Ever wondered where that golden popping corn in your Popper came from?
Popsmith president and co-founder Dave recently visited the farm and met up with Brian from Preferred Popcorn to learn all about how to grow popcorn, when to harvest it, and how to process the kernels — and it turns out, there’s incredible precision and passion that go into every kernel you pop.
Here’s what you should know:
What Makes Popcorn Special?
A popcorn kernel has a hard outer shell called the pericarp and a starchy interior with just the right moisture content — 13-14%. When you heat it up, that moisture transforms into steam and builds enough pressure to make the kernel explode inside-out.
This makes it completely different from sweet corn or field corn. These two types of corn can’t pop. We eat sweet corn fresh and use field corn for animal feed or processing. Popcorn, on the other hand, is actually a specific variety called Zea mays everta that's bred for popping.
How to Grow Popcorn
Variety Selection and Field Planning
Think all popcorn is the same? Brian taught us otherwise. Even within what looks like basic yellow corn, there can be several different varieties growing in the field. Farmers pick varieties based on their specific characteristics.
As Brian put it, some varieties are chosen for their vivid color. Think about it — if you were at the grocery store and had to pick kernels, you’d likely go for the brightest yellow since they remind you of movie theater popcorn.
Other varieties might be selected for their kernel size and even flavor.
SCALE CONSIDERATIONS: To put commercial farming into perspective, one single field Brian showed in the video spans 45 acres. That’s equivalent to 45 football fields of popcorn, which should yield about 200,000 kernels!
Field Identification
Want to know how farmers distinguish between popcorn and regular field corn? Brian shared that the only way you can tell one from the other is that popcorn has an umbrella-type tassel, while field corn is going to stick straight up. Beyond that, the plant health and the ear size look pretty much the same until they dry down.
Planting Popcorn
Planting popcorn seeds usually happens 2-3 weeks after the last frost, when soil temperatures consistently reach 60°F. Unlike sweet corn that farmers can plant in single rows, popcorn is planted in large blocks. This helps the wind carry pollen from plant to plant more effectively. The issue with having a single row of popcorn is that the pollen might just blow away instead of landing on nearby plants to create kernels.
Preparing the Field
Farmers prepare fields with well-draining soil, incorporating organic matter for fertility while making sure pH levels stay between 6.0-7.0. When that’s done, they plant the seeds 1-2 inches deep. They need to space them out well — the corn can grow up to 10 feet long!
Pollination
Farmers have to carefully time their irrigation and field management around pollination. Brian added that “the pollen has to fall off the tassel and touch those silks, these hairs on the ears. That goes down, and that's what makes the kernels that will appear on the ear corn later.”
Water Management
Farmers need to be mindful about when and how they water their popcorn fields. The plants need consistent moisture throughout the growing season, but the tricky thing is that too much water at the wrong time can mess up pollination.
That’s why they avoid sprinkler systems during pollination season, since water droplets can wash away the pollen before it reaches those silks Brian showed.
Height and Development
After tasseling, the corn grows about another foot and reaches its full height before the kernels form. Farmers keep a watchful eye on this growth, since healthy plant development is crucial for kernel development.
Fertilization
When the corn is knee-high, farmers side-dress their fields with nitrogen and do so again when the silks appear. They’re extra mindful not to over-fertilize, since this can delay maturity.
GOOD TO KNOW: Our popcorn is non-GMO. We don’t use harmful chemicals or pesticides that could damage the natural growing process or end up in your bowl.
How to Harvest Popcorn
Spoiler alert: harvesting popcorn is a lot more complicated than you think!
When to Know the Corn Is Ready for Harvest
Popcorn kernels typically reach maturity at 100-120 days, while sweet corn is picked while it’s young and tender (about 60-90 days after planting). Farmers like Brian watch out for the following indicators to determine whether it’s already time to harvest popcorn:
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Brown and papery husks
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Hard kernels that dent when pressed
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Stalks starting to turn brown
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Ears that are light when lifted (means there was proper moisture loss)
The Equipment Used to Harvest Popcorn
Farmers use modified combine harvesters specifically calibrated for popcorn. The combine picks the ears, strips the kernels from the cob, and separates the kernels from the chaff.
This machine works differently from your standard corn harvesters since popcorn requires gentle handling. Brian stressed that kernels have to be intact to pop. If the machinery is too close, it can damage the kernels and ruin all the farmers’ hard work.
Post-Harvest Handling
After combining, farmers transport the popcorn in trailers specially designed to minimize damage. Even the loading and unloading processes demand more cautious handling than other grains.
How Popcorn Is Processed
Popcorn kernels have to be inspected first before they’re placed in storage. Quality control specialists look at moisture levels, kernel sizes, and make sure there isn’t random field corn mixed in. They also regularly test-pop samples to guarantee the popcorn maintains optimal popping characteristics.
More on all of these below:
Cleaning
Before the kernels are sorted, they go through some cleaning machines that use screens and air to get rid of leaves, dirt, and anything else that shouldn’t be there.
Size and Weight Sorting
Then the kernels are placed in machines that shake them and separate them by size and weight. These basically act like giant sieves, with smaller and lighter kernels falling through different-sized screens, while the perfect kernels continue down the line. Any wheat kernels or undersized popcorn that somehow made it to the mix get filtered out.
Getting the Moisture Just Right
There’s also a machine that calculates the moisture content of the popcorn. You pour kernels into it, and it weighs each individual kernel to determine whether the batch hits that 13-14% sweet spot.
If the kernels aren’t quite there yet, they go into large commercial grain dryers. These massive dryers circulate warm air (never too hot — that would damage the kernels) for anywhere from half a day to two full days. The dryers constantly monitor and adjust the temperature and airflow, moving kernels around until they reach the right moisture levels.
The Pop Test
After visiting the field, this was probably our favorite part of the tour. Throughout the whole process, they take samples of the kernels and pop them to guarantee they not only look great but also reach the volume and size you expect your popcorn to be.
They measure how much the kernels expand when they pop (good popcorn should get about 35 times bigger) and count how many kernels actually pop (they want 98% or higher). If a batch doesn't meet these standards, it either gets more processing or doesn't make the cut.
Keeping Everything Fresh
All this processed popcorn is then stored in climate-controlled facilities where they keep the moisture content at precisely 13-14%. Too moist, and the kernels risk spoiling. Too dry, and they won’t pop.
The Passion Behind Your Favorite Snack
For farmers like Brian, who has been planting popcorn since 1979, what they do isn’t just a job. It’s a labor of love that requires expertise, patience, and genuine passion for what they do. And now that you know what the entire process involves, we bet you’ve gained a whole new appreciation for your go-to movie night snack.
Ready to experience the difference that expertly grown popcorn makes? Try our premium yellow popping corn in your Popper and taste the result of decades of farming expertise.
