Costco Chili Recipe: Hearty Beef and Bean Stew for Crowds

This chili delivers the bold, hearty flavors you’d expect from a Costco-style batch, scaled perfectly for home kitchens. I developed this after years of testing crowd-sized recipes in my tiny Boston kitchen.

The secret is slow-cooking ground beef and beans with a rich blend of spices until the flavors meld into something deep and satisfying. It’s designed to feed a group without sacrificing quality.

What you’ll get is a thick, robust chili with tender meat, soft beans, and a sauce that’s rich without being heavy. Every spoonful tastes like it simmered for hours—because it did.

Perfect for gatherings, meal prep, or a cozy night in. Here’s how to make it right.

Ingredients for Costco Chili

Pantry staples plus a quick stop at the butcher counter for this crowd-pleasing dish.

The beef is the foundation here. Ground chuck with 80/20 fat ratio gives you that rich, hearty texture Costco chili is known for. I grab mine from Whole Foods or Market Basket in Boston—both have great quality. The beans? Goya or Bush’s are my go-to brands (canned is fine, just rinse them well). For the tomatoes, San Marzano if you want to splurge, store brand if you don’t.

No kidney beans? Pinto beans work just as well. Out of tomato paste? One extra can of diced tomatoes plus a pinch of sugar gets you close. Fresh garlic is ideal but jarred minced at half the amount works in a pinch. The chili powder is doing heavy lifting, so use fresh stuff—if it’s been in your cupboard for years, it’s probably lost its punch (and that’s why your chili tastes flat).

This actually tastes better the next day once everything melds. Keeps 4-5 days in the fridge, freezes beautifully for 3 months. I always make a double batch—half for now, half for later (or for the freezer).

Step-by-Step Instructions for Hearty Beef and Bean Stew

Here’s the method I use to build layers of flavor in this crowd-pleasing dish.

Step 1: Brown the Ground Beef

Heat a large pot or Dutch oven over medium-high heat. Add the 1.5 lb ground beef and break it up with a wooden spoon as it cooks. You want to create small, even crumbles—this ensures every bite has the right texture.

Cook for 6-8 minutes until the beef is browned all over with no pink remaining. Drain off excess fat if needed, but leave about 1 tablespoon in the pot for flavor. This browning step builds a rich foundation for the chili.

Step 2: Sauté Aromatics and Build the Base

Reduce heat to medium and add the diced yellow onion to the pot. Cook for 3-4 minutes until softened and just starting to turn translucent. Stir in the 4 cloves minced garlic and cook for 30 seconds until fragrant.

Add the 2 tbsp tomato paste, 2 tbsp chili powder, 1 tbsp ground cumin, 1 tsp dried oregano, 1 tsp smoked paprika, 0.25 tsp cayenne pepper, 1.5 tsp salt, and 1 tsp black pepper. Stir well to coat everything in the spices and toast them for 1 minute—this wakes up their flavors.

Step 3: Simmer with Beans and Liquids

Pour in the 2 cups beef broth, then add the 2 cans diced tomatoes (with juices), 2 cans kidney beans (drained and rinsed), and 1 can black beans (drained and rinsed). Stir to combine, scraping up any browned bits from the bottom of the pot.

Bring the mixture to a boil, then reduce heat to low. Cover and let it simmer for 30-40 minutes, stirring occasionally. You’ll know it’s ready when the flavors meld together and the chili thickens slightly.

Step 4: Adjust and Serve

Taste and adjust seasoning if needed. I often find it needs a pinch more salt or chili powder at this stage. Let it sit for 5-10 minutes off the heat before serving—this allows the flavors to develop even further.

The chili should have a thick, hearty consistency with the beans and beef evenly distributed. Serve it hot, and watch it disappear—this recipe is designed to satisfy a crowd with its rich, comforting flavors.

Dietary Considerations for These Flavors

Gluten-Free Friendly

This chili is naturally gluten-free as written, since it relies on whole ingredients like ground beef, beans, and tomatoes. Just double-check your spice labels—some blends can contain hidden wheat. I always use McCormick or Penzeys for peace of mind. 💪

Dairy-Free Adaptations

Skip the optional cheese or sour cream toppings, or use dairy-free alternatives like Cashewgurt or Violife cheddar. The chili itself is completely dairy-free, so you won’t miss out on any core flavors.

Vegetarian Version

Swap the 1.5 lb ground beef for 1.5 lb crumbled tempeh or 2 cans lentils. Add an extra 1 tbsp soy sauce for umami depth. I’ve tested this with Lightlife crumbles—it fools even meat lovers.

Lower Sodium Option

Use low-sodium beef broth, rinse beans thoroughly, and reduce added salt to 1 tsp. Boost flavor with extra garlic or smoked paprika instead. It’s just as satisfying without the salt overload.

Spice Level Adjustments

For mild chili, omit the cayenne pepper and reduce chili powder to 1 tbsp. For extra heat, add 1 chopped jalapeño with the onions or a pinch of chipotle powder. I always keep Tajín on hand for custom heat. 🔥

Allergen Note

This recipe is free from the top 8 allergens (milk, eggs, fish, etc.) as written. If serving guests with allergies, confirm your spice brands are processed in allergen-free facilities.

Frequently Asked Questions