From Corn Kernel to Delicious Popcorn: A comprehensive guide on the popcorn making process detailing from preparation of the kernels to final bagging Popcorn is a delicious and popular snack for many, whether at weddings and events or while watching movies at home. Although popcorn can be bought ready-made in stores, it can also be easily prepared at home, and it can also be mass-produced in factories. The process of making popcorn is based on turning corn kernels into hard, puffy kernels using heat. In this field, there are many ways to prepare popcorn, from traditional methods using fryers to advanced methods used in factories. In this context, we will talk about the process of making popcorn in factories, where the process of converting corn grains into popcorn takes place, and this process includes several steps, starting from cleaning the corn grains and preparing them for the blowing process, all the way to packing them in the final bags. To watch a video on how to make popcorn, click here The basic steps in the method of making popcorn The steps of the method of manufacturing popcorn in factories differ from the method of preparing it at home, as the process of converting corn grains into popcorn takes place collectively and in an industrial manner. The basic steps in the method of manufacturing popcorn in factories include: 1- Grain cleaning: Grain cleaning is the process of removing impurities, dust, and unwanted parts from corn grains before turning them into popcorn. Grains are cleaned in factories using compressed air, where they are exposed to a strong stream of compressed air to remove any impurities or dust stuck on them. This is done in special cleaning machines called “grain cleaning machine” or “grain cleaner”. The grains are cleaned for several reasons, the first of which is to ensure the quality of the final popcorn, as the presence of impurities, dust and unwanted parts affects the taste and the final quality of the popcorn. The grains are also cleaned to protect the equipment used in the process of converting into popcorn, as the presence of impurities and unwanted parts can lead to damage to the equipment and reduce its lifespan. Finally, the kernels are cleaned to protect the health of the consumer, as the presence of impurities and unwanted parts can lead to spoilage of popcorn and poisoning of consumers. The grain cleaning process varies according to the factories and the tools used, and it may include the cleaning process in several stages, where different tools are used to effectively remove impurities, dust, and unwanted parts. The grain cleaning process in factories usually includes the following steps: 1- Grain sorting: Grains are carefully sorted to remove damaged grains or those containing unwanted seeds or parts. 2- Washing: The beans are washed using clean water to remove dirt and external impurities. 3- Drying: The grains are dried well using hot air or sunlight, to ensure that they are completely dry and do not contain any moisture. The factories follow the process of cleaning the grains periodically and regularly to ensure the quality of the final popcorn and avoid any health problems or risks. The grain cleaning process is one of the important factors in improving the quality of popcorn and avoiding any health problems for the consumer. 2- Preparing for blowing: The pre-popping process is the next step in the industrial popcorn process after the grain cleaning process. It is the process of preparing corn grains for blowing by exposing them to a high temperature and a certain humidity to prepare them for the blowing process. Preparation for blowing is done by placing the grains in a special room containing hot water vapor, in order to increase the moisture of the grains and prepare them for blowing. The temperature and humidity used in the preparation process for blowing vary according to the factories and manufacturing techniques used. The process of preparing for blowing aims to prepare the corn grains for puffing properly and suitable for the subsequent puffing process, as the grains are exposed to high temperature and a certain humidity to improve the ability of the grains to puff. The preparation for blowing is done for several reasons, the first of which is to increase the moisture of the grain and prepare it for blowing, which helps to improve the blowing process and prevents the grain from exploding before the appropriate time. Some factories use modern techniques to prepare for blowing, including: 1- Microwave drying: where the grains are exposed to the microwave for a short period to improve the ability of the grains to puff. 2- Preparation by high pressure: where the grains are subjected to high pressure to increase their ability to blow. 3- Infrared preparation: where the grains are exposed to infrared rays for a short time to improve the grains' ability to blow. The process of preparing for blowing is an important step in the popcorn manufacturing process, as it improves the quality of the final popcorn and reduces the possibility of exploding grains before the appropriate time. It also helps to increase the amount of popcorn produced for factories. 3- Blowing process: The blowing process is the primary step in the process of turning corn kernels into popcorn in factories. The blowing process takes place by exposing the corn grains prepared for blowing to high temperature and high pressure, which leads to the formation of bubbles inside the corn grains and thus greatly increasing their size. The temperature and pressure used in the blowing process vary according to the factories and manufacturing techniques used. The temperature and pressure depend on the desired size and shape of the finished popcorn, as they are adjusted according to the required specifications. The blowing process takes place in special machines called the "blowing machine", and the blowing process takes place automatically after the grains are subjected to appropriate pressure and temperature. The resulting popcorn is collected in special boxes and subsequently cooled before packaging. The blowing process is precisely controlled by adjusting the temperature and pressure in the blowing machine, and the process is monitored and controlled using special testing devices to ensure the quality of the final popcorn. The quality of the finished popcorn is affected by several factors, including the temperature and pressure used in the blowing process, the type of corn grain used, and the pre-puffing process that precedes the blowing process. The quality of popcorn is determined a
