The Popcorn Process

Popcorn FACTS How many quarts of popcorn do Americans consume each year? 17.3 billion quarts of popped popcorn How much popcorn does the average person eat per year? 68 quarts

Popcorn FACTS Americans consume more popcorn than the citizens of any other country January 30th is National Popcorn Day!

Popcorn FACTS There are six types of corn Popcorn is known as Zea mays everta Only this type of corn will POP!

Popcorn History Oldest popcorn discovered in New Mexico, USA (5,600 years old) Native Americans grew hundreds of varieties, invented “poppers”, and wore popcorn as a decoration Popcorn was served at the 1st Thanksgiving!

Popcorn History Colonial settlers used as “puffed” cereal for breakfast Popular during the depression and WWII due to its low cost

Important elements of popcorn The hard shell (pericarp) Moisture inside pericarp Starch

How popcorn “works” When popcorn is heated, the moisture inside causes the pericarp to burst The starch expands into “bubbles” which fuse together, creating the white, fluffy substance This process will only occur if the correct amount of moisture is present

Types of Popcorn There are two main types of Popcorn Kernels Butterfly kernels - large, light, and fluffy Mushroom kernels - used for coating

Growing popcorn Popcorn is planted between April 20th and May 10th usually A soil temperature of 10-13°C (50-55°F) is necessary

Harvesting Popcorn Popcorn is harvested when the kernel has moisture content of 16%-20%. Popcorn that is too dry may not pop well Popcorn that is too moist may spoil when stored

Summary Processing Harvest Moisture Destoner Shipping Packaging Conditioning Screen Cleaning Moisture Gravity Table Dirt and Debris Destoner Optical Sorter Bulk or Microwave popcorn Shipping Packaging Cooled Coated Popped Flavored Popcorn

Storing Popcorn Storing is also know as “conditioning” Once picked, the corn must be dried until it reaches its optimum moisture level of 13.5% to 14%

Cleaning popcorn Foreign material, broken kernels, corncobs, and dirt must be removed Cleaning process consists mainly of three parts: separating by size Separating by lower/higher densities optical sorting

Processing popcorn-step 1 Separating by Size uses a screen cleaner Has 2 screens (1 large holes and 1 small holes)

Processing popcorn-step 2 Separating by lower/higher densities uses a shaking gravity table Removes less dense cracked kernels & more dense dirt and stones

Processing popcorn-step 3 Optical Sorting separates kernels by color Optical Sorter inspects all kernels

packaging Bulk and Microwave Popcorn Must be packaged so that popcorn remains at the optimum moisture level Plastic is commonly used

Flavored Popcorn After cleaning, popcorn is popped, and while hot flavors are added in a large tumbling devise to coat the popcorn The coated popcorn is cooled The popcorn is then packaged and shipped

Which flavored popcorn is most people’s favorite? Caramel!

With a Built-In Salt Shaker                                                                                                                                         With a Built-In Salt Shaker                                                                                                                                         With a Built-In Salt Shaker                                                                                                                                         With a Built-In Salt Shaker