coco sugar

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MANUAL ON THE PRODUCTION OF COCONUT SUGAR MS. PEYANOOT NAKA Senior Scientist Horticulture Research Institute Department of Agriculture Chatuchak, Bangkok 10900 Thailand Tel: 662-9405484-5; Fax: 660 -5614667 Email: [email protected] [email protected] International Plant Genetic Resources Institute (IPGRI) Regional Office for Asia, the Pacific, and Oceania Serdang, 43400 Selango r Darul Ehsan, Malaysia September 2003

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Page 1: Coco Sugar

MANUAL ON THE PRODUCTION OF COCONUT SUGAR

MS. PEYANOOT NAKA Senior Scientist

Horticulture Research Institute Department of Agriculture

Chatuchak, Bangkok 10900 Thailand Tel: 662-9405484-5; Fax: 660 -5614667

Email: [email protected] [email protected]

International Plant Genetic Resources Institute (IPGRI)

Regional Office for Asia, the Pacific, and Oceania Serdang, 43400 Selangor Darul Ehsan, Malaysia

September 2003

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MANUAL ON THE PRODUCTION OF COCONUT SUGAR

Table of Contents

Contents

Page

Introduction 3 Coconut Palm Production and Marketing 4

General uses and export market 4 Areas and suitable varieties 4 Coconut sugar marketing 4 Diagram 1: Coconut Sugar Marketing Flow 5

Illustrative sample of coconut sugar and other products that could be produced from coconut sap

Coconut Sugar Granulated Sugar Coconut Nectar Coconut Toffy Coconut Baking Custard

6

Machineries Tools and Equipment 7 1. Machinery, tools and equipment for coconut sugar making 7

1.1 Tapping and collecting of coconut sap 7 1.2 Coconut sugar processing 8

2. Tools and equipment for making granulated sugar 9 3. Machineries, tools and equipment for producing coconut nectar 11 4. Tools and equipment for producing coconut toffy 11 5. Tools and equipment for producing coconut baking custard 12

Step by step description of the production process 13 Coconut Sugar 13

1. Tapping of coconut sap 13 2. Collecting coconut sap 15 3. Coconut sugar processing 16 Characteristics of coconut for sugar processing 21 Factors affecting quality of coconut sugar 21 Estimated cost and return for coconut sugar production 21

Other products that can be produced from coconut sap 22 A. Granulated Sugar 22

Estimated cost and returns of producing granulated sugar 25 B. Coconut Nectar 26

Estimated cost and returns of producing coconut nectar 28 B. Coconut Toffy 29

Estimated cost and returns of producing coconut toffy 30 D. Baking Coconut Custard 31

Estimated cost and returns of producing coconut baking custard 33 Table 1: List of Coconut Palm Sugar Exporter 34 Table 2: List of Melting Coconut Sugar Plants and Wholesaler 35 Table 3: Wholesale price of coconut sugar in Bangkok per 30 kg. Container (1991-

2000) 36

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Introduction Coconut farmers are suffering due to declining farm productivity and unstable markets for their traditional coconut products which are copra (dried kernel) and coconut oil. Even when the market is stable, farmers which tend an average of one hectare of coconut, earn a gross income of US$150 per hectare per year which is below the poverty line. The coconut farmer cannot afford to invest more in coconut production unless he/she earns more income. Consequently, the coconut industry suffers and coconut production on which about 50 million people depend for their income and nutrition is not sustainable. To address this problem, The International Plant Genetic Resources Institute (IPGRI) and the International Coconut genetic Resources Network (COGENT) is undertaking an ADB- and IFAD-funded research project on "Poverty Reduction in Coconut Growing Communities" to enhance the incomes of coconut farmers and their households under a coconut-based farming systems approach. The project will deploy COGENT's three -pronged strategy which consists of the following components:

a) Promoting on-farm coconut germplasm conservation through the characterization and maintenance of existing farmers' varieties and the introduction of high -yielding, adapted and high-value coconut varieties through community-managed nurseries. This approach could increase coconut farm yields by 3-6 times.

b) Production and marketing of high-value coconut products from the coconut kernel, husk, shell, water, wood and leaves and promotion of varieties suitable for these uses. This could increase the income of farmers by 5-10 times compared to those from copra.

c) Coconut-based Intercropping and village -level livestock and fodder production. This could increase farmers' income by 3 -5 times.

The strategy will be tested in three to six coconut growing communities per country. The project will involve a farmers' participatory approach and special focus will be made on developing and testing coconut-based income -generating activities to make them technically feasible, financially viable, socially acceptable and environmentally safe. Farmers and women members of the community will be directly involved to provide them direct benefits from these income generating technologies, rather than serving their traditional roles as supplier of raw materials from which they derive marginal incomes. Community members will be provided with technologies, skills training, technical experts and revolving funds which can be used to generate long -term capital for the community. The project will be implemented in 15 coconut growing countries worldwide. Each national project will involve 3-6 coconut growing communities, depending on the level of national and external funds genera ted for each country. Each community will consist of 300 -500 households. A national project leader with 50% of his/her time will manage the project in each country while a Community Coordinator devoting 100% of his/her time will coordinate the community activities. The ultimate objective of the project is to develop sustainable coconut-based income-generating technologies involving resource -poor farmers and their households to enhance their income and food security. It also aims to provide economic benefits to the whole community. If successful, the project results will be promoted to replicate the strategy nationwide in each of the 15 participating countries.

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Coconut Palm Sugar Production and Marketing General uses and export market Coconut sugar is mostly used for cooking, desserts, curries and some for raw material of food industries; eg. confectionery. Coconut sugar is made mainly by household industries where coconut is grown. The demand of export market is increasing. The United States of America is the biggest importer of palm sugar, others are Australia, Japan, United Kingdom, France, Canada, Saudi Arabia, Germany, Hong Kong, Netherlands, Malaysia, and others. There are nine coconut palm sugar exporters in Thailand mainly located in Bangkok. They export coconut sugarin boxes, cans and aluminum containers Please see Table1 for names and addresses of these exporters.. Areas and suitable varieties Coconut palms for sugar production are planted mostly in the provinces of Samut Songkram (Ampawa, Bangkon-tee, Muang), Samut Sakorn (Amphoe Ban Paew), Rajchaburi (Amphoe Wat pleng, Pag -toh) and Petchaburi (Amphoe Ban Laem). These Provinces have many rivers and canals, close to the sea, and represent an ideal environmental for coconut growth. There are many varieties of coconut for sugar making. Mostly are dwarf, eg. Moo-sri (yellow,green dwarf) Aromatic coconut (Nam hom, Nam wan) Sawi hybrid No.1 (WAWA) and tall varieties eg. Thale Ba, Suricha and Saibuaw. Coconut sugar marketing The average selling price of coconut sugar in 30 kg. Aluminum container varies from 315.38 baht in 1991 to 390.00 baht in 2000. Please see Table 2 for details. The highest average was in 1995 at 444.50, after which it stabilizes. Various players are involved. Farmers at the household level are producing raw coconut sugar. The sugar are then pick-up by either collector or wholesaler. The wholesaler are passing the sugar into another wholesaler or to collector from Bangkok which in turn are passing the sugar to retailers then to consumers. In other occasions, wholesaler are re-processing them before passing them to another processor and/or collectors in Bangkok or retailers. Table 3 presents list of sugar processors, which are located in Samut-Songkram, The marketing flow of coconut sugar is shown in the following Diagram 1.

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Diagram 1: Coconut Sugar Marketing Flow

Farmer

Retailer in province Wholesaler in province Collector

Consumer in province Melted coconut sugar

Sugar processor

Wholesaler/retailer province

Consumer

Collector from Bangkok

Wholesaler in Bangkok

Collector from province

Wholesaler in province

Retailer in Bangkok

Wholesaler/ retailer in province

Industry

Consumer Consumer Consumer Consumer

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Illustrative sample of coconut sugar and other products that could be

produced from coconut sap

Coconut Sugar Granulated Sugar Coconut Nectar Coconut Toffy

Coconut Baking Custard

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Machineries Tools and Equipment

1. Machinery, tools and equipment for coconut sugar making 1.1 Tapping and collecting of coconut sap

Tapping knife Collection vessel (bamboo or plastic)

Dry bark tree (Kiam or Prayom Bamboo paddle

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1.2 Coconut sugar processing

Pan (700 baht) Fuel

Stirring device (700 baht) Mechanical stirrer (5,200 baht)

Bamboo basket (250 baht) Mould form (5 baht)

Mould form Aluminum container (10 baht/container)

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Economical kiln (4 pans) (25,000 – 30,000 baht or US$625 -750) (US$1=40 baht)

chimney

pans

furnace

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2. Tools and equipment for making granulated sugar Pan (700 baht) Spatula (60 baht) Spatula like fork (70 baht) Aluminum foil or film and paper box

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3. Machineries, tools and equipment for producing coconut nectar

Stainless tank Boiler and bottle-filling machine

Sealer Labelling machine 4. Tools and equipment for producing coconut toffy Spatula, pan and stove

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5. Tools and equipment for producing coconut baking custard Stainless bowl Oven (20,000 baht) Battery type trays Aluminum containers

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Step by step description of the production process A. Coconut Sugar 1. Tapping of coconut sap

Ø the palm is first tapped for sugar when the second spathe emerges Ø when the spathe is 40 cm long , it is gradually pulled down and held in place with

string Ø after about 6 days the spathe should be correctly positioned for tapping Ø the spathe is cut about 6 cm from the tip Ø the sheath is peeled off, exposing the spikiest which are then tied down with Ø string

Step of Production

1.1 Select spathe that is approximately 40 cm long or 1 month old (unopened inflorescence)

1.2 Use tapping knife to cut from the bottom of inflorescence in longitudinal 4 cm length for pulling down and held in place with string

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1.3 The spathe is cut about 6 cm from the tip

1.4 It is gradually pulled down and about 3 mm is trimmed off at every collection (6-7 days)

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2. Collecting of coconut sap Ø sap is collected between 06.00 and 09.00 and again between 15.00 and 1800

every day Ø about 3 mm. are trimmed off at every collection Ø a cylinder of bamboo or aluminium is placed over the end of spathe Ø a single spathe may be tapped for up to one month, and a good variety may have

2 bunches in production simultaneously

Step of Production

2.1 Sap is collected 2 times a day, morning and evening and cylinder of bamboo or aluminum is placed over the end of the spathe

2.2 Single spathe may be tapped for up to one month

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3. Coconut sugar processing Ø after filtering, the sap is poured into a large pan holding about 60 litres Ø this is heated and bring to boil, so that evaporation takes place and the syrup

becomes sticky Ø the pan is taken from the fire and put on the tire wheel Ø slow continuous stirring to cool Ø stir the syrup with the stirring device until it nearly becomes hard Ø pour the sugar into the aluminium container or mould Ø evaporation takes about 2 hours usually between 10.00 and 12.00 daily Ø the ratio between sap and sugar is about 7:1 and yield is about 9 kg/pan.

Step of Production

3.1 The sap is taken to sugar processing plant which has 3 pans

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3.2 Filter before evapora tion

3.3 To prevent over boiling during evaporation, pan is covered with bamboo basket

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3.4 When syrup becomes sticky, take the pan out

3.5 Take the pan out and put on the tire wheel

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3.6 Use stirring device to stir syrup until it becomes hard

3.7 or use Mechanical Stirrer to stir syrup

3.8 Use spatula to transfer sugar to aluminum container

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3.9 or in desired mould forms…

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Characteristics of coconut for sugar processing

1. High concentration of sugar in sap, high yield (4 litre/spathe) 2. Thick and long inflorescence. 3. Produce inflorescence regularly and frequently 4. Soft to facilitate pulling down 5. Strong semi-dwarf trunk.

Factors affecting quality of coconut sugar

1. Cleanliness must be maintained through all stages of sugar production. 2. The spathe must be kept clean to prevent insect infestation. 3. The tools used must be thoroughly washed in hot water. 4. The syrup is filtered twice, firstly when growth from the field and then again when

boiled before evaporation. 5. The sugar is usually marketed in aluminum or zinc container which are filled over

a period of several days ensuring even consistency of the product.

Estimated cost and return for coconut sugar production 30 kg container Average yield per rai per

year Particulars Baht US

Dollar ($1=40b)

Baht US Dollar ($1=40b)

Gross Income Selling price (30 kg/container)

390 9.75 25,070 626.75

EXPENSES labor cost Tapping & collection 116 sugar processing 36 fuel cost 78 tree bark (Kiam or Pra-yom) 6 aluminum container 15 Others (fertilizer, maintenance, equipment, etc.

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TOTAL EXPENSES 282 18,126 453.15 NET INCOME 108 6,944

(x6.25=43,400 bath/ha./yr)

173.6/rai/yr or 1085/ha/yr

Assumptions: 1. The yield of production is 50 litre/rai/day or 1,928 kg/rai/yr translated into

64.28 container of 30 kgs per rai per year 2. I hectare = 6.25 rai

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Other product that could be produced from the coconut sap A. Granulated Coconut Sugar

Step of Production

1. Collect coconut sap and heat until 80% concentration is attained

2. While heating coconut sap to 80% concentrate, turn the pan right and left,

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3. Stir with stirring device, bring the pan down from the furnace

4. Continue stirring with fork–like spatula 5. When sugar is nearly dried, stir vigorously

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6. Keep stirring until the syrup turns into granulated sugar 7. Then parsed through a sieve to obtain uniform size

8. Packing is done by putting the granulated sugar in bottles or metalized film with size 4.5 X 8 cm, hexagonal longitudinal shape. Heat seal the sachet or the bottle.

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Estimated cost and returns of producing granulated coconut sugar* Per kg basis At average production

per year per household Particulars Baht US

Dollar ($1=40b)

Baht US Dollar ($1=40b)

Gross Income Selling price ( I kg of sugar)

50 1.25 120,000 3,000

EXPENSES Labor, fuel, packaging, others

12.22 29,328 733.20

NET INCOME 37.78 90,672 2,266.80 Efficiency of production (kg/day/household)

12 kg

At 200 production days per year

2,400 kgs

*based on Thailand experience

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B. Coconut Nectar Coconut nectar is a special beverage from coconut inflorescence. It is sweet, oyster white and translucent. It has high nutritive value, vitamins and minerals. Coconut nectar or sap can be used in two ways; served fresh as a beverage, or processed into coconut sugar. Both have been consumed by Thai people since time immemorial and are popular both in export and domestic market. The exporting countries are USA, Hongkong, Japan, UK, Canada and others. At present there are five factories in Samut Songkram Province, that has the highest maphrao tan in the kingdom.

Step of Production

1. The collected coconut sap is a ready-to-drink beverage once bark and inflorescence debris have been filtered out. Boil at 1000 C for 1 hour until concentration of solution becomes 18-20 brix. Leave the solutions for 1 hour for sediment to settle. Move clear solutions, filter and mix with boiling water, standardized to 15 brix.

2. Hot filling in glass bottle, 3. Sealing

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4. Sterilization at 121 0 C, for 15 minutes. 5. Cooling and labeling

6.Packaging in carton boxes

Coconut Nectar ready for sales, with shelf life of one year

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Estimated cost and returns of producing coconut nectar* Per kg basis At average

production/sales per day Particulars Baht US

Dollar ($1=40b)

Baht US Dollar ($1=40b)

Gross Income Selling price: box of 24 bottles 130 3.25 2,708 67.70 Per bottle** 10 .25 5,000 125 EXPENSES Labor, fuel, packaging, othe:rs

box of 24 bottles 110 2.75 2,291 57.30 Per bottle 4.58 .1145 2,290 57.30 NET INCOME box of 24 bottles 20 .50 417 10.42 Per bottle 5.42 .1355 2,710 67.75 Efficiency of production (kg/day/household)

500 bottles per day

*based on Thailand experience ** retail price

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C. Coconut Toffy Coconut Toffy is a sweet, creamy flavor candy. Coconut Toffy has a high fiber content and may help to prevent intestinal sluggishness. Making and consumption of toffy is a popular household pastime.

Step of Production

1. Typical recipe for coconut toffy uses about 1 kg coconut cream, 1 kg of coconut sugar, 250 gm of molasses

2. Mix coconut sugar with coconut cream, bring to boil

3. Add molasses in a cooking pan and the mixture is heated to boiling again.

4. The mixture is cooked until it hardens when dropped into cold water.

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Estimated cost and returns of producing coconut toffy* Per kg basis At average 10 pans

production/sales per day Particulars Baht US

Dollar ($1=40b)

Baht US Dollar ($1=40b)

Gross Income Selling price: Pack (of 10 pcs) 5 Pan (of 13 packs) 65 1.625 650 16.25 EXPENSES (per pan output)

Sugar I kg 16 Coconut cream 1 kg 10 Molasses .25 kg, Fuel, wrapper, etc

3

TOTAL EXPENSES 29 .725 290 7.25 NET INCOME 36 .9 360 9 Efficiency of production per day

10 pans

5. It is then poured into banana leave or banana sheath Allow to cool slightly.

6. Cut into the desired sizes, and individually wrapped in cellophane.

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E. Coconut Baking Custard Coconut baking custard is a Thai dessert cooked with coconut milk and coconut sugar or palm sugar. These desserts take time to cook and need more skill in their preparation than other desserts. Coconut baked custard (Khanom Mao Kaeng) requires at least 5 ingredients and takes at least 2 hours for its preparation. It is almost entirely a household industry and popular for domestic consumption. Petchaburi province in the west region of Thailand is well known for this dessert. There are many household-making coconut baking custard ,such as; Mae Sahuan, Mae Kim Lai, Mae Kim Lui, Mai Ubon, etc.

Step of Production

1. Ingredient: 1 cup coconut sugar, 6 medium eggs, 4 tablespoons rice flour, 1.5 cups coconut cream and taro.

2. Beating eggs with beater for about 2 minutes, add sugar and beat another 2-3 minutes. Add taro and stir in rice flour, stir the mixture over low beat until it become very thick and rubbery

3. Bakes about 30-40 minutes 4. Remove and set aside

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Coconut Baking Custard

5. Package in boxes Ready for sales

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Estimated cost and returns of producing coconut baking custard* Per kg basis At average 150 plates

production/sales per day Particulars Baht US

Dollar ($1=40b)

Baht US Dollar ($1=40b)

Gross Income Selling price per plate 25 3750 93.75 EXPENSES Sugar, cream eggs, flour electricity, etc

20 3,000 75

NET INCOME 5 750 18.75 Efficiency of production (plates/day)

150

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Table 1 List of coconut palm sugar exporter in Thailand

No. Name Address 1 Thai World Import Export Co., Ltd 517 Rama 3 Road, Bang Pongpang,

Yannawa, Bangkok Tel. 2940176

2 A & S World Trading Co., Ltd. 95/112 Rama 3 Road, Chongnontree, Yannawa, Bangkok Tel. 2843065-6,7384445

3 Oriental Food Co., Ltd 122 Ladprao 26 , Ladprao Road , Lad-yao, Chatuchak, Bangkok 10900 Tel. 9384477,395-1521

4 Jack-Huo Ko., Ltd.

3333/22-24 Chudprasert Road , Bangklao, Bang Koleam, Bangkok Tel .2916106

5 A-oon Food Product Co., Ltd. 39/9 Soi Anumanrajchaton, Suriwong Road, Bangrag, Bangkok Tel. 2361551

6 Search & Ser Import Export Co., Ltd 72 Soi King Thaksin 34, Bukhalo, Thonburi, Bangkok. Tel. 8760297-8

7 Bangkok Chilli Co., Ltd. 156-158 Yaowaraj Road , Sampanthawong, Bangkok .Tel. 2225578

8 Ratch Transport 124/710 Mo. 4, Tiwanon Road, Muang, Nonthaburi. Tel.5802603

9 Sunshine Food Trading Co., Ltd.

95/392 Rama 3 Road, Yannawa, Bangkok Tel. 2330135

Source : Department of Business Economics

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Table 2 List of melting coconut sugar plants and wholesalers

No. Name Address

1 Mrs.Duata Panpongwong 11 Moo 1 Tambol Bangchang, Amphoe Ampawa Samut Songkram.

2 Mrs.Sirikaman Chansri 172 Tambol Ampawa, Amphoe Ampawa, Samut-Songkram

3 Mr.Krut Podnirung 41 Moo 13 Tambol Suanluang, Amphoe Ampawa, Samut Songkram.

4 Mr.Manit Ruangsukul 206 Moo 4 Thambon Phai Pongpang, Amphoe Ampawa, Samut Songkram.

5 Mr.Somsak Sadsomang 39/4 Moo 7 Tambol Phai Pongpang Ampohoe Ampawa, Samut Songkram.

6 Mr.Krisada Fongchamtu 35/1 Moo.1 Tambol Phai Pongpang, Amphoe Ampawa, Samut Songkram.

7 Mr.Warapong Woratat 1/3 Moo.8 Tambol Bangprom, Amphoe Bangkunthi, Samut Songkram

8 Mr.Prasert Temtanasak 5/1 Moo 1 Tambol Jompruak Amphoe Bangkunthi, Samut Songkram.

9 Mr.Sa-aad Chai-oon 99 Moo 7 Tambol Phai Pongpang, Amphoe Ampawa, Samut–Songkram.

Mr.Suranant Tantiatimonkul

30/34 Moo 13 Tambol Kkradangnya, Amphoe Bangkunthi, Samut Songkram

Mr.Sa-aad Sahgrhgm 22/1 Moo 1 Tombol Jompruak, Amphoe Bangkunthi, Samut Songkram

Mr.Kasem Inthalurng 97/2 Moo 7 Tambol Phai Pongpang, Amphoe Ampawa, Samut Songkram.

Source : Office of Trade , Sumut Songkram province

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Table 3. Wholesale price of coconut sugar in Bangkok per 30-kg container Source : Department of Interior Trade Year Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Average

1991

1990

1992

1993

1994

1995

1996

1997

1998

1999

2000

290.25 285.00 267.50 251.25 277.50 296.75 348.75 357.50 346.25 347.50 358.75 357.50 315.38 366.25 332.50 309.16 287.50 297.50 311.25 331.25 341.25 356.25 350.00 386.25 362.50 335.97 382.50 358.75 335.00 335.00 345.00 337.50 377.50 377.50 376.25 365.00 350.00 365.00 358.75 365.00 375.00 360.00 345.00 347.50 340.00 356.50 355.00 352.50 370.00 365.00 369.00 358.38 367.50 370.00 385.00 375.00 340.00 350.00 360.00 362.50 360.00 360.00 360.00 360.00 362.50 350.00 365.00 365.00 360.00 486.00 486.00 486.00 486.00 486.00 486.00 486.00 486.00 444.50 385.00 385.00 380.00 380.00 380.00 380.00 380.00 380.00 410.00 385.00 395.00 410.00 387.50 393.00 429.00 398.00 380.00 389.00 397.00 406.00 412.00 458.00 461.00 46 1.00 486.00 422.50 360.00 360.00 350.00 420.00 400.00 400.00 450.00 510.00 510.00 510.00 500.00 500.00 439.17 400.00 400.00 400.00 400.00 390.00 370.00 370.00 390.00 400.00 400.00 400.00 400.00 393.33 400.00 400.00 400.00 350.00 400.00 - - - - - - - 390.00