I’ve always been obsessed with the smoky, sweet flavor of barbecue potato chips. When I first saw Jeff Mauro turn them into a versatile seasoning dust, it was a game-changer.

I immediately went to my kitchen to create my own Jeff Mauro BBQ Chip Dust Recipe, and the result was incredible.

This smoky, slightly spicy powder has become my secret weapon for adding a burst of flavor to everything.

It’s so easy to make, and now I sprinkle it on almost everything from chicken to popcorn.

Ingredients

Here are the simple ingredients you’ll need to create this fantastic seasoning.

1 bag BBQ potato chips: Any brand you love will work. The better the chip, the better the dust, so pick a favorite!
1 tablespoon smoked paprika: This is key for achieving that deep, authentic barbecue smokiness.
1 tablespoon garlic powder: Because garlic and barbecue are a match made in flavor heaven.
1 tablespoon onion powder: Adds a savory depth that rounds out the seasoning blend.
1 teaspoon cayenne pepper: This is optional, but a little bit adds a wonderful spicy kick.
Salt and black pepper, to taste: Remember that the chips are already salty, so add this sparingly and taste as you go.

Note: This recipe makes several servings, enough for about one cup of seasoning dust.

Variations

Customize your BBQ chip dust with these fun and flavorful variations.

Spicier Kick: Add an extra half teaspoon of cayenne pepper or a pinch of chili powder for more heat.
Sweeter Blend: Mix in a teaspoon of brown sugar to enhance the sweet notes of the barbecue flavor.
Different Chip Flavors: Don’t be afraid to experiment! Try this with jalapeño, sour cream and onion, or even plain salted chips for a completely different seasoning profile.
Herbaceous Twist: Add a teaspoon of dried oregano or thyme for a more complex, herbal flavor.

Cooking Time

This recipe comes together in under 20 minutes.

Prep Time: 5 minutes
Cooking Time: 12 minutes
Total Time: 17 minutes

Equipment You Need

You only need a few basic kitchen tools to make this recipe.

Baking Sheet: Used to spread the chips out and bake them for extra crispiness.
Parchment Paper: Prevents the chips from sticking to the baking sheet and makes cleanup a breeze.
Food Processor or Blender: This is essential for grinding the chips into a fine, consistent powder.
Airtight Container: For storing your finished BBQ chip dust and keeping it fresh.

How to Make Jeff Mauro BBQ Chip Dust Recipe?

This recipe is incredibly simple and turns your favorite snack into a versatile seasoning. Follow these steps to create a powder that will elevate your meals. The process starts with baking the chips to intensify their flavor and ensure they are perfectly crisp. This crucial step is what makes the final dust so crunchy and delicious. From there, you just need to grind and season.

Preheat and Bake the Chips

First, preheat your oven to 350°F (175°C). While the oven is heating up, line a baking sheet with parchment paper. Spread your BBQ potato chips in a single, even layer on the sheet. Bake them for about 10-12 minutes. You’ll know they’re ready when they look a little more golden and feel extra crispy. This step dries them out completely and deepens that BBQ flavor.

Cool and Grind

Once the chips are done baking, remove them from the oven and let them cool on the baking sheet for a few minutes. This is an important step because trying to grind hot chips can result in a clumpy, paste-like texture. After they have cooled, transfer the chips to a food processor or a high-powered blender. Pulse the chips until they transform into a fine powder.

Season and Store

Now it’s time to add the magic. Add the smoked paprika, garlic powder, onion powder, and cayenne pepper (if using) to the food processor with the chip dust. Add a small pinch of salt and pepper, remembering that the chips are already seasoned. Pulse a few more times until all the spices are thoroughly combined. Transfer your finished BBQ chip dust into an airtight container for storage.

Additional Tips for Making this Recipe Better

Having made this recipe many times, I’ve picked up a few tricks to make it even better.

I found that kettle-cooked chips work exceptionally well. Their thickness and extra crunch create a dust with a slightly better texture.
Don’t skip the baking step! The first time I made this, I was impatient and just blended the chips from the bag. Baking them makes a huge difference in the final flavor and texture.
When grinding, I pulse in short bursts instead of blending continuously. This gives me more control and prevents the dust from getting too oily.
Taste the dust before you put it in the container. Sometimes I add a little more garlic powder or a touch of brown sugar depending on what I plan to use it for.

How to Serve Jeff Mauro BBQ Chip Dust Recipe?

This seasoning is incredibly versatile. Sprinkle it generously over hot French fries or tater tots right out of the fryer. It’s also fantastic on popcorn for a movie night snack with a twist. For a main course, use it as a rub for chicken wings, pork ribs, or even steak before grilling. You can also toss it with roasted vegetables like corn on the cob or potatoes to give them a smoky, savory kick.

Nutritional Information

Here is an approximate nutritional breakdown for this seasoning.

Calories: 15 per serving
Protein: <1g
Carbohydrates: 2g
Fat: 1g

Make Ahead and Storage

This seasoning is perfect for making in advance and keeping on hand.

To store, place the BBQ chip dust in an airtight container or spice jar. Keep it in a cool, dry place like a pantry or cupboard, away from direct sunlight and heat. It will stay fresh and flavorful for up to two weeks.

I don’t recommend refrigerating the dust, as moisture can cause it to clump.

For longer-term storage, you can freeze the dust. Place it in a small, freezer-safe zip-top bag, removing as much air as possible. It will keep in the freezer for up to one month. Just let it come to room temperature before using.

Why You’ll Love This Recipe?

You’re going to want to make this BBQ chip dust again and again for so many reasons.

Incredibly Easy to Make: This recipe requires just a few simple steps and is ready in less than 20 minutes, making it a quick way to add major flavor to your meals.
Amazingly Versatile: You can use it on almost anything! From meats and vegetables to snacks like popcorn and fries, it adds a delicious smoky flavor to countless dishes.
Completely Customizable: It’s easy to adjust the spice level or sweetness to suit your personal taste. You can also experiment with different chip flavors for unique seasoning blends.
Reduces Food Waste: It’s a fantastic way to use up the broken chip pieces at the bottom of the bag that might otherwise get thrown away.