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Preheat oven to 300°F.
Line a large baking sheet with parchment paper or a silicone mat. Set aside.
Pop popcorn kernels using air popper into a large bowl.
In a small saucepan melt butter, brown sugar, corn syrup and 1 teaspoon salt together over medium heat. Bring to boil. Boil for 4 minutes without stirring. Remove from heat and let it cool for 2 minutes. It needs to stop boiling before you pour it on the popcorn.
Pour caramel mixture over popcorn and stir to coat evenly.
Pour popcorn into lined pan, sprinkle remaining salt on top (½ tsp – 1 tsp depending on your personal taste preference) and place in oven. Bake for 30 minutes, stirring every 10 minutes.
Allow popcorn to cool on a parchment lined counter.