The Popcorn Process Kelley Hughes

Popcorn FACTS Americans today consume 17.3 billion quarts of popped popcorn each year. The average American eats about 68 quarts per year. Americans consume more popcorn than the citizens of any other country. Americans today consume 17.3 billion quarts of popped popcorn each year. The average American eats about 68 quarts per year. Americans consume more popcorn than the citizens of any other country. Popcorn, also known to experts as zea mays everta, is one of six types of corn. It's the only type of corn that pops. Popcorn, also known to experts as zea mays everta, is one of six types of corn. It's the only type of corn that pops. January 30th is National Popcorn Day!

Popcorn History Oldest popcorn discover in New Mexico, USA: 5,600 years old Oldest popcorn discover in New Mexico, USA: 5,600 years old Native Americans grew hundreds of varieties, Native Americans grew hundreds of varieties, invented “poppers”, and wore as decoration Was served as the 1 st Thanksgiving 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) The hard shell (pericarp) Moisture Moisture –inside pericarp Starch Starch –inside pericarp

How popcorn “works” When popcorn is heated, the moisture inside causes the pericarp to burst 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 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 This process will only occur if the correct amount of moisture is present

Types of Popcorn Two main Types of Popcorn Kernels Two main Types of Popcorn Kernels -butterfly: large, light, and fluffy -mushroom: used for coating

Growing popcorn Popcorn is planted between April 20 th and May 10 th Popcorn is planted between April 20 th and May 10 th A soil temperature of 10-13°C (50-55°F) is necessary 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 is harvested when the kernel has moisture content of 16%-20%. Popcorn that is too dry may not pop well Popcorn that is too dry may not pop well Popcorn that is too moist may spoil when stored Popcorn that is too moist may spoil when stored

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

Storing Popcorn Storing is also know as “conditioning” 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% Once picked, the corn must be dried until it reaches its optimum moisture level of 13.5% to 14% Methods used for “conditioning” are a significant contributing factor in the quality of the popcorn Methods used for “conditioning” are a significant contributing factor in the quality of the popcorn

Effects of “conditioning” Seed Coat Integrity Seed Coat Integrity Appearance of the popcorn for customer satisfaction Appearance of the popcorn for customer satisfaction Maximum expansion potential Maximum expansion potential

Removing Moisture Several different methods can be used to remove moisture from popcorn during “conditioning” Several different methods can be used to remove moisture from popcorn during “conditioning” –Examples:  Natural Air-Drying  Natural Air-Drying with supplemental heat  Natural Air Equilibrium Moisture Content (EMC) window  Stirring

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

Processing popcorn-step 1 Separating by Size Separating by Size -Industry Example: Screen Cleaner  2 screens: 1 large holes & 1 small holes  Removes material larger and smaller than popcorn kernels

Processing popcorn-step 2 Separating by lower/higher densities Separating by lower/higher densities –Industry Example: Gravity Table & De-stoner  Gravity Table: removes less dense objects i.e. broken, cracked, and immature kernels  De-stoner: removes very dense objects from the corn i.e. stones, clumps of dirt, and small pieces of metal

Processing popcorn-step 3 Optical Sorting Optical Sorting –Industry Example: Optical Color Sorter  Uses high-resolution optics to inspect all kernels

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

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

Caramel Popcorn Caramel is the most popular flavor used to coat popcorn Caramel is the most popular flavor used to coat popcorn

Enjoying Popcorn Can be used an ingredient in pudding, candy, soup, salad and entrees Can be used an ingredient in pudding, candy, soup, salad and entrees Sold at cinemas, sporting events, ect. Sold at cinemas, sporting events, ect. Can be eaten with hands or with a Popcorn Fork with a built-in salt shaker Can be eaten with hands or with a Popcorn Fork with a built-in salt shaker With a Built-In Salt ShakerWith a Built-In Salt Shaker With a Built-In Salt ShakerWith a Built-In Salt Shaker With a Built-In Salt ShakerWith a Built-In Salt Shaker