Step 1: Prepare the Popcorn and Kettle Chips - Begin by popping your popcorn and measuring out 11 cups of plain unsalted popcorn. In a large mixing bowl, combine the popcorn with the slightly crushed Kettle Brand Sea Salt Kettle Chips. The chips should be crushed enough to mix in but still retain some of their crunch.
Step 2: Make the Caramel Sauce - In a medium saucepan, melt the 1/2 cup of unsalted butter over medium heat. Once melted, add in 1 cup of packed light brown sugar and 1/2 cup of corn syrup. Stir continuously until the mixture comes to a boil.
Step 3: Add Flavor and Texture - Once boiling, let the caramel mixture boil without stirring for about 4-5 minutes. Then, remove it from the heat and stir in 1 tsp of vanilla extract and 1/2 tsp of baking soda. The baking soda will cause the caramel to bubble up a bit, so be careful!
Step 4: Combine the Caramel with Popcorn and Chips - Quickly pour the hot caramel sauce over the popcorn and kettle chip mixture. Stir gently with a wooden spoon until all the popcorn and chips are evenly coated in caramel.
Step 5: Bake for Crunchiness - Preheat your oven to 250°F (120°C). Spread the caramel popcorn mixture onto a baking sheet lined with parchment paper. Bake in the preheated oven for 45 minutes, stirring every 15 minutes to ensure even coating and crispiness.
Step 6: Add Chocolate and Sprinkles - Remove the popcorn from the oven and let it cool for a few minutes. While it's still warm, sprinkle 3/4 cup of chocolate chips over the popcorn. The heat will melt the chocolate slightly, making it easier to mix in. If you desire, add sprinkles for an extra festive touch.
Step 7: Cool and Serve - Allow the Kettle Chip Caramel Popcorn to cool completely on the baking sheet. Once cooled, break it into clusters and store in an airtight container. Enjoy this delightful treat on its own or serve it at your next gathering!