The beef mound sits above the pot while the tomatoes bubble underneath, and that setup gives this chili a different kind of smoke than stirring raw ground beef straight into the base. I like that the beef stays in a substantial piece while it cooks; when it’s ready, you break it into bite-size crumbles and fold it through the beans and tomatoes.
Before the pot goes on the smoker, the onion and bell pepper soften in a Dutch oven, then garlic, tomato paste, and the spices get a quick minute in the heat. That short cook wakes up the spices without scorching the garlic. Once the tomatoes, broth, and pinto beans are in, the uncovered pot catches smoke as the beef cooks above it. The finished chili is thick with tender beans and rich, smoky beef.
Kitchen Note
If the beef reaches 160°F before the chili is gently simmering, take the beef out and let the pot keep smoking. There’s no advantage to leaving cooked beef over the heat just to wait for the chili.
Save this over-the-top pellet smoker chili for a cookout day when you want smoky beef, pinto beans, and a pot that simmers right under the meat.
Why the Beef Cooks Above the Chili, Not in It
In a typical pot of chili, ground beef gets browned first and stirred through the sauce early. This method takes a different route: the seasoned beef cooks on a rack above the chili base, with the Dutch oven uncovered on the pellet smoker. Smoke can reach the meat while it cooks, and the chili underneath gradually picks up that smoky character.
Keeping the beef in one mound also changes the texture. Instead of small crumbles simmering in the sauce for the whole cook, the beef cooks together first, then gets broken into bite-size pieces near the end. That gives you distinct pieces of beef throughout the chili rather than a uniformly fine, ground-meat texture. The pot and rack need to work as one setup: the rack must rest securely across the Dutch oven so the meat stays suspended over the base while smoke moves around it.
The uncovered pot matters, too. A lid would shield the chili from the smoker and hold in more moisture. With the pot open, the tomato-and-bean base can gently simmer while the beef cooks above it, building a smoky bowl without cooking the meat directly in the liquid.
What the Tomatoes, Beef, and Spices Each Bring to the Pot
- 85% lean ground beef — It has enough fat to keep the mound from turning dry over a long smoke, without adding as much rendered fat as a higher-fat blend. Mix it only until the Worcestershire sauce, salt, and pepper are distributed; a firm, overworked mound can cook up dense.
- Crushed and diced tomatoes — Using both gives the base body from the crushed tomatoes with small tomato pieces from the diced can. Plain canned tomatoes are the right choice here; seasoned varieties can bring extra salt or herbs that shift the balance.
- Pinto beans — Draining and rinsing keeps the canning liquid from carrying into the pot, where it could make the chili saltier and cloudier. The beans go into the base before smoking so their flavor has time to mingle with the tomatoes and broth.
- Tomato paste — Cooking it briefly with the aromatics concentrates its tomato flavor before the liquid goes in. Stir constantly during that minute so it warms and darkens slightly without sticking to the bottom of the pot.
- Chili powder, cumin, smoked paprika, and oregano — The chili powder and cumin give the base its familiar chili warmth; smoked paprika adds another smoky note alongside the pellet smoke. Dried oregano rounds out the spice mixture, so use dried rather than treating fresh herbs as a direct replacement.
- Low-sodium beef broth — It loosens the tomato base and carries beef flavor into the pot. Low-sodium broth gives you more control over the seasoning because the Worcestershire sauce and kosher salt already contribute salt.
Building the Base and Smoking the Beef Over It
Soften the aromatics before the smoker
Preheat the pellet smoker to 275°F with the lid closed; it takes about 15 minutes. While it heats, warm the vegetable oil in a 6-quart smoker-safe Dutch oven over medium heat, then cook the chopped onion and green bell pepper for 6–8 minutes, stirring occasionally. Look for softened vegetables, not browned edges. Add the garlic, tomato paste, chili powder, cumin, smoked paprika, and oregano, then stir constantly for 1 minute so the garlic doesn’t scorch.
Stir together the tomato and bean base
Add the crushed tomatoes, diced tomatoes, low-sodium beef broth, and drained, rinsed pinto beans to the pot. Stir until the tomato paste and spices are evenly mixed through the liquid, scraping the bottom so nothing stays stuck there. Remove the Dutch oven from the heat before setting up the meat. The base should be combined, not cooked down on the stovetop.
Season the beef and set the rack
In a medium bowl, gently mix the ground beef with the Worcestershire sauce, kosher salt, and black pepper until just combined. Shape it into a compact mound about 6 inches wide and 3 inches high; don’t press it into a hard, tight ball. Set the uncovered Dutch oven on the smoker grate, then rest a sturdy oven-safe wire rack securely across the pot. Place the mound in the center of the rack, directly above the chili.
Smoke, crumble, and finish the pot
Close the smoker and cook at 275°F for 2 1/2–3 1/2 hours, until the thickest part of the beef reaches 160°F and the chili is gently simmering. Use a thermometer in the thickest part of the mound rather than judging doneness by its exterior color. If the beef reaches its temperature before the chili simmers, transfer it to a plate and keep smoking the chili until it reaches a gentle simmer. Crumble the cooked beef into bite-size pieces, stir it into the chili, and smoke uncovered for 15–20 minutes, stirring once, until hot and gently bubbling.
Three Small Changes for a Different Pot of Smoker Chili
Turn down the chili powder
For a gentler bowl, use 1 tablespoon of chili powder instead of 2. The cumin, paprika, and oregano still give the base plenty of character, but the chili flavor will be less assertive.
Make the tomato texture smoother
Use crushed tomatoes in place of the diced tomatoes for a more even, less chunky base. The tomato flavor stays familiar, but you lose the distinct soft pieces of tomato in each spoonful.
Make it gluten-free
Replace the Worcestershire sauce with a gluten-free Worcestershire sauce, using the same amount. It keeps the savory seasoning in the beef while making the dish suitable for a gluten-free meal.
Storage and Reheating
- Refrigerator: Store in a covered container for 3–4 days. The beans will soften a little as they sit, but the chili keeps its hearty texture.
- Freezer: Freeze cooled chili in airtight containers for up to 3 months. Leave a little room at the top for expansion, then thaw it in the refrigerator.
- Reheating: Warm gently in a covered saucepan over medium-low heat, stirring occasionally, or microwave in a covered microwave-safe dish in short intervals. Heat leftovers to 165°F; high heat can scorch the thick tomato base before the center is hot.
Questions That Come Up While Making This Smoker Chili
Over-the-Top Pellet Smoker Chili with Ground Beef and Beans
Ingredients
Equipment
Method
- Preheat the pellet smoker to 275°F with the lid closed, about 15 minutes.
- Heat the oil in a 6-quart smoker-safe Dutch oven over medium heat, then add the onion and bell pepper and cook for 6–8 minutes, stirring occasionally, until softened.
- Add the garlic, tomato paste, chili powder, cumin, smoked paprika, and oregano; cook for 1 minute, stirring constantly.
- Stir in the crushed tomatoes, diced tomatoes, broth, and beans.
- Remove the Dutch oven from the heat.
- In a medium bowl, gently mix the ground beef with the Worcestershire sauce, salt, and pepper until just combined.
- Shape the beef into a compact mound about 6 inches wide and 3 inches high.
- Set the uncovered Dutch oven on the smoker grate.
- Rest a sturdy oven-safe wire rack securely across the pot and place the beef mound in the center of the rack above the chili.
- Smoke at 275°F with the lid closed for 2 1/2–3 1/2 hours, until the thickest part of the beef reaches 160°F and the chili is gently simmering.
- If the beef reaches 160°F first, transfer it to a plate and continue smoking the chili until it simmers.
- Crumble the cooked beef into bite-size pieces and stir it into the chili.
- Smoke the chili uncovered for 15–20 minutes, stirring once, until hot and gently bubbling.