Popcorn

**Popcorn** (**popped corn**, **popcorns** or **pop-corn**) is a variety of corn kernel which expands and puffs up when heated; the same names are also used to refer to the foodstuff produced by the expansion.

A popcorn kernel's strong hull contains the seed's hard, starchy shell endosperm with 14–20% moisture, which turns to steam as the kernel is heated. Pressure from the steam continues to build until the hull ruptures, allowing the kernel to forcefully expand, from 20 to 50 times its original size, and then cool.

Some strains of corn (taxonomized as *Zea mays*) are cultivated specifically as popping corns. The *Zea mays* variety *everta*, a special kind of flint corn, is the most common of these.

Popcorn is one of the six major types of corn, which includes dent corn, flint corn, pod corn, flour corn, and sweet corn.

## History

Corn was domesticated about 10,000 years ago in what is now Mexico. Archaeologists discovered that people have known about popcorn for thousands of years. In Mexico, for example, remnants of popcorn have been found that date circa 3600 BC.

Through the 19th century, popping of the kernels was achieved by hand on stove tops. Kernels were sold on the East Coast of the United States under names such as *Pearls* or *Nonpareil*. The term *popped corn* first appeared in John Russell Bartlett's 1848 *Dictionary of Americanisms*. Popcorn is an ingredient in Cracker Jack and, in the early years of the product, it was popped by hand.

Popcorn's accessibility increased rapidly in the 1890s with Charles Cretors' invention of the popcorn maker. Cretors, a Chicago candy store owner, had created a number of steam-powered machines for roasting nuts and applied the technology to the corn kernels. By the turn of the century, Cretors had created and deployed street carts equipped with steam-powered popcorn makers.

During the Great Depression, popcorn was fairly inexpensive at 5–10 cents a bag and became popular. Thus, while other businesses failed, the popcorn business thrived and became a source of income for many struggling farmers, including the Redenbacher family, namesake of the famous popcorn brand. During World War II, sugar rations diminished candy production, and Americans compensated by eating three times as much popcorn as they had before. The snack was popular at theaters, much to the initial displeasure of many of the theater owners, who thought it distracted from the films. Their minds eventually changed, however, and in 1938 a Midwestern theater owner named Glen W. Dickinson Sr. installed popcorn machines in the lobbies of his Dickinson theaters. Popcorn was making more profit than theater tickets, and at the suggestion of his production consultant, R. Ray Aden, Dickinson purchased popcorn farms and was able to keep ticket prices down. The venture was a financial success, and the trend to serve popcorn soon spread.

In 1970, Orville Redenbacher's namesake brand of popcorn was launched. In 1981, General Mills received the first patent for a microwave popcorn bag; popcorn consumption saw a sharp increase, by tens of thousands of pounds, in the years following.

At least six localities (all in the Midwestern United States) claim to be the "Popcorn Capital of the World;": Ridgway, Illinois; Valparaiso, Indiana; Van Buren, Indiana; Schaller, Iowa; Marion, Ohio; and North Loup, Nebraska. According to the USDA, corn used for popcorn production is specifically planted for this purpose; most is grown in Nebraska and Indiana, with increasing area in Texas. As the result of an elementary school project, popcorn became the official state snack food of Illinois.

## Popping mechanism

Each kernel of popcorn contains a certain amount of moisture and oil. Unlike most other grains, the outer hull of the popcorn kernel is both strong and impervious to moisture and the starch inside consists almost entirely of a hard type.

As the oil and water within the kernel are heated, they turn the moisture in the kernel into pressurized steam. Under these conditions, the starch inside the kernel gelatinizes, softens, and becomes pliable. The internal pressure of the entrapped steam continues to increase until the breaking point of the hull is reached: a pressure of approximately 135 psi (930 kPa) and a temperature of 180 °C (356 °F). The hull thereupon ruptures rapidly and explodes, causing a sudden drop in pressure inside the kernel and a corresponding rapid expansion of the steam, which expands the starch and proteins of the endosperm into airy foam. As the foam rapidly cools, the starch and protein polymers set into the familiar crispy puff. Special varieties are grown to give improved popping yield. Though the kernels of some wild types will pop, the cultivated strain is *Zea mays everta,* which is a special kind of flint corn.

## Cooking methods

Popcorn can be cooked with butter or oil. Although small quantities can be popped in a stove-top kettle or pot in a home kitchen, commercial sale of freshly popped popcorn employs specially designed popcorn machines, which were invented in Chicago, Illinois, by Charles Cretors in 1885. Cretors successfully introduced his invention at the Columbian Exposition in 1893. At this same world's fair, F.W. Rueckheim introduced a molasses-flavored "Candied Popcorn", the first caramel corn; his brother, Louis Ruekheim, slightly altered the recipe and introduced it as Cracker Jack popcorn in 1896.

Cretors's invention introduced the first patented steam-driven popcorn machine that popped corn in oil. Previously, vendors popped corn by holding a wire basket over an open flame. At best, the result was a hot, dry, unevenly cooked snack. Cretors's machine popped corn in a mixture of one-third clarified butter, two-thirds lard, and salt. This mixture can withstand the 450 °F (232 °C) temperature needed to pop corn and it produces little smoke. A fire under a boiler created steam that drove a small engine; that engine drove the gears, shaft, and agitator that stirred the corn and powered a small automated clown puppet-like figure, "the Toasty Roasty Man", an attention-getting amusement intended to attract business. A wire connected to the top of the cooking pan allowed the operator to disengage the drive mechanism, lift the cover, and dump popped corn into the storage bin beneath. Exhaust from the steam engine was piped to a hollow pan below the corn storage bin and kept freshly popped corn uniformly warm. Excess steam was also used to operate a small, shrill whistle to attract attention.

A different method of popcorn-making involves the "popcorn hammer", a large cast-iron canister that is sealed with a heavy lid and slowly turned over a fire in rotisserie fashion.

### Expansion and yield

Popping results are sensitive to the rate at which the kernels are heated. If heated too quickly, the steam in the outer layers of the kernel can reach high pressures and rupture the hull before the starch in the center of the kernel can fully gelatinize, leading to partially popped kernels with hard centers. Heating too slowly leads to entirely unpopped kernels: the tip of the kernel, where it attached to the cob, is not entirely moisture-proof, and when heated slowly, the steam can leak out of the tip fast enough to keep the pressure from rising sufficiently to break the hull and cause the pop.

Producers and sellers of popcorn consider two major factors in evaluating the quality of popcorn: what percentage of the kernels will pop, and how much each popped kernel expands. Expansion is an important factor to both the consumer and vendor. For the consumer, larger pieces of popcorn tend to be more tender and are associated with higher quality. For the grower, distributor and vendor, expansion is closely correlated with profit: vendors such as theaters buy popcorn by weight and sell it by volume. For these reasons, higher-expansion popcorn fetches a higher profit per unit weight.

Popcorn will pop when freshly harvested, but not well; its high moisture content leads to poor expansion and chewy pieces of popcorn. Kernels with a high moisture content are also susceptible to mold when stored. For these reasons, popcorn growers and distributors dry the kernels until they reach the moisture level at which they expand the most. This differs by variety and conditions, but is generally in the range of 14–15% moisture by weight. If the kernels are over-dried, the expansion rate will suffer and the percentage of kernels that pop will decline.

When the popcorn has finished popping, sometimes unpopped kernels remain. Known in the popcorn industry as "old maids", these kernels fail to pop because they do not have enough moisture to create enough steam for an explosion. Re-hydrating prior to popping usually results in eliminating the unpopped kernels.

Popcorn varieties are broadly categorized by the shape of the kernels, the color of the kernels, or the shape of the popped corn. While the kernels may come in a variety of colors, the popped corn is always off-yellow or white as it is only the hull (or pericarp) that is colored. "Rice" type popcorn have a long kernel pointed at both ends; "pearl" type kernels are rounded at the top. Commercial popcorn production has moved mostly to pearl types. Historically, pearl popcorn were usually yellow and rice popcorn usually white. Today both shapes are available in both colors, as well as others including black, red, mauve, purple, and variegated. Mauve and purple popcorn usually have smaller and nutty kernels. Commercial production is dominated by white and yellow.