Kettle Corn Business FAQ

Can you explain the pilot system / thermocouple feature?

What do you mean by "oven" design and why is it so important when popping kettle corn?

Is the size/capacity of the kettle important?

Is it hard to pop kettle corn? How long before I can "pop like a pro"?

What type of licenses and permits will I need?

What about Health Codes?

What will I need to purchase before my first show?

What ingredients do I need and where can I find them?

Where should I set up my kettle corn operation?

How do I book shows? Any tips?

How do I clean my equipment?

Q: Can you explain the pilot system/thermocouple feature?

A: Ever turn the gas on your outdoor grill, proceed to click the igniter button...click click click... click click....POOOF! Finally the gas ignites, blowing a flame in your face and scaring you half to death! Now, imagine that happening with 10 times the amount of gas!

Companies who offer spark ignition systems on their machines sell you this real and definite safety hazard!

Let me explain how our pilot system works. From the safety valve, there are actually two gas lines - one running to the burner, and one providing fuel to the pilot. The pilot flame is manually lit while the operator presses a safety "release" button. When the thermocouple senses heat from its pilot flame, it will then allow gas to flow to the main burner. Because of the constant pilot flame, the burner can be lit simply by using the ON/OFF handle. This is by far the easiest and safest method of operation....just ask someone who's had to manually light their burner hundreds of times a day because of spark igniter inconsistencies!

Note: A pilot burner without a thermocouple is unsafe. Without a thermocouple, the gas supply to the pilot burner will continue to flow, whether or not the pilot burner is lit. So, if for some reason the pilot flame goes out, gas will continue flowing and collect in the cabinet, creating a huge safety hazard. Don't risk it.

Bottom line, our machine's gas system will not threaten your safety, nor that of your staff or the public. Our systems utilize proper safety measures that will allow fire marshalls to inspect and pass your operation.

Q: What do you mean by "oven" design and why is it so important when popping kettle corn?

A: In your search for kettle corn equipment, you've probably seen several designs on the market. The first appears to be a homemade, basic, open frame. These machines are as simple as it gets; no sides, no lid - just a kettle held up by an angle iron or tubular steel frame with a burner mounted underneath. These types of units are the least efficient and definitely the hottest to operate. Wind can attack the flame from any direction, causing inconsistent flame patterns and sometimes actually blowing out the flame. These units do not trap the essential heat, compromising batch time.

Another model you may have seen is a glorified version of the above; it has three sides attached to the open frame. This is better, but still far from ideal. Wind still finds its way to the open side, causing havoc to the burner flame. Without a lid, both of these units are unbearably hot to operate. Heat always rises, first onto your arms and then into your face. Believe me, I've operated this style of kettlecorn equipment and honestly don't know how anyone can stand to do it for more than a few minutes - it's unbearable. Bottom line: no lid=HOT and inefficient.

North Bend has taken our experience and knowledge and created the perfect popping machine. The gap between the unit and the floor is directly proportional to the amount of combustion air needed to fuel the burner, yet small enough to keep out drafts. The side vent size is proportional to the amount of area needed to emit the flue gases of the burner, and specifically located so wind will not affect your burner flame. And so you have it - an efficient machine, and comfortable to operate.

Q: Is the size/capacity of the kettle important?

A: The kettle's capacity is important; however, the diameter, depth and shape of the kettle are even MORE important. The depth of the kettle should be deep enough to keep large batches of corn in the kettle as they pop (as you stir, the corn goes up the sides of the kettle), yet shallow enough that you can easily stir. A kettle with a spherical shaped bottom (like our 160 quart kettle) creates the best heat/flame distribution and allows for easier stirring. A kettle with a large diameter has more surface area in contact with the flame. Because the oil, corn and sugar can be spread out over this larger area, they heat up faster. This is one of the secrets to being able to produce massive amounts of kettle corn in a short amount of time. A kettle that's too deep is simply unnecessary, wasted volume. Consider this: an enormous 16 cup (8 pound) batch will yield around 100 quarts of popped kettle corn. Most vendors pop 8 cup (4 pound) batches, yielding 50 - 60 quarts popped kettle corn. We could easily add 4 inches to the top of our 160 quart kettle, which would increase the capacity to over 200 quarts - but it would still have the same popping production times.

A good example of how diameter size affects your popping is the comparison between our 160 quart kettle and the 80 quart mixing bowl a few of our competitors offer. For 5 years we manufactured an economy 80 quart popper. In 2007 we discontinued this model due to the shape, construction, and size of the actual kettle - not to mention an almost non-existent demand for this machine. An 80 quart kettle has a very narrow diameter in ratio to its depth. This forces you to stir with your arms extended over the kettle. All the heat from the inside of the kettle rises directly onto the popper's arms (Trust me, this is not good on a hot summer day!) The limited amount of heatable surface area prohibits large batches. Because the 80 quart bowl is actually a commercial mixing bowl, it has a "bump" on the bottom, made for the beaters to go around. This bump does not allow you to use the easy "one-handed, stand back and push/pull" stirring method. The 160 quart kettle is a North Bend Exclusive. It's made of a heavier gauge stainless steel, and the wok design makes popping kettle corn so much easier.

Q: Is it hard to pop kettle corn? How long before I can "pop like a pro"?

A: Many companies will tell you kettlecorn cooking is an art and requires extensive training, "secret" recipes and hours of experience to cook the "perfect" batch of corn. That may be, but the very first batch of corn we cooked in our kettlecorn machine was absolutely AWESOME! We sat there looking at each other with wide eyes and full mouths...WE made THIS? Actually, the very first time we (or actually, just Brad) tried to make kettlecorn was so funny. He decided to make it over the stove in my 8 Qt. cooking kettle. Needless to say, most of the batch popped all over the kitchen floor! The corn was popping, he was trying to pour in sugar and keep stirring it so it wouldn't burn, corn was popping up and hitting him in the face ... I was laughing and saying "You're cleaning up!" It tasted good, though! :)

Bottom line..... if you follow our kettle corn recipe and simple popping instructions, the only way you can mess up your kettlecorn is by burning it. The slightly sweet, slightly salty taste is just plain addicting. The best part of owning your own kettlecorn biz is this: you can take the basic recipe we provide you with and go make money! Or, experiment a little, make some modifications and you'll have your very own "secret" version! Some argue peanut oil is the "only way to go". However, some people are allergic to peanuts products so you'd need to consider that. We think pure corn oil has a great flavor. One guy told us he uses plain old Canola oil and can't tell the difference. Some like brown sugar for the caramel flavor it adds. One of our customers uses Vermont maple syrup. You can buy gourmet powders or syrups and make "gourmet kettle corn". The possibilities are endless. Good luck, and don't forget to HAVE FUN!

Q: What type of licenses and permits will I need?

A: Below are general guidelines.

1. Apply for a state license as a transient food vendor. You can locate your state's Sales TaxDepartment by visiting the Federation of Tax Administrators at www.TaxAdmin.org/fta/link. There is a small fee ($10-$25). This vendor's licensewill enable you to purchase your food products and any products used to clean your equipment tax-free at Wholesale Food Distribution Centers (Sam's Club, Costco, etc). As for charging sales tax, most states do not consider kettlecorn a taxable food.
2. You will need to apply for a Mobile or Temporary Food Service License. Mobile Food Service establishments are generally licensed by your local/county Health Department. The Department will provide you with applicable rules/regulations, forms, etc. There is a fee, ($15 - $200+, depends on your location) and you will need to renew your license annually. A physical inspection may be required before the permit is issued. In some states, your county of residence can issue a state-wide permit. Or, you can just get a license (per event) from the county you'll be popping in.
3. Sometimes, mostly in larger cities, you'll be required to get a "vendor" or "peddler" license if you're selling within city limits. Event coodinators should be able to confirm if this is neccessary.
4. You'll need liability insurance - shop around with your local insurance providers for the best rates. Check with the provider of your current auto or home-owners insurance first; they'll probably give you the best rates since it's an "add-on."
5. Do you have a name picked out for your kettle corn business? By registering your trade name, you'll have exclusive rights to its use. There is an initial filing fee. (approx. $20) Contact your Secretary of State for more information and forms. Most states provide the necessary forms from their web site. Of course, this is optional. :)

Some states do not require you to have a permit if you're doing less than 1 show per month.

Q: What about Health Codes?

A: Since health codes and regulations vary from state to state and county to county, contact your own local officials. Check with city officials, then county and state. The Health Departmentwill provide you with a list of guidelines. Keep in mind that requirements may change by crossing county or city limits. Here are some common, general rules taken from actual code.

Booth construction

Food service booths should be located on hard surfaces that are not subject to wet conditions. If the booth is set up on grass, provisions for ground cover must be made. Floor coverings must be smooth, non-absorbent, and easily cleanable. Booths must have overhead covers, such as tents or canopies, to protect food from poor weather conditions. Physical barriers such as counters or tables must be used to separate the food service area from the customers. All food contact surfaces are to be smooth, nonabsorbent, and easily cleanable. Foods are to be stored at least 6 inches off the ground and covered to prevent contamination. Foods and utensils must be covered to protect from insects, droplets, and manual contact.

Gravity flow hand-washing facilities must be provided in your booth. This consists of an insulated container with a spigot that can lock in open position - capacity of 2 gallons or more - filled with hot water, a tub or bucket to catch waste water, pump soap and paper towels. WASH HANDS FREQUENTLY!

Sanitizing

Wiping towels used for wiping down counters and table tops must be clean and used for no other purpose. The towels must be rinsed in sanitizing solution frequently. If you chose to use bleach as the sanitizer, the recommended concentration is 1 teaspoon of liquid bleach added to 1 gallon of cold water. Do not add soap to the water, because soap ties up the chlorine making the solution ineffective. Store all chemicals separate from food preparation, display and storage.

NOTE -- It has been found that flies actually avoid surfaces that have been wiped down with bleach solution.

Wash equipment and utensils in a four-step sanitizing process: washing in hot soapy water, rinsing in hot water, sanitizing and air drying.

Personnel

Effective hair restraints shall be worn by all workers. All food handlers must wash hands properly and frequently. Smoking is prohibited. Any food handler with an illness such as cold sores, infected cuts or colds is not to handle any food!

Equipment

All food contact surfaces are to be smooth, nonabsorbent, and easily cleanable.

Q: What will I need to purchase before my first show?

A: Our packages include accessories you cannot easily and conveniently purchase on your own. Below is a list of other essentials, as well as where you can find them.

If you purchase our Complete Mobile Concession Package, you will also need:

• A trailer to haul your kettle corn equipment. A large show may require thousands of pounds of supplies, so consider that when making your decision. Our equipment is lightweight - a great advantage when loading into the back of a van or truck. Some people are using their vans or pickups for small shows, and renting a U Haul trailer for larger shows. our Complete Mobile Concession Package will comfortably fit in a 6' by 12' trailer. Another option is installing our equipment in a concession trailer. While it will certainly cost more to get started, there are some advantages...simply pull up, open the windows and begin popping! On the other hand, some shows do not allow trailers on the grass, or limit them to the "food area." You may do much better set up in a tent close to the entertainment.
• Bags and twisty ties or tape to seal. You'll need to decide if you're going to offer 2 or 3 sizes. Is it worth the extra hassle to offer 3 sizes?

  Small - 8" x 14"
  Medium - 9" x 15"
  Large - 9" x 24"

• For the best prices on poly bags, visit CentralPack. You'll want 1.5 mil, flat poly bags; they come in cases of 1,000 for about $25 - $35. If you want a list of item numbers &current pricing, just send me an e-mail and I'll be happy to provide that info for you.
• If you want extra scoops, measures or ladles, visit Katom Restaurant Supply or AceMart.
• A Cash drawer or Change Aprons. Walmart has a nice selection of lockable cash drawers, also Staples and Office Max.
• Lightweight gloves to protect your hands while stirring.
• Disposable latex gloves to wear while bagging the corn.
• Fire extinguisher.
• Three plastic tubs for washing, rinsing and sanitizing.
• Chlorine bleach for sanitizing equipment. (1 tablespoon per gallon of water)
• Covered garbage container.
• Several 5 gallon buckets for catching and disposing used wash water.
• Paper towels
• Anti-Bacterial Cleanser or liquid hand soap.
• Propane Tanks. These can be purchased at any gas supply store. We recommend using a 30 lb. tank (or larger) and keeping a smaller tank for backup. One hour of heavy popping will burn about 5 pounds of propane.
• Ingredients! (see next question)

With Package #1, you will need all of the above, plus:

• A 6 or 8 ft. table for the front of your booth. You'll need this to sell from, and it will also help keep customers away from your kettle and the hot oil spatter. You can purchase a table at any home improvement or department store. We offer a customized 6' table cover to keep your booth looking neat and professional.
• An insulated 10 gallon water dispenser. (To store hot water for hand and equipment washing.) Visit AceMart for a great deal.

With Packages #2 or #3, you will need all of the above, plus:

• A tent with 3 sides, made of Flame Retardant Material. Some shows may require that you have a floor in your tent. Make sure the tent can be set up and taken down quickly. We offer a quality E-Z UP canopy package to give your booth a professional look.
• A second table to hold your ingredients and supplies.
• Airtight storage containers for your supplies and ingredients.
• A banner or sign announcing KETTLE CORN! (Look in your yellow pages under "signs"). Our canopy comes with printing (as shown in the pictures) on all four valances and the back wall.

Q: What ingredients do I need and where can I find them?

A:

Popcorn

Mushroom style popcorn is ideal for the kettle corn business. The kernels pop into large round "balls" and also hold up well to stirring, sugaring, bagging, etc. Weaver Popcorn is a great source for mushroom popcorn; they have distributors all over the US. Regular "Butterfly" style popcorn is also used by many vendors and can be purchased in 50 lb. bags at Sam's Club for around $10.

Oil

We highly recommend and use 100% pure corn oil. It has great flavor and is cost effective. Another big advantage - corn oil has a much higher flash point than other oils. This reduces the amount of smoke, and also lowers the risk of a flash oil fire. You might consider experimenting with different oils for different results. Many vendors use Soybean Oil, while others prefer Peanut Oil (take into consideration than many people are allergic to peanut products). The choice is yours. Oil can be purchased in bulk at Sam's Club or your local food wholesaler.

Sugar

Just "plain" granulated sugar is all it takes! Purchase it in bulk at Sam's Club or another food wholesaler.

Salt

It's just "salt!"

Q: Where should I set up my kettle corn operation?

A: Anywhere there are people! Watch the Entertainment section of your newspaper...if there's going to be a crowd, they're going to be hungry - be there! Be creative...think outside the box! Here's a list of ideas to get you started.

• Fairs/Festivals
• Store grand openings
• School events
• Outdoor Concerts
• Rodeos
• On the corner of a busy intersection
• Craft shows
• "Bike Night" at your local bars/restaurants
• Car shows / Drive-ins
• Busy gas stations
• Locally owned farm markets or grocery stores
• Music Festivals
• Auctions

Be creative! We just popped for a lady who wanted to put bags of fresh kettle corn in the motel rooms for her out-of-town son's wedding guests! I made cute little tags printed with the bride and groom's name and closed the bags with a pretty ribbon. Needless to say, our kettle corn was a huge hit! What about popping little bags of kettlecorn for wedding, bridal shower or baby shower favors?

Q: How do I book shows? Any tips?

A: You probably already have several shows in mind... but how can you find contact information? Begin by calling your Chamber of Commerce. Call your state tourism center and ask for information on festivals and special events. Watch newspapers...show coordinators often post an ad months prior to the show looking for vendors. Be nosy - go to the big events and ask other (non-competition) food vendors which shows are the best. Get as much information as you can from them.

There are some great online Festival Directories - check out our Helpful Links page for more info.

Don't be afraid to start small! You may not be able to book the biggest shows your first year in business...and that's OK. The medium sized crowds can be just as profitable because a larger percentage of the crowd will walk by YOUR stand. As a general rule of thumb for the small to medium sized shows: if you have a crowd of 200, expect to make $200. With a crowd of 1000, you might earn $1,000.

If there's another kettle corn vendor popping at a show you're interested in, ASK THEM TO PUT YOU DOWN AS A BACKUP! You never know what might come up at the last minute for the other vendor!

The best location at a show is either the entrance/exit points, or close to the entertainment. If you can, stay away from the other food vendors. Instead, try to locate yourself as close to the entertainment as possible; kettlecorn is a snack food, not a meal.

Q: How do I clean my equipment?

A: Your kettle corn equipment can be cleaned using soap and warm water. To sanitize it, rinse well with a solution of Clorox water (1 tablespoon per gallon of water). The stainless steel can be renewed to "new" condition by using "Boil-Out"...visit Twin Supply to purchase. Several other options are Cretor's Kettle Cleaner, Heat N Kleen or Carbon Kleen. You should be able to find these cleaners at your local concession supply store. The copper kettle can be washed with soap and water and polished with Wright's Copper Cleaner.

Feel free to contact us with any other questions you might have - we promise a prompt reply!