Spread the air-popped popcorn on a large baking sheet and pick out any unpopped or hard kernels, leaving only fully popped pieces.

Transfer the cleaned popcorn to a large mixing bowl and set aside.

Place the peanut butter, carob chips, and coconut oil in a small saucepan.

Warm over low heat, stirring constantly, until the mixture is fully melted and smooth.

Remove the saucepan from the heat and let the mixture cool for 2 to 3 minutes so it is warm but not hot.

Pour the warm peanut butter and carob mixture over the popcorn.

Gently toss with a spatula or your hands until the popcorn is lightly and evenly coated.

Sprinkle the crumbled turkey turkey bacon over the coated popcorn and toss again so the turkey bacon clings to the popcorn.

Line a baking sheet with parchment paper.

Drop small spoonfuls of the coated popcorn mixture onto the lined baking sheet, forming loose clusters.

Arrange the clusters in a single layer without stacking.

Let the clusters set at room temperature for 45 to 60 minutes, or refrigerate for 20 minutes, until firm and dry to the touch.

Once set, transfer the popcorn clusters to an airtight container.

Store in the refrigerator until serving and let a cluster sit at room temperature for a few minutes before offering to your dog.