Note that this article has been updated to reflect refinements that have been introduced to our popcorn process over the years. They are tweaks, but make the popcorn even better!
First and foremost, we have switched from Orville Redenbacher popcorn to Kernel Seasons. It tastes better, and also is GMO free.
Second, we pop our popcorn in coconut oil now, which lends a fantastic taste element which will also be familiar, because many (if not most) movie theaters use coconut-based oil for popping.
Third, we use clarified butter instead of just melted butter. This makes a *huge* difference in taste and texture. The clarified butter contains virtually no moisture, so the popcorn stays perfectly crisp, and the butter flavor is concentrated as well. See the sidebar on the right below for tips on how we make clarified butter for popcorn.
Below is the original article, with edits made to reflect the above three changes:
My favorite food is popcorn. I have loved it since I was young, and I have spent a large portion of my adult lifetime refining my recipe to the point where it is perfect to me, and it seems to be popular with those to whom I serve it. There is nothing magical or difficult about the making of this popcorn, nor are the ingredients exotic or hard to find. Any reasonably handy kitchen person should be able to make it with no problem. However, the exact combination of process and ingredients has been perfected through almost 20 years of refinement, and I wanted to share it with my fellow popcorn lovers (and also maybe win a few converts to the manual process).
To make Perfect Popcorn, you need the right equipment. First and foremost, do NOT use a popcorn popper of any kind. They all trap too much steam, which makes the popcorn soggy instead of crispy. Even those with vented tops still have slant-side domed lids, which increase the condensation of steam inside the popper before it can vent. Perfect Popcorn is made in a pot on the stove, using a manual process. Trust me, it’s worth it.
The pot I use is a heavy, expensive 9.5 quart stainless steel pot from Dansk, which I got as a gift from my in-laws, and have used several times a week ever since (thanks Sherry and Bill!!) The bottom is heavy, and contains a copper disk sandwiched between the inner and outer stainless steel layers. The pot you use should be as thick and heavy as possible to ensure even heat distribution and to eliminate scorching. Scorching is the kiss of death to popcorn, as even a few scorched kernels will assault your nose and taste buds, busting your popcorn eating groove. Also, if you can, stay away from non-stick pots, as their surfaces also promote the condensation of steam, and most are not heavy enough to ensure proper heat distribution.
Next, you need a tiny metal saucepan