Cook the Protein: In a large pot, brown the ground meat over medium heat until fully cooked. Drain any excess fat. For a vegetarian version, skip this step or cook lentils until tender and drain well.

Sauté the Veggies: Add onion, bell pepper, and garlic to the pot. Cook 5–7 minutes until softened and fragrant.

Build the Base: Stir in diced tomatoes (drained), tomato paste, and broth. Mix until the paste dissolves and the mixture is uniform.

Add Beans and Spices: Stir in black beans, kidney beans, chili powder, cumin, smoked paprika, oregano, salt, and pepper. Add optional cocoa or chipotle if using.

Simmer Low and Thick: Reduce heat and simmer 20–30 minutes, stirring occasionally. You want a thick chili with minimal excess liquid. Adjust seasoning to taste.

Cool Completely: Spread the chili in shallow containers or pans to cool quickly. Do not load a dehydrator with hot food.

Dehydrate: Line dehydrator trays with fruit-leather sheets or parchment. Spread chili in thin, even layers (about 1/4 inch). Dry at 135–145°F (57–63°C) for 8–12 hours, until completely dry and brittle in spots. Break up any thick areas and continue drying as needed.

Optional: Dehydrate Separately: For faster drying and better texture, dehydrate beans and sauce/meat on separate trays. Then combine once everything is fully dry.

Condition the Batch: After drying, let the chili cool, then place loosely in a large jar or bag for 24 hours to “condition.” Shake occasionally. If condensation appears, it needs more drying.

Portion and Pack: Divide into single servings (about 1–1.5 cups dry per meal, depending on appetite). Vacuum-seal or store in freezer-grade zip bags with an oxygen absorber for longer shelf life.

On-Trail Rehydration: Add boiling water at a 1:1 to 1:1.5 ratio (by volume), stir, seal, and wait 10–15 minutes. Adjust water to reach your preferred thickness.