Step 1: Prepare the Popcorn Place your popped popcorn into a very large mixing bowl. It is important to sift through the popcorn with your hands first to remove any unpopped kernels, as biting into a hard seed inside a soft popcorn ball can be quite unpleasant. Set the bowl aside while you prepare the marshmallow coating.
Step 2: Melt the Marshmallow Mixture In a large saucepan over medium-low heat, melt the butter completely. Add the marshmallows and stir constantly with a rubber spatula until the mixture is smooth and creamy. Once melted, remove the pan from the heat immediately and stir in the alcohol-free vanilla and the salt until well combined.
Step 3: Combine and Fold Pour the warm marshmallow mixture over the popcorn in the large bowl. Use a greased spatula to gently fold the popcorn until every piece is evenly coated with the sticky marshmallow. While the mixture is still slightly warm but not hot, sprinkle in the chocolate candies and festive sprinkles, giving it one last gentle toss to distribute them.
Step 4: Shape the Popcorn Balls Grease your hands generously with a little bit of butter or oil to prevent sticking. Scoop up about a cup of the mixture and gently press it between your hands to form a ball roughly the size of a baseball. Do not pack the ball too tightly, or it will become hard to bite. Place the finished balls on a sheet of parchment paper to cool and set completely.
