Can be made ahead and frozen. 2 gallons popped corn Bring corn syrup, brown sugar and salt to a boil. Add butter and return to boil. Remove from burner. Let cool slightly.
Divide popcorn into two parts and lay on two greased cookie sheets.
Pour equal amounts of caramel over each. Stir gently until coated. Can be formed into popcorn balls if desired. Allow to set for about two hours. Spread mixture evenly over pan.