The Popcorn ProcessThe Popcorn Process

Kelley HughesKelley Hughes

PopcornPopcornFACTSFACTS

Americans today consume 17.3 billion Americans today consume 17.3 billion quarts of popped popcorn each year. The quarts of popped popcorn each year. The average American eats about 68 quarts per average American eats about 68 quarts per year. Americans consume more popcorn year. Americans consume more popcorn than the citizens of any other country.than the citizens of any other country.

Popcorn, also known to experts as zea Popcorn, also known to experts as zea mays everta, is one of six types of corn. It's mays everta, is one of six types of corn. It's the only type of corn that pops. the only type of corn that pops.

January 30th is National Popcorn Day!

PopcornPopcornHistoryHistory

Oldest popcorn discover in New Mexico, USA: Oldest popcorn discover in New Mexico, USA: 5,600 years old5,600 years old

Native Americans grew hundreds of varieties,Native Americans grew hundreds of varieties,invented “poppers”, and wore as decoration

Was served as the 1st Thanksgiving Colonial settlers used as “puffed” cereal for

breakfast Popular during the depression and WWII due

to its low cost

Important elements of popcornImportant elements of popcorn

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

– inside pericarpinside pericarp StarchStarch

– inside pericarpinside pericarp

How popcorn “works”How popcorn “works”

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

The starch expands into “bubbles” The 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 moisture is presentcorrect amount of moisture is present

Types of PopcornTypes of Popcorn

Two main Types of Popcorn KernelsTwo main Types of Popcorn Kernels

-butterfly: large, light, and fluffy -butterfly: large, light, and fluffy

-mushroom: used for coating-mushroom: used for coating

Growing popcornGrowing popcorn

Popcorn is planted between April 20Popcorn is planted between April 20thth and May 10and May 10thth

A soil temperature of 10-13°C (50-A soil temperature of 10-13°C (50-55°F) is necessary55°F) is necessary

Harvesting PopcornHarvesting Popcorn

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

Popcorn that is too dry may not pop Popcorn that is too dry may not pop wellwell

Popcorn that is too moist may spoil Popcorn that is too moist 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 corn must be dried Once picked, the corn must be dried until it reaches its optimum moisture until it reaches its optimum moisture level of 13.5% to 14%level of 13.5% to 14%

Methods used for “conditioning” are Methods used for “conditioning” are a significant contributing factor in the a significant contributing factor in the quality of the popcorn quality of the popcorn

Effects of “conditioning”Effects of “conditioning”

Seed Coat Integrity Seed Coat Integrity Appearance of the popcorn for Appearance of the popcorn for

customer satisfaction customer satisfaction Maximum expansion potential Maximum expansion potential

Removing MoistureRemoving Moisture

Several different methods can be Several different methods can be used to remove moisture from used to remove moisture from popcorn during “conditioning”popcorn during “conditioning”– Examples:Examples:

Natural Air-DryingNatural Air-Drying Natural Air-Drying with supplemental heatNatural Air-Drying with supplemental heat Natural Air Equilibrium Moisture Content Natural Air Equilibrium Moisture Content

(EMC) window (EMC) window StirringStirring

Cleaning popcornCleaning popcorn

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

Cleaning process consists mainly of Cleaning process consists mainly of three parts:three parts:– separating by sizeseparating by size– Separating by lower/higher densitiesSeparating by lower/higher densities

– optical sortingoptical sorting

Processing popcorn-step 1Processing popcorn-step 1

Separating by SizeSeparating by Size

-Industry Example: Screen Cleaner-Industry Example: Screen Cleaner 2 screens: 1 large holes & 1 small holes2 screens: 1 large holes & 1 small holes Removes material larger and smaller than Removes material larger and smaller than

popcorn kernels popcorn kernels

Processing popcorn-step 2Processing popcorn-step 2

Separating by lower/higher densitiesSeparating by lower/higher densities– Industry Example: Gravity Table & De-Industry Example: Gravity Table & De-

stonerstoner Gravity Table: removes less dense objects Gravity Table: removes less dense objects

i.e. broken, cracked, and immature kernelsi.e. broken, cracked, and immature kernels De-stoner: removes very dense objects from De-stoner: removes very dense objects from

the corn i.e. stones, clumps of dirt, and the corn i.e. stones, clumps of dirt, and small pieces of metalsmall pieces of metal

Processing popcorn-step 3Processing popcorn-step 3

Optical SortingOptical Sorting – Industry Example: Optical Color SorterIndustry Example: Optical Color Sorter

Uses high-resolution optics to inspect all Uses high-resolution optics to inspect all kernels kernels

packaging Bulk and Microwave Popcornpackaging Bulk and Microwave Popcorn

Must be packaged so that popcorn Must be packaged so that popcorn remains at the optimum moisture remains at the optimum moisture levellevel

Plastic is commonly usedPlastic is commonly used

Flavored PopcornFlavored Popcorn

After being cleaned, popcorn is After being cleaned, popcorn is poppedpopped

While hot, flavors are added in a While hot, flavors are added in a large tumbling devise to coat the large tumbling devise to coat the popcornpopcorn

The coated popcorn is cooledThe coated popcorn is cooled The popcorn is then packaged and The popcorn is then packaged and

shippedshipped

Caramel PopcornCaramel Popcorn

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

Enjoying PopcornEnjoying Popcorn

Can be used an ingredient in Can be used an ingredient in pudding, candy, soup, salad and pudding, candy, soup, salad and entrees entrees

Sold at cinemas, sporting events, ect.Sold at cinemas, sporting events, ect. Can be eaten with hands or with a Can be eaten with hands or with a

Popcorn Fork with a built-in salt Popcorn Fork with a built-in salt shakershaker

                                                                                                                                       

With a Built-In Salt Shaker

                                                                                                                                       

With a Built-In Salt Shaker

                                                                                                                                       

With a Built-In Salt Shaker