Prep Time: 0 min. • Cook Time: 15 min.Preheat oven to 250°F. Line a rimmed baking sheet or roasting pan with aluminum foil, and grease with cooking spray. Pop 1 cup of popcorn kernels according to instructions on package and set aside. Melt butter in a large stockpot pot over medium-high heat. Add brown sugar and corn syrup, stirring to combine. Bring to a rolling boil, then reduce the heat to low and let simmer for 5 minutes, stirring every 30 seconds, until the mixture is a deep golden color. Turn off the heat and slowly whisk in salt, baking soda and vanilla, being very careful as the mixture may bubble and splatter. Stir in the popcorn and toss until it is evenly coated with the caramel, being sure to scrape the caramel off the bottom of the pot.
Spread the mixture onto the prepared baking sheet or pan in an even layer. Bake for 15-20 minutes, stirring to toss every 5 minutes, until the caramel corn has turned a deep amber color. Remove the caramel corn from the oven and transfer to a surface covered with parchment or wax paper to cool. Once it reaches room temperature, use your hands or a spoon to break up the caramel corn, then store in an airtight container for up to a week.
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