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Pop the corn kernels using an air popper. It is crucial not to use oil during popping, as the caramel will not stick otherwise. Set aside the popped popcorn in large foil baking pans.

In a medium saucepan, combine the butter, brown sugar, dark corn syrup, and salt.

Cook and stir the mixture over medium heat until all ingredients are melted and thoroughly combined, forming a smooth caramel sauce. Bring the mixture to a gentle boil and let it cook for 5 minutes, stirring occasionally.

Remove the caramel sauce from the heat and immediately stir in the baking soda. The mixture will foam up.

Pour the freshly made caramel sauce evenly over the air-popped popcorn in the large foil baking pans. Gently mix the popcorn and caramel using a spatula or similar utensil until every piece of popcorn is evenly covered with the caramel sauce.

Preheat your oven to 250°F. Place the caramel-coated popcorn into the preheated oven and bake for a total of one hour. During this hour, remove the popcorn from the oven and break it up/stir it thoroughly every 15 minutes to ensure even baking and crispness.

After 60 minutes of baking and stirring, remove the caramel popcorn from the oven. Allow it to cool for about 5 minutes for the caramel to harden and become brittle and crunchy before serving.


Pop the corn kernels using an air popper. It is crucial not to use oil during popping, as the caramel will not stick otherwise. Set aside the popped popcorn in large foil baking pans.

In a medium saucepan, combine the butter, brown sugar, dark corn syrup, and salt.

Cook and stir the mixture over medium heat until all ingredients are melted and thoroughly combined, forming a smooth caramel sauce. Bring the mixture to a gentle boil and let it cook for 5 minutes, stirring occasionally.

Remove the caramel sauce from the heat and immediately stir in the baking soda. The mixture will foam up.

Pour the freshly made caramel sauce evenly over the air-popped popcorn in the large foil baking pans. Gently mix the popcorn and caramel using a spatula or similar utensil until every piece of popcorn is evenly covered with the caramel sauce.

Preheat your oven to 250°F. Place the caramel-coated popcorn into the preheated oven and bake for a total of one hour. During this hour, remove the popcorn from the oven and break it up/stir it thoroughly every 15 minutes to ensure even baking and crispness.

After 60 minutes of baking and stirring, remove the caramel popcorn from the oven. Allow it to cool for about 5 minutes for the caramel to harden and become brittle and crunchy before serving.
