Instructions

1. Preheat your oven to 250°F (120°C). Line two large baking sheets with parchment paper or silicone baking mats.
2. Using an air popper or large pot, pop the popcorn kernels until you have approximately 12-14 cups of fresh popped corn. Carefully transfer the popped corn to a very large mixing bowl, removing any unpopped kernels.
3. In a medium heavy-bottomed saucepan, combine granulated sugar, unsalted butter, light corn syrup, and salt. Heat over medium-high heat, stirring constantly until the mixture begins to boil.
4. Stop stirring and allow the caramel mixture to cook for 4-5 minutes without touching, until it reaches a deep golden amber color. The temperature should be around 300°F (hard crack stage) on a candy thermometer.
5. Remove the caramel from heat and quickly whisk in baking soda and vanilla extract. The mixture will foam and become lighter in color and texture.
6. Immediately pour the hot caramel over the popped popcorn, using a spatula to gently fold and coat the popcorn evenly. Work quickly as the caramel will start to harden.
7. Spread the caramel-coated popcorn onto the prepared baking sheets in an even, single layer. This ensures crispy, well-coated corn.
8. Bake in the preheated oven for 30 minutes, stirring every 10 minutes to ensure even caramelization and crispness.
9. Remove from oven and let cool completely on the baking sheets. The caramel corn will become crunchier as it cools.
10. Break into clusters and serve. Store in an airtight container at room temperature for up to 5 days.