Smoked Mac and Cheese

5 from 23 votes

This smoked mac and cheese is creamy, cheesy, and loaded with smoky flavor—an easy side dish or main for BBQs, holidays, or weeknights.

Prep Time15

Cook Time45

Total Time1

Course: Entree

Cuisine: American

Keyword: baked pasta, mac and cheese, smoked mac and cheese, outdoor cooking, smoker recipes, smoked mac and cheese with bacon

Servings: servings

Calories: 769kcal

Author: Renae Gerhardstein

Equipment

smoker (or gas or charcoal grill
12-inch cast iron skillet or large foil pan
saucepan to prepare the cheese sauce

Ingredients

1 pound elbow macaroni or other small pasta, such as penne or shells
½ cup butter
4 tablespoons all-purpose flour
2 cups half-and-half
2 teaspoons ground mustard
2 teaspoons ground white pepper *See Note 1
½ teaspoon salt
4 ounces softened cream cheese cut into cubes
12 ounces sharp cheddar cheese shredded and divided *See Note 2
6 ounces Gruyere cheese shredded *See Note 2

Bacon Bread Crumb Topping

1 cup bread crumbs *we like to use sourdough bread crumbs
¼ pound bacon cooked and crumbled (may substitute with 1/3 cup bacon bits)

Instructions

If the cast iron skillet is not already well seasoned, use canola oil (or another high smoke point oil) to grease the insides. If using a foil pan, grease with non-stick cooking spray. Set aside.
Prepare and preheat the smoker to 250ºF.
Boil macaroni in salted water to al dente according to box directions. **Do not completely cook the pasta, as It will continue cooking in the smoker.
Drain in a colander and set aside. *Do not rinse the cooked pasta with water or the cheese sauce may end up watery.
Melt butter in a 4-quart (or larger) saucepan over medium heat. Whisk in flour and cook for 1 minute.
Gradually whisk in half-n-half (about 1/2 cup at a time). Reduce burner heat to medium-low and allow mixture to cook for 3 minutes.
Stir in 2 cups of cheddar (reserving 1 cup), the gruyere, cream cheese, and seasonings. Continue cooking on medium-low heat until sauce is smooth and bubbly, stirring frequently.
Taste for seasoning, and add more salt and/or pepper if needed.
Add the cooked macaroni to the pot of cheese sauce. Using a large spoon, stir to combine. Pour contents into the prepared skillet or foil pan. Sprinkle remaining cup of cheddar cheese in an even layer over the mac and cheese.
In a small bowl, use a small spoon to stir bread crumbs and crumbled bacon to combine. Sprinkle topping over the mac and cheese casserole.
Smoke at 250ºF for 45 minutes. Serve right away, or for a crispier, more golden brown topping, place the smoked mac and cheese under an oven broiler for 5 minutes.
Serve warm. Store leftovers in an airtight storage container in the refrigerator for up to 5 days.

Notes

If you want to cook the bacon mac and cheese in the oven, prepare according to directions shown, but bake in a 300ºF oven for 35-40 minutes, or until topping is light golden brown.

Black pepper may be substituted for white pepper, but black pepper will be noticeable in the mac and cheese sauce.
For semi-hard cheeses like cheddar and Gruyere, the general rule of thumbs is that 4 ounces yields 1 cup of shredded cheese.
The sauce may seem runny at first, but it will thicken during the smoking or baking process.

Recipe Variations:

Smoked mac and cheese with pulled pork: Stir in shredded pork before smoking for a hearty, protein-packed twist. The smoky meat pairs perfectly with the creamy smoked macaroni and adds extra richness to each bite.
Cherry and hickory wood blend: For a deeper smoke flavor, try using a blend of cherry and hickory wood pellets in your smoker. This combo adds a slightly sweet yet robust taste that complements the cheese beautifully.
Four-cheese blend: Swap out some of the cheddar and Gruyere for Colby Jack and Gouda cheese. These cheeses melt well and create an ultra-creamy sauce with bold, comforting flavor.

Storing Instructions:

Keep leftovers in an airtight container in the refrigerator, and use them up within 5 days.
Reheat it in the microwave using half power (50%) and in 30-second increments, until it’s hot all the way through. Don’t try to heat it up too quickly or the cheese sauce might separate.
Freezing is not recommended for this pellet grill mac and cheese recipe. This is because as frozen dairy products thaw, they often break down and take on an unpleasant, grainy texture.

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