Here's an old thread of mine with pics:
or just read it here:
Mark's chipotle process revealed
First step: pick and rinse a $hitload of peppers. The first picture shows japs, rocoto's and hot cherry peppers; basically, everything that was rep/ripe that day.
Second step, remove stems. I do this by simultanoeusly crushing the pepper while yanking on the stem. This step also doubles the surface area which means less drying time.
Third step, load the smoker(s). I employed both my UDS and my Bandera.
1 big round tray in my UDS and 4 rectangular trays in my Bandera.
Fourth step, smoke/dry until the peppers are leathery. This took about 10 hours at 150 to 200 deg. F.
Fifth step, dry in the oven at about 150 Deg. F. until crisp. This went on overnight.
Final step, process in a blender with short pulses into the final product; a flakey powder that about halfway filled up a gallon ziplock bag