H&E Sod Nursery, a third-generation sod farm based approximately 40 miles south of Chicago, has reported significant improvements in product shelf life, sales performance, and inventory efficiency following the adoption of vacuum cooling technology supplied by Weber Vacuum Cooling Group.
The farm, which has been in operation since 1947, currently manages over 900 acres of turf production and supplies a variety of clients, including landscape contractors, golf courses, and major retailers such as Home Depot and Lowe's.
Operational background
President Darin Habenicht, who oversees the day-to-day operations, explains that the decision to implement vacuum cooling came as a response to challenges associated with product perishability and the demands of vendor-managed inventory systems.
"We sell a perishable product, and under vendor-managed inventory, we're only paid for what passes through the register," he says. "That means shelf life directly impacts our bottom line."
Traditionally, rolled sod generates heat through microbial activity shortly after harvest, particularly in warmer months, leading to reduced shelf life. In some cases, the product may be unsellable within hours.
© H & E Sod Nursery
On the left are loaded vacuum coolers. On the right are measurements of temperature after 48 hours outside: 74 degrees F
Cooling technology and process
The Weber vacuum cooling system installed by H&E Sod allows the farm to cool 16 sod pallets from over 100°F down to 33°F in under an hour. According to Darin, this process extends the viable shelf life of sod from hours to several days, particularly during peak summer temperatures.
"We started testing the system in July last year and shut it down at the end of October. In that period, we cooled 2,257 pallets," he shares. "This year, we've already cooled 3,310 pallets and expect that number to grow, with several weeks remaining in the season."
He notes that depending on the end-use, the sod is cooled to different temperatures. For retail garden centers, pallets are cooled to 33°F to maximize shelf life. For contractor deliveries, where the sod is laid within 24 hours, it is typically cooled to around 60°F.
Sales and performance metrics
Since integrating the vacuum cooling process, H&E Sod Nursery has reported notable year-over-year improvements in both pallet sales and sell-through performance. In the 2024 season, the company shipped a total of 1,672 pallets and sold 1,079.46 of those, resulting in a sell-through rate of 64.5 percent. So far in the 2025 season, shipments have increased to 2,018 pallets, with 1,505 pallets sold, raising the sell-through rate to 74.56 percent.
The increase in sell-through rate represents a gain of over 10 percentage points, with an additional 425.5 pallets sold compared to the previous year. The farm estimates this equates to approximately $119,500 in additional revenue from box stores alone, and potentially $150,000 when accounting for other garden centers.
"My sell-through rate at Home Depot, for example, went from 66% last year to 76% this year. Some stores are even in the low 90s."
Waste reduction and customer feedback
The improved shelf life has also led to a reduction in waste, particularly at retail locations. In 2023 returns to Home Depot/Lowes was 4.82% we sold 97.4K units that year. Last year sales where down 75.5K units sold but returns fell 3.71%. Currently we have sold 105.5K units and returns have dropped to 3.09% over 1300 less units returned vs 2023.
"At the Landscape supply centers, waste is almost non-existent. We're still seeing some returns at Home Depot, but overall, waste is significantly lower."
He also notes that for specialty products, such as bentgrass used on golf courses, the cooling process contributes to reduced transplant stress and improved rooting success.
In addition to the cooling process itself, H&E Sod has adjusted its harvest and delivery schedule to optimize labor and product handling. Rather than cutting sod during early morning hours, the team now harvests in the afternoon, cools overnight, and delivers in the morning.
For more information:
Sylvia van Uden, Sales Director
Weber Vacuum Group
Tel.: +31 612 819 917
[email protected]
www.webervacuum.group
