Hickory-Smoked Smoked Mac & Cheese
Five-cheese skillet bake with smoky crust, 90 minutes.
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Ingredients
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Method
- 15 min
Cook macaroni according to package directions until al dente. Drain and set aside. Shred all cheeses. Warm the milk gently on the stovetop or in the microwave. Get all your ingredients measured and ready.
Why it matters
Having all your ingredients prepped and ready for the cheese sauce will ensure a smooth, lump-free sauce without rushing.
Common mistake
Overcooking the macaroni. It will cook more in the smoker, so al dente is key for texture.
- 15 min
Cook macaroni according to package directions until al dente. Drain and rinse with cold water to stop cooking. Shred all cheeses (Cheddar, Gouda, Monterey Jack, Parmesan), and cube the cream cheese. Set aside.
Why it matters
Cooking al dente ensures the pasta doesn't get mushy during the long smoking process, and rinsing stops carry-over cooking. Shredding your own cheese prevents anti-caking agents from affecting the sauce's texture.
Common mistake
Overcooking the pasta, leading to a gummy texture in the final dish.
- 225°F15 min
Preheat your pellet grill to 225°F. Cook elbow macaroni according to package directions until al dente, usually 7-9 minutes. Drain and set aside.
Why it matters
Cooking the pasta al dente prevents it from becoming mushy during the smoking process and allows it to absorb more of the cheesy sauce.
Common mistake
Overcooking the pasta at this stage, leading to a mushy final product.
- 5 min
In a large pot or Dutch oven, melt the butter over medium heat. Whisk in the flour and cook for 1-2 minutes, stirring constantly, until a thick paste forms and loses its raw flour smell.
Why it matters
The roux is the thickening agent for your cheese sauce. Cooking it thoroughly removes the raw flour taste.
Common mistake
Not cooking the roux long enough, resulting in a sauce that tastes like flour.
- 10 min
In a large skillet (ideally cast iron for oven-to-smoker), melt butter over medium heat. Whisk in flour and cook for 1-2 minutes to create a roux. Gradually whisk in milk and heavy cream until smooth and slightly thickened. Stir in Dijon mustard, smoked paprika, salt, and pepper.
Why it matters
A well-made roux is the foundation of a creamy cheese sauce, ensuring it thickens properly without lumps.
Common mistake
Not cooking the flour long enough in the roux, which can result in a raw flour taste.
- 10 min
In a large saucepan or Dutch oven, melt 4 tablespoons of butter over medium heat. Whisk in the flour and cook for 2 minutes, constantly stirring, to create a roux. Gradually whisk in the whole milk and heavy cream until smooth. Bring to a simmer, stirring, until the sauce thickens slightly.
Why it matters
A well-cooked roux is the foundation of a creamy cheese sauce, preventing a grainy texture and providing proper thickening.
Common mistake
Adding liquids too quickly or not whisking enough, resulting in lumps in the sauce.
- 10 min
Gradually whisk in the warmed milk to the roux, a little at a time, to create a smooth sauce. Continue whisking until the sauce thickens. Reduce heat to low and stir in the dry mustard, salt, and pepper. Add the shredded cheddar, smoked gouda, Gruyere, Provolone, and Parmesan cheeses, stirring until completely melted and smooth. Remove from heat.
Why it matters
Adding warmed milk prevents lumps. Melting the cheese slowly over low heat creates a silky, homogenous sauce.
Common mistake
Adding all the milk at once or adding cold milk, which can cause lumps.
- 10 min
Remove the sauce from heat. Stir in the softened cream cheese until fully melted and smooth. Add the shredded Cheddar, Smoked Gouda, Monterey Jack, and Parmesan cheeses, stirring constantly until all cheese is melted and the sauce is uniform and creamy. Season with kosher salt, black pepper, and smoked paprika.
Why it matters
Removing from heat before adding cheese prevents scorching and ensures a smooth, emulsified sauce. Cream cheese adds an extra layer of creaminess and stability.
Common mistake
Cooking the cheese sauce over high heat, which can cause the cheese to separate and become oily.
- 10 min
Remove the skillet from heat. Add cream cheese and stir until fully melted and smooth. Gradually add the shredded cheddar, smoked Gouda, Fontina, and grated Parmesan, stirring constantly until all cheeses are melted and the sauce is creamy. Taste and adjust seasonings as needed.
Why it matters
Removing from heat before adding cheese prevents the sauce from breaking or becoming oily. Adding cheeses gradually ensures even melting and a smooth texture.
Common mistake
Adding all the cheese at once or overcooking the cheese sauce, which can make it grainy.
- 5 min
Add the cooked elbow macaroni to the cheese sauce in the skillet and stir to coat evenly. Ensure the entire surface is covered.
Why it matters
Evenly coating the pasta ensures every bite is packed with cheesy goodness and prevents dry spots.
Common mistake
Not mixing enough, leaving some pasta dry and unappetizing.
- 5 min
Add the cooked macaroni to the cheese sauce and stir until evenly coated. Pour the mixture into a 12-inch cast iron skillet or other heavy, oven-safe dish.
Why it matters
A cast iron skillet allows for excellent heat retention and helps develop a great crust on the mac and cheese.
Common mistake
Using too small a dish, leading to overflow in the smoker.
- 5 min
Add the cooked macaroni to the cheese sauce and stir gently to ensure all noodles are evenly coated. Pour the mixture into a 12-inch cast iron skillet or other heavy, oven-safe pan.
Why it matters
Using a cast iron skillet allows for excellent heat retention and helps develop a desirable smoky crust on the mac and cheese.
Common mistake
Over-mixing the pasta, which can break fragile noodles.
- 225°F1h 30m
Place the cast iron skillet directly on the grates of your preheated 225°F pellet grill. Close the lid and smoke for 90 minutes. Do not stir during smoking to allow a smoky crust to form on top.
Why it matters
Low and slow smoking allows the Pecan wood to infuse a deep, rich smoky flavor into the cheese and pasta, while the still surface promotes the development of that desirable smoky crust.
Common mistake
Opening the lid too frequently, which extends cook time and reduces smoke penetration.
- 225°F15 min
Preheat your pellet grill or smoker to 225°F (107°C). Add pecan wood for smoke. Allow the smoker to come to a stable temperature and produce clean, blue smoke.
Why it matters
A stable temperature is critical for consistent cooking. Pecan wood provides a balanced, nutty, and slightly sweet smoke that complements the cheesy dish without overpowering it.
Common mistake
Putting food on before the smoker reaches temperature or while producing 'dirty' white smoke, which can impart bitter flavors.
- 10 min
Carefully remove the skillet from the smoker. Let the mac & cheese rest for 5-10 minutes before serving. This allows the sauce to set slightly and intensifies the flavors.
Why it matters
Resting allows the cheese sauce to re-distribute and set, resulting in a creamier, more cohesive dish when served.
Common mistake
Serving immediately, which can result in a runny sauce and less developed flavor.
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