Preparation Steps

• Prepare your popcorn. Place 0.5 cup popcorn kernels in a glass microwave-safe bowl. Cover the bowl with a microwave-safe plate. Microwave for 2-5 minutes, or until there are 1-2 seconds between popping kernels. Carefully remove the hot bowl from the microwave. Repeat this process for a second batch, for a total of 1 cup kernels and about 12-13 cups popped corn.
• Pour the popped popcorn into a very large buttered bowl and set aside. Using a deep bowl, like the top of a cake saver, makes it easier to stir when adding the sauce.
• In a medium saucepan, add water and 0.25 cup unsalted butter. Heat over medium-low heat until the butter is completely melted.
• Add the corn syrup, granulated sugar, and kosher salt to the saucepan. Continue heating over medium-low heat, stirring constantly with a metal spoon, until the mixture starts to simmer. You'll see tiny bubbles forming around the edge of the pot, then covering the entire surface. This typically takes about 5 minutes.
• Continue to heat the syrup over medium-low heat, stirring constantly. Use a digital or candy thermometer to check the temperature until it reaches between 235-240°F (113-116°C). This usually takes approximately 7-8 minutes. Remove the sauce from the heat and stir in the vanilla extract.
• Drizzle the hot sauce evenly over the popped popcorn in the large buttered bowl. Stir with a buttered rubber spatula until all the popcorn is thoroughly coated. Ensure any sauce collected at the bottom of the bowl is evenly distributed. Let the popcorn mixture cool slightly.
• Lay out a large piece of parchment paper or waxed paper on your countertop. With buttered hands, scoop up the popcorn mixture and press it together lightly until it forms a ball, roughly the size of a baseball. Place the formed popcorn ball on the parchment or waxed paper to set. Repeat this process until all the popcorn mixture has been formed into balls.
• Allow the popcorn balls to cool completely and set. Once cool, transfer them into individual sealable baggies or use fold-top baggies tied with festive ribbon for gifting or storage.