Name: Kettle Chip Caramel Popcorn Recipe
Prep time: 15 min
Cook time: 1 h 10 min
Total time: 1 h 25 min
Cuisine: American
Ingredients: 11 cups popped plain unsalted popcorn; 4 cups Kettle Brand Sea Salt Kettle Chips, slightly crushed to about 2 1/2 cups; 1/2 cup unsalted butter; 1 cup packed light brown sugar; 1/2 cup corn syrup; 1 tsp vanilla extract; 1/2 tsp baking soda; 3/4 cup milk chocolate or semi-sweet chocolate chips; Sprinkles (optional)

You know that magical moment when salty meets sweet and crunchy? That’s exactly what happens with this Kettle Chip Caramel Popcorn Recipe. The addition of kettle chips adds a brilliant salty crunch that pairs perfectly with the buttery caramel — trust me, you’re going to want to make this again and again.

A large white bowl is filled with a festive mix of popcorn and chip pieces, all covered in a shiny caramel glaze that makes the snack look sticky and sweet. The popcorn is golden and white, topped with thin drizzles of milk chocolate in wavy lines. Tiny red, green, and white round sprinkles are scattered all over, adding bright, colorful dots. The bowl sits on a white marbled surface with a red plaid cloth slightly visible in the background, giving a warm holiday feel. Photo taken with an iphone --ar 2:3 --v 7

Jump to:

Why You'll Love This Recipe
Ingredients & Why They Work
Make It Your Way
Step-by-Step: How I Make Kettle Chip Caramel Popcorn Recipe
Top Tip
How to Serve Kettle Chip Caramel Popcorn Recipe
Make Ahead and Storage
Frequently Asked Questions:
Final Thoughts
Kettle Chip Caramel Popcorn Recipe

Why You'll Love This Recipe

This Kettle Chip Caramel Popcorn Recipe quickly became one of my favorite treats to whip up for movie nights and casual get-togethers. It’s just the right balance of crunchy, sweet, and salty, with that unexpected twist from the kettle chips that makes each bite exciting.

Unique Flavor Combo: The salty crunch of kettle chips mixed with rich caramel creates a mouthwatering contrast you won’t find in regular caramel popcorn.
Easy to Make: With simple pantry ingredients and straightforward steps, you can have this snack ready without fuss.
Perfect for Sharing: It’s a great treat for parties, gifts, or just binge-watching your favorite shows.
Customizable Touches: Add sprinkles or drizzle with chocolate to fit your mood and occasion.

The image shows a close-up of a snack mix mostly made of popcorn covered in a shiny caramel glaze, with slices of golden brown apple pieces mixed in. The popcorn and apple slices are drizzled with thin lines of milk chocolate on top. Small red, white, and green round sprinkles are scattered throughout, adding bright spots of color. The mix looks crunchy and sticky with a rich texture. The background is a white marbled surface. photo taken with an iphone --ar 2:3 --v 7

Ingredients & Why They Work

Every ingredient plays a role in delivering that irresistible crunch-and-caramel combo. When you combine them thoughtfully, you end up with popcorn that’s both crispy and perfectly coated with caramel—and the kettle chips bring that salty personality.

Flat lay of fresh popped plain unsalted popcorn fluffy and white, a small pile of slightly crushed golden sea salt kettle chips, a small white ceramic bowl with melted golden unsalted butter, a small white ceramic bowl filled with packed light brown sugar crystals, a small white ceramic bowl of glossy amber corn syrup, a small white ceramic bowl holding rich dark brown vanilla extract, a small white ceramic bowl with fine off-white baking soda powder, a small white ceramic bowl filled with smooth semi-sweet chocolate chips, a tiny mound of colorful round sprinkles — all arranged symmetrically on a clean white marble surface, soft natural light, photo taken with an iPhone, professional food photography style, fresh ingredients, white ceramic bowls, no bottles, no duplicates, no utensils, no packaging --ar 2:3 --v 7 --p m7354615311229779997

Popped Plain Unsalted Popcorn: Starting with unsalted popcorn lets you control the saltiness, so the kettle chips really shine.
Kettle Brand Sea Salt Kettle Chips: The star of this recipe, crushed to the right size so they mix well without overpowering.
Unsalted Butter: It adds richness without extra salt, helping create a smooth caramel base.
Light Brown Sugar: Moist and flavorful, brown sugar deepens the caramel’s taste with subtle molasses notes.
Corn Syrup: Keeps the caramel soft and chewy instead of hardening into candy.
Vanilla Extract: Brings warmth and enhances the caramel’s flavor.
Baking Soda: Added at the end to aerate the caramel, creating a lighter, melt-in-your-mouth coating.
Milk or Semi-Sweet Chocolate Chips: Melts into ribbons that add chocolatey richness, balancing salty and sweet perfectly.
Sprinkles (Optional): For a festive pop of color, especially fun during holidays or celebrations.

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Note: You'll find the complete list of ingredients, along with their exact measurements, in the printable recipe card at the bottom of this post.

Make It Your Way

I've played around a lot with this recipe, and what I really love is how easy it is to customize. Sometimes I swap out the chocolate drizzle for white chocolate, or toss in a handful of chopped nuts for extra texture. You can totally make this your own.

Variation: Adding a pinch of cayenne for a subtle kick is something I tried on a whim—it’s surprisingly addictive if you like a little heat with your sweet and salty.
Dietary Switch: Use dairy-free butter and dark chocolate to make it vegan-friendly without losing flavor.
Seasonal Twist: Swap sprinkles for crushed peppermint candies during winter for a festive vibe that guests love.

Step-by-Step: How I Make Kettle Chip Caramel Popcorn Recipe

Step 1: Prep Your Popcorn & Kettle Chips

First, pop your popcorn if you haven’t bought it pre-popped—just make sure it’s plain and unsalted. Toss the popcorn and slightly crushed kettle chips together in a large bowl to prepare for the caramel. The chips shouldn’t be crushed too fine; about bite-sized pieces work best to maintain that satisfying crunch.

Step 2: Make the Caramel Sauce

Melt your butter over medium heat in a saucepan, then mix in brown sugar and corn syrup. Stir constantly as it comes to a boil to prevent burning. Once boiling, resist the urge to stir and let it bubble gently for 5 minutes—this sets the perfect caramel consistency. If you have a candy thermometer, aim for 252°F. Remove from heat quickly, then stir in vanilla and baking soda; the mixture will foam up—don’t be alarmed, it’s supposed to. This little fizz makes the caramel lighter and easier to coat your popcorn.

Step 3: Coat the Popcorn Mixture

Pour the hot caramel over the popcorn and chips carefully and toss with a large spoon or spatula to coat evenly. Work quickly but gently so you don’t break apart the popcorn too much. Spread the coated mixture in a single layer on a lined baking sheet—you want even coverage for the next step.

Step 4: Bake for Crispy Perfection

Bake in your preheated 250°F oven for one hour, stirring every 15 minutes. This slow bake helps the caramel set and crisp up without burning. If you want to add sprinkles, toss them on right after this bake while the popcorn is still warm. Then let the entire batch cool completely before moving on.

Step 5: Drizzle with Melted Chocolate

Pop the chocolate chips into a microwave-safe bowl and heat on 50% power in 30-second increments, stirring each time until smooth. Transfer the melted chocolate to a resealable bag, cut a tiny tip from the corner, and drizzle over your cooled popcorn. Let it set at room temperature or in the fridge before breaking into clusters.

Top Tip

From my many batches of this Kettle Chip Caramel Popcorn Recipe, I’ve learned a few tricks that make all the difference. These tips have saved me from sticky messes and uneven coatings more times than I can count.

Don’t Skip the Baking Soda: It sounds odd, but that foaming step helps the caramel be less dense and less likely to clump.
Even Tossing: Stirring the popcorn every 15 minutes while baking keeps the caramel from pooling and ensures every piece crisps beautifully.
Use a Large Bowl: When coating with caramel, bigger is better to avoid spills and make tossing easier.
Don’t Overcrowd the Bake Sheet: Spread your popcorn in a single layer; piles will steam and stay soggy.

How to Serve Kettle Chip Caramel Popcorn Recipe

Garnishes

I often top mine with rainbow sprinkles to add a cheerful touch, especially for parties or kids’ gatherings. Sometimes I sprinkle flaky sea salt to amp up that salty-sweet vibe even more. Either way, the garnish is totally optional but fun for a bit of flair.

Side Dishes

This snack pairs beautifully with a simple charcuterie board or a fruity punch. But honestly, I love serving it straight up for movie nights—it’s all you need for a satisfying snack.

Creative Ways to Present

I’ve wrapped small batches in cute cellophane bags tied with ribbon to give as gifts during the holidays. For bigger gatherings, I set out a popcorn bar with toppings like mini M&Ms, crushed nuts, and extra caramel drizzle for guests to customize their servings.

Make Ahead and Storage

Storing Leftovers

This popcorn keeps best in an airtight container at room temperature, away from humidity. I usually store mine in a large glass jar or a sealed plastic container, and it stays fresh and crunchy for up to a week.

Freezing

I’ve frozen leftovers successfully in zip-top freezer bags, but I recommend checking for condensation when thawing. Sometimes it softens the popcorn slightly, so enjoy it quickly after defrosting for best texture.

Reheating

If the popcorn loses crunch, pop it in a low oven (about 250°F) for 5-10 minutes to refresh that crispiness. Just keep a close eye so it doesn’t burn or melt the chocolate drizzle.

Frequently Asked Questions:

Can I use other types of chips instead of kettle chips?

You can, but kettle chips add a distinctive robust crunch and saltiness that really elevates this popcorn. Regular potato chips might get soggy faster or lack that satisfying texture. If you use another chip, try thick-cut or sturdy ones to maintain crunch.

How long does the popcorn stay fresh?

Stored in an airtight container at room temperature, this caramel popcorn stays fresh and crispy for up to one week. Avoid humid environments to keep it crunchy longer.

Can I make this recipe gluten-free?

Absolutely! All the ingredients are naturally gluten-free, but always double-check your kettle chips and sprinkles to ensure they don’t contain gluten additives.

What’s the best way to melt the chocolate for drizzling?

Microwaving chocolate chips at 50% power in 30-second intervals with stirring between each is the easiest way to get a smooth, lump-free drizzle. Alternatively, you can use a double boiler on the stove but be careful not to overheat.

Final Thoughts

I’ve always found that this Kettle Chip Caramel Popcorn Recipe is more than just a snack—it’s a little celebration in a bowl. Whether you’re sharing it with friends or indulging solo, it never fails to delight with its mix of textures and flavors. Give it a try—you might just have a new favorite popcorn recipe on your hands.