P O P C O R N
shape and texture of the kernel but the main desired attribute is its expansion rate. Most corn when it pops takes on an irregular shape and is referred to as ‘flake’ or ‘butterfly’ popcorn. Others take on a more rounded shape and are referred to as ‘ball’ or ‘mushroom’ corn. Yellow popcorn is the most commonly used for commercial applications since it is less fragile than the white version mostly consumed in the home. The kernels are rounded in shape and have a medium brown colour. Within this group there are several options available to the buyer.
Years in the Making Preferred Popcorn grows 25 different genetic variations to meet the needs of its customers. “That starts with yields of sampling from which we test over 100 different varieties and narrow it down to make sure we’re growing the best crop,” Peace explains. “If you genetically modify it, you change the genetic code of the popcorn and get the attributes you want in one year,” he says. “We do not do that. We employ doctoratelevel biologists to help us selectively breed over many years to achieve the attributes we want. Each variety has a specific use and a specific customer in mind when we grow it.”
Heavy-duty equipment is needed for the growing process
The theatre owner buys popcorn by weight and sells it by volume (in a box or bag). High expansion translates directly to increased profitability. Each percentage point of increased expansion is a reduction in raw material cost.
Popcorn hybrids with a thicker protective outer seed
“If you’re a cinema owner you want as much volume out
coating have a greater expansion ratio but this is not the only
of that bag as possible because it means you can sell more
important trait. Other variables include grain yield, kernel
servings,” says Peace. “The expansion level is very important.
length, popping expansion, kernel and protective layer
It is written into all the contracts we have for major cinema
thickness, heat transfer ability, and the amount of protein in
owners.” Expansion is measured as a ratio that compares the
the expansion capacity will help processors identify and breed
number of popped popcorn servings produced from a
high quality popcorn. The moisture content of the hybrid will
specific amount of unpopped popcorn. The test is
also determine the expansion of the popcorn. In addition,
performed with a Metric Weight Volumetric Test (devised
cracks and abrasion on the outside of the kernels will reduce
by Cretors - and they also make the MWVT machines) and
popping expansion; which is what both breeding and
the test is recognised as standard by the popcorn industry.
processing is designed to weed out.
Popcorn Expansion This is the heart (kernel?) of the whole popcorn industry. Different varieties will produce different sized and shaped pieces of popcorn when popped, which has an impact on the cinema owner’s profit. This percentage variance can be quite significant which is why processors go to great lengths to grow varieties with the right (pop-for-buck) ratio. Expansion level is the key metric. This is the amount of growth in volume that the corn goes through in the popping process. In general, the more the corn expands the better the product. High expansion corn is desirable for both the consumer and the manufacturer. From a consumer’s point of view high expansion corn is more tender and has fewer partially popped kernels that are hard to chew. 3 8
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0 6 / 2 2
13.5%
kernels. Understanding which popcorn traits are related to
For example, an expansion of 42:1 means that 1 gram of
unpopped popcorn will produce approximately 42 cubic centimetres of popped popcorn. The higher the MWVT number, the greater the volume of popped corn per weight of unpopped corn. A typical rate would be 42-44. The customer usually equates high expansion corn with
high quality. For the manufacturer, high expansion will create a physically larger bag for the same weight and may be considered better value by the customer. High expansion corn also usually indicates a low percentage of unpopped kernels or scrap. In this case corn is not only purchased by
Popcorn is usually delivered to the user with moisture content between 13.5-14.5% which is when it pops best.
weight but also sold by weight.
From Field to Customer One of the largest contributors to popcorn quality is the processing that the corn is subjected to after being picked. Much of this is automated. www.cinematech.today
