A method of synthesizing puffed and expanded popcorn product from cornmeal, the method comprises the steps of: pre-treating corn kernels/corn seeds; grinding the pre-treated corn kernels/corn seeds; obtaining a cornmeal, and wherein the cornmeal comprises corn particles with a plurality of particle sizes; the cornmeal comprises corn particles of a plurality of sizes, and wherein the corn particles with a particle size of greater than 1000μ are present in a concentration of 5% w/w, and wherein the corn particles with a particle size of 500-1000μ are present in a concentration of 45-50% w/w, and wherein the corn particles with a particle size of 250-500μ are present in a concentration of 25-30% w/w, and wherein the corn particles with a particle size smaller than 250μ are present in a concentration of 25%w/w, adding the cornmeal into a cylinder/barrel in an extruder through a feeder; adding water into the cylinder/barrel in the extruder through the feeder to obtain a cornmeal paste; grinding and mixing the cornmeal paste in the cylinder/barrel by a twin screw mechanism in the extruder, and wherein the twin screw mechanism is a hammer type twin screw mechanism; cooking the cornmeal paste under a preset temperature and preset pressure conditions to obtain a cooked cornmeal, and wherein the preset temperature and preset pressure is produced by the twin screw mechanism, and wherein the temperature is controlled and regulated in the cylinder/barrel at the extruder; transferring the cooked cornmeal to the end of the extruder with a spiral motion of the twin screw mechanism; extruding the cooked cornmeal out of the cylinder/barrel in the extruder under preset pressure through a plurality of die holes to obtain a popcorn product, and wherein the cooked cornmeal is extruded out of the plurality of die holes to achieve an irregular shape, and wherein the cooked cornmeal after extrusion has same surface, porosity, texture, taste and shape of a regular popcorn, and wherein the cooked cornmeal with irregular shape is cut into a plurality of pieces of desired length after extrusion out of the plurality of die holes to obtain the popcorn product, and wherein the cut cornmeal/popcorn product is cooled and dried on a vibrating separation system or a sieve, the temperature is controlled in the cylinder/barrel at the extruder by circulating a hot water outside the cylinder/barrel in the extruder, and wherein the hot water is circulated outside the cylinder/barrel in the extruder to produce the temperature for cooking the cornmeal in the barrel/cylinder at the extruder. pre-treating corn kernels/corn seeds; grinding the pre-treated corn kernels/corn seeds; obtaining a cornmeal, and wherein the cornmeal comprises corn particles with a plurality of particle sizes; the cornmeal comprises corn particles of a plurality of sizes, and wherein the corn particles with a particle size of greater than 1000μ are present in a concentration of 5% w/w, and wherein the corn particles with a particle size of 500-1000μ are present in a concentration of 45-50% w/w, and wherein the corn particles with a particle size of 250-500μ are present in a concentration of 25-30% w/w, and wherein the corn particles with a particle size smaller than 250μ are present in a concentration of 25%w/w, adding the cornmeal into a cylinder/barrel in an extruder through a feeder; adding water into the cylinder/barrel in the extruder through the feeder to obtain a cornmeal paste; grinding and mixing the cornmeal paste in the cylinder/barrel by a twin screw mechanism in the extruder, and wherein the twin screw mechanism is a hammer type twin screw mechanism; cooking the cornmeal paste under a preset temperature and preset pressure conditions to obtain a cooked cornmeal, and wherein the preset temperature and preset pressure is produced by the twin screw mechanism, and wherein the temperature is controlled and regulated in the cylinder/barrel at the extruder; transferring the cooked cornmeal to the end of the extruder with a spiral motion of the twin screw mechanism; extruding the cooked cornmeal out of the cylinder/barrel in the extruder under preset pressure through a plurality of die holes to obtain a popcorn product, and wherein the cooked cornmeal is extruded out of the plurality of die holes to achieve an irregular shape, and wherein the cooked cornmeal after extrusion has same surface, porosity, texture, taste and shape of a regular popcorn, and wherein the cooked cornmeal with irregular shape is cut into a plurality of pieces of desired length after extrusion out of the plurality of die holes to obtain the popcorn product, and wherein the cut cornmeal/popcorn product is cooled and dried on a vibrating separation system or a sieve, the temperature is controlled in the cylinder/barrel at the extruder by circulating a hot water outside the cylinder/barrel in the extruder, and wherein the hot water is circulated outside the cylinder/barrel in the extruder to produce the temperature for cooking the cornmeal in the barrel/cylinder at the extruder.