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Turfgrass production: an avenue for farmer's prosperity

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 Advances in Floriculture and Landscape Gardening

23.
Turfgrass production: an avenue for farmer’s prosperity
S L Chawla, Roshni Agnihotri, Sudha Patil and R A Gurjar

I ndia has been bestowed with wide range of climate and physio-geographical conditions and as such is
most suitable for growing various kinds of horticultural crops especially ornamental crops of all kind in
one area or the other. Increasing urbanization, raised standards of living has resulted into rapidly growing
domestic market of landscaping industry. Among ornamentals, most important soft-component is lawn, i.e.
heart of the garden. Turfgrass provides a forgiving and resilient surface for many recreational activities and
is the traditional “green carpet” visitor’s associate with parks. Sod is also effective in increasing cooling
of surfaces, improving air and water quality, and assisting in flood prevention by draining water. It is the
same plain old ordinary sod, the kind a great number of golf courses, nurseries, landscape contractors, and
private parties are always eager to buy.

A vital aspect in any business venture is profitability potential thus sod production is no exception to
that. With a growing suburban population, demand for sod remains strong. Grass can really and truly
be a cash crop that does pay USA farmers over $6,000 an acre. Turfgrasses are ubiquitous in the urban
landscape round the world and turf industry is a consolidated sector of the economy in some countries
such as USA, China, Australia, UK, Netherland and Denmark. Globally, this industry is serving more than
700,000 athletic fields, over 17,000 golf courses. The turfgrass industry is expanding all over the world
and has annual associated revenues in excess of $ 20 million each year. Currently, in the USA, there are
more than 62 million acres of maintained turfgrass including lawns, parks, golf courses, highway, etc. For
2009, the United States Department of Agriculture reported 1,412 farms had 368,188 acres (149,000.4 ha)
of sod in production. The total number of international cricket grounds in India is 46, more than 500
domestic cricket grounds and athletic fields are also in operation. According to the scarce data gathered
by golf associations, sports experts and Association of Indian Nurserymen, turfgrasss industry covers
more than 30,000 acres, in which around 4,500 acre is under turfgrass cultivation and sod production.
Ganu Farm Group, the largest sod producer and supplier of India, having an area of 300 acres under high
quality turfgrass production. Indian turfgrass industry is growing at the rate of 10 per cent annually. Due
to varied agroclimatic conditions in India, abundant sunlight and water, availability of skilled and semi-
skilled labour as well as technical knowhow, sod production business can prove to be a boon to farmers.

WHAT IS SOD?

Sod or turf is grass and the part of the soil beneath it held together by the roots, or a piece of thin
material. Turfgrass sod is a mature grass cover, which is produced, in an intensively managed agricultural
operation. It is removed intact with a minimal amount of soil, transplanted in another area and instantly
forms a grassy turf cover. In British english such material is more usually known as turf, and the word
“sod” is limited mainly to agricultural senses (for example for turf when ploughed). Sod is grown on
specialist farms. The farms that produce this grass may have many varieties of grass grown in one location
to best suit the consumer’s use and preference of appearance.

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Why Sodding?

Sodding is the most commercial component in this context which is in high demand due to its fast
establishment and increase in cost of living index in most cities. As the people residing in the cities are
becoming conscious of their health and greenery. Turfgrass industry has opened up as a money spinner
industry for sod farmers and nursery men all across the country due to higher returns in per unit area as
compared to other horticultural crops and tremendous demand in domestic as well as international market.

Many prized cultivars (such as tifdwarf) only reproduced by vegetative means (not via seed) and there sod
cultivation is the only means of producing additional plants in less time. Sod protects land from wind and
water damage thus making it is valuable for erosion control. There is a decreased chance of installation
failure in sodded sites than of those seeded. Seeding is restricted to certain periods of the year whereas
sodding can be done any time in the growing season. Locations that are sodded with turf require irrigation
for a shorter time after planting than those seeded sites. In sodded area, there should be no need to apply
herbicides for weed control for up to 2-4 years. Mowed grass discourages rodents, snakes, ticks and other
pests from habituating, as they prefer longer more protective areas. Sod also serves to enrich soil as their
extensive root system decays to form humus. There are other health benefits associated with sod. Turfgrass
reduces high temperatures by natural transpiration cooling. Turfgrass absorbs pollutants such as carbon
dioxide from the air and traps dust and dirt with organic chemicals from the atmosphere. Photosynthesis
occurring in the lawn releases a large quantity of oxygen into the atmosphere. A decrease in weeds will
help to control pollen, which causes allergic reactions. Lush green turfgrass serves as a playing area for
recreation. Turfgrass creates a beautiful environment that may contribute to increased real estate value.

PRE-REQUISITES FOR TURF BUSINESS ESTABLISHMENT

Selection of Site

One of the greatest obstacles in the planning phase of building a sod operation is finding a production site.
There are numerous factors to consider when starting sod production viz., ideally, the location should be
close to market because sod is a perishable product thus does not live for very long once harvested. Quick
delivery is another bonus of being located close to target market. Typically, a rule of thumb of 100 miles
or closer is used when selecting a site for sod production. Another important factor is accessibility to
major roads and highways for improving economic efficiency by reducing transportation costs. As a sod
farm, producer’s reputation will be built upon being able to deliver great sod consistently that is durable,
adaptable and will stay strong.

Soil, Water and Other Factors

Several agronomic factors should be considered viz., soil type, drainage and availability of quality water,
levelling and the development of an efficient irrigation system. When considering soil type, depth of the
soil and the uniformity in soil depth within a field needs to be considered besides optimum pH, EC and
available nutrients. Harvesting is very difficult on sod that is grown on heavy ground or clay because
it gets too heavy when it is wet and too hard when it is dry. Thus, the best soil is sandy or sandy-loam/
alluvial soil. The quality of soil is a determining factor. Sod farms need to have soil that is rich enough
to be able to grow a wide variety of different grasses. It is possible to improve the quality of the soil over
time by infusing it with compost and other nutrients, but that is a process that takes time. So starting out

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with a rough patch of land and then correcting it may not be the best solution. Land topography should be
flat to no slope because erosion of the seeds and seedlings can occur on sloped soils. Not only does the site
need to provide good nutrient balance, it also needs to have good soil and surface drainage.

Adequate drainage reduces the potential for disease and weed infestation. By avoiding disease and weed
problems, one is also avoiding additional input costs such as fungicides and herbicides. By limiting input
costs, ultimately profit potential is being increased. Need for tile drainage and drainage ditches should be
considered. The presence of a perennial source of water is must and if a natural body of water (such as a
lake) is not available or does not provide adequate water, additional methods would be necessary to ensure
available water. Ensuring sufficient quality water supply is essential from an economic and production
standpoint. By choosing a site with regular supply of quality water means protecting the business against
unforeseen obstacles such as drought, etc. If drought happens to sod business, then one can lose cash with
every dead blade of grass. That’s why every sod farm needs some form of backup irrigation with quality
water.

Initial Investment and Start Up Cost

A sod farm start up takes a lot of capital investment. The highest cost is incurred in land and procurement
of equipment for the sod farm. Some specialized equipments are needed for timely delivery to customers.
The equipment minimally necessary to operate on sod farm iare sod cutter, tractor, plough, planting drill,
mower, roller, fertilizer spreader, skid steer loader and delivery vehicle. General sprinklers for irrigation
and other related equipments are also needed. One also needs a good skilled/semi-skilled labour force.

Establishing Markets

Is there any demand for sod in particular area? Some market research is necessary before just start growing
some grass out in a field somewhere. Is there enough new construction available to warrant a sod farm?
Are there numerous professional sports stadiums nearby that use natural grass as their turf? Do certain
varieties of sod respond better to the natural conditions of local climate than others? These questions
need to be asked where one is planning to set up a farm. By answering all of these questions, one is able
to get the research data which depicts if a sod farm is even a viable business opportunity in proposed
area. Another very important aspect to consider when planning a sod farm is who exactly is going to be
buying the produce? Sod marketing is different than marketing of traditional agronomic crops because
there is no guaranteed market for sod. Producing a quality sod at a relatively low cost does not always
ensure profit. The relationship between economic success and consumer demand for sod are positively
correlated. Thus, when demand goes up the chance for economic profits go up. However, when demand
goes down, so do profitability chances too. Landscapers and real state contractors make up the largest
portion of sod consumers by accounting for 70% of total sod sales. By networking and finding markets for
sod, ultimately one may maximize profit potential by securing a market share in particular region.

Marketing to a Specific Niche

It’s better to focus on a specific niche than all potential sod customers because it’s a more effective way
of being able to show off sod growing expertise. Many sod farms begin with marketing efforts that are
directed to the home owner and some make good contacts with stadiums/parks. The decision made here
should be based on potential profitability and market size for the niche.

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Others

When considering starting a sod operation, often there are issues that get overlooked. A very intense
management is required to run a sod enterprise and deliver the product in good quality, quantity as well
as given time-frame. A manager of a sod operation should have a good knowledge of irrigation schedule
and its rate, nutrition; weed control, pest and disease management, turf machinery as well as good
business sense. If one of these aspects gets overlooked, it could lead to potential financial losses. Another
consideration that should be taken into account is establishment time for both the turf and the operation.
Like any other agronomic crop, turf takes time to establish itself. Thus, it is not profitable immediately
after it is planted. Likewise, the sod operation is not immediately profitable as a business. It takes time,
effort and resources to establish a successful marketing scheme. Establishing a successful marketing
scheme will eventually lead to the development of a client base and repeat customers.

SOD PRODUCTION BASICS

Because turfgrass varies substantially in use, so do turf management practices. Below are some of the
common practices utilized in sod production:

Planting:

The end product quality depends on many preliminary factors like planting material (best variety in
demand, purity of seeds, seed quality), planting season and suitable planting technique (seeding/sprigging/
plugging). A well-prepared seed bed is critical to commercial sod production by seeding. The field should
first be cleared and then smoothed to eliminate high spots and depressions. Fields are typically ploughed
and disked to reach fine tilth, then firmed with a corrugated roller. Prior to seeding fields must be cultivated
and tilled to 20-25 cm. Remove stones at seedbed preparation to a minimum depth of 4 inches. Soil tests
are conducted to determine pH (limiting or acidifying the soil) before turf establishment. Lime can be
applied to the soil to increase the pH to 5.5-6.0 on organic soils and 6.0-6.5 on mineral soils. Ensure that
the site is well drained, as excess water will cause problems and delays. The field should be free from
weedy perennial grasses such as quackgrass, bermudagrass and nut sedge, etc. prior to seeding. Grading
of the seedbed must be done to ensure the seedbed is as smooth as possible and to remove all debris
and objects which interfere with seeding and harvesting. A culti-packer is used to level the soil. The
preparation of a level of land immediately prior to seeding to remove micro-depressions will reduce the
depth that the cutter bar on the harvester must be set at to avoid scalping during harvest. Working with
dry soil prevents soil clumps or crusting of the surface layer. Seeds are planted with dibblers cum seeders,
which places the seeds at the appropriate depth and rolls and packs soil around the seeds.

Seed germination time varies with species and conditions but ranges between 1-2 weeks. A uniform seeding
is essential. Planting operations will vary with the equipment available. Culti-packer type seeders are the
most widely used means of seeding since the seed is placed at a shallow depth and firmed by rolling in a
single operation. Adequate contact of the seed with the soil cannot be over emphasized. The seed can also
be broadcast, mixed lightly into the soil and rolled. However, this requires additional labour and is not
practical for large acreages. Machines with large flat tyres or flotation operations are desirable because
they eliminate tracks from truck tires that interfere with seeding and harvesting. Large width tyres provide
low ground pressure necessary to decrease compaction when working on new seedlings and netting.

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The best time to seed cool season turfgrasses is in late summer and early fall while monsoon/spring is
good for warm-season grass. Seeding during spring face an increase in competition from weeds and
annual grasses. There are also stresses from moisture and temperature. Uniform stands are more difficult
to achieve this way. Some sod producers have been able to improve sod strength and reduce production
time from seeding to harvest by installing netting immediately after planting. Tall fescue and Cynodon
turf can be harvested in 6 months after seeding when netting is used, whereas Kentucky bluegrass/Zoysia
turf may require 12 to 18 months to harvest. Sprigging is a method where recently harvested sod mats
are cut into slender rows and replanted in the field. It is advised not to settle for cheap grass seed because
there are usually plenty of weeds and impurities that come up with the sod. Use of a grass seeder instead
of hand spreading, the seeds yield more consistent results.

Selection of Species/Variety

There are many species used for sod production. The selection of the turfgrass species is dependent on
the particular species or variety, market demand and the adaptation to the environment where the sod will
be planted. There are two types of grasses, viz, warm season and cool season. Cool season turfgrasses
are grown in temperate areas, viz., Himachal Pradesh, Jammu and Kashmir, etc. Cool season turfgrass
varieties can be grown alone as well as in mixture of 2 or more varieties called blend which ensures high
adaptability. Warm season turfgrasses are mainly required for most of the metro locations all over India
as they cover tropical and subtropical areas.

Kentucky bluegrass (cool season): Vigorous rhizome development and its broad adaptation to cool,
humid environmental conditions. It is for use in sunny to slightly shady locations however Kentucky
bluegrass is susceptible to powdery mildew causing thin patches to form in shady areas. Excellent
colour and texture make it a high quality turf for residential lawns, golf courses, sports fields, office and
commercial lawns.

Creeping bentgrass (cool season): It is a fine textured, very dense, low growing species. There are high
maintenance costs associated with mowing and disease control. It is mainly used for putting and bowling
greens, fairways and tees.

Perennial ryegrass (cool season): It is a medium textured, shiny leafed, moderately fast growing species
that exhibits good wear tolerance but lacks cold hardiness. This species is usually found on lawns, sport
fields and fairways.

Fine-leaved fescues (cool season): It are very fine and less attractive. These include creeping red fescues,
chewing fescues, hard fescues and sheep fescues. These are shade-adapted, drought tolerant and ideal for
low maintenance situations.

Tall fescue (cool season): It is a course textured, drought resistant and wear tolerant species. It has
weak sod forming characteristics due to lack of adequate rhizome development therefore it has a longer
production period and requires that a greater amount of soil be removed during harvesting to facilitate
moving. When damaged, it is non-recuperative. For use in sports fields and low maintenance areas that
are mowed at a higher height.

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Weeping alkaligrass (cool season): It is a salt and alkaline pH tolerant species

Bermudagrass (warm season): Most commonly used grass cover for golf courses and sports fields across
India. It tolerates a wide range of climates. Established bermudagrass form a dense plant canopy. The
aggressive and resilient nature makes it an excellent turfgrass. Its one noted weakness is shade tolerance.

 Selection 1/ Calcutta doob Bermudagrass

It is a light green, fine textured, aggressive and traffic-tolerant cultivar with drought tolerance.
 Tifdwarf

It is a dark green, very fine textured, highly dense cultivar with good recuperative potential. It one of the
most commercially used turfgrass cultivar in golf green and tee for golf courses in India. It is a very good
cultivar for sports field also.

St. augustine grass (warm season): It is warm season, perennial grass tolerant to salty water. It has wide
bladed (coarse) and ash green colour and does not handle cold weather very well. This grass is planted
vegetatively (plugs, sod) as seeds are not usually available commercially each season due to production
difficulties.

Centipedegrass (warm season): It is a low maintenance grass, which retains its color in the harsh
winters and greens quickly in the spring.

Carpetgrass (warm season): Axonopus compressus is a broad leaved species of grass. It is often used
as a permanent groundcover and turf in moist, low fertility soils, particularly in shaded situations. It is
generally too low-growing.

Establishment and Maintenance

When producing sod, the turf growers primary concern is to develop sod by enhancing root and rhizome
development and stolon growth. The quality of the above ground portion of the sod is a concern to turf
growers, but is less than that of the below ground portion. When selecting a turfgrass, choosing a species
that has good root development for efficient, early sod cutting is a key-point to remember. Irrigation is
very important in sod production as it supplements natural precipitation and increases sod production. EC
of water should be less than one while pH should be 6.5-7.0. The quantity depends on the soil texture,
natural precipitation potential evapo-transpiration and the rate of grass growth (up to 24 inches water per
season). Excess moisture will lead to stresses such as a lack of oxygen for rooting, an increase in weeds
and diseases and increased difficulties in mowing. High salts in water may inhibit plant root water uptake,
therefore increasing production time for a crop. Frequent irrigation at low rates is common during the
establishment of the sod but as it matures less frequent applications at heavier rates are preferred. Mowing
of sod starts the following spring after seeding or as soon as it can be cut. Many growers use gang mowers
and some wide rotary mowers.

Mowing the grass encourages the root system to spread through the rhizomes and eventually produces a
mat of roots tough enough to harvest is formed. Turf should be mowed every 4-5 days to promote lateral
growth of the shoot extensions and therefore induce root knitting. For hybrid bermudagrass, mowing
should be every 2-3 days. At the time of mowing, not more than one third of the plant is removed. The
preferred heights for different species are different. If mowing is delayed due to rain or other circumstances,

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clippings from the grass may need to be removed. Before harvesting older sods, vertical mowing the turf
to remove dead plants and clippings is necessary. Fertilization recommendations vary with different soil
and sod varieties. Nitrogen is the main maintenance fertilizer applied except in areas where nutrients
are found to be limiting. The application of nitrogen is important to ensure rapid growth and proper sod
formation. Most nitrogen is applied in spring and fall, depending on the time of seeding. Light rates
are applied throughout the summer as needed for maintenance and to enhance colour before harvest.
Phosphorus and potassium fertilizer rates should be determined by a soil test. To correct the heaves and
depressions surface levelling by rolling must be done three to four times per year. Herbicides should be
applied early in the harvest cycle to control weeds. Disease and insect damage is less common in sod
production.

Cropping Cycle

The average turnover for turf is 1.5 - 2.5 years depending on climate and the intensity of management;
however it is possible to harvest only after 8-12 months of seeding. The peak demand for sod supply is
from April to May in India. To decrease cropping time, select a quick knitting cultivar.

Sod Quality

High quality sod should possesse uniformity, good density, free from serious pest, diseases and weeds.
Also has acceptable colour, adequate sod strength for handling, sufficient maturity in terms of carbohydrate
reserves. Rhizome or stolon development is the most important factor in sod strength and sod rooting
capability with minimal amount of thatch.

Sod Harvesting and Shipping

Sod is ready to harvest as soon as the rhizomes and roots have developed and knitted enough to permit
handling the sod pieces without tearing. The sod should be moist but excessive moisture should be
reduced to avoid excess weight and therefore excess shipping costs. Sod cutters cut sod to 30, 45, 60 and
100 cm width generally. The thickness of the sod removed depends on the turfgrass species, the type and
uniformity of the soil and the development of the rhizomes and roots of the sod. Thin cut sod is easier to
handle and will root faster than thick but the thicker sod offers more resistance to drought than the thin
sod. Poor sod density must be cut thicker to facilitate handling and to compensate for the lack of sufficient
root development. It is better to harvest between 6 - 8 am and when the soil temperature is minimal

Equipment for sod cutting comes in different widths. Each unit cuts one square meter and mechanically
rolls the sod. The actual cutting is done using a sod harvester, which attaches to tractor. The harvester has
two blades. The first cuts at an angle into the ground to lift the sod out of the dirt. The second cuts straight
up and down at intervals, separating grass slabs. The cut grass travels up a conveyer belt where two
operators stand on a platform and stack the grass slabs on a pallet. An operator in front drives the tractor
and keeps the harvester from drifting off course. Once a pallet becomes full, it is dropped onto the ground
and a new one is carried over to replace it. The full pallet is picked up by a forklift which carries from the
field. Pallets are then loaded on trucks. It is usually harvested 10 - 18 months after planting, depending
on the growing climate and variety or species. It is harvested using specialized equipment, precision cut
to standardized sizes. Sod is typically harvested in small square or rectangular slabs, or large 4-foot-wide
(1.2 m) rolls. A new innovation is the use of the Big Roll harvester or the Palletless Brouwer system. The

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big roll allows one to harvest 60 cm wide strips. Because of decreased labour costs in this method, big
rolls can bring in a higher profit. Big roll sod is often used in sports fields and other large sodding jobs.
Netting can be incorporated under the sod as it is being harvested to allow for the harvesting of young or
weak turf. Sod is then placed in a truck for transportation to consumers. It is covered with a damp canvas
to reduce drying during shipment.

Shelf Life

In hot weather sod must be laid within 12 hours before it is dried by the heat. Transplanted sod will also
die if there is an insufficient supply of water. Several factors can increase sod heating such as a high
soil temperature at harvest time, a high nitrogen fertility level, excessive irrigation and the presence of
clippings.

Soil Loss during Sod Production

The amount of soil lost at harvest varies depending on the time of harvest, soil type and moisture content.
According to research done at the University of Guelph (TPIC), 1 cm of soil is removed at harvest. 9.4
mm of soil and 8.5 mm of thatch was associated with the soil removed in the sod roll. Many sod growers
grow carrots and potatoes in rotation with sod to manufacture soil. After harvesting, many roots remain in
the soil and are tilled under. Soil scientists have studied soil loss during sod production and concluded that
commercial turfgrass production will not deplete topsoil. Their findings showed that turfgrass actually
improves farmland by adding organic materials and nutrients to the soil. They also stated that the turfgrass
opens up the soil to accept greater amounts of moisture and reduces water and wind erosion of the soils.

Advances

The Mississippi State University has developed a hydroponic method of cultivating sod. For the very
few sod farms that export turf internationally, this soil-less sod may travel both lighter and better than
traditional sod. Additionally, since the sod is not grown in soil, it does not need to be washed of soil down
to the bare roots (or sprigs), so time to export is shortened.

CONCLUSION

A sod operation requires intense management, capital outlays as well as a good business sense. There
are numerous risks associated with sod production. However, by minimizing input costs and producing
a quality product, a well-managed sod operation in the right economic environment has the financial
efficiency to stand on its own.Create a business plan for your sod farm business. Details of the expenses
for getting the business open, as well as the costs of operating. Consider how much profit you expect to
make in the short term, as well as the long term. Factor in where the investment capital for the land and
equipment is going to come from and the costs of interest. With this information in hand, it is easier to
approach a financial institution for a loan if you need one.

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