Prep Time: 10 minutes | Cook Time: 20 minutes | Total Time: 30 minutes | Serves: 4 people
Key Takeaways
- Quick comfort food – Ready in just 30 minutes from start to finish
- One-pot wonder – Minimal cleanup with maximum flavor
- Smoky depth – Barbecue smoked sausage creates rich flavor without hours of cooking
- Meal prep champion – Tastes even better the next day and freezes beautifully
Why You’ll Love This Barbecue Smoked Sausage Chili Recipe
Need a hearty meal that doesn’t take all day? This barbecue smoked sausage chili hits all the right notes.
Most chili recipes need hours to build flavor. Not this one.
By using smoked sausage, you get that slow-cooked taste in just 30 minutes. It’s perfect for busy weeknights or weekend game days when you want something satisfying without the wait.
Nutrition Facts
| Nutrient | Amount per Serving |
|---|---|
| Calories | 425 |
| Protein | 28g |
| Carbohydrates | 32g |
| Fiber | 9g |
| Fat | 21g |
| Sodium | 880mg |
| Sugar | 7g |
What You’ll Need
Ingredients
| Ingredient | Amount |
|---|---|
| Smoked sausage (beef or pork) | 1 pound (about 4 links) |
| Yellow onion | 1 medium, diced |
| Red bell pepper | 1 medium, diced |
| Garlic | 3 cloves, minced |
| Chili powder | 2 tablespoons |
| Cumin | 1 tablespoon |
| Smoked paprika | 1 teaspoon |
| Oregano | 1 teaspoon |
| Tomato paste | 2 tablespoons |
| Fire-roasted diced tomatoes | 1 (14.5 oz) can |
| Beef broth | 1 cup |
| BBQ sauce | 1/4 cup |
| Black beans | 1 (15 oz) can, drained and rinsed |
| Kidney beans | 1 (15 oz) can, drained and rinsed |
| Brown sugar | 1 tablespoon |
| Kosher salt | 1 teaspoon (to taste) |
| Black pepper | 1/2 teaspoon |
Toppings (Optional)
- Shredded cheddar cheese
- Sour cream
- Sliced green onions
- Chopped cilantro
- Sliced jalapeños
- Crushed tortilla chips
Kitchen Equipment
| Tool | Purpose |
|---|---|
| Dutch oven or large pot | Main cooking vessel |
| Sharp knife | Chopping ingredients |
| Cutting board | Prep surface |
| Wooden spoon | Stirring |
| Measuring cups and spoons | Accurate measurements |
| Can opener | Opening canned ingredients |
| Colander | Draining and rinsing beans |
| Small bowl | Holding spice mixture |
Substitutions and Dietary Adjustments
- Gluten-free option: Check that your BBQ sauce and smoked sausage are gluten-free
- Meat options: Andouille, kielbasa, or turkey sausage all work well
- Beans: Any combination of beans works (pinto, white, etc.)
- Vegetarian option: Use plant-based sausage and vegetable broth
- Heat level: Adjust chili powder amount or add cayenne for extra kick
Super-Detailed Step-by-Step Instructions for Beginners
Preparation Phase
- Set up your workspace (2 minutes)
- Wash your hands thoroughly with soap and water
- Clear a large space on your kitchen counter
- Place your cutting board in the center of the workspace
- Put a small trash bowl nearby for scraps
- Beginner tip: Organization makes cooking much easier and less stressful!
- Gather all ingredients (3 minutes)
- Take all ingredients out of the refrigerator and pantry
- Place them together on the counter so everything is within reach
- Check that you have all items listed in the ingredients section
- Beginner tip: This is called “mise en place” (everything in its place) and is a crucial step professional chefs never skip
- Prepare the beans (2 minutes)
- Place a colander in the sink
- Open both cans of beans using your can opener
- Pour beans into the colander
- Rinse thoroughly with cold water until the water runs clear
- Let drain while you prepare other ingredients
- Beginner tip: Rinsing canned beans removes excess sodium and improves texture
- Prepare the tomatoes and broth (1 minute)
- Open the can of fire-roasted tomatoes but leave them in the can for now
- Measure 1 cup of beef broth using a liquid measuring cup
- Measure 1/4 cup BBQ sauce using the same measuring cup (after pouring out the broth)
- Beginner tip: For wet ingredients, place the measuring cup on a flat surface and bend down to check at eye level for accuracy
- Prep the vegetables (5 minutes)
- For the onion:
- Cut off both ends of the onion
- Cut in half from top to bottom
- Peel off the outer skin
- Place flat side down on cutting board
- Make vertical cuts about 1/4 inch apart
- Rotate and make horizontal cuts to create 1/4-inch dice
- Beginner tip: Keep root end intact while cutting for stability
- For the bell pepper:
- Stand pepper upright and cut around the stem in a circle
- Remove stem and seeds
- Cut pepper in half
- Remove any remaining white membranes
- Place flat side down and cut into 1/4-inch strips
- Turn and cut across strips to create 1/4-inch dice
- Beginner tip: Red peppers are sweeter than green peppers
- For the garlic:
- Separate 3 cloves from the head
- Place flat side of knife on each clove and press firmly to crush
- Remove papery skin
- Mince finely by making very small cuts in multiple directions
- Beginner tip: A garlic press works too if you have one!
- For the onion:
- Prep the sausage (2 minutes)
- If sausage is in casings, you can either:
- Leave in casing and slice into 1/2-inch rounds, or
- Remove casing by slicing lengthwise and peeling it off
- Cut sausage into even 1/2-inch pieces
- Beginner tip: Slightly frozen sausage is easier to slice neatly
- If sausage is in casings, you can either:
- Measure the spices (2 minutes)
- Place a small bowl on the counter
- Using measuring spoons, measure:
- 2 tablespoons chili powder
- 1 tablespoon cumin
- 1 teaspoon smoked paprika
- 1 teaspoon oregano
- Add all to the same bowl and set aside
- Beginner tip: Level off each spoon with a flat edge like a knife or spatula for accurate measurements
Cooking Phase
- Heat your pot (1 minute)
- Place dutch oven or large pot on stove
- Turn heat to medium
- Allow pot to heat up for about 1 minute
- Beginner tip: To test if the pot is hot enough, flick a tiny drop of water in it – if it sizzles, you’re ready
- Brown the sausage (5 minutes)
- Add sliced sausage to the hot pot in a single layer
- Let cook undisturbed for 2 minutes
- Stir and flip pieces, then cook for another 2-3 minutes
- Look for browning on multiple sides and edges
- Beginner tip: Don’t overcrowd the pot; cook in batches if needed
- Beginner warning: Be careful of splattering oil; use long utensils and stand back a bit
- Cook the vegetables (5 minutes)
- Add diced onion and bell pepper to the pot with browned sausage
- Stir to combine everything
- Cook for 3-4 minutes, stirring occasionally
- Vegetables should soften and become translucent
- Add minced garlic and stir continuously for exactly 30 seconds
- Beginner warning: Watch garlic closely! It burns easily and will taste bitter if browned
- Beginner tip: You’ll know garlic is ready when it smells fragrant but hasn’t changed color
- Bloom the spices (1 minute)
- Add your pre-measured spice mixture to the pot
- Stir continuously for 30-60 seconds, coating all ingredients
- The spices should become fragrant
- Add tomato paste and stir for another 30 seconds
- Beginner tip: Blooming spices in oil releases their flavors and aromas
- Beginner warning: Don’t skip this step or rush it – it’s crucial for flavor development
- Add liquid ingredients (2 minutes)
- Pour in the entire can of fire-roasted tomatoes with their juice
- Add the measured beef broth
- Pour in BBQ sauce
- Using your wooden spoon, scrape the bottom of the pot thoroughly
- Beginner tip: Scraping the bottom of the pot is called “deglazing” and lifts all the flavorful browned bits
- Add beans and seasonings (1 minute)
- Add the drained and rinsed black beans and kidney beans
- Sprinkle in 1 tablespoon brown sugar
- Stir everything together until well combined
- Beginner tip: The brown sugar balances acidity from tomatoes and adds depth
- Simmer the chili (10 minutes)
- Increase heat to medium-high until mixture begins to bubble
- Once bubbling, reduce heat to medium-low
- Allow chili to simmer uncovered for 10 minutes
- Stir occasionally to prevent sticking
- Beginner tip: A gentle simmer means small bubbles breaking the surface, not a rolling boil
- What’s happening: The flavors are melding and the sauce is thickening
- Final seasoning adjustments (2 minutes)
- After simmering, taste a small spoonful (be careful, it’s hot!)
- Add 1 teaspoon kosher salt and 1/2 teaspoon black pepper
- Stir and taste again
- Adjust if needed:
- For more heat: add extra chili powder (1/4 teaspoon at a time)
- For more sweetness: add extra BBQ sauce (1 tablespoon at a time)
- For more depth: add extra smoked paprika (1/4 teaspoon at a time)
- Beginner tip: Always taste before serving and adjust seasonings – this is what good cooks do!
- Rest before serving (5 minutes)
- Turn off heat
- Let chili rest for 5 minutes
- This allows flavors to meld and sauce to thicken slightly
- Beginner tip: Use this time to prepare your toppings and serving bowls
Serving Phase
- Prepare toppings (while chili rests)
- Shred cheese if not pre-shredded
- Chop green onions into thin slices
- Chop cilantro finely
- Slice jalapeños (remove seeds for less heat)
- Place each topping in separate small bowls
- Beginner tip: Offering a variety of toppings lets everyone customize their bowl
- Serve and garnish (1 minute)
- Ladle hot chili into bowls, filling about 2/3 full
- Allow everyone to add their choice of toppings
- Recommended serving size: about 1.5 cups of chili per person
- Beginner tip: Warn everyone that the bowls will be hot!
Troubleshooting
| Problem | Solution |
|---|---|
| Too thick | Add beef broth, 1/4 cup at a time, stir and check consistency |
| Too thin | Simmer uncovered for 5-10 more minutes, or add 1 tablespoon of cornmeal and stir well |
| Too spicy | Add more BBQ sauce (1 tablespoon) or a dollop of sour cream to each serving |
| Not spicy enough | Add cayenne pepper (1/8 teaspoon at a time) or hot sauce (few drops at a time) |
| Too acidic | Add 1/2 teaspoon more brown sugar and 1 tablespoon more BBQ sauce |
| Beans too firm | Simmer 5-10 minutes longer, checking texture every few minutes |
| Tastes bland | Add 1/2 teaspoon more salt, 1/4 teaspoon more cumin, and a splash of Worcestershire sauce |
| Burnt bottom | If just slightly burnt, don’t scrape the bottom. If badly burnt, transfer to a new pot leaving burnt bits behind |
Variations to Try
Tex-Mex Style
- Add 1 cup of corn kernels with the beans
- Use 1 teaspoon of chipotle powder instead of smoked paprika
- Top with crushed tortilla chips and avocado slices
Smoky Maple Twist
- Replace brown sugar with 1 tablespoon maple syrup
- Add 1/2 teaspoon liquid smoke with the broth
- Use bourbon-infused BBQ sauce
Spicy Beer Chili
- Replace 1/2 cup of beef broth with dark beer
- Add 1 diced jalapeño with the onions and peppers
- Increase chili powder to 3 tablespoons
Storage & Reheating
Refrigerator
- Cool chili completely before storing (no more than 2 hours at room temperature)
- Transfer to airtight containers with lids
- Refrigerate for up to 4 days
- Beginner tip: Divide into meal-sized portions before refrigerating for easy reheating
Freezer
- Cool completely before freezing
- Use freezer-safe containers or heavy-duty freezer bags
- Leave 1/2 inch of space at the top for expansion
- Label with name and date
- Freeze for up to 3 months
- Beginner tip: Lay freezer bags flat for faster thawing and space-saving storage
Reheating From Refrigerator
- Stovetop: Place in saucepan over medium-low heat. Add 2 tablespoons water or broth. Stir occasionally until hot throughout (about 5-7 minutes).
- Microwave: Place in microwave-safe bowl. Cover loosely with microwave-safe lid or paper towel. Heat on high for 1 minute, stir, then heat in 30-second intervals until hot throughout.
- Beginner tip: Always stir reheated chili for even heating
Reheating From Frozen
- Thaw overnight in refrigerator (safest method)
- For quick thawing, place sealed container in bowl of cold water for 30 minutes
- Once thawed, reheat using refrigerated instructions above
- Beginner warning: Never thaw food at room temperature for safety reasons
Safety Notes & Important Tips
- Temperature safety: Cook sausage to an internal temperature of 160°F
- Food safety: Refrigerate leftover chili within 2 hours of cooking
- Reheating safety: Reheat chili to an internal temperature of 165°F
- Cutting safety:
- Always cut on a stable surface
- Keep fingers curled under when chopping
- Use a sharp knife (dull knives cause more accidents)
- Burn prevention:
- Use oven mitts when handling hot pots
- Stand back when adding ingredients to hot oil
- Keep pot handles turned inward on the stove
- Beginner prep tip: Chop all vegetables before starting to cook
- Flavor boost: The chili tastes even better the next day
- Time-saving tip: Prep double batch and freeze half for future meals
This barbecue smoked sausage chili recipe transforms simple ingredients into a satisfying meal. The combination of smoky sausage and sweet BBQ sauce creates a depth of flavor that usually takes hours to achieve.
What makes this recipe special is how quickly it comes together without sacrificing taste. Plus, it’s endlessly customizable based on what you have on hand.
Try it once, and this hearty, 30-minute chili might just become your new go-to comfort food.
