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The Popcorn Process

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.

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The Popcorn Process

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  1. The Popcorn Process Kelley Hughes

  2. PopcornFACTS • 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. • January 30th is National Popcorn Day!

  3. PopcornHistory • Oldest popcorn discover in New Mexico, USA: 5,600 years old • 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

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

  5. 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

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

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

  8. 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

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

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

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

  12. Removing Moisture • 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

  13. 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

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

  15. Processing popcorn-step 2 • 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

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

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

  18. Flavored Popcorn • After being cleaned, popcorn is popped • 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

  19. Caramel Popcorn • Caramel is the most popular flavor used to coat popcorn

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

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