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)

Crunchy, sweet, and with that unexpected salty twist, this Kettle Chip Caramel Popcorn Recipe is an absolute game-changer! It’s like your favorite movie snack got a grown-up makeover—trust me, once you try it, you’ll be hooked.

A close-up view of a red bowl filled with caramel popcorn mixed with light brown potato chips. The popcorn is coated with a shiny caramel layer, drizzled with thin lines of chocolate, and sprinkled with small red, green, and white round sprinkles. Some popcorn and chips are spilled around the bowl on a white marbled surface with a red and green cloth in the background. The texture of the caramel popcorn is slightly shiny and sticky, while the potato chips are smooth and crisp. 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

I first stumbled upon this combo when I wanted something crunchy but a little salty to balance the sweet caramel. The pop of kettle chips adds such a fun, addictive texture that you don't get with regular caramel popcorn. I’ve made it dozens of times, and it’s always a crowd-pleaser.

Unique Texture Pairing: The kettle chips bring an irresistible crunch that perfectly contrasts the soft caramel coating.
Sweet and Salty Harmony: That sea salt from the kettle chips balances the caramel sweetness, making it less cloying.
Easy Yet Impressive: Despite the gourmet vibe, this recipe comes together with simple steps and common ingredients.
Customizable Fun: Chocolate drizzles and sprinkles let you add your personal flair and seasonal twists.

This image shows a close-up of a mix of caramel popcorn and thin apple slices spread in one even layer. The popcorn is golden and shiny from caramel coating, with some white fluffy parts visible. The apple slices are light yellow with some texture, mixed within the popcorn. Thin dark brown chocolate lines are drizzled diagonally over the whole mix. Small red, green and white round sprinkles are scattered on top, adding tiny specks of color. The whole scene is laid on a white marbled texture. photo taken with an iphone --ar 2:3 --v 7

Ingredients & Why They Work

This recipe combines basics you probably have with a clever surprise—those kettle chips. Each ingredient pulls double duty to deliver a satisfying taste and texture combo. When shopping, look for good quality kettle chips and fresh popcorn to get the best results.

Flat lay of a large simple white ceramic bowl filled with fresh popped plain unsalted popcorn, a small white bowl holding slightly crushed golden kettle chips, a small white bowl containing rich golden melted butter, a small white bowl with packed light brown sugar, a small white bowl with glossy amber corn syrup, a small white bowl with smooth semi-sweet milk chocolate chips, a tiny white bowl with light tan baking soda powder, and a small white bowl with translucent vanilla extract liquid, all ingredients fresh and natural, perfectly arranged in balanced symmetry, placed 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: Acts as a neutral canvas to soak up that luscious caramel without extra salt overpowering the balance.
Kettle Brand Sea Salt Kettle Chips: Crucial for the signature crunch and salty note; crushing them slightly helps them stick and distributes flavor.
Unsalted Butter: Creates the rich base for the caramel, and using unsalted lets you control the salt.
Light Brown Sugar: Adds deep molasses flavor and gives the caramel its classic golden color.
Corn Syrup: Keeps the caramel smooth and prevents crystallization for that perfect sticky texture.
Vanilla Extract: Enhances the overall flavor with warm, sweet undertones.
Baking Soda: Reacts to create a lighter, airy caramel coat that isn’t too heavy or sticky.
Chocolate Chips (Milk or Semi-Sweet): A decadent finish that offers richness and a little snap when you bite in.
Sprinkles (Optional): Fun for a festive touch, personalizing the look and adding a pop of color.

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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

One of the best things about this Kettle Chip Caramel Popcorn Recipe is that you can tailor it to suit your taste or dietary needs. I often switch up the chocolate drizzle or add a pinch of cayenne for heat when I want a little kick.

Variation: Once, I swapped kettle chips for plain salted ones and added chopped nuts – it was deliciously crunchy but didn’t have quite the same salty punch. The kettle chips really are the star here.
Dietary Modifications: For a dairy-free version, use coconut oil instead of butter and check your chocolate chips for vegan options – it works surprisingly well!
Seasonal Flavors: During the holidays, I sprinkle festive sprinkles on top and sometimes mix in crushed peppermint candies for a cool twist.

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

Step 1: Prep and Combine the Popcorn & Chips

First, pop your plain unsalted popcorn and set it aside in a large bowl. Then, grab your kettle chips—crush them slightly so they measure around 2 ½ cups. Toss the popcorn and chips together gently. This mix gives you those little crunchy surprises you’ll love. Make sure your bowl is extra large because the caramel coating adds bulk later on.

Step 2: Make the Caramel Sauce

In a 2-quart saucepan, melt the butter over medium heat. Stir in light brown sugar and corn syrup until the mixture comes to a boil. Now, this is key: let it boil for about 5 minutes without stirring. If you’re using a candy thermometer, aim for 252°F—that’s the sweet spot for coating without burning.

Remove it from heat quickly, stir in vanilla extract and baking soda. Watch as it foams up—that’s the magic happening. The baking soda lightens the caramel, so it wraps the popcorn and kettle chips without weighing them down.

Step 3: Coat and Bake

This part can get a little messy but stay patient. Carefully drizzle the hot caramel over your popcorn and kettle chip mix. Use a big spoon or spatula to toss everything so every piece gets that glossy coat. Spread it out evenly on a baking sheet lined with a silicone liner or parchment paper.

Bake in a 250°F oven for an hour, tossing every 15 minutes. The repeated tossing helps prevent clumps and encourages an even bake. If you’re adding sprinkles, sprinkle them on as soon as it comes out of the oven for the best stick.

Step 4: Add the Chocolate Drizzle

While the caramel popcorn cools, melt your chocolate chips in the microwave at 50% power in 30-second intervals, stirring well between each. Once smooth, transfer the chocolate into a small plastic bag, snip a tiny corner, and drizzle over the cooled popcorn. Let the chocolate set at room temperature or pop it in the fridge for a quicker finish.

Step 5: Break and Store

Once everything's set and cooled, break the popcorn into bite-sized clusters. Store it in an airtight container at room temperature to keep that crunch. I find it lasts beautifully for up to a week if you don’t eat it all right away!

Top Tip

I’ve learned some handy tricks that make this Kettle Chip Caramel Popcorn Recipe foolproof and extra tasty. These little tips can save you a lot of stress and help you wow your friends with that perfect crunchy coating.

Don’t Skip the Baking Soda: It might seem odd, but the soda helps the caramel get airy and evenly coat the popcorn without being too sticky.
Use a Candy Thermometer or Timer: Five minutes of boiling is critical—too short and your caramel will be too soft; too long and it might burn or be too hard.
Mix While Baking: Tossing the popcorn and chips every 15 minutes prevents clumps and encourages even coating and crunch.
Cool Completely Before Storing: This keeps your popcorn crisp rather than soggy from trapped moisture.

How to Serve Kettle Chip Caramel Popcorn Recipe

Kettle Chip Caramel Popcorn - Serving Suggestion

Garnishes

I love topping mine with festive sprinkles for holidays like Halloween or Christmas—it adds a cheerful color pop and a bit of extra fun. Sometimes, a sprinkle of flaky sea salt on top of the chocolate drizzle amps up the salty-sweet vibe perfectly.

Side Dishes

For movie nights, I like pairing this popcorn with a tall glass of cold milk or a creamy hot chocolate. It also works great alongside dark chocolate bark or fruit skewers for a snack spread that balances sweet and savory.

Creative Ways to Present

One time, I served this popcorn in small mason jars tied with twine as party favors—everyone loved the personal touch and the crunchy treat inside. You could also layer it in a decorative bowl with other snacks or drizzle extra melted chocolate for a fancy touch.

Make Ahead and Storage

Storing Leftovers

I store leftover kettle chip caramel popcorn in an airtight container at room temperature—usually a large glass jar or a tightly sealed plastic container works best. Keeping it away from humidity helps it stay crunchy for up to a week.

Freezing

Freezing isn’t my go-to because it can affect the texture a bit, but if you must, use a freezer-safe bag and thaw it fully before serving to avoid sogginess. Still, fresh is definitely best here.

Reheating

If your popcorn loses a little crunch, just pop it in a warm oven at 250°F for 5 to 10 minutes to refresh that caramel coating and crisp it back up—just be careful not to burn anything.

Frequently Asked Questions:

Can I use flavored popcorn instead of plain?

Using flavored popcorn can work but I recommend plain unsalted because it lets you control the saltiness and prevents competing flavors with the kettle chips and caramel. Flavored popcorn might clash or overwhelm the taste.

What’s the best way to crush the kettle chips?

I usually put them into a large zip-top bag and gently press with a rolling pin or the bottom of a sturdy pan until the chips break into smaller, bite-sized pieces. Avoid pulverizing into crumbs—you want noticeable crunchy chunks!

Can I make this recipe without chocolate?

Absolutely! The chocolate drizzle is optional and adds extra flavor, but the caramel and kettle chips alone make for an incredible treat. You can also try drizzling caramel sauce or sprinkling sea salt as alternatives.

How long does this popcorn stay fresh?

Stored properly in an airtight container at room temperature, this popcorn stays fresh and crunchy for up to one week. Beyond that, it may start to lose its crispness but should still taste good.

Final Thoughts

This Kettle Chip Caramel Popcorn Recipe has such a special place in my snack rotation because it feels both indulgent and unique. Sharing it with friends always leads to surprised smiles and "Where did you get this?!" questions. It’s easy enough to make at home but tastes like you bought it at a fancy shop. I’m excited for you to try it and make it your own — this crunchy, sweet-and-salty treat just might become your new favorite snack too.