[Transcriber’s Note: This ebook was created in honor of Distributed
Proofreaders’ 20th Anniversary.
Italic font is indicated by _underscores_, bold font by =equal
signs=, and larger font by +plus signs+.
The symbol ‡ denotes an illustration description that is not part of
the original work.]
+KNOTT’S
POP-CORN BOOK+
DEDICATED TO
THE HEALTH
THE HAPPINESS
THE WEALTH
OF ALL PEOPLE
CONTENTS:
Pop-Corn, the Grain and its Handling
The Popping of Corn
Factory Planning
The Right Way to Handle the Batch
What to do with Corn that Does Not Pop
Raw Materials
Paper and Packages
The Cooking of Syrup
Recipes and Formulas
Distribution
National Confectioners’ Association
How to Figure Costs
Pop-Corn Machinery
_COMPILED BY_
E. R. KNOTT
PUBLISHED BY
+E. R. KNOTT MACHINE CO.+
BOSTON, MASSACHUSETTS
Copyrighted, 1920
_By_ E. R. KNOTT
[Illustration: ‡(In color)
‡Styles of pop-corn made on Knott’s Pop-Corn Machines
E. R. KNOTT
MACHINE COMPANY
BOSTON]
WHEN BETTER POP-CORN
MACHINES ARE MADE
+KNOTT+ WILL MAKE THEM
The Illustration in Colors
You see a few of the many attractive styles in which you can put up
pop-corn made on Knott’s Pop-Corn Machines.
The top package, a pop-corn brick, is extensively sold from Maine to
New Jersey along the Atlantic coast at beaches and parks in summer.
The center picture of bar pop-corn, either ground or whole, is a New
England favorite. The top bar has the paper folded back as it is held
while eating by biting off the bar.
The lower left is a package of whole corn fritters or crispettes, while
at the right is shown a crispette on top of some ground corn fritters.
The center upper piece is called “two-fers” because it sells two for a
penny. It is a New England piece. The lower center is a penny cake.
These last four pieces are winter goods.
The flavors are Molasses (yellow), Chocolate (brown), Vanilla (white),
Checkerberry or Wintergreen (pink).
This Book has been Printed:--
(1) Because now is the time to enter into the manufacture of pop-corn.
(2) Because every district will soon have its pop-corn factory.
(3) Because your customers will realize that only goods of local
manufacture and high quality, under your trade-mark, are dependably
fresh and wholesome.
(4) Because people are buying more pop-corn than ever before.
(5) Because the demand for pop-corn ground and whole, in squares, bars,
fritters, etc., in New England is as substantial as the demand for
crackers.
(6) Because pop-corn has great possibilities.
(7) Because pop-corn may be put before the public in many ways.
(8) Because if one style is not salable in a certain locality there are
enough that will be, as there are plenty of styles to choose from.
(9) To show that you should trade-mark your goods.
(10) To show that the “price toboggan” had better coast empty.
(11) To give you guidance, so that no matter what may be your problem
you may eventually achieve success.
(12) Because pop-corn makers are scarce as compared to the demand for
them, and it is hoped that this will assist in the training of capable
men.
(13) Because pop-corn made on quality builds business.
(14) Because we want to increase the consumption of pop-corn.
This is the kind of a book that you get properly balanced in your mind
if you READ IT THREE TIMES, one after the other. Even after the third
time you will find something that you passed over without noticing at
the other readings.
CHAPTER I
THE WORLD-WIDE FOOD-CONFECTION
AFTER every man, woman and child gets to know its pleasant taste and
its food value, the world consumption of pop-corn is going to be
something tremendous.
Consider that pop-corn contains the whole of the grain, and that the
grain is thoroughly cooked. It is a healthful, nourishing food. It
is pure. It is a poor man’s confection and food combined. It is too
palatable for the rich man to ignore. It is considered by “Uncle
Sam” to be such a valuable article that through the United States
Agricultural Department, he has published two pamphlets for free
distribution, Farmers’ Bulletins No. 553, “Pop-corn for the Home,” and
No. 554, “Pop-corn for the Market.” By permission of the department we
avail ourselves of some of the information there given.
[Illustration: The ear]
[Illustration:
Unpopped Kernels and Popped Kernels of White Rice Pop-Corn
(With Permission of the U. S. Department of Agriculture.)]
Out of the more than twenty varieties of pop-corn you are advised to
use White Rice, as that makes the largest popped kernel compared to the
size of the raw kernel, and it is the most common commercial pop-corn.
As it is the expanding of the moisture in pop-corn by turning into
steam that explodes and cooks the grain, it is necessary to have the
right quantity of moisture, about twelve per cent., and to have that
moisture evenly distributed throughout the kernel, and the kernel
otherwise in fit condition for popping.
Some of the things that spoil the popping quality of corn are:
Seed from which the crop is raised not being acclimated to the locality
in which it is planted.
Other kinds of corn growing near the pop-corn.
Picking before the pop-corn has fully ripened, or picking after the
coming of frost.
Not sufficient ventilation while curing.
Too much drying out; shelled corn dries out faster than corn on the cob.
Shelling the corn too long before popping.
Defects in the kernel itself.
Damage from moths which produce weevils.
Insufficient heat, giving poor popping results.
You see that it is really a delicate proposition to deliver pop-corn to
you that will give you the best results. Therefore, it is not safe for
you to buy pop-corn of any but reliable dealers.
Seventy pounds of ears, air-dried, constitute a bushel.
Fifty-six pounds of shelled pop-corn make a bushel.
One hundred pounds of ears should give eighty pounds of shelled
pop-corn.
There are the same number of food units in:--
One brick of Pop-corn.
One-fifth of a pound of Roast Beef.
Four servings of Oatmeal.
Four Eggs.
One-third pound Roast Lamb.
One pint Milk.
To be more accurate, here is the percentage of proteid, fat,
carbohydrates and the number of calories in one pound of each of the
foods noted.
Proteid Fat Carbohydrates Calories
Peanuts, 25.8 38.6 24.4 2560
Sugar, 00 00 100 1857
Pop-corn, 11 11 78 1860
Cocoanut, 4 77 19 2800
Raisins, 3 9 88 1600
Oatmeal (boiled), 18 7 75 300
Roast Beef, 18 82 00 1800
Eggs, 32 68 00 760
Roast Lamb, 40 60 00 900
Milk, 19 52 29 300
[Illustration: ‡Two round cakes of pop-corn]
Chart of Manufacturing Procedure
MOLASSES SUGAR
| CORN SYRUP
| | RAW
| | CORN
| | |
GREASE STOCK STOCK |
SALT TANK TANK POPPING
COCOANUT \ / MACHINE
CHOCOLATE --------- STOVE / |
COLOR | _________/ |
| / |
FLAVOR ---- MIXER ------- GRINDER
____________/ | \
/ / | \
/ / | \
BUTTERED BRITTLE PANS MOULDING MACHINE FOR
CORN TANK MARBLE | CRISPETTES
| | DODGER
| PRESS BRICKS, BISCUITS
| | OR BALL
| | /
| CUTTING /
| MACHINE /
| | / PAPER
PACKING TABLE ---- BOXES
STRING
LABELS
This chart of manufacturing process shows at what point each ingredient
enters the batch.
It shows the arrangement of operations.
It shows what type of goods is the easiest to make and what takes the
most machinery to complete. It condenses on one page the underlying
principles of pop-corn confection manufacture.
Study it carefully. In this chart you will find the answer to your
question of how to arrange your factory--at what point in the work a
certain material is added to the confection.
It shows what materials are required to manufacture pop-corn confection
and shows what set of machines are necessary to make a particular type
of corn confection.
It shows what machines are the essential ones in the business.
SCHEDULE OF EQUIPMENT
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
|A|B|C|D|E|F|G|H|I|J|K|L|M|N|O|P|Q|R
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Salted Pop-Corn |×|×| | | | | | | | | | | | | | | |
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Buttered Pop-Corn |×|×| | | |×|×| | | | |×| | | | | |
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Crispettes, various colors |×|×|×|×| |×|×|×| | | | |×| | | | |
and flavors | | | | | | | | | | | | | | | | | |
----------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Dodgers, various colors |×|×|×|×| |×|×|×|×| | | |×| | | | |
and flavors | | | | | | | | | | | | | | | | | |
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Biscuits, various colors |×|×|×|×| |×|×| |×|×| | | |×|×| | |
and flavors | | | | | | | | | | | | | | | | | |
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Penny Squares and Bars |×|×|×|×| |×|×| |×|×|×| | | | | |×|
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Bricks |×|×|×|×| |×|×| |×|×|×| | | | | |×|×
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Sticks |×|×|×|×| |×|×| |×|×|×| | | | |×| |
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Brittle |×|×|×|×| |×|×| | |×| | | | | | | |
---------------------------------+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-+-
Key
=A= Popper No. 2002-3 Page 19
=B= Sifter No. 112 Page 20
=C= Two Stock Tanks No. 2013-1 Page 25
=D= Measure 2 qt. Graduated
=E= Paddle No. 2006-1 Page 41
=F= Stove No. 113-1 Page 25
=G= Mixer No. 114-2 Page 29
=H= Crispette Machine S F 3 Page 38
=I= Grinder No. 109-1 Page 22
=J= Press No. 110-1 Page 33
=K= {Cutting Machine No. 111 Page 35
{Cutting Machine No. 115 Page 37
=L= Buttered Corn Tank No. 2019-1 Page 41
=M= Wrapping Form Page 31
=N= Biscuit Mould No. 2002-1 Page 31
=O= 5 Biscuit Pans No. 2007-2 Page 31
=P= 5 Stick Pans No. 2007-3 and Mould No. 2002-4 Page 39
=Q= 5 Pans No. 2007-1 Page 31
=R= 5 Transfer Racks No. 2022-1 Page 35
This schedule illustrates in a different way from the “Chart of
Manufacturing Procedure” on page 9 what you require as an equipment for
the manufacture of any one of the regular types of Pop-Corn Confection.
Pop-Corn Bars, “Penny Squares and Bars” as the line is called, requires
as you see by the ×’s, these machines--Popper, Sifter, Stock Tanks,
Measure, Stove, Mixer, Grinder, Press, Cutting Machine, 5 Pans--thus
you get a definite list of the tools for a complete plant, for the
particular product.