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 addictive about the crunch mixed with sweetness in this **Kettle Chip Caramel Popcorn Recipe**—a perfect combo of salty meets sweet that just melts in your mouth. It’s one of those treats that’s fun to make and even better to share with friends or family during cozy movie nights.

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 can’t get enough of this Kettle Chip Caramel Popcorn Recipe because it’s a delicious twist on a classic snack. The crunchy, salty kettle chips folded into the caramel popcorn create a satisfying texture and flavor that’s totally unique. Plus, it’s surprisingly easy to pull together—even on a busy day.

Salty & Sweet Harmony: The kettle chips add that perfect salty crunch which compliments the rich caramel coating beautifully.
Simple Ingredients: You don’t need a long list of fancy things; the magic comes from just a few pantry staples and the kettle chips.
Fun to Customize: Whether you want to drizzle chocolate or add sprinkles, it’s easy to make it your own.
Crowd-Pleaser: It’s always a hit at parties and makes the perfect gift when wrapped up in a cute jar.

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

Each ingredient in this recipe plays a key role in creating the irresistible texture and flavor. The kettle chips bring that unique salty crunch, while the caramel is smooth, sweet, and sticky enough to coat everything perfectly. Here’s a quick rundown of why these items come together so well:

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

Plain popped popcorn: Freshly popped popcorn gives you that airy base to soak up the caramel without collapsing under the weight.
Kettle Brand Sea Salt Kettle Chips: These add a salty, buttery crunch that stands out beautifully against the caramel’s sweetness.
Unsalted butter: Creates a rich, smooth caramel base without adding conflicting saltiness.
Light brown sugar: Brown sugar lends a deeper, molasses flavor that makes this caramel more complex than plain sugar.
Corn syrup: Keeps the caramel glossy and prevents it from crystallizing, which helps everything stay nice and sticky.
Vanilla extract: Adds warmth and rounds out the sweetness with a subtle background note.
Baking soda: Reacts with the caramel to create a lighter, fluffier texture that coats better.
Chocolate chips (milk or semi-sweet): A luscious drizzle on top balances the caramel with a creamy, slightly bitter touch.
Sprinkles (optional): Bring a fun pop of color and whimsy, perfect for gifting or parties.

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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 recipe is pretty fantastic as is, but I love tweaking it to suit different moods. Sometimes I add a sprinkle of cayenne for a spicy kick or mix in some chopped nuts for extra crunch. You can totally play around with it—and that's half the fun!

Variation: One time, I swapped the milk chocolate drizzle for dark chocolate and added chopped toasted almonds—trust me, it’s heavenly and feels upscale.
Dietary: Want it dairy-free? Use coconut oil instead of butter and skip the chocolate drizzle or use a dairy-free alternative.
Seasonal twist: Add pumpkin pie spice or cinnamon around fall for an autumn-inspired treat.

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

Step 1: Gather and Set Up Your Popcorn and Chips

Start by popping plain, unsalted popcorn—either on the stove or in an air popper, whatever you prefer. Once it’s popped, measure out 11 cups and place it in a large mixing bowl. Then crush your kettle chips just a little—to about 2 ½ cups—and add them to the popcorn. Set this mix aside nearby because your caramel sauce will be ready soon, and timing is everything here!

Step 2: Make the Caramel Sauce

Melt the unsalted butter in a medium saucepan over medium heat. Then stir in the brown sugar and corn syrup, bringing the mixture to a boil while stirring constantly to avoid burning. Once it’s boiling, set a timer for 5 minutes, but don’t stir—that allows the caramel to reach the perfect temperature. (If you have a candy thermometer, aim for about 252°F.)

After 5 minutes, immediately remove the pan from heat and stir in the vanilla extract and baking soda. Watch the mixture foam up—this is key for a fluffy, airy coating. It might look scary, but it's normal and part of what makes this caramel so good!

Step 3: Coat and Bake Your Popcorn Mix

Carefully drizzle the hot caramel over your popcorn and kettle chips, then toss everything gently but thoroughly to coat every piece. The caramel sets quickly, so work fast but cautiously—the sauce is hot!

Spread the coated popcorn evenly across a baking sheet lined with a silicone mat or parchment paper. Bake at 250°F for 1 hour, stirring or tossing every 15 minutes to prevent burning and help the caramel coat evenly. If you’re adding sprinkles, sprinkle them on right after baking, while the caramel is still warm.

Step 4: Melt and Drizzle the Chocolate

Place your chocolate chips in a microwave-safe bowl and heat them at 50% power in 30-second intervals, stirring in between, until completely melted and smooth. Pop the melted chocolate into a small resealable plastic bag, seal it, and snip off a tiny corner to drizzle the chocolate evenly over the cooled popcorn.

Let the chocolate set at room temperature or in the fridge, then break the popcorn into serving-size pieces. Store everything in an airtight container at room temperature—you’ll want to dig in quickly, believe me!

Top Tip

From my experience, a few little tricks make this kettle chip caramel popcorn shine even brighter—so I want to share those nuggets to help you nail it on your first try.

Don’t rush the boil: Allow the caramel to boil for the full 5 minutes without stirring for that perfect chewy texture.
Use fresh popcorn: Stale popcorn won’t crisp up right and might lead to soggy results, so pop it fresh just before starting.
Mix gently but thoroughly: When coating, toss the popcorn slowly to avoid crushing the chips too much while ensuring every piece gets caramel-lovin’.
Bake and toss: That one hour in the oven with stirring is what solidifies the crunch—skip it and you’ll get clumps instead of crisp bites.

How to Serve Kettle Chip Caramel Popcorn Recipe

kettle chip caramel popcorn - Serving Suggestion

Garnishes

I love topping mine with colorful sprinkles—especially for birthdays or movie nights with kids. Sometimes a little flaky sea salt on top after baking elevates the salty-sweet balance even more. These tiny touches really make the snack feel special.

Side Dishes

This popcorn pairs perfectly with a simple cheese board or a chilled glass of sparkling lemonade. For movie marathons, having some fresh fruit slices on the side balances out the richness of the caramel beautifully.

Creative Ways to Present

I’ve gifted this popcorn in mason jars tied with rustic twine and little custom tags for holidays—everyone loved the personal touch! You can also go all out and serve it in paper cones for kids’ parties or package it in festive bags as party favors.

Make Ahead and Storage

Storing Leftovers

I store leftover kettle chip caramel popcorn in airtight containers at room temperature, ideally in a cool, dry place. It stays fresh and crunchy for up to a week—though honestly, it rarely lasts that long around here!

Freezing

Freezing’s not my go-to for this recipe because it can affect the crispness, but if you need to stash it longer, wrap it tightly in plastic wrap and then foil, thaw at room temperature before serving.

Reheating

If your popcorn loses crunch, popping it in a 250°F oven for 5-7 minutes can bring back a bit of the crisp texture—just watch carefully so it doesn’t burn.

Frequently Asked Questions:

Can I use other brands of kettle chips for this recipe?

Absolutely! While I recommend Kettle Brand Sea Salt for its perfect salty flavor and sturdy crunch, feel free to try your favorite kettle chips. Just crush them slightly before adding to make sure the sizes blend well with the popcorn.

What’s the best way to avoid sticky clumps in the caramel popcorn?

To avoid clumps, make sure to toss the popcorn gently while the caramel is still hot and to stir the mixture every 15 minutes while baking. This keeps the coating even and prevents the pieces from sticking together too much.

Can I make this recipe gluten-free?

Yes! Both popcorn and kettle chips are naturally gluten-free (just confirm the brand you use), and the caramel ingredients don’t contain gluten. This recipe suits gluten-free diets without any swaps needed.

How long does this popcorn stay fresh?

Stored properly in an airtight container at room temperature, your kettle chip caramel popcorn will stay fresh and crunchy for about 5 to 7 days. After that, it might start to lose its signature crispness.

Final Thoughts

I always think of this Kettle Chip Caramel Popcorn Recipe as a little magic in a bowl. The combination of salty kettle chips and sweet, buttery caramel brings so much joy—and it’s so simple to make at home. I really hope you give it a try and feel that same delight I do every time I bite into a crunchy, caramel-coated chip. Trust me, you’ll want this recipe bookmarked for all your snack emergencies and special gatherings!