How to get him: you craft him
Yes, if you craft HumanTestSubject, RigellianQueen, RigellianShrub, SpookyWalls, RigellianHuts, PumpkinHouse, peacock, DonutTortureDevice, Bulldozer-saurous or the Hover-copter it will reduce your total ingredients.
For Hugo you need: 300 Broken Fences, 300 Rotten Eggs and 250(?) CandyCorn.
On the weekend you can buy Candycorn in the shop and you can always buy bronzebags (that is guaranteed to contain a fence and an egg). You can also choose "get it now" when you have no bags left to open - this will reduce your ingredients as well.
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D'oh! - Em