The Popcorn ProcessThe Popcorn Process

PopcornPopcornFACTSFACTS

How many quarts of popcorn How many quarts of popcorn do Americans consume each do Americans consume each year?year?

17.3 billion quarts of popped 17.3 billion quarts of popped popcorn popcorn

How much popcorn does the How much popcorn does the average person eat per year?average person eat per year?

68 quarts68 quarts

PopcornPopcornFACTSFACTS

Americans consume Americans consume more popcorn more popcorn than than the citizens of any the citizens of any other countryother country

January 30th is National Popcorn Day!

PopcornPopcornFACTSFACTS

There are There are sixsix types of corntypes of corn

Popcorn is Popcorn is known as known as Zea Zea maysmays evertaeverta

OnlyOnly this type of this type of corn will corn will POP!POP!

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!

PopcornPopcornHistoryHistory

PopcornPopcornHistoryHistory

Colonial settlers Colonial settlers used as “used as “puffed” puffed” cerealcereal for for breakfastbreakfast

Popular during Popular during the the depression depression and WWIIand WWII due to due to its its lowlow cost cost

Important elements of popcornImportant elements of popcorn

The hard shell The hard shell (pericarp)(pericarp) MoistureMoisture

– inside pericarpinside pericarp StarchStarch

– inside pericarpinside pericarp

How popcorn “works”How popcorn “works”

When When popcorn is heatedpopcorn is heated, the , the moisture moisture inside causes the inside causes the pericarp pericarp to burstto burst

The The starch expands into “bubbles”starch expands into “bubbles” which fuse together, creating the which fuse together, creating the white, fluffy substance white, fluffy substance

This process will only occur if the This process will only occur if the correct amount of moisturecorrect amount of moisture is present is present

Types of PopcornTypes of Popcorn

There are There are twotwo main main types of Popcorn types of Popcorn KernelsKernels

Butterfly kernelsButterfly kernels - - large, light, and large, light, and fluffyfluffy

Mushroom kernelsMushroom kernels - - used for coatingused for coating

Growing popcornGrowing popcorn

Popcorn is Popcorn is planted between planted between April 20April 20thth and May and May 1010thth usuallyusually

A A soil soil temperaturetemperature of of 10-13°C (50-55°F) 10-13°C (50-55°F) is necessaryis necessary

Harvesting PopcornHarvesting Popcorn

Popcorn is Popcorn is harvested harvested when the kernel has when the kernel has moisture content of moisture content of 16%-20%. 16%-20%.

Popcorn that is Popcorn that is too too drydry may not pop well may not pop well

Popcorn that is Popcorn that is too too moistmoist may spoil may spoil when storedwhen stored

SummarySummary

Harvest Conditioning

Moisture

ProcessingScreen Cleaning

Gravity Table

Destoner

Optical Sorter

Packaging

ShippingCoated

Popped

Bulk or Microwave popcorn

Flavored Popcorn

Cooled

Dirt and Debris

Storing PopcornStoring Popcorn

Storing is also know as Storing is also know as “conditioning”“conditioning”

Once picked, the Once picked, the corn must corn must be driedbe dried until it reaches its until it reaches its optimum moisture level of optimum moisture level of 13.5% to 14%13.5% to 14%

Cleaning popcornCleaning popcorn

Foreign material, broken kernels, Foreign material, broken kernels, corncobs, and dirt must be removedcorncobs, and dirt must be removed

Cleaning processCleaning process consists mainly of consists mainly of three parts:three parts:– separating by separating by sizesize– Separating by Separating by lower/higher lower/higher

densitiesdensities– opticaloptical sorting sorting

Processing popcorn-step 1Processing popcorn-step 1

Separating by Size uses a Separating by Size uses a screen screen cleanercleaner

Has Has 2 screens2 screens (1 large holes and 1 (1 large holes and 1 small holes)small holes)

Processing popcorn-step 2Processing popcorn-step 2

Separating by Separating by lower/higher lower/higher densities uses a densities uses a shaking gravity shaking gravity tabletable

Removes less Removes less dense cracked dense cracked kernels & more kernels & more dense dirt and dense dirt and stonesstones

Processing popcorn-step 3Processing popcorn-step 3

Optical Sorting separates Optical Sorting separates kernels by kernels by colorcolor

Optical SorterOptical Sorter inspects all inspects all kernelskernels

packaging Bulk and Microwave Popcornpackaging Bulk and Microwave Popcorn

Must be Must be packagedpackaged so so that popcorn that popcorn remains at the remains at the optimum optimum moisture levelmoisture level

PlasticPlastic is is commonly usedcommonly used

Flavored PopcornFlavored Popcorn

After cleaning, popcorn After cleaning, popcorn is popped, and while is popped, and while hot hot flavors are addedflavors are added in in a large tumbling devise a large tumbling devise to coat the popcornto coat the popcorn

The coated popcorn is The coated popcorn is cooledcooled

The popcorn is then The popcorn is then packaged and shippedpackaged and shipped

Flavored PopcornFlavored Popcorn

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

Caramel!Caramel!

                                                                                                                                       

With a Built-In Salt Shaker

                                                                                                                                       

With a Built-In Salt Shaker

                                                                                                                                       

With a Built-In Salt Shaker