Southwest Chuck Roast Chili with Bourbon

Why Use Chuck Roast For Chili?

Chuck roast is an excellent choice for chili when you want substantial pieces of beef instead of the finer texture of ground meat. This cut comes from the shoulder and contains connective tissue and marbling that make it well suited to slow cooking. As the beef simmers, the connective tissue gradually softens, helping the meat become tender and contributing body to the cooking liquid. For this recipe, I recommend buying a boneless chuck roast and cutting it into bite-sized pieces yourself. That lets you control the size of the beef and trim away thick pieces of exterior fat or tough connective tissue. Choose a roast with visible marbling, and cook the chili until the beef is fork-tender rather than relying on the clock alone.

For another Southwestern-inspired chili, try my New Mexico-style Cowboy Chili and explore a different take on a hearty bowl of red.

Why I Coat The Beef In Flour

I like to coat the chuck roast pieces lightly in flour before browning them. I've made this chuck roast chili both with and without coating the beef in flour, and I prefer the floured version. The flour helps the cubed beef develop a crispier exterior as it browns, while the coating gradually softens as the chili simmers. That softened flour helps thicken the cooking liquid, giving the chili a richer, heartier sauce that clings to the beef. It's an extra step, but one I think makes a difference in the finished dish.

What Makes This Chili Different?

Bourbon, roasted Hatch chiles, and New Mexico Chimayo red chile powder give this chuck roast chili its distinctive Southwestern flavor. The bourbon is added after browning the beef and aromatics, allowing you to scrape up the browned bits from the bottom of the pot. Roasted Hatch chiles contribute their own pepper flavor, while the red chile powder and chili seasoning bring different elements of the chili’s spice profile.

The goal is balance: rich beef flavor, a well-seasoned tomato and broth base, and chile flavor that complements rather than overwhelms the bourbon. Because chile heat varies by pepper and product, taste the finished chili and adjust the seasoning to suit your preference.

Bourbon in Chili

Bourbon gives this chuck roast chili its rustic character, adding depth to the rich beef and Southwestern chile flavors. I add it after browning the beef and aromatics, using it to deglaze the pot and capture the flavorful browned bits. As the chili slowly simmers, the bourbon becomes part of a hearty, savory base that complements the tender beef, roasted Hatch chiles, and red kidney beans.

Why Red Kidney Beans?

I use canned red kidney beans because their firm texture and deep red color work well in this hearty beef chili. They add substance and make the dish a satisfying meal, complementing the tender cubes of chuck roast.

Drain the beans before adding them to the pot. If you prefer pinto beans, they are a suitable alternative, although they’ll give the chili a slightly different appearance and texture. You can also leave the beans out if you prefer a bean-free chili.

Prefer a more traditional beef-and-bean chili? Try my Award-Winning Beef and Bean Chili for another hearty, satisfying take on this classic comfort food.

Ingredients You’ll Need

Spices To Make Chuck Roast Chili

The beauty of this recipe is that you can make it as spicy hot as you want. The recipe calls for one teaspoon New Mexico Red Chile Powder and Hatch Chile Peppers. Choose mild, medium or hot for these.

• Pickapeppa Sauce: Search it out on the condiment aisle. Adds savory complexity and a tangy, slightly sweet note. Pickapeppa has a distinctive fruit-and-spice character; Worcestershire is a convenient alternative with a different flavor profile.
• Chili seasoning with an “i” is a prepared spice blend intended for chili. Depending on the brand, it may contain ground chile peppers, cumin, oregano, garlic, onion, and other seasonings. Choose a good-quality blend.
• Red Chile Powder: A single blend chili powder, I prefer Chimayo Chile Powder from New Mexico, is not the same thing as a commercial chili seasoning blend. It contributes red chile flavor.
• Hatch Chile Peppers: Bring the distinctive flavor of roasted green chiles to the chili. Choose mild, medium, or hot peppers according to your heat preference. If fresh Hatch chiles aren’t available, use canned roasted Hatch chiles.

Ingredients For The Chili

• Canned Tomatoes: Add acidity and tomato flavor to balance the rich beef and bourbon. Petite diced tomatoes are a good choice because their smaller pieces blend into the sauce more readily.
• Red Kidney Beans: Believing that beans are essential for a satisfying chili, I've chosen canned red kidney beans. They not only complement the rustic theme of this recipe but also keep the color rich and dark.
• Onion: Sweet or yellow onion.
• Honey: Adds a touch of sweetness that balances the tomatoes and chile flavors. It should complement the savory ingredients rather than make the chili taste sweet.
• Bourbon: Used to deglaze the pot after browning the beef and aromatics. It contributes the rustic character that distinguishes this chili. Choose a bourbon suitable for cooking rather than using an expensive bottle.
• Beef Broth or Beef Stock: Is the savory base for the liquid.
• Beef Chuck Roast: Choose a boneless roast with good marbling.

A Note About Chile Powder and Chili Seasoning

This recipe uses both New Mexico red chile powder and chili seasoning because they serve different purposes. New Mexico red chile powder is a ground chile ingredient, while chili seasoning is a blend of spices formulated for chili. They aren’t interchangeable, and using both creates a more layered flavor. Reference my article Chili vs. Chile for more information.

How To Make Chuck Roast Chili

The key to tender chuck roast chili is to brown the beef well and give it enough time to soften during a gentle simmer. Work in batches so the beef develops a browned surface instead of steaming in a crowded pot. After adding the bourbon, scrape the bottom of the pot to release the browned residue. Then simmer the chili partially covered until the beef is fork-tender, checking the texture as it cooks.

1. Step 1: Prepare and flour the beef: Trim excess exterior fat and tough connective tissue from the chuck roast. Cut the beef into bite-sized pieces, pat beef dry with a paper towel and season with salt and pepper, and toss with the flour until lightly coated. Shake off any excess flour. The flour will help give the chili its rich, thick consistency as it simmers.
2. Step 2: Brown The Beef: Heat a large skillet or Dutch oven over medium-high heat. Add half the vegetable oil. When hot, add half the beef in a single layer and brown it well, turning as needed. Transfer the browned beef to a plate and repeat with the remaining oil and beef. Tip: Don’t crowd the pan. If too much beef is added at once, it releases moisture and steams instead of developing a browned crust. That browning builds the savory foundation of the chili.

3. Step 3: Cook The Onion and Garlic: When the second batch of beef is nearly browned, add the diced onion and cook for a couple of minutes, stirring. Add the chopped garlic and cook for about 30 seconds, until fragrant. Avoid letting the garlic burn.
4. Step 4: Deglaze The Pan With Bourbon: Transfer the beef and onion mixture to a plate. Pour the bourbon into the hot pot and scrape the bottom with a sturdy spatula to loosen the browned bits. Let the bourbon simmer for about 3 minutes, stirring occasionally. This step captures the flavor developed during browning. The simmer helps reduce the liquid, but it should not be assumed to remove all the alcohol.

5. Step 5: Add The Remaining Ingredients: Return the browned chuck roast and onion mixture to the pot. Add the beef broth, diced tomatoes with their liquid, drained kidney beans, roasted Hatch chiles, New Mexico red chile powder, chili seasoning, honey, and Pickapeppa or Worcestershire sauce. Stir to combine. Bring the mixture to a gentle simmer, then reduce the heat to low. Partially cover the pot, leaving the lid slightly ajar.
6. Simmer until the beef is fork-tender. Cook for approximately 2 to 3 hours, stirring occasionally. Maintain a gentle simmer rather than a rolling boil. The beef is ready when a fork pierces it easily and the pieces are tender.

Make Ahead, Storage and Reheating

• Make Ahead: Absolutely yes. As with any soup, stew or chili the flavors mature and are always better the next day. Make this chili in advance for meal prep or if entertaining.
• Storage: Store Chuck Roast Chili in a sealed container in the refrigerator for up to four days. It will also freeze well and keep for three months. I like to use zip-lock style freezer bags. Just stand them to to fill, squeeze the air out, and making sure they’re well sealed, lay flat to optimize freezer space.
• To Reheat: Thaw the chili overnight in the refrigerator. Re-heat in a sauce pan or in individual bowls in the microwave. The 50% power feature on your microwave is your best friend. Gently reheat individual servings in 30 second increments to gently reheat. A gentle reheat will also keep the beef from drying out.

Recipe for Chuck Roast Chili with Bourbon

This chili with chuck roast brings together tender beef, bourbon, roasted Hatch chiles, and red kidney beans in a rich, savory sauce. The flour coating is an extra step I prefer because it contributes to the beef’s browned exterior and the chili’s hearty consistency. Give the pot time to simmer, taste and adjust the seasoning, and serve with your favorite toppings for a satisfying bowl of Southwestern comfort food.

Explore More Chili Recipes

And if you’re soup lovers like us, don’t miss my Soup Category. You’ll find lots of great recipes including the most popular chili recipe on my site for Colorado Pork Green Chili.

Roasted Hatch chiles bring a distinctive Southwestern flavor to this chili. If you love cooking with them, explore more recipes featuring roasted Hatch Chile Peppers.