Popcorn (Zea mays var. “Everta”) is a delicious snack and one of the most consumed worldwide. Thanks to its ability to pop at high temperatures (177-210°C) in a short time (90 to 180 seconds), it allows for the use of the whole grain while preserving its nutritional properties, such as phenolic compounds and anthocyanins, which are potent antioxidants. This results in the production of an whole grain ready-to-eat snack.
From an ancient sacred crop to an innovative healthy snack
Maize has been a staple for humans since pre-Hispanic times. It was the primary ingredient in the diets of Mexican pre-Hispanic cultures, which also utilized it as offerings to the gods during ceremonies. Maize originated in Mexico, where the highest diversity of native varieties exists, all of which are descended from a common ancestor: Teosinte. Over thousands of years, human domestication and selection have naturally enhanced these varieties.
Nowadays, the search for improved popcorn aims to generate novel puffed maize products with nutritional properties that can serve as potential functional foods. One example is popcorn made from a high-oil-content hybrid, a type of maize rich in fatty acids, mainly monounsaturated fatty acids such as oleic and linoleic acids, which, combined with other compounds, exhibit health benefits. However, the popping process is essential to maintain these nutritional properties and health benefits. The thermal process in popcorn production impacts its nutritional composition and quality.
Quality parameters for a perfect pop
Popcorn must meet specific criteria to be considered high quality. These characteristics, known as quality parameters, include:
- Volume expansion: Measure the expansion ratio that occurs when the grain pops.
- Expansion time: The time required for a batch of grains to complete the popping process, from the start of heating until the last grain has popped.
- Popping folding: The ratio between the volume of popped grains and a standard grain weight.
- Yield percentage: The proportion of grains that successfully pop and expand during the popping process.
- Residual percentage: The proportion of unpopped grains after the popping process.
Study- Which thermal process pops best?
The research published by Luzardo-Ocampo and colleagues analyzed the effect of different thermal processes on the nutritional composition and quality of popcorn from 5 oily maize hybrids. The three thermal processes analyzed were microwave, hot air, and wet cooking. Microwave heating is one of the most used methods due to its popularity, ease, and quick process for popping popcorn. Hot air can create low-fat products because it does not use oil, whereas wet cooking uses cooking oil, which gives popcorn a better flavor.
Nutritional benefits in every pop
The following phenolic compounds were identified in the hybrids analyzed in the study: p-coumaric acid, ferulic acid, and ferulic acid derivatives. Additionally, phytosterols such as campesterol, stigmasterol, and β-sitosterol were identified. These compounds offer benefits to human health, with phenolic compounds acting as antioxidants, anti-inflammatory agents, and potential anticancer and anti-obesogenic agents. Meanwhile, phytosterols help inhibit the absorption of dietary cholesterol in the small intestine, reduce blood cholesterol levels, and lower the risk of cardiovascular diseases.
Impact on popcorn quality parameters
The study found that hot air treatment delivered the best overall results among the three thermal processes, particularly in terms of volume expansion, the most critical quality parameter, as it significantly influences consumer purchasing decisions. However, this method also required the longest expansion time. In contrast, microwave treatment showed the shortest expansion time but the lowest volume expansion and a higher residual percentage (unpopped kernels). Wet cooking had a similar expansion time to microwaving but differed in other quality aspects.
Popcorn: A Crispy and Light Option
Popcorn is an excellent option as the demand for healthier, ready-to-eat snacks grows due to its nutritional profile. This study shows that high-oil hybrids can produce popcorn with excellent popping qualities and valuable nutritional content, but the results depend on the thermal process used. Hot air has proven to be an effective popping method, as it does not require oil and results in popcorn with a high-volume expansion, making it a healthy and convenient snack.
For more details of this interesting research, read the complete paper by Luzardo-Ocampo, I., Chuck-Hernández, C., Preciado-Ortiz, R. E., Serna-Saldívar, S. R. O., Antunes-Ricardo, M., & Escalante-Aburto, A. (2025). Popcorn quality parameters and nutritional properties of oily maize (Zea mays var. ‘Everta’) hybrids subjected to different thermal treatments. Food Chemistry, 463, 141307. https://doi.org/10.1016/J.FOODCHEM.2024.141307
