Pop Science: Inside a Popcorn Kernel
Most corn does not pop, but one special type does. Popcorn kernels look like tiny stones, yet each one is a sealed package with three main parts. The hard, shiny outer shell is called the hull. Inside is a starchy center, and within that starch is a small amount of water.
When the kernel is heated, the water inside starts to turn into steam. Steam takes up much more room than liquid water, so pressure builds inside the sealed hull. The hull of popcorn is unusually strong and nearly waterproof, so it holds the pressure for a moment longer than the hull of other corn would. Meanwhile the hot starch softens into a gel-like state.
At last the pressure becomes too great. The hull ruptures with a pop, and the soft starch bursts out and expands into a foam. As it cools in the air, the foam hardens into the light, crunchy shape we know. Pieces of the hull often stay attached, and sometimes they get stuck in your teeth.
Some kernels never pop. They may have dried out too much, so there is not enough water to make steam, or they may have a tiny crack in the hull that lets steam leak out. That is why popcorn should be stored in a sealed container instead of an open bag, and why a fresh bag usually pops better than an old one.