Smoked Mac and Cheese (Pellet Grill Recipe)

When the sun is out and the smoker is running, I want a recipe that doesn’t require me to be stuck in the kitchen while everyone else is outside. This Pellet Grill Smoked Mac and Cheese is my go-to for backyard barbecues, pool days, and more because it’s effortless and comforting.

As we head into the summer season, the grill and smoker get used the most around our home. This Pellet Grill Smoked Mac and Cheese made on the pellet grill is another great recipe to add to your list of Pellet Grill Recipes! It has a rich, cheesy sauce with a subtle wood-fired flavor that you just can’t get out of the traditional oven. Plus, make it gluten-free with just a simple swap of pasta.

Table of contents

• What is Smoked Mac and Cheese?
• What you’ll love about this Recipe
• Ingredient Notes
• Step-by-Step Instructions
• Tips for the Best Smoked Mac and Cheese
• Variations of Pellet Grill Smoked Mac and Cheese
• Frequently Asked Questions
• What to serve with Smoked Mac and Cheese
• Storage Tips
• More Pellet Grill Recipes

What is Smoked Mac and Cheese?

Smoked Mac and Cheese is a twist on the classic comfort food that uses a pellet grill or smoker to infuse the pasta and creamy sauce with a wood-fired flavor. This version is specifically designed for a pellet grill, resulting in the perfect cheesy consistency that thickens into a baked macaroni and cheese as it smokes.

What you’ll love about this Recipe

• Ready in just a few hours, it can be smoked right alongside your meat!
• Easy to make gluten-free.
• Always a kid-friendly, crowd-pleaser because we all love mac and cheese!
• Uses pantry staples, making it a budget-friendly option that feeds a crowd.
• Amazing wood-fire flavor that you just can’t get in the oven or pressure cooker.
• All made in an aluminum pan, which makes for easy cleanup!
• If you are looking for a Ninja Foodi version, be sure to check out this Ninja Foodi Mac and Cheese.

Ingredient Notes

• Elbow Macaroni or Gluten-Free Elbow Macaroni – The best classic choice, as it holds the cheese sauce. I like to use Barilla Gluten-Free if you need a gluten-free option.
• Whole Milk – The whole milk and evaporated milk are combined to create a rich base that does not separate under high heat.
• Evaporated Milk – Combined with whole milk for the rich, creamy base.
• Unsalted Butter – Along with the milk, this makes the base of the creamy sauce.
• Cream Cheese – This provides the velvety, creamy texture.
• Muenster Cheese – This combination of cheese mixed with wood-fired flavor gives the best texture and taste.
• Colby Jack Cheese – Paired with Muenster Cheese for the best texture and taste, for the best melt, use your own blocks and grate them with a cheese grater.
• Kosher Salt – The salt enhances the flavor profile.
• Ground Mustard – Adds the tangy flavor alongside the dairy.
• Ground Black Pepper – Enhances the overall flavor.

Step-by-Step Instructions

1. Boil pasta in salted water according to package, then drain and rinse in cold water to stop cooking process.
2. Start your pellet grill and set the temperature to 180 degrees F. Any pellets can be used, we used oak pellets.
3. In a large bowl, combine the cooked pasta, milk, evaporated milk, cubed butter, cubed cream cheese, Muenster and Colby Jack cheeses, reserve a little cheese for topping.
4. Sprinkle seasonings on top and mix in well.
5. Lightly spray a square foil pan with cooking spray and transfer the mac and cheese to the aluminum square pan.
6. Place the pan on the pellet grill and smoke for 30-45 minutes depending on how smoky you want the cheese to be.
7. Stir to blend the melted mac and cheese and sprinkle the reserved cheese on top.
8. Cover with foil.
9. Increase the temperature to 400 degrees F and cook until the sauce is thickened, about 20-30 minutes, then remove the foil and cook for an additional 10-15 minutes until the top is browned.
10. Remove from the smoker and let rest for 10 minutes before serving.
11. Store leftovers in fridge.

Tips for the Best Smoked Mac and Cheese

• Shred your own cheese – pre-shredded cheese is coated in potato starch to prevent melting, freshly grated cheese will melt much better under high heat.
• Use a cold water rinse – To remove the starch, especially with gluten-free pasta, wash under cold water once the boiling is complete.
• Pellet selections – For a Pit Boss or Traeger, I recommend oak, hickory, or apple pellets. Oak and Hickory will give the mac and cheese a bold BBQ flavor, while the apple is sweet and mild.
• Gluten-free – For gluten-free use, gluten-free elbow macaroni. I use the Gluten-Free Barilla brand.

Variations of Pellet Grill Smoked Mac and Cheese

• Make it gluten-free with a simple swap of gluten-free pasta.
• Add a tablespoon of BBQ rub to the cheese mixture for a savory spicy flavor.
• Stir in pre-cooked bacon bits or pork before the final phase to add a protein kick.

Frequently Asked Questions

It’s best to use a block of cheese instead of pre-shredded cheese. The pre-shredded cheese has extra ingredients in it to keep it fresh longer, which makes it not melt as well as blocks of cheese.

It’s also best to use a variety of cheeses, not just cheddar.
In this case, we added Muenster Cheese too. Muenster has a low melting point and absorbs the smoky flavor, making it the optimal choice.

If you want to use something other than Muenster, you could use Mozzarella, but do not use fresh mozzarella as it is too watery; you would want to use a block of low-moisture mozzarella.

This recipe works perfectly with any brand, including Pit Boss, Traeger, and Green Mountain. The key is the pellets and the right temperature during the smoke phase.

Yes, the pellet grill does not provide enough consistent moisture to cook dry pasta, so it must be boiled and cooked first. Remember to rinse with cold water before moving on to combine the cheese and pasta.

Do not skip the evaporated milk; this is an emulsifier to keep the sauce creamy at a high temperature.

The pasta can be boiled in advance up to 24 hours; it needs to be stored separately from the other ingredients until ready to prepare and smoke.

Hickory, Oak, or Apple are our favorites for this recipe. If you are smoking meats, you can use the same pellets you are using for your proteins and smoke them together. I like to use a wood pellet blend most of the time, too.

What to serve with Smoked Mac and Cheese

We love to pair Smoked Mac and Cheese with a variety of pellet grill recipes that we cook right along with it, here are some of the best pairings:

Pellet Grill Chicken Thighs

Smoked Drumsticks

Pellet Grill Smoked Baby Back Ribs

Smoked Bologna

Onion Soup Burgers

Storage Tips

Once fully cooled, store leftovers in an airtight container for up to 3-4 days. When ready to reheat, heat in the oven at 350 degrees F for 10-12 minutes, and add a splash of milk to restore the creaminess.

This pellet grill smoked mac and cheese is proof that a restaurant-style side dish is possible with just a few minutes of prep work. I make this regularly, and if I can do it, so can you! Fire up that Pit Boss or Traeger and grill the best show-stopper side dish!

More Pellet Grill Recipes

• Smoked Chicken Drumsticks (Pellet Grill)

• Pellet Grill Smoked Little Smokies

• Pellet Grill Balsamic Steaks

• Smoked Mushrooms (Pellet Grill Recipe)