In a Dutch oven, cook ground beef until no longer pink. Drain fat.: The moment the meat hits the hot surface you will hear a sharp sizzle, and that sound is your ally; it signals browning, which produces rich, nutty aromas as proteins and sugars caramelize. As you break the ground beef apart with a spatula, look for pieces that turn deep brown along their edges, not pale gray. That browning creates fond on the pot bottom, which adds savory complexity when deglazed or combined with the next ingredients. A common mistake is overcrowding the pot, which causes steaming instead of browning; work in batches if necessary to preserve that sizzle and achieve those caramelized bits.
Add remaining ingredients. Bring to a boil, reduce heat to simmer and cook 30 to 45 minutes.: After the meat is browned, you will notice glossy pools of rendered fat collecting in the pot. Carefully pour off or spoon out excess fat so the chili doesn’t become greasy, but leave a spoonful to carry flavor. The remaining surface fat will shimmer and help the spices bloom when added, releasing their aromas into the warm oil. If you remove too much fat you might lose flavor and the spices will feel muted, so keep a little bit for that flavor bridge between meat and sauce.
Add remaining ingredients: When you add the dried onion flakes , crushed garlic , salt , cumin , dried oregano , chili powder , Rotel diced tomatoes and green chilies , tomato sauce , beef broth , and chili beans , the pot will go quiet in the best way as aromas bloom. The liquid will steam and lift the spice scent into the air, and you should notice herbaceous and tomato notes marrying with the beef. Stir gently until everything looks integrated; the color should shift to a deeper, unified red with flecks of green from the chilies. A frequent misstep is tossing everything in and immediately turning off the heat. Allowing the mixture to warm helps flavors meld and releases aromas for a cohesive profile.
Bring to a boil: As the surface tightens and small bubbles begin to appear across the top, you will see the pot come into a rolling simmer. That initial boil helps to bring temperatures up quickly so the flavors begin fusing. Watch carefully because vigorous boiling can cause splatter and make the chili reduce too quickly. The sound will change from a gentle simmer to a more assertive bubbling; that’s your cue to adjust heat.
Reduce heat to simmer and cook 30 to 45 minutes: Once reduced to a simmer, you will witness a transformation; the sauce will thicken slowly, becoming glossy and clinging to the meat and beans. Aromas will deepen and meld, with the chili powder mellowing and the Rotel diced tomatoes and green chilies integrating into the sauce. Stir occasionally to prevent sticking, and check texture after about 30 minutes to see if it has reached the thickness you prefer. If the chili is too thin, continue to simmer uncovered until it thickens. A typical error is rushing this stage with higher heat; that can toughen meat and concentrate saltiness, so maintain a patient, low simmer for the best mouthfeel.