Interest in the use of popped sorghum in food products has resulted in a niche market for sorghum hybrids with high popping quality but little work has been done to assess the relative effects of field processing methods of grain on popping quality. This study evaluated the relative effects of harvest moisture and threshing methods on the popping quality of sorghum grain. A grain sorghum hybrid with good popping quality was produced during two different years in Texas wherein it was harvested at two moisture levels (low and high) and grain was removed from panicles using five different threshing methods (hand, rubber belt, metal brushes and two metal concave bar systems). Years, harvest moisture content and threshing method influenced all three popping quality measurements (popping efficacy, expansion ratio and flake size), but threshing method had an order of magnitude larger effect than either moisture level or year. While many of the interactions were significant, they did not influence the general trends observed. As such, the threshing methods with less direct impact force on the grain (hand and rubber belt) had higher popping quality than those samples threshed with greater impact force on the grain (metal-based systems). The popping quality differences between threshing system are likely due to a reduction in kernel integrity caused by the impacts to the kernel that occurred while threshing the grain. The results herein indicate that field processing of the grain, notably threshing method has significant impacts on the popping quality and should be taken into consideration when grain sorghum is harvested for popping purposes.