How is Popcorn Made?

An archaeological dig took place in a rock shelter in New Mexico, in 1948. The area where the first kernels of corn were found is known as Bat Cave. It is questionable how old the corn actually was that was found, when first analyzed it was said they were between 4000 to 5000 years old. There was further analysis done on the cobs of corn, which were recorded as being 1,752 years old. Another sample of cobs only was dated at 2,249 years old. The age of the cobs are inconsistent, but still, the first kernels are certainly very old.

Popcorn was very popular in the 1890's up until the time of the Great Depression when it became so expensive. It was sold in bags for 5-10 cents per bag during the Depression, which was expensive at that point in time. Nowadays, most of the maize for popcorn making is grown in Indiana, Nebraska, and some areas of Texas.

This is a cereal grain product, and as with all cereal grains it contains starch and oil. The starch inside each kernel is of a hard thick consistency. The oil and water inside the kernel are heated to such a degree that the moisture turns to pressurized steam. The starch inside the kernel becomes like a gel as it softens. As the pressure increases with heat of up to about 135 psi and a temperature of 180 degrees C the hull of the kernel ruptures. The hull ruptures causing an increase of steam, the starch and protein expands causing the kernel to go into a puff ball shape. As the foam cools it relaxes into the shape of a crispy popcorn ball.

If heated too quickly the steam in the outer hulls can rupture prematurely before the starch gets a chance to turn to gel. This stops the kernels from popping fully leaving a hard center in the popcorn pieces. When heated too slowly the kernels will not pop at all. The pressure will not rise, the hull will not break, and no popping will occur.

Kernels can come in a variety of colors, but they will always be white when they pop. A popped kernel of corn in known in the industry as a flake. The flake can be butterfly shaped, or mushroom shaped. Mushroom flakes are often used for packaged popcorn as the shape is more rigid and less likely to crumble than the butterfly shape.

This snack food is often served with salt, or it is sweetened, such as caramel corn. Popcorn has been served at cinemas and sporting events since 1912. The popcorn machine was originally invented in Chicago, Illinois, by Charles Cretors, in 1885. Before this machine was invented popcorn was popped in a wire basket held over an open flame. In some parts of Northern America and the Balkan peninsula popcorn pieces are threaded onto a string, and used as a wall or Christmas tree decoration. In Lake Forest, Illinois the worlds largest piece of popcorn was made in 2006. It weighed 3,415 pounds, measured 8 feet, and had a circumference of 24.6 feet.

Source: http://en.wikipedia.org/wiki/Popcorn