Kettle Corn How To

How to do Kettle Corn Updated Jul 30, 2016, 1:17 PM

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Kettle Corn at Goshen Farmers Market Edwardsville, IL USA Saturday Morning May till October‎ > ‎

How to do Kettle Corn

Hello this is some info on kettle corn from Tomgatelysr@gmail.com

I first started doing Kettle corn with a 80 quart aluminum pot. I also rigged up a burner from stuff used for my propane barbecue. I was able to do a couple of shows with this setup but the popcorn taste burnt.

Kettle

First you need to get a suitable Kettle, call antique places, flea markets, if they know or have seen anyone with kettles. I have seen them as planters in driveways. Must not have holes in bottom. Holes in sides or cracks on sides may be acceptable you just can not have oil draining into fire.

I use a 3 legged cast iron 22" diameter at the top and 14" deep approx Kettle. Get one that one person can pick up. I used a drill and a steel wire wheel to remove rust and other unwanted material from kettle. This took a couple of hours and then some soap and water cleaning. Kettle turns black after use. I paid 120.00 for this kettle.

Burner

They are sold at Sams sometimes and are called a turkey fryer. I have seen them on eBay also.

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Burner Stand used for kettle corn 21 3/4 inches from ground to top ring.

Does not have to be this exact size.

Manufactured by

Metal Fusion INC

712 St George Ave

Jefferson LA 70121

504 736 0201

I ordered the 89 pkp King Kooker 1-800-783-3885 for 60.47 from Shauna on 3-01-01

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Kettle and Burner (Pivots to Pour)

The little leg of the kettle is placed inside the top ring of the burner. I used to bend over to pour the kettle out. This caused a backache. Now I simply move my arms to pour kettle lifting at back and holding down at front keeping back straight. I keep my foot on the bottom ring of burner to keep it from falling over. The little leg of the kettle pivots on the top ring of the burner so the weight of the kettle stays on the stand. This is a little tricky at first but after a few tries easy. Some uncoordinated cooks may still drop the kettle on to the

initial catch bin.

Paddle

I just buy a regular 8.00 canoe paddle from Walmart. I then use a jigsaw to round it at the bottom so it contours to the bottom of the kettle better. I then sand the entire flat surface to remove varnish.

After years of buying Walmart paddles finally bought a piece of wood and made my own. This one has lasted for 3 years and no sign of breaking.

Propane

At first use the barbecue size propane tank these are 20 pound. The burners attach to these and you are ready to cook. I would bring two of the small propane cans to a show. After a couple of shows (or when its best for you)get a 100 pound propane tank. Go to a place that sells propane and ask what there deal is on the big tanks. Some places just give you the tank and you fill it there. Some places rent you a tank and you just keep it as long as you need it. If you get a larger 100 pound tank you will have to get a extension for your burner. The place that gave you the tank will sell you an extension and a regulator to turn the fire up and down. The burners I have bought came with a regulator for the 20 lb tank these regulators work on the 100 lb tank also.

I now use 40lb tanks easier to carry/

Windscreen

I use a trifold plywood piece for a windscreen. This keeps the wind from blowing out the fire and also keeps the heat off of me. Buy a cheap 4x8 plywood sheet. 2 end pieces 42" height x 26" wide , 1 middle piece 42"x 31", 1 strip 42" x 1.5". Screw strip on right edge of middle section. Attach ends with hindges.(see Picture) This is made to fold flat for storage.

Tables

I use 3, 5' heavy folding tables like a school cafeterias but shorter. Sams may sell these.

You can use 2 tables for starters.

Tent

I bought a easy up tent from Sams. I used a cheaper plastic tent before.

Plastic catch bins.

I use a cheap square plastic catch bin and lid for the initial catch bin.

I purchased 2 sturdier plastic bins from a restaurant supply place. I drilled 7/16 holes in the bottom of one of the bins. We pour the popped corn into the initial catch bin. Then move it to the bin with holes in it. After a few minutes it cools and the bagger shakes this bin to remove unpopped kernels from Kettle Corn. The bin with holes in it stays in the other sturdy bin that has no holes. This bottom bin catches alot of the unpopped kernels.

Popcorn Bags

8005445926 The place I get bags now is out at Westport 30 minutes drive west of the St Louis Arch. You could call and see if they will ship bags to you and prices on that. I get the plastic bags here and the paper at sams.

Purchase bags and twist ties From Mid Continent Paper West Port Plaza area St Louis, MO 800-544-5926

bags 5x5x30 .0007mil big bags 2 feet long

bags 9 ¾ x 15 x 4 ½ plastic 1 foot long about the same as a loaf of bread

bags are #4 White small paper bag by from Sams Club discontinued

Popcorn (The good old days all these prices are from pre 2007)

Purchase at Sams 50 pound bag cost 10.00 buy 2 for most shows 5 for big shows.

Vegetable Oil

Purchase at Sams 35 pound box. Buy 1 box per bag of corn. cost about 14.00 per box.

Sugar

Purchase at Sams 25 pound bag. Buy 1 bag per bag of corn.

Salt

Purchase at Aldis buy a box bring 2 full containers to show.

Miscellaneous

We bought 3 plastic stack-able drawers from Walmart to keep bags in on table at booth.

A large pot with lid and ladle to put oil into. A long Lighter to start propane fire. 2 cup plastic measure, 1 tablecloth for each table(the table you cook off of may use a disposable plastic tablecloth). A zippered pouch for change I usually start with 150.00, 100.00 5's and 50 1's but 50.00 would be enough. Snow shovel, broom, trash can.

I purchased a 12 x 10 piece of AstroTurf and put that down to keep oil off of places that have nice concrete. I also put down cardboard to keep oil off of my astroturf.

Method

Arrive at location about 30 minutes before start, find person in charge to verify exact set up location. Put down stuff to save concrete or set up over grass. Set up booth.

I sometimes run a cleaner batch. Put in a small amount of oil 1/4 cup, 1/4 cup corn pop and discard. We use the initial catch bin and lid under it. The batches are swept out in 2 stages, first the popped corn is pushed into the initial bin by the helper with the paddle and second the initial bin is moved and kernels left in kettle are then raked into initial catch bin lid and discarded.

Make the first batch; I have vegetable oil poured from box into large metal pot on table. I use ladle to put 3 cups of oil into kettle. I let this heat for a couple of minutes. If oil starts to smoke it is to hot start cooking. I then put 4 cups of corn and 2 cups of sugar in right away. I then start to stir with the paddle. This batch will not pop out of kettle as bad as cleaning batch because the stuff in there catches some of the popping corn. I always wear sunglasses or some glasses and use regular cotton gloves to handle kettle. I bring a hot mit incase the kettle gets hot and hold it with that and the gloves if needed. I stir constantly until the popping slows and the batch is ready to pour out. I then say "ready".

The helper stops whatever they are doing and takes the paddle. I now tip the kettle the helper rakes out the corn on top, moves the initial catch bin, rakes kernels into initial catch bin lid. I then set down kettle and put in more oil without turning off fire. I usually make about 3 batches to start without shutting off. The helper then moves the cooked corn to the secondary

catch bin with holes in it to cool. The helper can now apply salt pour in a good amount, maybe a 1/8 of a cup per batch. After the corn cools the helper shakes the bin till kernels are out and puts corn into plastic bags. Some times you are so busy the cook gets to shake and all the helper can do is take money. In this instance you must cook ahead I use 2 wooden runners and put them under the front table. Here we store popped corn until sold. Be careful you do not want to have a whole lot of leftovers. Also it is not good to cook a whole lot ahead because the smell of the cooking and the action in the booth draws some sales.

After show find dumpster and pitch everything you can there.

Calling and Finding Shows

This is hard when you are first starting out. I keep a file on the pc called shownotes that is now 37 pages long. As I make my calls I write or type in what happened. You need to get your calendar filled with the weekends you are going to work. I have gotten to the point where I want to only work Kettle corn on Saturday and be off on Sunday. I work during the week at a vending job.

At first I called every little town in my area. Like I called chamber of commerce I asked when are you having any festivals in your town? They usually know of a phone number to call of the person that is in charge of the festival. You call them and they say they already have Kettle Corn or they say they only do thier own food or they may say come on down. If they say come on then ask how much the booth fee is. Keep booth fees low! Find another show if booth fee is over 250.00. Booth fees of 50.00 or less are what I like. Some times you can pay when you get there explaining it may rain or have wind over 25 mph and you may not be able to set up at all. Some school craft shows will do this.

If you are at a show it is good to ask the people there where are you going next week? Tell me some good shows you do. And write down the dates and location call if you are open or want to upgrade.

Look in the newspaper and on internet for a calendar of events in local newspapers website. Street fest or craft shows on the street where the little town goes there are usually the best. Some of these can be dogs though. If you go to a bad one do not go back if you do a good one be sure to do it again.

Good luck in your fundraising efforts.

If you make a grand a day using my methods here I ask that you send me a one time 5.00 dollar payment by paypal to tomgatelysr@gmail.com

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