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1. Preheat oven to 300 degrees F. Remove all unpopped kernels from popped popcorn. Put popcorn and, if desired, nuts into a 17x12x2-inch roasting pan. Keep popcorn warm in the oven while making the caramel mixture.
2. Butter a large piece of foil; set aside. For caramel, in a medium saucepan, combine brown sugar, butter, and corn syrup. Cook and stir over medium heat until mixture boils. Continue boiling at a moderate, steady rate, without stirring, for 5 minutes more.
3. Remove saucepan from heat. Stir in baking soda and vanilla. Pour caramel over popcorn; stir gently to coat. Bake for 15 minutes. Stir mixture; bake for 5 minutes more. Spread caramel corn on prepared foil; cool. Place caramel corn in gift container; cover with plastic wrap.