Theory Overview:
Producing Quality
Homemade Popcorn
Presented by
Stephen M. Perry
Document #: TRN-PPT-003
Effective: 14MAR05
Theory Overview Outline
Producing Quality Homemade Popcorn
• Purpose and Scope
• Background and History
• Process Theory
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Introduction
Materials
Equipment
Techniques
• Quiz
• References
Purpose
Why is this necessary?
• Conceptually, this overview is a sample
component of Ideal Knowledge Transfer™.
• Information covered in this presentation
addresses some of the reasoning behind the
selected methodologies.
• By addressing the history and theory involved,
key information is better retained and knowledge
can develop.
Scope
What is covered?
• This presentation includes pertinent information related to
producing quality homemade popcorn:
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History
Process Theory
Materials
Techniques
• This module provides supplemental information beyond
what is included in other materials, such as:
o
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Standard Operating Procedure (SOP)
Demonstration Video
• Generally speaking, detailed step-by-step instructions and
instructional highlights have been omitted.
Background
How did this come about?
• The “Producing Quality Homemade Popcorn”
example was chosen as a simple, fun example to
illustrate the possible benefits of Ideal
Knowledge Transfer™.
• Stephen Perry, the founder of Kymanox, started
making homemade popcorn in the mid-1980s and
refined the process over the years after much
experimentation.
History of Popcorn
Early
• It is believed that the first use of wild and early
cultivated corn was popping. 1
• The writings of Peruvian Indians in 1650 say,
“They toast a certain kind of corn until it bursts.
They call it pisancalla, and they use it as a
confection.” 1
• During the Depression, popcorn at 5 or 10 cents
a bag was one of the few luxuries down-and-out
families could afford. 1
History of Popcorn
Recent
• Microwave popcorn was the very first use of
microwave heating in the 1940s. 1
• Popcorn went into a slump during the early
1950s, when television became popular.
Attendance at movie theaters dropped and, with
it, popcorn consumption. When the public began
eating popcorn at home, the new relationship
between television and popcorn led to a resurge
in popularity. 1
• Americans today consume 17 billion quarts of
popped popcorn each year. 1
Process Theory
Introduction
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• Popping corn kernels requires heat to drive a phase change
in the small amount of water (i.e., moisture) that normally
resides in a kernel.
• As the water quickly transforms from a liquid to a gas state,
the volume it occupies increases by a factor of 1700 – thus
providing the explosive force for popping.
• It is important that the heat is transferred quickly, avoiding
pervaporation which allows water to escape without creating
the explosive force.
• The latent moisture in a kernel is therefore critical; kernels
should be stored properly to keep their moisture content
stable.
Process Theory
Materials
• Popcorn kernels
• Heat transfer medium
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Oil (traditional)
Air (hot air popper)
Electromagnetic
radiation (microwave)
• Seasonings
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Butter
Salt
Others (not
recommended)
Materials
Popcorn Kernels
• Premium kernels are essential for quality
popcorn.
• The world’s best popcorn is grown in the
Midwest:
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Illinois, Indiana and Iowa (USA)
• Desirable kernel characteristics:
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Relatively large and plump
White or yellow in color
Ideal moisture content (13-14%) 1
Proper packaging to ensure moisture stability
High popped to un-popped volume expansion ratio
(>35:1) 1
Materials
Heat Transfer Medium
• A key factor impacting how a kernel pops is how
heat is transferred to the kernel.
• Oil is the traditional medium; it has several
advantages over air and microwaves:
Provides even and continuous contact with the kernel
and heating equipment – thus maximizing heat transfer
o Adds flavor to the popped corn
o Requires no special equipment
o
• Corn, safflower and canola oils are best and
other oils can impart an unwanted taste, e.g.,
olive, or are not as healthy, e.g., coconut.
Materials
Seasonings
• Although dry popped corn has taste, its taste can
be enhanced with simple seasonings:
Real butter provides the best taste and does not contain
trans-fat that is associated with margarine
o A small amount of salt magnifies the corn and butter
flavors
o
• Sugar, caramel, cheese and other flavorings are
common but are too dominate and can interfere
with the taste of the corn.
Process Theory
Equipment
• Popping equipment desirable characteristics:
Ability to transfer heat to heat transfer medium quickly
and evenly
o Avoid burning
o Allow steam to escape
o
• Holding equipment desirable characteristics:
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Cool slowly and evenly
Allow moisture to escape
Allow for transferring, mixing and serving
Equipment Table of Options
Device
Traditional
Covered Pot
Mechanical
Popcorn
Popper
Hot Air
Popper
Microwave
Picture
Advantages
Disadvantages
Reliable and
consistent; not a
specialty unit;
easy to clean
Ensures proper
mixing and
venting
Good technique
required
Ability to
produce low-fat
popcorn
Loud operation;
overly dry popcorn;
specialty unit ($ +
space)
Popping dependant
on power rating;
must buy prepackaged popcorn
Ease-of-use;
disposable
clean-up
Moving parts; hard
to clean; specialty
unit ($ + space)
Equipment
Traditional Covered Pot
• Although simple, the traditional covered pot may be the best
choice for making quality homemade popcorn.
• The pot interior should be made of good quality stainless
steel (e.g., 18/10) and have a smooth finish on the inside:
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No pitting or visible corrosion
Free of char and scorch stains (impacts heat transfer)
Aluminum core and exterior desirable (provides even heating)
• The pot height should be close to 4 inches:
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Allows steam to escape
Accounts for expected volume expansion if a single layer of
kernels is used
Equipment
Holding Containers
• Cooling and mixing container: paper bag
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Low heat capacity material (i.e., paper) prevents condensation
during cooling
Absorbs and wicks moisture – keeping popcorn dry and fluffy
Large volume allows for easy bulk cooling and mixing
Disposable and recyclable
• Serving container: open bowl
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Easy access
Decorative
• Storage container: covered bowl
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Air-tight for moisture control
Preserves freshness
Process Theory
Techniques
• Technique is critical for consistent high quality,
high yielding popcorn
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Preheating
Popping
Cooling
Seasoning
Serving and storage
Techniques
Preheating
• The water inside the kernel need to reach >100°C so that
steam can be created and cause the pressure to build and to
provide the explosive “pop.”
• The temperature inside the kernel is related to:
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Exterior kernel temperature, which is related to
Oil temperature, which is related to
Pot temperature , which is related to
Stove temperature, which is the heat source
• The stove, pot and oil should be individually preheated to
allow for optimal thermal equilibrium and temperature
gradients.
• Indicating kernels are used to verify when the oil has
reached popping temperature of approximately 210 to
230°C.
Techniques
Popping
Single
Layer
• For maximum batch yield without compromising other factors, pop
as many kernels as it takes to form a single layer in the pot.
• Mixing is critical during both heating and popping of the kernels:
Keeps kernels evenly coated with hot oil; minimizes temperature
variations in the pot
o Moves displaced, non-popped kernels to the bottom of the pot so they
can return to the oil for popping
o
• Opening the lid during popping:
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Allows steam to escape
Keeps popped kernels dry, light and fluffy
• Remove from heat after popping rate declines - not when it has
stopped:
Popping popcorn kernels absorb heat from the oil, pot and stove –
once in decline, the temperature of the pot and oil begins to rise
significantly and can cause oil to smoke, imparting a bad taste
o Prevents burning and scorching
o
Techniques
Cooling
• Cooling is a critical yet often unmanaged step in popcorn
production.
• Fresh, hot popcorn needs to cool in a controlled fashion:
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Avoids unwanted condensation
Paper is ideal surface:
 Absorbs moisture
 Wicks moisture
 Low heat capacity
o
Glass, porcelain or metal are not recommended:
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The surface of the popped corn cools too quickly
Water condenses on the popped corn
Impacted corn becomes dense – an unwanted mouth-feel attribute
Corn does not remain fresh as long during storage
Techniques
Seasoning
• Seasoning is a personal preference, but most popcorn
enthusiasts celebrate popcorn with simple butter and salt.
• The oil used provides flavor – use only sparing amounts of
real butter and salt.
• Slowly drizzle butter evenly over the popcorn, mixing
frequently:
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Do Coat the popcorn evenly and lightly
Don’t soak or drench the popcorn
• After butter seasoning, carefully add salt to taste:
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Salt will stick to popcorn
Dispense slowly over wide area, mixing frequently
Techniques
Serving and Storage
• Dispose the paper bag before serving; although it has great
utility, it has unappetizing aesthetics.
• Serve the popcorn in a bowl that has easy access for:
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grabbing and eating
dispensing to smaller bowls
• Popcorn is best consumed immediately after it is prepared.
If any popcorn is leftover, store it in an air-tight container at
room temperature:
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Be sure popcorn is also at room temperature before sealing
container; this will minimize moisture and extend storage time
Popcorn should remain fresh for up to 3 days
Quiz
Select the best answer
???
1. What is causes a kernel to pop?
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[A] rapid vaporization of water
[B] applied heat at a slow rate
[C] chemical reaction with oil
2. What can a paper bag do for popped popcorn?
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[A] Is an ideal container for initial cooling
[B] provides a handy container for mixing/seasoning
[C] all of the above
3. If popcorn kernels were baked at 80°C (i.e., 176°F), what
would happen?
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[A] some would pop
[B] the kernels would dehydrate and be unsuitable for popping
[C] all would pop
Quiz, Continued
Select the best answer
???
1. When selecting an oil, what should be considered?
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[A] taste compatibility with corn
[B] smoking point and saturated/trans fat content
[C] all of the above
2. Why is preheating oil is necessary?
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[A] burns off extra oil
[B] ensures optimal thermal conditions and rapid heating of
kernels
[C] minimizes risk of fire
3. What is a drawback of microwave popcorn?
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[A] independent selection and control of the materials is not
possible
[B] it is quick, clean and disposable
[C] radiation damages the corn flavor
Quiz Answers
Best Answers Listed
1.A
2.C
3.B
4.C
5.B
6.A
References
1. Popcorn Board
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Address: 401 N. Michigan Ave., Chicago, IL 60611
URL: www.popcorn.org
2. Walton Feed, Inc.
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Address: U135 N. 10th, PO Box 307, Montpelier, ID 83254
URL: www.waltonfeed.com
Contact Information
For more information, contact Kymanox at
info@kymanox.com
or visit
www.kymanox.com