Hearty Smoked Sausage and Kale Chili

Why You'll Love This Recipe

• Hearty and satisfying: smoky sausage, beans, and greens make this a full meal in a bowl.
• Greens-forward but cozy: plenty of kale for nutrients, surrounded by a rich, tomato-chili broth.
• Weeknight-friendly: ready in under an hour with simple, everyday ingredients.
• Flexible and forgiving: easy to adjust the spice level or swap in what you have on hand.

Grocery List

• Produce: 1 medium yellow onion, 3 cloves garlic, 1 small bunch kale, 2–3 green onions (for garnish, optional)
• Dairy: Sour cream (for serving, optional), shredded cheddar cheese (for serving, optional)
• Pantry: 12 ounces smoked sausage (andouille, kielbasa, or similar), olive oil, 1 can diced tomatoes (14.5 ounces), 1 can red kidney beans (15 ounces), low-sodium chicken or vegetable broth, tomato paste, chili powder, ground cumin, smoked paprika, dried oregano, crushed red pepper flakes, salt, black pepper

Full Ingredients

For the Chili with Smoked Sausage & Kale

• 1 tablespoon olive oil
• 12 ounces smoked sausage (such as andouille, kielbasa, or other fully cooked smoked sausage), sliced into 1/4-inch rounds
• 1 medium yellow onion, diced (about 1 1/2 cups)
• 3 cloves garlic, minced
• 2 tablespoons tomato paste
• 1 1/2 tablespoons chili powder
• 1 teaspoon ground cumin
• 1 teaspoon smoked paprika
• 1/2 teaspoon dried oregano
• 3/4 to 1 teaspoon fine sea salt, plus more to taste (amount depends on saltiness of sausage and broth)
• 1/2 teaspoon freshly ground black pepper
• 1/4 teaspoon crushed red pepper flakes (optional, adjust to desired heat)
• 1 can (14.5 ounces) diced tomatoes, with their juices
• 1 can (15 ounces) red kidney beans, drained and rinsed
• 2 cups low-sodium chicken broth (or vegetable broth for a pork-free base)
• 4 packed cups chopped kale (about 1 small bunch), tough ribs removed and leaves cut into thin ribbons

For Serving (Optional Garnishes)

• Sour cream or plain Greek yogurt
• Shredded sharp cheddar or Monterey Jack cheese
• Thinly sliced green onions or chopped fresh parsley
• Extra crushed red pepper flakes or hot sauce, for extra heat
• Crusty bread or warm cornbread, for serving alongside

Step-by-Step Instructions

Step 1: Prep the sausage and vegetables

Set out a large, heavy-bottomed pot or Dutch oven (4- to 5-quart capacity works well). Slice the smoked sausage into 1/4-inch rounds. Dice the onion and mince the garlic. Rinse the kale, pat it dry, strip out the thick center ribs, and cut the leaves into thin ribbons or bite-sized pieces. Having everything prepped before you start cooking makes the rest of the recipe smooth and stress-free.

Step 2: Brown the smoked sausage

Place the pot over medium-high heat and add the olive oil. Once the oil is hot and shimmering (about 1–2 minutes), add the sliced smoked sausage in a single layer. Cook for 4–5 minutes, stirring occasionally, until the sausage is browned on the edges and some of the fat has rendered into the pot. Browning builds flavor and gives the chili its smoky depth. Use a slotted spoon to transfer the sausage to a plate, leaving the flavorful drippings in the pot.

Step 3: Soften the aromatics

Reduce the heat to medium. Add the diced onion to the pot and cook, stirring occasionally, for 4–5 minutes, until it turns translucent and slightly golden around the edges. If the pot looks very dry, drizzle in another teaspoon of oil. Add the minced garlic and cook for 30–60 seconds, stirring constantly, just until fragrant. Avoid browning the garlic, as it can quickly become bitter.

Step 4: Toast the spices and tomato paste

Stir in the tomato paste, chili powder, ground cumin, smoked paprika, dried oregano, salt, black pepper, and crushed red pepper flakes (if using). Cook this mixture for 1–2 minutes, stirring frequently, until the tomato paste darkens slightly and the spices smell toasty and aromatic. This step blooms the spices in fat, giving the chili a richer, more rounded flavor rather than a raw, powdery taste.

Step 5: Add tomatoes, beans, sausage, and broth

Pour in the diced tomatoes with their juices, scraping the bottom of the pot with a wooden spoon to release any browned bits. Add the drained and rinsed kidney beans, the browned smoked sausage (and any juices on the plate), and the chicken broth. Stir well to combine. Increase the heat to medium-high and bring the mixture just up to a boil.

As soon as it bubbles, reduce the heat to low or medium-low to maintain a gentle simmer (small, steady bubbles; roughly 190–200°F / 88–93°C if you like to measure). Simmer uncovered for 20 minutes, stirring occasionally. This reduces the liquid slightly, lets the flavors meld, and softens the beans and sausage in the seasoned broth.

Step 6: Stir in the kale and finish simmering

Add the chopped kale to the pot. At first it will look like a lot, but it wilts down quickly. Stir gently until all the leaves are coated in the hot liquid and begin to soften. Continue to simmer for 5–10 minutes, stirring occasionally, until the kale is tender but still a lively, deep green. If you prefer very soft greens, give it the full 10 minutes; for a bit more texture, start tasting around 5–6 minutes.

Step 7: Adjust seasoning and serve

Taste the chili and adjust the seasoning. Depending on your sausage and broth, you may want an extra pinch of salt or a bit more black pepper or crushed red pepper flakes for heat. If the chili is thicker than you like, stir in an extra 1/4–1/2 cup of broth or water and simmer briefly. If you prefer a thicker, stew-like texture, let it simmer a few more minutes uncovered.

Ladle the chili into warm bowls. Top with a dollop of sour cream or Greek yogurt, a sprinkle of shredded cheddar, and sliced green onions if you like. Serve hot, with crusty bread or cornbread on the side for dipping into the smoky, tomato-kale broth.

Pro Tips

• Choose your sausage wisely: A fully cooked, well-smoked sausage (like andouille or kielbasa) gives the chili its signature flavor. Leaner sausages will work but may offer a bit less richness.
• Slice kale into thin ribbons: Cutting the kale into narrow strips helps it cook quickly and evenly, giving you tender greens instead of oversized chewy pieces.
• Control the heat level: Start with a light hand on crushed red pepper flakes. You can always add more at the end or offer hot sauce at the table so everyone can customize their bowl.
• Let it rest: If time allows, let the chili sit off the heat, covered, for 10–15 minutes before serving. The flavors continue to meld as it rests.
• Brighten at the end: A small squeeze of lemon juice or a splash of apple cider vinegar stirred in right before serving can wake up the flavors and balance the richness of the sausage.

Variations

• Extra-vegetable version: Add 1 diced red bell pepper and 1–2 diced carrots along with the onion. Sauté until softened before continuing with the recipe. This adds sweetness, color, and extra nutrients.
• Spicy andouille chili: Use spicy andouille sausage, increase the chili powder to 2 tablespoons, and bump the crushed red pepper flakes to 1/2 teaspoon for a more fiery bowl.
• Bean-forward variation: Add a second can of beans (black beans or pinto beans work well) and increase the broth by 1/2 cup. This stretches the recipe to feed more people and makes the chili even heartier.

Storage & Make-Ahead

This chili stores and reheats beautifully, making it ideal for meal prep. Let the chili cool to room temperature, then transfer it to airtight containers. Refrigerate for up to 4 days. Reheat gently on the stove over medium-low heat, adding a splash of water or broth if it has thickened too much, and stir occasionally until hot throughout.

For longer storage, freeze in freezer-safe containers or zip-top bags (flattened for easy stacking) for up to 3 months. Thaw overnight in the refrigerator, then reheat on the stove or in the microwave, stirring occasionally. Add fresh toppings like sour cream, cheese, and green onions after reheating for the best texture and flavor.

Nutrition (per serving)

Approximate values per serving (1/4 of the recipe, without optional toppings): about 520 calories; 27 g protein; 30 g fat; 35 g carbohydrates; 9 g dietary fiber; 9 g sugar; 1,300–1,500 mg sodium (varies significantly with sausage and broth brands). Adding cheese and sour cream will increase the fat and calorie content. These numbers are estimates and will vary based on exact ingredients used.