Pellet grill mac and cheese is hands-down one of the most flavorful comfort foods you can make on your Pit Boss or any pellet smoker. This recipe is simple, crowd-pleasing, and guaranteed to be the star of your next BBQ. You can dial up or dial down the amount of smoke flavor you want to impart, leading to the perfect meal for you and your guests.
We’ll walk you through how to make the creamiest pellet grill mac and cheese, explain how smoking it enhances the flavor, and share expert tips to take this dish from good to jaw-droppingly great.
🔥 Pellet Grill Mac and Cheese: Step-by-Step Instructions
We’ve adapted the recipe below from a variety of websites online, and from our own experience cooking this dish for friends and family. We tend to like a variety of cheeses beyond just sharp cheddar cheese, and we think the Monterrey Jack and Gouda help impart a depth of flavor that you won’t find anywhere else.
Ingredients for Pellet Grill Mac and Cheese
Below is a simple ingredient list for your pellet grill mac and cheese:
- 1 lb elbow macaroni
- 4 tbsp butter
- 1/4 cup all-purpose flour
- 3 cups whole milk
- 2 cups heavy cream
- 2 cups sharp cheddar cheese (freshly grated)
- 1 cup Monterey Jack cheese (freshly grated)
- 1 cup gouda cheese (smoked gouda if desired, freshly grated)
- Salt & pepper to taste
- 1/2 tsp paprika
- 1/2 tsp garlic powder
- 1/2 tsp mustard powder (optional)
- 1/2 cup panko breadcrumbs (for topping)
- 2 tbsp melted butter (for topping)
Equipment
You’ll need a few things on hand to make sure you are able to deliver on a great dish for you and your guests:
- Cast iron skillet (preferably 12″). We personally love the Lodge Cast Iron 12″ Skillet.
- Pellet grill (Pit Boss, Traeger, Z Grills, etc.) Are you in the market for a smoker? Check out our comprehensive review of top pellet grills on the market today.
- Mild wood pellets (oak, apple, cherry, or maple). You’ll want to pick the right pellet wood as this has a big impact on the type of flavor that the smoke imparts on the pellet grill mac and cheese.
Instructions
Below are step by step instructions on how to cook pellet grill mac and cheese.
- Preheat Your Pellet Grill: Set your smoker to 225°F. Preheating helps stabilize internal temperatures and sets you up for consistent results.
- Cook the Pasta: Bring a large pot of salted water to a boil. Cook the elbow macaroni until just al dente (about 1-2 minutes less than the package suggests). Drain and set aside.
- Make the Cheese Sauce: In a large saucepan over medium heat, melt the butter. Whisk in the flour to make a roux, stirring for 1–2 minutes until golden. Slowly whisk in the milk and cream. Stir until thickened (about 5–7 minutes). Lower the heat and stir in the shredded cheeses. Mix until smooth. Add seasonings: paprika, garlic powder, mustard powder, salt, and pepper.
- Combine & Assemble: Fold the cooked pasta into the cheese sauce. Pour everything into your cast iron skillet. In a small bowl, combine panko and melted butter. Sprinkle on top of the mac and cheese.
- Smoke the Mac and Cheese: Place the skillet on your pellet grill grates. Smoke for 60 minutes at 225°F. For more smoke flavor, leave it on for up to 90 minutes. For less, try 45 minutes.
- Serve Hot: Let rest for 5–10 minutes, then dig in and enjoy the smoky, creamy goodness.
Why Smoke Mac and Cheese on a Pellet Grill?
Mac and cheese is already a crowd-pleaser, but smoking mac and cheese on a pellet smoker like a Pit Boss adds depth and complexity that you just can’t get in the oven.
Pellet grills use real hardwood pellets to infuse food with subtle smoke flavor while maintaining steady low temperatures. That’s perfect for mac and cheese, which benefits from slow cooking that allows flavors to meld.
Smoked mac and cheese on a Pit Boss is different from your average baked mac. You get a crisp, golden crust on top, a creamy center, and those amazing smoky undertones that transform the dish into something unforgettable.
Whether you’re using a pellet smoker or a dedicated Pit Boss grill, the end result is next-level comfort food.
- 1001 sq. in. cooking space
- WiFi enabled pellet and gas combo grill
- 26 lb hopper capacity
Pro Tips for the Best Pellet Grill Mac and Cheese
✅ Use a Cast Iron Skillet
A cast iron skillet is a game-changer when it comes to pellet grill mac and cheese. It distributes heat evenly, retains that heat like a champ, and transitions beautifully from stovetop to smoker. The high sides and consistent surface temperature help prevent burning and promote even browning of the breadcrumb topping. We recommend a 12-inch skillet—it holds just the right amount of pasta and cheese for most family meals and still fits easily on any pellet smoker, from a Traeger to a Pit Boss. Cast iron also develops flavor over time, and if you take care of it, your skillet will only make your mac and cheese better with each cook.
- Comes pre-seasoned, ready to use; includes red handle holder
- Use on stove, grill, oven, over campfire, and more
✅ Grate Your Own Cheese
This may seem like a small detail, but it makes a huge difference in both taste and texture. Store-bought shredded cheese is coated in anti-caking agents like cellulose that prevent clumping—but also prevent it from melting smoothly. Freshly grated cheese melts more uniformly, giving you that luscious, silky-smooth cheese sauce you want in every bite. Plus, you can choose your own blend of high-quality cheeses. Try combining sharp cheddar for bold flavor, Monterey Jack for creaminess, and smoked gouda for a savory depth that amplifies the pellet grill’s natural smoke.
✅ Choose the Right Pellets
Wood choice matters more than you might think. For pellet grill mac and cheese, you want to let the cheese flavors shine, so lighter woods are key. Apple, cherry, maple, or oak pellets give you that signature smokiness without overwhelming the delicate dairy flavors. Stronger woods like mesquite or hickory can be overpowering—your creamy cheese sauce might end up tasting more like a campfire than a comfort dish. If you’re set on using hickory, try cutting it with a milder wood for balance. Brands like Pit Boss and Z Grills offer great mild wood pellet blends that work beautifully for smoked mac and cheese.
✅ Customize the Smoke Level
Pellet smokers vary widely in smoke output depending on the model, settings, and pellet type. Some models (like select Pit Boss grills) offer adjustable smoke settings—take advantage of that! We recommend starting with a high smoke setting for about 60 minutes at 225°F. For more intense smoke flavor, especially if you’re using milder wood, leave it on for 75–90 minutes. For a lighter smoke touch, 45 minutes should do the trick. Always remember: it’s easier to add more smoke next time than it is to remove too much. Keep notes on each cook so you can dial in your perfect flavor.
✅ Don’t Overcook the Pasta
It’s easy to overdo pasta when you’re baking or smoking it. Keep in mind that the pasta will continue cooking in the cheese sauce and again while it smokes. You want to boil it just until it’s al dente—firm to the bite. This way, it maintains texture even after absorbing creamy cheese and gentle smoke. Overcooked pasta can turn mushy, and that can ruin the overall mouthfeel of the dish. Also, use a sturdy pasta like elbow macaroni or cavatappi that holds up well to extended cooking and mixing.
These pro tips will help you master smoked mac and cheese on any pellet grill—whether you’re using a Pit Boss, Traeger, or Z Grills. The devil’s in the details, and nailing these five areas will elevate your dish from backyard BBQ side to smoked comfort food legend.
Pit Boss Mac and Cheese Flavor Add-Ins
Want to level up your Pit Boss mac and cheese even more? Try adding in one or two of these mix-ins—each one brings something delicious and unique to the party:
- Brisket – Smoked brisket adds deep, beefy richness and a little bark crunch to the creamy mac. Be sure to use brisket that’s already been cooked low and slow—preferably with a nice smoke ring and bark. Chop or shred it finely and fold it into the mac after the cheese sauce is mixed in but before it hits the smoker. The smoky brisket flavor complements the mild wood smoke from your pellet grill beautifully.
- Pulled Pork – A natural pairing with mac and cheese, pulled pork adds juicy, sweet-savory notes that play well with the creaminess. Aim for pork that’s already sauced lightly or seasoned well—too much BBQ sauce can overpower the cheese. Like brisket, fold it in before smoking so the flavors meld together.
- Smoked Sausage – Sliced or diced smoked sausage (like andouille, kielbasa, or even jalapeño cheddar) adds a savory, slightly spicy kick. The smoky meat blends wonderfully with the cheese, and the firmer texture adds nice contrast. Lightly pan-sear the sausage before adding to enhance the flavor and prevent sogginess.
- Chorizo – Crumbled and cooked chorizo infuses the entire dish with bold, smoky, and slightly spicy character. Spanish-style chorizo adds a deep paprika punch, while Mexican-style chorizo brings more spice and fat. Brown it well and drain excess grease before mixing it in.
- Bacon – This one’s a classic for a reason. Use crispy, chopped bacon to add a salty, crunchy bite to your smoked mac and cheese. Don’t just mix it all in—consider reserving a bit to sprinkle on top after the cook for an added texture pop. You want it cooked until just shy of brittle so it holds up against the creamy base.
- Lobster – If you’re feeling fancy, lobster turns this dish into upscale decadence. Tender lobster meat (claw or tail) folded into cheesy pasta and kissed by smoke? Incredible. Cook and chop the lobster beforehand, and add it just before smoking so it warms through without becoming rubbery. Drizzle with a little butter just before serving.
- Ham – Diced smoked or honey-baked ham offers a mild, salty sweetness that complements the cheese sauce beautifully. It’s also great for using up leftovers from a holiday meal. For best results, sear the ham cubes briefly in a skillet to caramelize the edges before folding them into the mac.
Just fold in 1–2 cups of your cooked meat of choice before placing the skillet on the smoker. These flavorful additions turn your smoked macaroni and cheese Pit Boss style into a full-on meal worthy of a backyard BBQ spotlight—or even a main course for special occasions
Make-Ahead Tips
You can prepare this entire dish (pasta + cheese sauce + toppings) ahead of time and refrigerate it, covered, for up to 24 hours. When you’re ready, just place it directly on your pellet grill or smoker and add an extra 15–20 minutes to the smoke time.
FAQ: Pellet Grill Mac and Cheese
Q: Can I use mesquite or hickory pellets?
A: You can, but be careful—strong woods like mesquite can overpower the cheese. Stick with lighter woods unless you want bold smoke flavor.
Q: How long should I smoke mac and cheese on a Pit Boss?
A: Typically, 1 hour at 225°F is the sweet spot. If your smoker produces less smoke or you’re using mild wood, go 75–90 minutes.
Q: Can I bake this in the oven instead?
A: Absolutely. Bake at 350°F for 30–40 minutes. But to get that smoked mac and cheese Pit Boss flavor, nothing beats the pellet grill.
Q: What’s the best cheese combo for smoking?
A: A mix of sharp cheddar, Monterey Jack, and gouda (especially smoked gouda) melts well and gives you depth of flavor.
Q: Do I need a Pit Boss or will any pellet smoker do?
A: Any pellet grill or smoker will work as long as you can maintain 225°F. Smoked mac and cheese on a pellet smoker is delicious regardless of brand.
Final Thoughts: Pellet Grill Mac and Cheese
Whether you’re firing up a Pit Boss, Traeger, or Z Grills, this smoked mac and cheese on a pellet grill recipe is a must-try. It’s rich, creamy, and packed with layers of flavor that only smoking can bring out.
Don’t be surprised if it becomes the most requested dish at your next backyard BBQ. And with just a few simple ingredients and your favorite pellet smoker, it’s an easy win every time.
👉 Got leftover brisket or pork? Toss it in and make this a full-blown feast. Happy smoking!
Pellet Grill Mac and Cheese [& Tips]
Equipment
- Pellet grill
- 12" cast iron skillet (or a 9" x 13" disposable aluminum pan)
Ingredients
- 1 lb elbow macaroni noodles can substitute shell pasta
- 1/2 cup butter unsalted
- 1/4 cup flour
- 2 cups whole milk
- 1 cup heavy whipping cream
- 4 oz cream cheese softened
- 3 cups cheddar grated
- 1.5 cups gouda grated
Topping
- 1 cup Panko breadcrumbs
- 1/4 cup butter melted
- 1 cup cheddar cheese shredded
Instructions
- Preheat your pellet grill to 225ºF. Set the smoke setting to high (don't worry about this if you can't customize your smoke setting)
- Cook your pasta according to the instructions on the box and strain
- In a cast iron skillet, melt butter and whisk in flour until smooth
- Whisk in whole milk and heavy whipping cream. Once the mixture begins to bubble, reduce heat to simmer and stir in cream cheese
- In small amounts at a time, consistently add shredded cheeses while whisking. As soon as a small handful of shredded cheese smoothly combines with mixture, add more cheese and keep whisking
- After the shredded cheese has been whisked in, add the cooked pasta to the skillet. If you're adding something like brisket, lobster, pork, or something else we suggested in the post, do that now
- Toss pasta in sauce until all noodles are evenly and thoroughly coated
- Place the last cup of shredded cheddar cheese on top of the mac and cheese
- Combine Panko and melted butter and evenly pour on top of the entire skillet
- Transfer skillet to the pellet grill and close the lid
- Keep the temperature at 225ºF for an hour while the mac and cheese smokes
- Remove the skillet from the grill and serve while it's still warm and enjoy!
Nutrition
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