Smokehouse Bacon Macaroni & Cheese

Smoked mac and cheese is more than just a side dish; it’s a culinary revelation that transforms a beloved classic into an unforgettable experience. Imagine rich, velvety cheese sauce enveloping tender macaroni, all infused with a deep, earthy smokiness that tantalizes your taste buds. This isn’t your grandma’s mac and cheese – this is an elevated, sophisticated, yet incredibly comforting version perfect for any occasion. Our ultimate smoked mac and cheese recipe features a luxurious blend of sharp cheddar and creamy Gruyère, kicked up with a hint of spice, and topped with crispy bacon and toasted sourdough breadcrumbs. The secret lies in a low-and-slow cook on your smoker or pellet grill, allowing every ingredient to meld into a symphony of irresistible flavor and texture.

Whether you’re hosting a lively backyard barbecue, a casual cookout, or a festive holiday gathering, this smoked mac and cheese recipe is guaranteed to be the star of the show. Its gooey cheese and perfectly crispy topping make it the ultimate companion to a variety of smoky mains, from juicy grilled turkey burgers and tender saucy ribs to mouth-watering pulled BBQ chicken sliders. The robust smoky flavor complements almost any grilled meat, ensuring it’s a crowd-pleaser every single time. Prepared in a trusty cast iron pan or a convenient foil tray, this dish is perfectly suited for your smoker, pellet grill, or a dedicated Traeger mac and cheese setup, making the cooking process seamless and enjoyable.

Why This Smoked Mac and Cheese Recipe Stands Out

While classic baked or stovetop macaroni and cheese holds a special place in our hearts, introducing it to the smoker elevates the experience to an entirely new level. This isn’t just about adding smoke; it’s about developing a complex flavor profile and achieving an unparalleled texture that makes this dish truly extraordinary.

• Unparalleled Smoky Flavor: The smoky essence from the pellet grill penetrates every noodle and creamy crevice, creating a depth of flavor that an oven simply cannot replicate. This slow infusion of smoke, especially when combined with a generous layer of crispy bacon on top, makes for an irresistibly savory dish. Who can resist the allure of bacon combined with perfectly smoked cheese?
• Effortless, Hands-Off Cooking: One of the greatest advantages of this recipe is its simplicity. After a bit of initial prep to create the luscious cheese sauce and combine the ingredients, the smoker does most of the heavy lifting. This largely hands-off approach frees you up to enjoy your guests or focus on other elements of your meal, without the constant need for stirring or supervision.
• Perfect for Any Gathering: This mac and cheese is incredibly versatile. It’s robust enough to be a standalone meal, yet complements virtually any main dish at a potluck, game day party, or holiday feast. Its ability to freeze well (if prepared for later baking) and transport easily makes it a go-to for events where you need to bring a show-stopping dish.
• Gourmet Comfort Food: This recipe takes comfort food and gives it a sophisticated twist, appealing to adults and children alike. The rich blend of cheeses, the subtle spice, and the crunchy topping create a textural contrast that makes every bite exciting.

Ingredient Notes and Substitutions for Perfect Pellet Grill Mac and Cheese

Crafting the perfect pellet grill mac and cheese starts with understanding your ingredients. Each component plays a crucial role in achieving that creamy, cheesy, smoky perfection. Here’s a detailed look at what you’ll need and how to make thoughtful substitutions.

• Elbow Macaroni: This classic pasta shape is ideal for mac and cheese because its curved, hollow form holds onto the rich cheese sauce beautifully. However, don’t limit yourself! Other small, sturdy pasta shapes like medium shells, farfalle (bowtie pasta), or even penne work wonderfully. The key is choosing a shape that will capture and deliver maximum cheesy goodness with every forkful.
• Butter: Unsalted butter is highly recommended as it gives you complete control over the dish’s saltiness. If you opt for salted butter, be sure to significantly reduce or completely omit any additional salt called for in the recipe to avoid an overly salty outcome.
• All-Purpose Flour: Flour is essential for creating a roux, which thickens the cheese sauce to that desirable creamy consistency. For those requiring a gluten-free option, an equal amount of gluten-free all-purpose flour blend works well. Alternatively, cornstarch or arrowroot powder can be used as thickeners; just remember to create a slurry with cold liquid before adding them to hot sauce to prevent lumps.
• Half-and-Half: This dairy staple strikes a perfect balance, providing luxurious creaminess without the excessive richness of heavy cream. For an extra indulgent experience, heavy cream can be used. If you’re looking to slightly reduce the fat and calories, whole milk or 2 percent milk are viable alternatives, though they will yield a slightly less decadent sauce.
• The Cheese Blend: Our recipe features a trio of cheeses: tangy cream cheese for an extra smooth texture, sharp cheddar for classic flavor, and nutty Gruyère for sophisticated depth. The most crucial tip for exceptional results is to buy cheese in blocks and shred it yourself. Pre-shredded cheeses often contain anti-caking agents that can interfere with melting, resulting in a less smooth and flavorful sauce. Experiment with other high-quality meltable cheeses like Colby Jack, Fontina, or Smoked Gouda for different flavor profiles.
• Breadcrumbs: Panko breadcrumbs are our top choice for their superior crunch and texture, creating a light yet satisfying crust. Traditional breadcrumbs also work, or for a unique twist, try crushed crackers (like Ritz or saltines) for a buttery, savory topping.
• Bacon: Bacon is a game-changer here, adding a salty, smoky crunch that complements the creamy pasta. For the best results, use standard thin-cut bacon. Thick-cut bacon tends to render fat slower and can remain chewy or soggy, rather than achieving the desired crispy texture that enhances the dish.
• Seasonings: Don’t underestimate the power of a good seasoning blend. Ground mustard adds a subtle tang and enhances the cheese flavor without making the dish taste “mustardy.” White pepper offers a milder, less visible heat compared to black pepper, ensuring the cheese remains the visual star. Adjust salt to taste, especially after incorporating all the cheese, as cheeses vary in their inherent saltiness.

Creative Recipe Variations for Your Smoked Macaroni and Cheese

Once you’ve mastered the basic smoked macaroni and cheese, the possibilities for customization are endless. Here are some exciting variations to inspire your culinary creativity:

• Smoked Mac and Cheese with Pulled Pork: For a truly hearty, protein-packed main course, stir in some tender, shredded smoked pulled pork before placing the dish in the smoker. The rich, smoky pork pairs incredibly well with the creamy cheese sauce, adding a layer of savory goodness to each bite. This transforms a side into a satisfying meal.
• Exploring Wood Flavors: The type of wood pellets or chips you use dramatically impacts the final smoky flavor. For a deeper, more complex smoke, try a blend of cherry and hickory wood. Cherry adds a subtle sweetness and fruity note, while hickory offers a robust, classic barbecue flavor. Applewood is another excellent choice for a milder, sweeter smoke that complements dairy beautifully. Pecan wood provides a rich, buttery, and slightly nutty flavor.
• Elevate Your Cheese Blend: Expand beyond the traditional three cheeses. Consider a four-cheese blend by incorporating Colby Jack for its excellent melting properties and mild, creamy taste, or Gouda for its sweet, nutty notes and smooth texture. A touch of smoked cheddar can also amplify the smoky profile. Remember, always opt for block cheese and shred it yourself for the best melting and flavor.
• Crispy Panko Apple Topping: For a unique sweet and savory crunch, mix panko breadcrumbs with melted butter and a sprinkle of apple seasoning or finely diced dried apple bits. This unexpected topping adds an intriguing flavor contrast and an extra layer of texture. Broil it briefly at the end for a golden, irresistible crust. This variation is particularly delicious when made with a whole milk base for an extra creamy foundation.
• Spice It Up: For those who love a bit of heat, consider adding a pinch of cayenne pepper, a dash of hot sauce to the cheese sauce, or even some finely diced jalapeños (deseeded for less heat) to the mix before smoking.
• Vegetarian Boost: Incorporate sautéed mushrooms, caramelized onions, or roasted bell peppers into the pasta mixture before smoking for added flavor and texture.

Essential Equipment for Smoking Mac and Cheese

Having the right tools makes all the difference when venturing into the world of smoked mac and cheese. Here’s what you’ll need to set yourself up for success:

• Smoker or Grill: The star of the show! A pellet smoker (like a Traeger) is ideal for consistent, low-and-slow smoking. However, you can achieve fantastic results using a gas or charcoal grill with a smoker box or indirect heat setup. The goal is to maintain a consistent low temperature for that perfect smoky infusion.
• 12-inch Cast Iron Skillet or Large Foil Pan: A cast iron skillet is perfect for its even heat distribution and ability to develop a beautiful crust. Plus, it goes straight from the smoker to the table for an impressive presentation. A large disposable foil pan is a convenient alternative, especially for potlucks or when you want easy cleanup. Ensure it’s sturdy enough to hold the heavy pasta and cheese.
• Heavy-Bottomed Saucepan: Essential for preparing the rich and creamy cheese sauce. A 4-quart or larger saucepan will give you ample room to whisk the roux and melt the cheeses without overflow.
• Whisk and Silicone Spatula: A whisk is crucial for smooth roux and cheese sauce, preventing lumps. A silicone spatula is perfect for stirring and ensures you scrape all the cheesy goodness from the pan.

How to Master Traeger Mac and Cheese: Step-by-Step

Creating irresistible Traeger mac and cheese is a straightforward process, but a few key techniques will ensure a perfect outcome every time. Follow these steps for a dish that’s rich, smoky, and perfectly cheesy.

1. Prepare Your Vessel and Smoker:
   • If using a cast iron skillet, ensure it’s well-seasoned. If not, lightly grease the inside with a high smoke point oil like canola or avocado oil. If using a foil pan, a non-stick cooking spray will suffice. Set aside.
   • Preheat your smoker or pellet grill (e.g., Traeger) to 250°F (121°C). Allow it to come to temperature and stabilize to ensure consistent smoking.
2. Perfectly Cook the Pasta:
   • Bring a large pot of generously salted water to a rolling boil. Add your elbow macaroni (or chosen pasta) and cook until it is just barely al dente. This means it should still have a slight chew and be slightly undercooked. It is critical to avoid overcooking at this stage, as the pasta will continue to cook and absorb moisture in the smoker. Mushy pasta is the nemesis of great mac and cheese!
   • Once cooked, drain the pasta thoroughly in a colander. Do not rinse the pasta with water. The starches left on the surface of the macaroni help the cheese sauce cling beautifully, resulting in a richer, creamier final product.
3. Craft the Silky Cheese Sauce:
   • In a 4-quart (or larger) heavy-bottomed saucepan, melt the butter over medium heat.
   • Whisk in the flour and cook for about 1 minute, creating a smooth roux. This removes the raw flour taste and forms the base for your thick sauce.
   • Gradually whisk in the half-and-half, adding about ½ cup at a time. This slow addition helps prevent lumps. Reduce the burner heat to medium-low and allow the mixture to gently simmer for 3 minutes, stirring occasionally, until it begins to thicken slightly.
   • Add the softened cream cheese (cubed), 2 cups of the shredded sharp cheddar (reserving 1 cup for topping), the shredded Gruyère, ground mustard, white pepper, and salt. Continue cooking on medium-low heat, stirring frequently with a silicone spatula, until all the cheeses are completely melted and the sauce is smooth and bubbly.
   • Taste the sauce for seasoning and adjust with more salt or pepper if needed. Remember, the saltiness of cheeses can vary.
4. Assemble Your Smoked Masterpiece:
   • Add the barely al dente cooked macaroni to the pot of warm cheese sauce. Using a large spoon or spatula, gently stir until every piece of pasta is thoroughly coated in the luxurious cheese sauce.
   • Pour the entire mixture into your prepared cast iron skillet or foil pan.
   • Evenly sprinkle the remaining 1 cup of shredded cheddar cheese over the top of the mac and cheese.
5. Prepare the Crispy Topping:
   • In a small bowl, combine the breadcrumbs and crumbled cooked bacon. Mix them well with a small spoon.
   • Generously sprinkle this bacon breadcrumb topping over the cheesy pasta casserole. Adding the topping before smoking allows it ample time to crisp up and develop deep flavor as it cooks.
6. The Smoking Process:
   • Carefully transfer the skillet or pan to your preheated smoker.
   • Smoke at 250°F (121°C) for approximately 45 minutes, or until the mac and cheese is bubbly around the edges and the topping is golden brown and crispy.
   • For an Extra Crispy Topping: If your topping isn’t as golden and crispy as you’d like after smoking, you can briefly place the dish under an oven broiler for 3-5 minutes. Watch it carefully to prevent burning, as broilers can brown quickly.
7. Serve and Store:
   • Serve your homemade smoked mac and cheese warm, directly from the skillet or pan.
   • Store any leftovers in an airtight container in the refrigerator for up to 5 days.

Serving Suggestions and Perfect Pairings

This smoked mac and cheese is so rich, creamy, and undeniably comforting that it’s designed to be shared. It makes a fantastic addition to any backyard BBQ, holiday spread, or even a cozy weeknight dinner. Its versatility means it pairs well with a variety of dishes, elevating your entire meal.

For a balanced meal, consider serving it alongside lighter fare. A crisp green salad with a bright vinaigrette provides a refreshing contrast to the richness of the cheese. Grilled or roasted vegetables, such as asparagus, broccoli, or bell peppers, add essential freshness and a touch of earthiness. For a truly Southern-inspired feast, a slice of warm cornbread or fluffy biscuits makes an excellent accompaniment.

Want to make this dish the main event? It’s hearty enough to stand on its own! Simply add a simple coleslaw or some steamed or roasted broccoli for a no-fuss dinner that satisfies completely. For game day or tailgating, this mac and cheese is a must-have. Pair it with other crowd-pleasers like stuffed jalapeño poppers or a savory pellet grill tri-tip. Explore more of our tailgate food ideas for a winning spread!

Storing and Reheating Smoked Mac and Cheese: FAQs

To enjoy your delicious smoked mac and cheese long after it’s fresh out of the smoker, proper storage and reheating techniques are key. Here are some frequently asked questions and tips to keep your leftovers as creamy and flavorful as possible.

More Easy Pasta Recipes To Love…

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Smoked Mac and Cheese

Renae Gerhardstein

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.

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Course:
Entree

Cuisine:
American

Servings:

8
servings

Prep Time:

15
minutes

Cook Time:

45
minutes

Total Time:

1
hour

Calories:
769

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
• ½ teaspoon salt
• 4 ounces softened cream cheese cut into cubes
• 12 ounces sharp cheddar cheese shredded and divided
• 6 ounces Gruyere cheese shredded

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

1. 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.
2. 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.
3. Melt butter in a 4-quart (or larger) saucepan over medium heat. Whisk in flour and cook for 1 minute. Gradually whisk in half-and-half (about 1/2 cup at a time). Reduce burner heat to medium-low and allow mixture to cook for 3 minutes.
4. Stir in 2 cups of cheddar (reserving 1 cup), the Gruyère, 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.
5. 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.
6. 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.
7. 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.
8. 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 Gruyère, the general rule of thumb 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.

Nutrition

Serving:
1
serving

|

Calories:
769
kcal

|

Carbohydrates:
60
g

|

Protein:
31
g

|

Fat:
45
g

|

Saturated Fat:
26
g

|

Polyunsaturated Fat:
2
g

|

Monounsaturated Fat:
11
g

|

Trans Fat:
0.5
g

|

Cholesterol:
132
mg

|

Sodium:
997
mg

|

Potassium:
329
mg

|

Fiber:
3
g

|

Sugar:
6
g

|

Vitamin A:
1275
IU

|

Vitamin C:
1
mg

|

Calcium:
644
mg

|

Iron:
2
mg

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