Inauthentic but genuine: my take on a recipe for chili powder


(if you are not interested in the how’s and why’s, you can just jump to the recipe.)chili powder

My parents are from out west and so I grew up eating home-cooked Mexican food. Now with a family of my own, we often do the same — with some differences of course. I’m much more likely to do some research and try to create more authentic dishes than my parents and of course now there is a general focus on fresh, quality ingredients. Back in the ’70s? Not so much.

Surprisingly though, “authentic” had very little to do with me creating my own chili powder. My first discovery on researching this was that chili powder, like so many “Mexican” dishes in the U.S. has nothing to do with Mexican cuisine. While there are various accounts about who invented it, and I think the best claim for inventing what most of us use goes to one Willie Gebhardt. If you read through that article, you’ll see that chili powder was basically the invention of an German immigrant to America looking for a way to preserve chilies.

First, chili was only a seasonal food during the late 1800s as fresh chilies were not available during the fall and winter months. Moreover, no known method for keeping chilies fresh existed at the time. Although dried chilies were known, they were mostly reconstituted with hot water and then diced and served in the chili. However, their texture was tough and they lost much of their flavor. Fresh chilies were preferred. Willie discovered that if he dried his chili peppers and ground them into a flavoring powder, he could keep the concoction fresh for months at a time.

And so chili powder was born. The current commercial process used to create it is, from what I’ve been able to discover, basically the same – the dried chilies and spices are soaked in a combination of water and alcohol, the liquid is expelled/drained and the cakes of spice mixture are then dried at around 125° F. Now, I’ve made a bit of an amateur study of herbs and the preservation of them (drying, extracts, etc.) and I know that if you’re trying to preserve as much of the original flavor as possible, you don’t soak plant-based materials in liquid, remove the liquid, and then subject it to more heat. What’s left over has as much in common with unprocessed dried chilies as an old tea bag has with unused loose tea. So I set about to see if I could make something better.

It should be noted that, according to some websites, the U.S. government has standards for the labeling of what can be sold as chili powder. Unfortunately, with the many reports of lead and salmonella contamination of commercial chili powders, I don’t think that makes me feel any safer. One of my goals in this was to use as many whole, unprocessed ingredients as possible, as that’s honestly the best way to avoid many contamination issues. Can spices, even whole ones, still contain bad stuff? You bet. But I try to buy from trustworthy sources and I know nothing I do in the processing of these ingredients is going to introduce something I don’t want.

In addition to the above reasons, there were a few other factors that served as inspiration for this recipe.

  1. I wanted a lot of flavor and not crazy amounts of heat. This was both to make this as general purpose as possible and to meet the needs of several “baby-mouths” in my family. If you want more heat, you can either use different peppers or just add however much cayenne powder you wish. But the focus of this is really to create layers of flavor.
  2. I’m not a huge fan of Indian cuisine, but I love the culture that’s built up around it – particularly the masala. These spice mixtures, while sold here in the U.S. in bland plastic containers with words like “Authentic!” printed on it, are in India all different based on geography and family. The preparation and ingredients are matters of familial, ethnic, and regional identity and in chili powder, I saw the opportunity to create essentially the North American version of that. So experiment with what I have outlined below and make it your own.
  3. In that same spirit, I’ve outlined a “base” recipe and then highlight some additional ingredients and preparation steps that you can look at – either to do yourself, or perhaps give you ideas of your own.

JB’s Chili Powder


Where possible, I’ve linked to my usual sources for ingredients, but please feel free to buy from wherever you want. Also, be aware that when I make this, it’s usually a batch four times as big, so some of my sources are geared to much larger amounts than called for in this recipe.

Do me this favor: do not buy spices from the supermarket. Even with whole spices, sitting forever on shelves under bright fluorescents in clear bottles is not a good thing. If you have access to a Latin market, try there as there will be enough turnover to help ensure some sort of freshness — otherwise, the Internet is your friend.


Lightly roast the chiles over lowish heat, being careful not to burn them. The ancho in particular may require a little bit longer. You’re trying to bake as much of the moisture out of them as possible (yes, dried chilies can and do still have moisture in them). What I often do is after grilling dinner, when the coals have burned down a bit, I’ll stick the chilies in — making sure that they are only receiving indirect heat. If you have some wood chips or there was already wood chunks on the coals, all the better in my opinion. Of course, if you hate fire and fun, all of this can be done in an oven too (but not the microwave for goodness’ sake!).

How you do you know when they’re done? Well, this is one of the other ways my recipe goes off the beaten path. Google “DIY chili powder” and almost all of them will tell you to remove the stem and seeds before you roast them. I, of course, laugh at convention – and with good reason. By keeping the stem and seeds, you have essentially a deflated balloon. When the pepper is placed on the heat, the air and water that is left inside starts expanding and re-inflating the pepper. You can see exactly what I mean in this video:

Ideally, slow roast the peppers (with smoke added if you wish) at about 250° F for about 5 minutes and then find a little bit of direct heat right over the coals (or in a skillet on high if doing this the not-fun, no-fire way) and keep turning them until they start to inflate and remove them before there’s any burning. Seriously – these are for the most part mild peppers, but you do not want to breath in smoke from burning chilies. BAD IDEA.

When done, the chilies will have softened to an almost leather-like consistency. Remove from heat and layout in a thin layer on a cookie sheet or cooling rack to cool down. As soon as they are safe to touch, remove the stem and split open to remove seeds BUT FIRST, get some gloves.

Remember, you’re not just touching peppers as you would when cutting fresh ones, you’re digging around, pulling off stems and removing seeds. Even with relatively mild peppers like these, your day will go very quickly south if you touch anywhere on your body with hands covered in chili oil. You’ve been warned! Oh, and if using the chipotle peppers, get to them as soon as you can. As they have already been roasted and smoked, when they cool off, they’ll basically be as hard as rocks. At the very least, get them de-stemmed and split in half as soon as you can – the seeds can come out after they’ve cooled more if necessary.

If you want more heat in the final chili powder, I suggest going with hotter peppers but still taking the seeds out – yes that is where the heat is, but ground up in a powder (if you can get them ground up at all) it adds an unpleasant bitterness.

For now, hold off on grinding the  peppers — we’re going to get a little help with that first. But do check to see if there are any that aren’t quite crisp all the way around yet and finish them off in a toaster oven or on the stove top. We need them as crispy as possible without actually being burnt.

Spice mix and preparationcumin

As the peppers are completed, put them aside and then assemble the following:
(and yes – these are, unless otherwise specified, all by weight, not by volume – trust me, this works much better)

Possible additions (I actually use all of these)

Before the next step, I advise toasting the cumin seeds and then, along with the sea salt and the cacao nibs, run them through the food processor, a separate small spice grinder, or a mortar and pestle (if you have one …which you totally should). Otherwise they may be a little too chunky to break down.

Bringing it all together

Now, some people use dedicated spice grinders for this and ol’ Willie Gebhardt used a coffee grinder for his, but I prefer the food processor. Most spice grinders are too small for this type of application and electric coffee grinders (yes, even the nice burr ones) tend to overheat oil-rich items (especially sticky, soft, dried peppers), imparting a scorched taste to the finished product. The food processor with its big chopping blade and ample space will work much better.

So go ahead and put your de-stemmed and de-seeded peppers in the food processor, and start pulsing the blade. After a few pulses, add about half the spice mixture above and pulse on and off for about 30 seconds. Now add the rest of the spice mixture and continue pulsing for another 30 to 60 seconds until the mixture is as fine a powder as it will get and well mixed. The idea is that the spices themselves will help break down the chilies.

Now you can go ahead and stop there if you wish, but if you want to help make sure the powder is as fine as possible, what I do is put it, in small batches, through a strainer-sifter. Take whatever is left that didn’t go through the sifter and run it through the food processor again (or a smaller spice grinder or a mortar and pestle if you have one …which you totally should). You’ll likely always end up with a few larger flakes rather than a perfectly uniform powder, but that’s not necessarily a bad thing. The main thing is to make sure all the seeds have been removed, as well as possible, at each step.


So we’ve completed this Herculean task of making our own chili powder! Yay! Go us! Now put it in your cupboard and be happy! Wait…

Your cupboard/spice cabinet is in your kitchen, right? Probably not too far away from your stove top, microwave, oven, etc. And there’s probably quite a bit of light in there, huh? For most spices bought from a mega-mart, that’s probably not going to do any more harm to them then has already been done. But this chili powder – it deserves better.

Here’s what we don’t want: light, heat, and air. So we need something preferably opaque, in a stable, cool environment and an air-tight container. Let’s take a page from how you should be treating your coffee: put it in the freezer. In an airtight container in the freezer, this stuff will keep at almost peak freshness for …well, a lot longer than the six months or so that Mr. Gebhardt managed, that’s for sure. And please make sure the container truly is air tight, and the container is non-reactive (so no plastics!). If you take care of it, it will take care of you.

Smoked Sea Salt

smoked sea saltIt hardly seems fit to call this a recipe. It’s just too easy. But since I continue to get questions about it, here you go:

On a large steel cooking sheet or aluminum pan, spread about 2 lbs of coarse sea salt. In your grill or smoker (again, this works really well if you start it after a normal grilling session), add in some wood (presoaked for at least 4 hours in water). I’ve used oak, hickory, maple, apple, cherry, pecan, and mesquite — and various combinations thereof. Put the cookie sheet with the salt on the grill, close the grill and go do something else for 20 minutes. Come back and with a metal or silicone spatula, stir the salt around. If you need to add more wood, do that too. Now go do something else for about 20 to 30 minutes. Or an hour. It doesn’t really matter at this point. It’s not like you can burn the salt after all! Basically, get it as smokey as you want and bam! You’re done!

So what to do with it after that? Well, you can use it in a chili powder recipe obviously. And it makes a great fancy finishing salt. On top of a quality dark chocolate, it’s pretty much divine, or a couple of grains added to a dish of ice cream with a chocolate or butterscotch sauce will rock your socks off. Basically, whatever you want. My family likes it so much, we bought one of these and put it, fresh ground, on pretty much everything — but especially on popcorn with a little of that True Lime I mentioned above. Best. Popcorn. Ever.


Chocolate Chip Cookie Ice Cream (no dough!)

Photo of Chocolate Chunk Cookie Ice Cream with ingredients in background

Photo of Chocolate Chunk Cookie Ice Cream with ingredients in backgroundWhen inspired to create a new recipe, it is often as a result of finding something in an existing recipe or product that doesn’t quite work for me. For example, my Yeast-Raised Waffles were the result of my father’s use of a similar recipe from the Fannie Farmer Cookbook when I was growing up and me thinking they were almost perfect and then setting about to make them absolutely perfect once I had my own damn waffle iron 🙂

This recipe had similar origins, but in this case, it was dissatisfaction with a product not a recipe – namely Chocolate Chip Cookie Dough Ice Cream. Wildly popular since I believe Ben & Jerry’s first introduced it some time in the ’80s, I’d always liked it, but it fell short in a couple areas. First, while it is tasty, its blobs of dough mixed in a vanilla base are like little oases of flavor in an otherwise unremarkable sea of vanilla-ness. Secondly, in the many imitators and commercial versions out there now, more often than not you get low-quality vanilla ice cream mixed with low-quality cookie “dough” (sarcastic air quotes most definitely called for). What to do?

And then it hit me. Why add dough to the ice cream when you could make the ice cream TASTE like the cookie? And not like cookie dough, but like an actual baked cookie! Because my daughter has an egg allergy, I decided to work off a Philadelphia-style ice cream recipe (made without eggs) and why look any further than Alton Brown’s “Serious Vanilla Ice Cream“? I sat down and compared the ingredient lists of that ice cream and my favorite chocolate chip cookie recipe (to be published later!). I then did a little research. Then scribbled some notes. Then I did a lot of thinking – taste testing in my head as it were.

I wanted something that had the buttery richness of the chocolate chip cookie dough and the toffee notes from the brown sugar. I wanted something where the walnuts (a requirement of my cookie recipe, but pecans may be substituted if you absolutely must) had that oven-baked texture of a nut that hitched a ride on a cookie on a trip through an oven. I wanted big, assertive chocolate chunks – just like I use in my cookies (“chips” are for wusses. Chocolate chunks are definitely the way to go).

After all that, I sketched out how I thought the recipe should go and have made it a couple of times now with surprisingly few alterations. What I bring you now is the result of all this research and experimentation. I still consider this recipe a “draft” and I know there are probably better ways to do this, but figured I’d put it out in the world and hopefully inspire someone to improve upon it. If anyone tries this, please let me know how it turns out and if you have any suggestions!

Chocolate Chip Chunk Cookie Ice Cream (no dough!)

By Jason Byrne,
partially based on Alton Brown’s Serious Vanilla Ice Cream recipe

Prep Time: Ten hours
Cooking Time: Around an hour


  • 2 Tbsp. Salted butter
  • 2 Tbsp. sugar (white granulated or I often use a Turbinado sugar)
  • 1 1/2 cup whole milk
  • 1 1/2 cup heavy whipping cream
  • 1/2 cup dark brown sugar
  • 1/2 cup white granulated sugar
  • 1/2 tsp. real vanilla extract
  • 1/2 tsp. cocoa powder
  • 1 cup candied walnuts, broken or chopped into pieces (see recipe below)
  • 1 cup chocolate chunks (I prefer Baker’s brand)

Combine candied walnuts and chocolate chunks in a small bowl and put in freezer.

In a sauté pan, heat 2 tablespoons of sugar on moderately high heat in a heavy-bottomed 2-quart or 3-quart saucepan. As the sugar begins to melt, stir vigorously. As soon as the sugar comes to a boil, stop stirring but keep moving around pan gently. As soon as all of the sugar has melted and turned dark amber in color, add 2 tablespoons of the salted butter to the pan. Whisk until the butter has melted and as much of the butter has become incorporated as possible. Now, because of the proportions, this will not come together like a regular caramel sauce and there may be little bits of melted better that refuse to mix in with the sugar. This is totally okay, as in addition to caramel notes, we’re also looking for the butter to brown a slight bit. Keep on low heat and while keeping it all in motion, add the milk and cream. If caramel bits are not melting, you can bump up the heat a little. Now add the dark brown and white granulated sugar, stirring until well combined. Add the vanilla extract and the cocoa powder.

Adjust heat to medium. Attach a frying or candy thermometer to inside of pan. (If you do not have a thermometer, bring the mixture just barely to a simmer. As soon as you see a bubble hit the surface, remove it from the heat. Do not let it boil) Stirring occasionally, bring the mixture to 170 degrees F. Remove from heat and allow to cool slightly. Pour mixture into lidded container and refrigerate mixture overnight to mellow flavors and texture.

Process mixture in ice cream freezer according to unit’s instructions. The mixture will not freeze hard in the machine. Once the volume has increased by 1/2 to 3/4 times, and reached a soft serve consistency, spoon the mixture back into a lidded container. Add frozen candied walnuts pieces and chocolate chunks to mix and quickly and thoroughly incorporate into the ice cream. The longer it takes, the worse it is for the ice cream. Once everything is incorporated, seal container and harden in the freezer at least 1 hour before serving.

The result?

Because this is a Philly-style ice cream rather than a French-style (made with egg yolks and first cooked as a custard), the ice cream itself is a little lighter tasting than some traditional ice creams, but with so many developed and complex flavors, it really hits your tastebuds. You could modify a French-style recipe and do this, but with all the other flavors going on, I think it might end up to be almost too rich tasting. What started out as necessity because of my daughter’s allergy ended up actually being my preference. I love serendipity in cooking!

Instead of whole chocolate chunks, you can go for smaller chips or chop up the chunks in a food processor a bit before mixing in. The candied walnuts bring additional “cookie” flavors as well as added texture.

While still undeniably ice cream, because of all those cooked butter and sugar flavor notes, you really do end up with something that tastes like a baked cookie. And not just in dribs and drabs, but with every spoonful.

As stated earlier, this is a draft recipe and probably will (and should) be revised a bit. But even in this fairly initial state, the resulting ice cream is one of my favorites.

Candied Walnuts

  • 1/4 cup unsalted butter
  • 1 cup walnut halves
  • 1/4 cup packed brown sugar

Melt the butter in a large skillet over medium-high heat. Add the walnuts and cook, stirring, until golden brown and toasted, 3 minutes. Add the sugar and cook, stirring, for 1 minute. Transfer to a piece of waxed paper to cool.