Preheat oven to 250 degrees.: You will notice a steady, low warmth filling your oven, which prepares it to dry the caramel coating gently without browning it. This low temperature is crucial because it dehydrates the caramel slowly, letting it set to a crisp finish instead of burning. A common mistake is using a hotter oven to speed things up, which causes the sugar to scorch; resist the urge and trust the slow approach.
Divide popped popcorn equally between 2 lightly greased 13 x 9 baking pans or bigger pans.: When you spread the fluffy popcorn into pans, you should see an even, single layer with air pockets intact, not compressed clumps. Greasing the pans keeps the popcorn from sticking, and dividing into two pans ensures even coating and heat circulation while baking. Avoid piling the popcorn too deep, because dense areas will not crisp properly and will stay chewy.
Combine salt, butter, brown sugar, corn syrup, molasses, ginger and cinnamon in a large heavy saucepan or pot. Bring heat up to medium high until it comes to a full boil (foamy). I used a pot/pan with high sides because the mixture will boil up and you don't want it to spill.: As the mixture heats, smell shifts from dairy to caramelized sweetness, then to spicy molasses aromatics. The foam signals boiling sugar, and the high sided pot prevents sticky overflow. Use stable heat so the mixture transitions evenly; moving it to high heat too quickly can create hot spots and localized burning.
Boil for 3 minutes after mixture comes to a full boil then remove from heat.: During this short boil the sugar dissolves fully and the syrup thickens, creating a glossy sheen, and the scent deepens to a rich caramel. Timing matters here because underboiled syrup will not set, while overboiled syrup can become brittle or bitter. A common misstep is misreading a roiling boil; set a timer for accuracy.
Stir in baking soda. Mixture will foam up.: The moment you mix in baking soda you will see dramatic foaming, almost like volcanic bubbles, and the color lightens. This reaction aerates the caramel, producing a delicate texture on the popcorn once it sets. Don not skip stirring thoroughly, because uneven distribution yields pockets of dense caramel. Be prepared for the foam, and stir gently to avoid splatter.
Pour over popcorn in prepared pans and toss to coat. You will continue to stir and coat as it bakes so don't worry if it's not completely covered. Make sure popcorn is in a single layer as much as you can.: When poured, the sauce should cascade in ribbons and smell luxuriously spiced. Use a sturdy spatula or wooden spoon to fold, ensuring that every crevice gets touched by the caramel. It is okay if coverage looks patchy at first, because baking and intermittent stirring will distribute the coating. Avoid overmixing which can crush the popcorn .
Bake for 45-60 minutes, stirring every 15 minutes. Don't over bake or the mixture can burn. The popcorn will still appear soft while hot but will turn crisp as it cools.: In the oven you will hear a soft crackle as moisture leaves the caramel, and the aroma will intensify to a roasted caramel and spice blend. Stirring every 15 minutes exposes all surfaces to dry out evenly, preventing burnt edges and ensuring uniform crispness. A typical error is skipping the stirs which leads to uneven texture, with some parts chewy and others overdone.
Cool completely. Melt almond bark according to package directions. Drizzle over cooled popcorn. You can put it in a ziploc bag and snip the corner off for more controlled drizzling or just do it with a fork. Wait for the drizzle to set or you can speed this up by popping it in the fridge for a couple of minutes. Break into pieces and enjoy. You can place it in clear plastic cones, wrap with a ribbon, and give away!: As the popcorn cools, the caramel snaps audibly and the scent calms into a warm, spiced sweetness. Melting almond bark gives you a smooth white ribbon to decorate, and the chilled drizzle sets with a clean snap. Use a bag or fork to control pattern, and resist breaking it while slightly warm, because it will deform; letting it set fully ensures neat clusters. A frequent mistake is drizzling while the popcorn is still hot, which causes the almond bark to melt and lose its shape.