He was tested for coconut & is allergic. He was positive for every nut known to man - right down to the tiny little pine nut. So unfortunately sounds like he'll have to continue to skip the popcorn. I know it's such a small part of Disney but it's everywhere you look. Disappointing for him even though he knows it's a no-no. But I still think Disney is the best place to vacation for those with food allergies. They've always gone above & beyond for us. Takes a great deal of stress off of this worrisome mommy!
Sorry to hear he is allergic to coconut too. As an adult who is anaphylactic to milk, tree nuts, peanuts, and seafood (fish, shellfish, etc), coconut in its various forms is one of the things I am really glad I can still have.
We also think Disney is the best place to vacation with food allergies; I have consistently had great experiences at both WDW and on
DCL. makes traveling so much easier.
I have traveled elsewhere for work and leisure and accommodating the food allergies was quite a challenge. So much easier on a Disney trip.
An idea for your WDW trip that may just work: (and you can try the popcorn at home to make sure you like it)
Ingredients:
Skinny Pop popcorn (flavour of your choice -- I have tried
Original and
White Cheddar and love them both!!
http://skinnypop.com/our-popcorn/ )
Plastic popcorn bucket (from WDW; see below)
Recipe:
Acquire
empty Disney popcorn bucket (so it was not knowingly cross-contaminated).
Clean popcorn bucket thoroughly.
Fill with Skinny Pop popcorn. ENJOY !
I really like the (simpler style) plastic buckets WDW sells with their popcorn (for an extra charge of course). They are a great souvenir and can be used for all kinds of things at home

I am reasonably sure that at one of those popcorn stands they would sell you an empty new plastic bucket, even if you had to pay the full cost and thus are paying for popcorn you don't get (or maybe they could give you the popcorn in a normal cardboard container ?).
I like this simple style of them:
http://www.disneyfoodblog.com/wp-content/uploads/2013/06/Animal-Kingdom-Souvenir-Popcorn-Bucket.jpg and
http://parksandresorts.wdpromedia.c...content/uploads/2015/09/popbuckLARGE15363.jpg .
But there are also crazy fancy styles like these:
http://disneyparks.disney.go.com/blog/2013/05/who-can-resist-disney-parks-popcorn/ According to that Disney post, the buckets were $12 each in 2013.
So, bucket acquired, you need popcorn !!
Becoming dairy allergic several years ago, I quickly learned that pretty much almost all microwave or prepared popcorn has milk ingredients. Very disappointing (I did eventually find a small number of microwave ones that are safe; and have recently discovered a microwave popper that uses normal plain kernals and pops them -- and can do it with no oil at all -- which is great for home, but not for travel).
A couple years ago I discovered the SKINNY POP brand of pre-popped popcorn. I fell in love. I cried. I yelped. I did a little dance in the Walgreen's store I found it in (and ignored the strange looks). Since then I have found it in more and more stores, including several near me.
Here's the deal with it. Their website:
http://skinnypop.com/ . I really like the
Original and
White Cheddar flavours. From their
Original product page (
http://skinnypop.com/our-popcorn/original/ ): (QUOTE)
Ingredients: Popcorn, sunflower oil and salt.
Our products are made in our allergen free production facility and are completely nut, egg, and dairy free.
no artificial ingredients // non GMO // gluten free // dairy free // peanut free // tree nut free // preservative free // no artificial flavors // zero trans fat // a good source of fiber // and delicious!
(END QUOTE)
For me, this stuff is SAFE. It is DELICIOUS. It is some kind of wonderful. I love it. I have to ration it at home. YMMV and you may want to contact the company to confirm product safety for your family.
For WDW and DCL trips, I have both brought a package with me, and ordered a package to be delivered to our resort (I ordered from
Amazon and have Amazon prime, but there are many alternatives). Also, given how easy it is to find around here now, I would expect you could find it at grocery stores in Orlando. The Skinny Pop website has a store locator on it. Bring some sandwich/quart ziploc bags and it is easy to portion out for snacks. And of course, from the big bag you can fill the Popcorn Bucket !!

If you want, Skinny Pop DOES come in small snack size pouches, too; but of course it is usually cheaper to get the bigger bags.
It won't be exactly WDW popcorn. But it will be popcorn in the WDW bucket, AT WDW, which is half the fun of the popcorn anyway !

(and it is very yummy popcorn, did I mention that???).
Hope this helps !!
SW