Popcorn Shelling Day

Today we used our new corn sheller and new tub (an old fashioned no.3 wash tub, yes they still make those!) and shelled out all the popcorn.  The new corn sheller worked great!  We bought the sheller from Pleasant Hill Grains in Nebraska and it is just like the vintage ones, works the same, but is new and shiny.  For about 10 days we have had the popcorn ears in a large box with a grate on the bottom (same one we used for hops drying), with a fan blowing underneath.  Today we felt the popcorn was dry enough to shell.  Now we have to put the shelled popcorn into trays to dry further, and then test pop from time to time to see if we have the right moisture content for popping.   When we do, then the popcorn goes into storage jars.  We will have plenty of popcorn for Christmas gifts, and to sell at our market booth.   Everyone seems to love our homegrown popcorn!   This year we got about 2/3 of last year's yield.  It was a dry summer, followed by a very wet end of summer.  Next year we plan on planting about twice as much or more.
     Here are some photos of the process today.   We have a few kinks to iron out yet........like a way to prevent the corn from being slung all over the place. and perhaps a motorized crank for next year.   The whole process took us only about 3 hours. 

Some of the popcorn ears ready to shell.  They are dry enough to put through the corn sheller.

We set up in the dining area to do this.  I have just finished shelling an ear, and I'll throw it in the scrap bucket next to me.

We had a problem with the corn flying all over the place during the shelling process, so we thought maybe a plastic bag would help to direct the corn flow.   It didn't help at all.

What finally helped a lot was a "deflector" Harold made and screwed onto the support board.   We also put a tablecloth on the floor to catch a lot of the pieces that seemed to fly out.   The ears of corn are inserted into the top, the handle is turned, the teeth of the sheller strip the popcorn from the ear, and the empty ear is returned through the green part.  Harold built a nice frame to set the tub and sheller on, making it a very stable base for shelling.

Here is about 95 lbs of popcorn!  A little less than last year, but we're happy!