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)

There’s something utterly irresistible about the sweet-and-salty combo in this Kettle Chip Caramel Popcorn Recipe. The crunch from kettle chips mixed with gooey caramel popcorn? Trust me, once you make it, you’ll see why it’s a total game-changer for snack time or parties.

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 recipe nails that perfect mix of crunchy, sweet, and salty — and the kettle chips add the most satisfying extra layer of texture and flavor. I love pulling this out at casual get-togethers where everyone keeps sneaking more handfuls!

Unexpected Crunch: The kettle chips bring a salty, crispy surprise that takes classic caramel popcorn to a new level.
Easy to Make: With just a few pantry staples and simple steps, you can whip this up without stress.
Customizable: From chocolate drizzle to sprinkles, you can tweak the sweetness and visuals your way.
Great for Sharing: It’s perfect for parties, movie nights, or a special at-home treat that people can’t stop talking about.

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

This kettle chip caramel popcorn mix is all about balancing sweet, salty, and rich buttery flavors with satisfying crunch – the ingredients come together beautifully to create that craveable snack you keep reaching for.

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: The base is neutral so it lets the caramel and chips shine without overpowering salt.
Kettle Brand Sea Salt Kettle Chips: Slightly crushed, these add a bold, crunchy salty layer that's unique here.
Unsalted Butter: Provides richness and a silky texture to the caramel coating.
Light Brown Sugar: Brings deep molasses notes that make the caramel extra flavorful.
Corn Syrup: Keeps the caramel smooth and gives that perfect chewy crunch after baking.
Vanilla Extract: A subtle warmth that rounds out the caramel sweetness perfectly.
Baking Soda: Lightens the caramel mixture with a little foam, helping it coat the popcorn evenly.
Milk or Semi-Sweet Chocolate Chips: Adds a smooth, melty chocolate drizzle that pairs wonderfully with salty chips.
Sprinkles (Optional): For a pop of fun and color, especially at 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

One of my favorite things about this kettle chip caramel popcorn recipe is how easily you can play around with it. I often swap out chocolate chips for white chocolate or add a sprinkle of sea salt at the end for an extra crunch.

Chocolate Swap: I once used dark chocolate chips instead of milk, and the deep bitterness contrasted beautifully with the sweet caramel and salty chips.
Nutty Twist: Toss in chopped toasted pecans or almonds after baking for some nutty aroma and texture.
Spicy Kick: A tiny pinch of cayenne or smoked paprika in the caramel adds a fun surprise that wakes up your taste buds.

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

Step 1: Prep Your Popcorn & Chips

Start by popping about 11 cups of plain unsalted popcorn – I like air-popping it or using a stovetop pot for fresh, crisp results. Meanwhile, gently crush your kettle chips so you get about 2.5 cups worth but still some chunky bits here and there. Toss both in a large mixing bowl and set aside – this combo is going to be magical coated in caramel.

Step 2: Make Your Caramel Sauce

In a medium saucepan over medium heat, melt ½ cup unsalted butter. Once melted, stir in 1 cup packed light brown sugar and ½ cup corn syrup. Bring the mixture to a boil while stirring constantly – this keeps everything smooth and prevents burning. Let it boil without stirring for exactly 5 minutes (I usually set a timer). If you have a candy thermometer, look for about 252°F – that’s perfect for a chewy caramel.

Step 3: Flavor and Combine

Remove the caramel from heat and quickly stir in 1 teaspoon vanilla extract and ½ teaspoon baking soda. It will foam up big time – this is normal and helps make your coating lighter and less sticky. Immediately drizzle the hot caramel over your popcorn and kettle chips, working carefully because it’s super hot! Toss everything gently but thoroughly to coat every bit.

Step 4: Bake and Toss

Spread the coated popcorn mixture evenly on a silicone-lined baking sheet. Bake at 250°F for 1 hour, tossing every 15 minutes to keep the popcorn from clumping too much. This slow bake is key to drying the caramel just right, so it’s crisp but not rock hard. Right after baking, if you want to get festive, sprinkle some colorful sprinkles on top while it’s still warm.

Step 5: Drizzle with Chocolate

Pop your chocolate chips (¾ cup milk or semi-sweet) into a microwave-safe bowl and melt at 50% power in 30-second bursts, stirring well in between, until smooth. Transfer the melted chocolate to a small bag, snip a tiny corner, and drizzle it artfully over the popcorn spread out on parchment. Let the chocolate set at room temperature or in the fridge before breaking into clusters.

Top Tip

Having made this Kettle Chip Caramel Popcorn Recipe many times, I’ve found a few tricks that really make a difference in perfecting the texture and flavor.

Even Coating: Use a large bowl and toss gently but thoroughly when drizzling caramel to ensure every piece gets a lovely glaze.
Temperature Timing: Don’t rush the 5-minute boil at 252°F; it’s crucial for the right chewy consistency. I always use a candy thermometer to be sure.
Baking Patience: Tossing during baking helps avoid popcorn clumps and promotes that perfect crisp without burning.
Chocolate Drizzle: Thin the melted chocolate slightly with a tiny splash of oil if needed — it flows better and looks gorgeous drizzled all over.

How to Serve Kettle Chip Caramel Popcorn Recipe

kettle chip caramel popcorn - Serving Suggestion

Garnishes

I love adding rainbow sprinkles right after baking because the warm caramel helps them stick, and it makes this sweet snack visually festive—perfect for birthday parties or holidays. Sometimes, a little flaky sea salt on top elevates the sweet and salty combo even more.

Side Dishes

This popcorn is fantastic on its own but also pairs wonderfully with simple drinks like iced coffee, sparkling lemonade, or even a light beer if you’re hosting a casual gathering. For dessert spreads, it balances out rich brownies or creamy vanilla ice cream perfectly.

Creative Ways to Present

I’ve served this in big mason jars tied with twine for grab-and-go snacks, or piled it high in a decorative bowl lined with parchment paper when friends come over. For holiday gifting, pack into cellophane bags with a personalized tag—it’s always a crowd-pleaser!

Make Ahead and Storage

Storing Leftovers

I keep leftover kettle chip caramel popcorn in an airtight container at room temperature. It stays crisp and delicious for up to a week, though honestly, it rarely lasts that long at my house!

Freezing

If you want to freeze it, wrap tightly in plastic wrap and place in a freezer-safe bag. Thaw at room temperature before serving. Freezing might soften the crunch a bit, but it’s still tasty and perfect for prepping snacks ahead of time.

Reheating

To re-crisp popcorn that has softened a bit, spread it on a baking sheet and warm in a 300°F oven for 5–7 minutes. Let it cool before munching to revive that irresistible crispiness.

Frequently Asked Questions:

Can I use different chips instead of kettle chips?

Absolutely! While kettle chips add that signature crunch and saltiness, thin regular potato chips or even pretzel pieces work well for a slightly different texture and flavor. Just avoid chips that are too thick or heavily flavored, so they don’t overpower the caramel popcorn.

How do I prevent the caramel from sticking to the bowl or burning?

Stir constantly during the initial melting and sugar dissolving phase to avoid burning. When boiling, keep the heat moderate and time precisely for 5 minutes at 252°F if using a thermometer. Also, using a saucepan with a thick bottom helps distribute heat evenly.

Can I make this recipe gluten-free?

Yes! All the ingredients in this recipe are naturally gluten-free, but always check your kettle chips and any sprinkles for gluten-containing additives. This snack is a safe and tasty option for gluten-sensitive friends.

What's the best way to melt chocolate for the drizzle?

Melting the chocolate in short 30-second microwave bursts at 50% power is key to preventing scorch or graininess. Stirring well between intervals helps ensure a smooth, glossy finish perfect for drizzling. You can add a tiny bit of vegetable oil or shortening if your chocolate gets too thick.

Final Thoughts

Honestly, this Kettle Chip Caramel Popcorn Recipe is one of those happy accidents in my kitchen that quickly became a staple. It’s fun to make, impressive to serve, and way too delicious to keep to yourself. Give it a try—you’ll be amazed at how a few simple ingredients can come together into your new favorite treat. Trust me, you’re going to want to keep the recipe close.