Introduction

The Whirley Pop stovetop popcorn maker has earned a reputation among home coffee roasters as one of the most effective and affordable tools for small-batch roasting. Originally designed for making popcorn, its hand-crank agitation system and aluminum construction make it well-suited for roasting coffee beans. This method offers more control than electric popcorn poppers while remaining accessible to beginners.

Whirley Pop roasting produces batches of 3-4 ounces, which is ideal for home consumption and allows you to experiment with different roast levels without committing to large quantities. The manual agitation ensures even heat distribution, while the transparent lid lets you monitor the beans throughout the process.

Required Equipment

Essential Items:

Whirley Pop stovetop popcorn maker
Infrared thermometer (gun-style)
Electric hot plate or gas burner
Kitchen timer
Metal colander or cooling tray
Oven mitts or heat-resistant gloves

Additional Helpful Items:

Small fan for cooling
Scale for measuring beans
Notepad for recording roast details
Well-ventilated area or range hood

Step-by-Step Roasting Process

Preparation (5 minutes)

Set up your roasting area with good ventilation, as the process produces smoke and chaff
Measure 3-4 ounces of green coffee beans
Preheat your hot plate to medium-high heat
Have your cooling setup ready nearby

Initial Heating (3-5 minutes)

Place the empty Whirley Pop on the hot plate and begin turning the crank slowly and steadily
Use the infrared thermometer to monitor the internal temperature, aiming for 400-450°F
Once the desired temperature is reached, add the green beans
Continue cranking at a steady pace—approximately one full rotation per second

Drying Phase (4-6 minutes)

The beans will initially appear pale and smell grassy
Continue steady agitation while monitoring temperature with the infrared thermometer
Maintain temperature between 400-450°F by adjusting heat as needed
Beans will gradually change from green to yellow during this phase

First Crack (8-10 minutes total roast time)

Listen carefully for the first audible “crack”—it sounds similar to popcorn popping but more subdued
Visually, beans will have progressed from yellow to light brown
First crack typically occurs around 385-400°F internal bean temperature
The cracking will be sporadic at first, then increase in frequency
Continue agitation throughout this phase

Development Phase (10-12 minutes total roast time)

After first crack begins, monitor both color and sound closely
For a light roast: stop shortly after first crack ends
For medium roast: continue 1-2 minutes past first crack
Beans will progress from light brown to medium brown during this time

Second Crack (12-14 minutes total roast time)

Second crack sounds sharper and more brittle than first crack
Beans will be medium-dark brown when second crack begins
For medium-dark roast: stop early in second crack
For dark roast: continue through second crack, but monitor carefully to avoid burning

Finishing the Roast

When your desired roast level is reached, immediately remove the Whirley Pop from heat
Quickly pour beans into the metal colander
Shake or stir the beans to remove loose chaff
Use a small fan to accelerate cooling—be aware that this will blow chaff around, so consider doing this outdoors or in an area where cleanup is easy
Continue agitating beans until they reach room temperature (5-10 minutes)

Visual and Audio Cues

Color Progression:

Green → Pale yellow → Golden yellow → Light brown → Medium brown → Dark brown → Very dark brown

Audio Cues:

First crack: Sounds like corn popping, occurs around 8-10 minutes
Quiet period: Brief pause between first and second crack
Second crack: Sharper, more frequent sounds, occurs around 12-14 minutes

Tips for Success

Temperature control is crucial—too high and you’ll scorch the outside while leaving the inside underdeveloped. Too low and the roast will take too long, resulting in baked flavors. Consistent agitation prevents uneven roasting and hot spots.

Be prepared for the Whirley Pop to become more difficult to crank as the roasting progresses, especially during first and second crack when the beans expand and release oils. If you’re struggling to maintain smooth agitation or if the temperature climbs too quickly, briefly remove the Whirley Pop from the heat source while continuing to crank, then return it to the burner. This technique helps prevent scorching while maintaining bean movement.

Keep detailed notes of your roasting sessions, including bean origin, batch size, timing of cracks, final temperature, and your assessment of the results. This information becomes invaluable for replicating successful roasts.

Allow roasted beans to rest for 12-24 hours before brewing to let CO2 outgas and flavors settle. Store in containers with one-way valves that allow CO2 to escape while preventing oxygen from entering, or use airtight containers if valve containers aren’t available. Keep beans away from light and heat, and use within 2-3 weeks for optimal flavor.

The Whirley Pop method requires attention and practice, but it offers an engaging introduction to the art and science of coffee roasting while producing quality results at a fraction of the cost of dedicated roasting equipment.