. The containerboard mills set an all-time quarterly sales volume record and our box plants set new third quarter record for total corrugated product shipments, as well as shipments per day.
By utilizing the capability of both machines at our Jackson Alabama mill to produce containerboard, we were able to reach our desired inventory levels to better serve our customer demand, help minimize the transportation challenges we continue to experience, and build some inventory ahead of the DeRidder mills fourth quarter outage.
We manage very effectively, the execution of numerous initiatives and capital projects to reduce cost through efficiency, productivity, and optimization improvements across our manufacturing locations.
We continue to put tremendous effort into managing certain material, equipment, and labor availability issues to keep our customers supplied and their needs and their capital projects on track.
With no relief from the supply chain obstacles that we, our customers, and our suppliers continue to face along with unprecedented inflation-related challenges, the combination of all of these efforts are critical to our success going forward.
The improvements in execution our employees deliver constantly across many fronts is what allows us to continuously improve margins. After successfully completing the planned maintenance outage at the Jackson mill during the third quarter, the mill restarted with the number 1 machine making corrugated medium rather uncoated freesheet grades, utilizing a mix of Virgin Kraft and DLK fiber based on the needs of our customers. This was required to help meet continued strong demand from our box plant customers, meet our targeted inventory levels prior to year-end, and help supply the needs of our box plant acquisition that we anticipate acquiring later this quarter.
Similar to the number 3 machine at Jackson, the smaller number 1 machine is highly efficient. It's a versatile machine and with minimal capital required to repurpose a deinking plant to handle DLK. The machine was very quickly able to produce high-quality medium for the box plants. Although still capable of producing uncoated freesheet products, we plan to continue producing medium on the machine over the next several months as our internal and external packaging demands warrants. This gives us the opportunity to further evaluate the machine's capabilities and to process -- and process changes that might be required to potentially produce medium permanently in a cost-effective manner.
We'll also use the period to further refine our estimates and assumptions to fully understand the potential of the entire mill to produce containerboard on both machines at their optimal cost and quality. This will also allow us to evaluate our strategic containerboard supply capabilities for providing the necessary runway to grow our Integrated Downstream box demand.
We are committed to being fully integrated and we have a track record of ramping up our internal capacity according to our customers' demand requirements.
The previously announced conversion of the J3 machine to linerboard remains on track with no changes to the schedule we discussed on last quarter's call.
We will continue to serve our paper customers with both machines at our International Falls mill, which is capable of producing all of Jackson's paper grades as well as available inventory produced on the number 1 machine at Jackson.
I'll now turn it over to Tom, who will provide further details on containerboard sales, our corrugated business, and the box plant acquisition that I mentioned.