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 for snack lovers. It’s the perfect mix of buttery caramel and crispy kettle chips that’ll have you reaching for more every time.

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

I can’t overstate how much I adore this Kettle Chip Caramel Popcorn Recipe. It’s not just your average caramel popcorn — the kettle chips add a fantastic crunch and just the right amount of saltiness, creating a snack that’s truly addictive. It’s great for movie nights, gifting, or just treating yourself after a long day.

Unique Crunch: The kettle chips bring an extra crisp texture that takes this popcorn to the next level.
Perfect Sweet & Salty Balance: Caramel and sea salt kettle chips are a match made in snacking heaven.
Fun to Make: Making the caramel sauce and mixing it all together is a really satisfying hands-on experience.
Great for Sharing: Whip up a batch for friends or family and watch it disappear fast!

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 recipe blends familiar snack pantry staples with a few caramel-making essentials that come together beautifully. Each ingredient has a special role to create the perfect sweet, salty, and crunchy treat.

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

Plain unsalted popcorn: Provides a neutral, crispy canvas so every kernel gets coated perfectly in caramel without added salt.
Kettle Brand Sea Salt Kettle Chips: Adds a unique salty crunch that complements the caramel’s sweetness — don’t skip this!
Unsalted butter: The base for the caramel’s rich flavor and silky texture.
Light brown sugar: Offers that deep molasses sweetness essential for that classic caramel flavor.
Corn syrup: Keeps the caramel smooth and prevents crystallization, making for that perfect glossy coating.
Vanilla extract: Adds warmth and rounds out the caramel flavor.
Baking soda: Lightens the caramel by creating tiny bubbles, so the coating isn’t too dense or sticky.
Milk or semi-sweet chocolate chips: A drizzle of chocolate on top adds a beautiful finish and extra layer of flavor.
Sprinkles (optional): For a fun pop of color and a little festive flair.

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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

This Kettle Chip Caramel Popcorn Recipe really invites customization. I love to mix things up depending on my mood or the occasion, and you should definitely make it your own by trying a few variations.

Variation: One time, I swapped the kettle chips for spicy chili lime chips – it created an amazing sweet, salty, and spicy kick that was so unexpected and delicious.
Dietary Modifications: For a dairy-free version, try using coconut oil instead of butter and check that your chocolate chips are dairy-free too.
Seasonal Change: During holidays, I sprinkle crushed peppermint candies or nuts on top for an extra festive twist.
Sweetness Level: You can tweak the brown sugar amount to make it less sweet, just watch the caramel texture.

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

Step 1: Popcorn and Kettle Chips Ready

Start by popping 11 cups of plain unsalted popcorn – if you want to keep it healthy, air-popped works best. Then crush your kettle chips lightly; you’re aiming for about 2 ½ cups of slightly broken pieces that’ll mingle nicely with the popcorn without disappearing completely. Toss them together in a very large mixing bowl because the caramel will need plenty of space.

Step 2: Making the Caramel Sauce

Melt ½ cup unsalted butter over medium heat in a 2-quart saucepan. Stir in 1 cup packed light brown sugar and ½ cup corn syrup, bringing it all to a boil while stirring constantly. The key here is to let it boil for exactly 5 minutes without stirring after it reaches a boil—this steady heat is what develops that luscious caramel flavor. If you have a candy thermometer, 252°F is your sweet spot.

Step 3: Add Vanilla and Baking Soda

Immediately remove the caramel from heat and stir in 1 teaspoon vanilla extract plus ½ teaspoon baking soda. It’ll foam up and double in size, so be sure to stir well quickly but carefully – this aeration ensures your caramel will coat evenly without being too sticky or dense.

Step 4: Toss and Bake

Pour your hot caramel mixture over the popcorn and kettle chips, then toss rapidly using a spatula or your hands (careful, it’s hot!). Spread everything out on a baking sheet lined with a silicone mat. Pop it in the oven at 250°F for one hour, making sure to stir and toss the popcorn every 15 minutes – this steady baking step helps the caramel set perfectly crisp and evenly coated. If you’re adding sprinkles, do that right when you take the popcorn out of the oven.

Step 5: Drizzle with Chocolate

While the popcorn cools, melt ¾ cup chocolate chips gently in the microwave at 50% power, stirring every 30 seconds until smooth. Pour the melted chocolate into a small resealable bag, cut a tiny tip off the corner, and drizzle the chocolate over the popcorn. Let it set completely at room temperature or in the fridge before breaking into pieces.

Top Tip

From my many batches, here are some game-changing tips that will help you nail this Kettle Chip Caramel Popcorn Recipe just like I do every time.

Even Tossing: Toss thoroughly but gently when coating popcorn so every bite is caramel-kissed without clumping.
Watch the Boil: Timing the 5-minute boil is crucial for caramel texture—too short and it’s sticky; too long and it can burn.
Use Silicone Mats: Baking on silicone instead of parchment prevents sticking and helps even caramel setting.
Chocolate Drizzle Patience: Let the popcorn cool before adding chocolate so it sets beautifully without melting the caramel.

How to Serve Kettle Chip Caramel Popcorn Recipe

kettle chip caramel popcorn - Serving Suggestion

Garnishes

I keep things simple by adding a sprinkle of rainbow nonpareils or edible glitter for festive occasions. Sometimes a pinch of flaky sea salt sprinkled right after baking balances the sweetness even more beautifully. It’s a small touch that makes a big difference.

Side Dishes

This caramel popcorn pairs wonderfully with a cup of hot coffee or tea, especially while binge-watching your favorite series. For parties, I like serving it alongside fresh fruit or a cheese platter—the sweet and salty notes contrast nicely.

Creative Ways to Present

Try packing your Kettle Chip Caramel Popcorn Recipe into mason jars tied with rustic twine as thoughtful homemade gifts. For celebrations, filling decorative bowls or festive tins makes it feel extra special and inviting.

Make Ahead and Storage

Storing Leftovers

Stored in an airtight container at room temperature, this popcorn stays crunchy and flavorful for up to a week. I always recommend waiting until it’s completely cool before sealing – trapping in warmth can cause stickiness.

Freezing

Freezing isn’t my preferred method, but if you want to save some for later, place cooled popcorn in a zip-top freezer bag with air squeezed out. Thaw at room temperature before serving to regain crispness.

Reheating

If the popcorn softens a bit, a quick 5-7 minute bake at 275°F on a lined sheet will help recrisp it beautifully. Just watch to avoid burning your caramel or chocolate drizzle.

Frequently Asked Questions:

Can I use flavored popcorn instead of plain in this Kettle Chip Caramel Popcorn Recipe?

It’s best to use plain, unsalted popcorn because the caramel and kettle chips already provide plenty of flavor and salt. Flavored popcorn might compete with or overpower the caramel coating.

What’s the best way to crush kettle chips for this recipe?

I usually place the kettle chips in a large zip bag and gently crush with a rolling pin or bottom of a heavy glass. You want pieces about 1 to 2 inches big — not too fine, but small enough to mix evenly with popcorn.

Can I skip the chocolate drizzle?

Absolutely! The chocolate drizzle is optional and adds a lovely final touch, but the caramel-coated popcorn and kettle chips are delicious on their own if you prefer to skip it.

How do I know when the caramel is ready during cooking?

Once your caramel mixture boils, set a timer for 5 minutes without stirring. If you’re using a candy thermometer, it should reach about 252°F. This ensures the perfect chewy yet crisp caramel texture.

Final Thoughts

This Kettle Chip Caramel Popcorn Recipe quickly became one of my go-to treats when I want a little indulgence with a twist. It’s easy enough for a lazy afternoon and impressive enough to share as a gift or at a gathering. Once you try it, you’ll see why it's such a crowd-pleaser. I can’t wait for you to make it and hear what you think — trust me, it’s a keeper!