Orville Redenbacher's

The health concerns regarding microwave popcorn are a result of the way it’s packaged. For the corn to pop, the kernels are submerged in boiling fat inside the bag until a buildup of steam in the kernels causes them to burst. To prevent the liquid fat from seeping through, the bags are lined with a chemical called perfluorooctanoic acid, which, unfortunately for microwave popcorn lovers, has been linked to cancer and other nasty things.

I set out on a mission to make better homemade microwave popcorn with only natural ingredients, and without using costly popping gadgets. I also wanted to avoid using plastic, tape, or metal, such as staples. My solution is a new method of prepping the kernels, but like many other techniques I researched, it requires paper lunch bags. I was dismayed to find some discussions about the potential for problems using brown paper bags in your microwave oven, such as fire, but I had absolutely no issues any of the many times I did it. No smoke, no sparks, nothing looking at all dangerous was going on inside my cooking box. The USDA states that using paper bags in your microwave, “may cause a fire, and may emit toxic fumes,” yet the internet is full of microwave popcorn recipes calling for paper bags. I chose to still share my recipe and technique, but ultimately leave it up to you to decide if it’s a hack recipe you feel safe using. If you’d rather stay on the safe side, see the Tidbits for an alternate technique. 

My Orville Redenbacher's Movie Theater Butter Popcorn copycat recipe starts with clarifying butter so that it’s pure fat, without any milk solids or water. Butter is about 16 percent water and if any of that stays in the mix, your popcorn will be on a fast trip to Soggytown. Once the butter is clarified, we’ll combine it with popcorn and salt and freeze it into pucks that can be saved for weeks until you are ready to make quick popcorn.

When it’s popcorn time, a puck goes into a small bowl, which goes inside two interlocking paper bags. After a warming session, you hit the “popcorn” button on your microwave oven and the popcorn will pop just like the store product (you may have to add another 30 seconds or so of cooking time). The first bag will soak up the excess butter that splashes around inside as the popcorn pops, and the second bag will keep the butter from messing up your oven.

To serve, pull the bags apart over a big bowl, and you’ll have a fresh batch of hot microwave popcorn coated perfectly with real butter and salt. 

If you're like me and you like things spicy, try sprinkling your copycat Orville Redenbacher Movie Theatre Popcorn with my original Hell Flakes to create what we like to call "Hell Corn".