Preheat the oven to 200°F.
Line 1 or 2 12x17-inch baking sheets with silicone baking mats or parchment paper.
Place the air-popped popcorn in a very large mixing bowl. Alternatively, spread the popcorn directly onto the prepared baking sheets.
Remove any unpopped kernels from the popcorn before adding the caramel.
In a medium saucepan, combine the packed light brown sugar, light corn syrup, unsalted butter, salt, and cream of tartar.
Place the saucepan over medium heat.
Stir constantly as the butter melts and the mixture begins to combine.
Continue stirring until the mixture reaches a simmer around the edges.
Once the mixture is simmering, stop stirring.
Allow the caramel to bubble undisturbed for 4 minutes. If using a candy thermometer, the caramel should reach 234–235°F.
Remove the saucepan from the heat.
Immediately stir in the baking soda.
Stir carefully, as the caramel will bubble, foam, and increase in volume.
Pour the hot caramel over the prepared popcorn.
Using a large spoon or spatula, gently stir the popcorn until evenly coated with caramel.
Work slowly and carefully, as the caramel will begin to thicken as it cools.
Spread the coated popcorn evenly onto the prepared baking sheet or sheets, if it is not already on them.
Bake for 1 hour.
Gently stir the caramel corn every 20 minutes during baking to help coat the popcorn evenly and prevent excessive clumping.
Remove the caramel corn from the oven.
Allow it to cool on the baking sheet for at least 30 minutes.
Once cooled, break apart any large clusters as desired.
Store the cooled caramel corn in an airtight container at room temperature.
Serve as a snack, party treat, bake sale item, or homemade gift.