Pellet Grill Smoked Mac and Cheese

Name: Pellet Grill Smoked Mac and Cheese
Prep time: 25 min
Cook time: 45 min
Total time: 1 h 10 min
Yield: 6 servings
Cuisine: American
Ingredients: 1 lb Elbow macaroni (dry); 1 tbsp Kosher salt (for boiling and seasoning); 6 tbsp Unsalted butter; 0.25 cup All-purpose flour; 3 cups Whole milk; 4 oz Cream cheese (softened); 3 cups Sharp cheddar cheese, shredded; 1 cup Smoked Gouda, shredded; 1 tbsp Dijon mustard; 1 cup Panko breadcrumbs

A creamy, smoky mac and cheese finished on a pellet grill for a subtle bark and deep barbecue flavor. Rich cheese sauce, a crunchy buttery panko top, and a kiss of smoke make this an ideal BBQ side that pairs perfectly with ribs, brisket, or grilled chicken.

0.0(0 reviews)

Prep: 25m · Cook: 45m · Total70 mins

DifficultyMedium

Serves6

AuthorJake

Ingredient Spotlight

Smoked Gouda, shredded

A Gouda-style cow’s milk cheese that has been exposed to smoke, giving it a pronounced smoky aroma and a slightly sweet, savory flavor; Gouda is Dutch in origin. It’s semi-soft, melts smoothly, and adds a distinct smoky depth to dishes like mac and cheese. You can find it at supermarket deli/cheese counters, specialty cheese shops, or well-stocked grocery stores. Good substitutes are regular Gouda combined with a pinch of smoked paprika or a drop of liquid smoke, or a smoked cheddar or fontina for similar melt and flavor.

Ingredient Spotlight

Panko breadcrumbs

Light, flaky Japanese-style breadcrumbs made from crustless white bread that produce a very crisp, airy crunch compared with regular breadcrumbs. They have a neutral taste and are commonly used for breading and as a crunchy topping. Panko is widely available in the Asian foods aisle of supermarkets and at Asian markets. Substitutes include regular fine breadcrumbs (won’t be as airy), crushed cornflakes or crushed saltines for extra crunch, or homemade dried breadcrumbs pulsed coarsely.

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Jake's note

"This recipe shines at backyard BBQs and potlucks — it holds up well on a buffet and picks up just the right amount of smoke without overpowering the cheese. Home cooks will love how simple it is to make on a pellet grill and how reliably crowd-pleasing the result is."

Pellet Grill Smoked Mac and Cheese

This smoked mac and cheese is not a novelty trick so much as a small, reliable upgrade to a comfort-food classic: the pellet grill gives the béchamel-based sauce a faint, wood-fired backbone and the top a delicate toasted crust that a conventional oven can’t quite mimic. The pairing of sharp cheddar and smoked Gouda creates a balance—the cheddar gives the savory tang and body, while the Gouda layers in a rounded, smoky creaminess that holds up when you finish the dish on the grill. Texturally, the goal is contrast: tender pasta cushioned in a glossy, clingy cheese sauce with a crisp, buttery panko cap that fractures against the spoon.

This version is for the home pitmaster who wants a dependable, crowd-pleasing side without overcomplicating the cook. It thrives alongside ribs, brisket, or grilled chicken, and it’s forgiving: undercook the pasta slightly, shred your own cheese for smoother melt, and keep a bit of pasta water handy to rescue a sauce that’s too tight. The low-and-slow smoke phase builds flavor without drying the surface, while a brief temperature bump at the end delivers a deeper crust—small adjustments that make this mac and cheese feel like a true barbecue companion.

Plan your timing

Enter your target meal time:

5:45 pm–5:59 pm→Cook the pasta

5:59 pm–6:13 pm→Make a roux

6:13 pm–6:27 pm→Make the cheese sauce and combine with pasta

6:27 pm–6:41 pm→Top with buttery panko

6:41 pm–6:55 pm→Smoke on the pellet grill until bubbly and golden

Ingredients

Yield

Instructions

Cook the pasta

Bring a large pot of water to a rolling boil and add the kosher salt. Add the elbow macaroni and cook 1–2 minutes less than package directions so it is slightly under al dente (about 6–7 minutes). Drain well and set aside, reserving ½ cup of the pasta cooking water in case you need to loosen the sauce later.

For this step

1 lbElbow macaroni (dry)
1 tbspKosher salt (for boiling and seasoning)

Make a roux

In a medium saucepan over medium heat, melt 4 tablespoons of the butter. Whisk in the flour and cook, whisking constantly, for 1–2 minutes until the mixture is bubbly and fragrant but not browned. This cooks out the raw flour taste and forms the base that will thicken your cheese sauce.

For this step

6 tbspUnsalted butter
0.25 cupAll-purpose flour

Make the cheese sauce and combine with pasta

Slowly whisk the milk into the roux and bring to a gentle simmer, stirring until the sauce thickens, 3–5 minutes. Reduce heat to low and whisk in the cream cheese until smooth, then remove from heat and stir in the shredded cheddar and smoked Gouda until melted and silky. Stir in the Dijon mustard and season with additional salt and freshly ground black pepper to taste, then fold the drained pasta into the sauce until evenly coated, adding a splash of reserved pasta water if needed to loosen.

For this step

3 cupsWhole milk
4 ozCream cheese (softened)
3 cupsSharp cheddar cheese, shredded
1 cupSmoked Gouda, shredded
1 tbspDijon mustard

Make the cheese sauce and combine with pasta

Top with buttery panko

Transfer the mac and cheese to a 9x13-inch oven-safe baking dish or cast-iron skillet. Melt the remaining 2 tablespoons of butter and toss with the panko breadcrumbs until evenly coated, then sprinkle the crumbs over the top of the pasta for a crunchy finish.

For this step

1 cupPanko breadcrumbs

Smoke on the pellet grill until bubbly and golden

Preheat your pellet grill to 225–250°F (107–121°C) with a mild wood (apple, cherry, or maple) for 10–15 minutes. Place the dish on the grill grates and smoke uncovered for 30–45 minutes until the center is hot and the top is lightly browned; for a deeper crust, increase heat to 350°F (177°C) for the last 5–10 minutes. Remove from the grill, let rest 5 minutes, then serve warm alongside your smoked mains.

Tips from the kitchen

Undercook the pasta slightly

Cook the elbows 1–2 minutes less than package directions so they finish in the sauce and don’t become mushy after smoking.

Reserve pasta water

Keep the ½ cup of starchy cooking water to loosen the sauce; a tablespoon or two will restore silkiness without watering down flavor.

Shred cheese fresh

Buy blocks and shred them yourself—the pre-shredded bags contain anti-caking agents that can make the sauce grainy and prevent smooth melting.

Start with room-temperature dairy

Soften the cream cheese and let the milk warm slightly before adding to the roux to avoid lumps and speed up a glossy finish.

Choose mild fruit woods

Use apple, cherry, or maple for a gentle smoke that complements rather than competes with the cheese; reserve hickory or mesquite only if you want a pronounced barbecue note.

Variations & substitutions

Spicy Jalapeño Kick

Fold in 1/2 cup diced roasted jalapeños or a teaspoon of chipotle in adobo to the sauce and swap half the panko for crushed tortilla chips for Tex‑Mex flair.

Bacon and Scallion Upgrade

Stir in 6 slices of cooked, crumbled bacon and top with sliced scallions after smoking for savory crunch and freshness.

Gluten-Free Option

Use a gluten-free pasta and substitute a 1:1 gluten-free all-purpose flour blend in the roux; gluten-free panko or crushed rice crackers make a crisp topping.

Lighter Three-Cheese Version

Replace half the butter with olive oil, use 2% milk, and swap half the cheddar for Gruyère to reduce fat while keeping a nutty complexity.

Storage & make-ahead

Store leftovers in an airtight container in the refrigerator for up to 3–4 days. To reheat, warm in a 325°F oven (covered) until heated through, then uncover for 5–8 minutes to re-crisp the topping; you can also finish briefly on the pellet grill at 350°F for 5–10 minutes. For longer storage freeze in a shallow, airtight pan for up to 2 months—thaw overnight in the fridge before reheating.

What to serve with it

Serve this mac and cheese as a hearty side to smoked brisket, baby back ribs, or spicy grilled chicken, and contrast it with a bright vinegar-based slaw or pickled vegetables to cut the richness. For beverages, try a crisp pilsner or an off-dry Riesling to balance the smoke and fat, or a citrusy margarita if you’ve added jalapeño or chipotle notes.

Frequently asked questions

Can I smoke the mac entirely at higher heat to shorten time?

You can increase heat, but higher temps risk drying the pasta and melting the topping too quickly; smoke at 225–250°F for most of the time, then bump to 350°F for the last 5–10 minutes to develop a deeper crust.

My sauce turned grainy—what went wrong?

Graininess usually comes from overheating the cheese or using pre-shredded cheese with anti-caking agents; remove from heat before adding cheese and stir gently until just melted, or use freshly shredded blocks.

How do I get more smoke flavor without overpowering the cheese?

Extend the low-temperature smoke time by 10–15 minutes or use a slightly stronger fruit wood like cherry, but avoid heavy woods like mesquite which can clash with dairy flavors.

Can I make this ahead and finish on the grill later?

Yes—assemble and refrigerate the baked pan (unbaked or baked) for up to 24 hours; bring it closer to room temperature before placing on the pellet grill and allow a few extra minutes to reach bubbling heat.

Is the panko topping essential, and can I swap it?

Panko adds a light, crunchy contrast but you can swap with seasoned breadcrumbs, crushed crackers, or a mix of Parmesan and breadcrumbs for more nuttiness; ensure whatever you use is toasted with butter so it crisps on the grill.

About the author

Jake

Hello, I'm Jake. I started this recipe site with the idea that I hated recipe websites that overwhelm you with long stories and ads just to see plain content that's not helpful. My goal is to provide you with quality recipes, simple ideas and a fun cooking experience. There's lots of fun things to cook, and I think as you browse the site you'll find that TopShelf.Recipes is the place for quality recipes on the web.

See all recipes by Jake →

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Ingredients

6 servings

Step 1: Cook the pasta

Elbow macaroni (dry)1 lb
Kosher salt (for boiling and seasoning)1 tbsp

Step 2: Make a roux

Unsalted butter6 tbsp
All-purpose flour0.25 cup

Step 3: Make the cheese sauce and combine with pasta

Whole milk3 cups
Cream cheese (softened)4 oz
Sharp cheddar cheese, shredded3 cups
Smoked Gouda, shredded1 cup
Dijon mustard1 tbsp

Step 4: Top with buttery panko

🛒 BuyPanko breadcrumbs1 cup

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Nutrition Facts

Per serving: about 2¾ cups

Calories1042

Total Fat59.8g

Saturated Fat35.4g

Trans Fat1.3g

Polyunsaturated Fat3.2g

Monounsaturated Fat10.6g

Total Carbohydrates83.2g

Dietary Fiber3.9g

Total Sugars1.9g

Protein42.1g

Nutrition values are estimated from USDA ingredient data and may vary based on preparation, brands, and portion sizes. Values are provided for informational purposes only.

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