Creamy, Cheesy, and Kissed with Real Smoke Flavor
There’s regular mac and cheese… and then there’s Smoked Mac and Cheese. This recipe takes your classic, creamy baked mac and cheese to the next level by infusing it with real wood smoke, giving it that rich, savory BBQ edge that’s hard to resist.
I’ve made this recipe dozens of times — for backyard cookouts, potlucks, and holiday dinners — and it’s always the first thing to disappear. The balance of smoky, gooey, cheesy comfort with that subtle crust on top? Pure magic.
⭐ Why You’ll Love This Recipe
Creamy, velvety cheese sauce made from scratch
Infused with real smoke from your pellet grill or smoker
Uses a blend of flavorful cheeses for richness and meltability
Easy to make ahead and bake when ready
The ultimate side dish for BBQ, brisket, ribs, or even on its own
🛒 Ingredients
Pasta:
1 lb elbow macaroni (or cavatappi)
Cheese Sauce:
4 tbsp unsalted butter
1/4 cup all-purpose flour
3 cups whole milk
1 cup heavy cream
2 cups sharp cheddar cheese, shredded
1 cup gouda (or smoked gouda), shredded
1 cup mozzarella, shredded
1 tsp Dijon mustard
1/2 tsp garlic powder
Salt and black pepper, to taste
Optional Topping:
1/2 cup panko breadcrumbs
2 tbsp melted butter
Extra shredded cheddar for topping
🔥 Smoked Mac and Cheese – Step-by-Step Process
Step 1: Cook the Pasta
Start by bringing a large pot of water to a rolling boil. Salt the water generously — it should taste like the sea. This is your only chance to season the pasta itself, so don’t be shy. Once boiling, add 1 pound of elbow macaroni (or your favorite sturdy pasta shape like cavatappi). Cook the pasta until it’s just shy of al dente — about 1 minute less than the package instructions suggest. You want the pasta to still have a slight bite to it, as it will continue cooking later in the smoker. Once done, drain the pasta thoroughly but do not rinse it. Rinsing removes the starch that helps the cheese sauce cling to the noodles. Set the pasta aside while you prepare the cheese sauce.
Step 2: Prepare the Roux
In a large saucepan over medium heat, melt 4 tablespoons of unsalted butter. Once the butter is fully melted and slightly foamy, sprinkle in 1/4 cup of all-purpose flour. Immediately begin whisking the flour into the butter to form a smooth paste — this is called a roux, and it’s essential for thickening your cheese sauce without lumps. Continue whisking constantly for about 1 to 2 minutes. You don’t want the roux to brown; it should stay pale and smell slightly nutty. Cooking off the raw flour taste during this stage is important, so don’t rush it. The roux should bubble gently as it cooks.
Step 3: Build the Creamy Cheese Sauce
Once your roux is ready, slowly pour in 3 cups of whole milk while whisking continuously. This step is critical — adding the milk too fast can result in a lumpy sauce. Once the milk is incorporated, add 1 cup of heavy cream for richness and body. Continue to cook the mixture over medium heat, whisking frequently, until the sauce begins to thicken. This usually takes about 5 to 7 minutes. You’ll know it’s ready when the mixture is thick enough to coat the back of a spoon. At this point, reduce the heat to low to prepare for melting the cheese.
Step 4: Add the Cheese and Seasonings
With the heat on low, begin stirring in your cheeses gradually. Add 2 cups of shredded sharp cheddar first, followed by 1 cup of gouda (or smoked gouda if you want more smokiness), and 1 cup of shredded mozzarella. Stir constantly and patiently until the cheese is completely melted and the sauce is smooth and velvety. Next, stir in 1 teaspoon of Dijon mustard and 1/2 teaspoon of garlic powder. These may seem like small additions, but they make a big impact on flavor — the mustard enhances the sharpness of the cheese, while the garlic powder adds subtle warmth. Taste the sauce and season with salt and freshly ground black pepper to your liking.
Step 5: Combine the Pasta with the Cheese Sauce
Now it’s time to bring everything together. Add your cooked and drained pasta to the pot of cheese sauce. Using a large spatula or wooden spoon, fold the pasta gently into the sauce until every noodle is fully coated. Be gentle — you don’t want to break up the pasta. At this stage, the mixture should be rich, creamy, and luxurious. It may look a little looser than traditional baked mac and cheese, but that’s okay — it will firm up slightly as it smokes.
Step 6: Transfer to a Smoker-Safe Pan
Pour the mac and cheese mixture into a cast iron skillet, a disposable aluminum pan, or any oven-safe baking dish that fits your smoker setup. Use a spatula to smooth out the top into an even layer. This dish will not only make it easier to smoke but also help develop a nice golden surface. If you’re cooking for a crowd or bringing it to a BBQ, aluminum trays work great for transport and easy cleanup.
Step 7: Add the Optional Topping (If Using)
If you like a little texture contrast, now’s the time to add a crunchy topping. In a small bowl, mix together 1/2 cup of panko breadcrumbs with 2 tablespoons of melted butter. Stir until all the breadcrumbs are evenly coated. Sprinkle this mixture evenly over the top of the mac and cheese. For even more cheesy goodness, you can also add a handful of shredded cheddar over the breadcrumb topping. This step is totally optional, but it adds a beautiful golden crust and some satisfying crunch.
Step 8: Smoke the Mac and Cheese
Preheat your smoker to 225°F. Use a mild wood like apple, cherry, or pecan — something that will gently enhance the cheese without overpowering it. Avoid strong woods like mesquite or hickory for this dish. Place the pan of mac and cheese directly on the smoker grates. Do not cover it — you want the smoke to gently kiss the surface and infuse the entire dish. Smoke the mac and cheese for about 45 minutes to 1 hour. You’re not looking to cook it further, but rather to add depth, aroma, and that beautiful touch of smoke. You’ll know it’s ready when the edges are bubbling slightly, the top is golden, and you can smell a rich, cheesy-smoky aroma when you lift the lid.
Step 9: Rest and Serve
Carefully remove the mac and cheese from the smoker and place it on a heat-safe surface. Let it rest for about 5 minutes before serving. This allows the sauce to thicken slightly and makes it easier to scoop. Serve it straight from the skillet or tray while it’s hot and melty. It’s perfect as a side dish for brisket, ribs, smoked chicken, pulled pork — or honestly, it’s incredible all by itself.
📦 Storage & Reheating
Fridge: Store in an airtight container for up to 4 days
Freezer: Freeze before smoking for up to 2 months (thaw overnight before smoking)
Reheat: Cover with foil and bake at 350°F for 20 minutes, or microwave individual portions with a splash of milk
⚠️ Common Mistakes to Avoid
Overcooking the pasta → Always cook just shy of al dente
Using pre-shredded cheese → It won’t melt as smoothly
Too much smoke → 45–60 mins is enough to flavor without overpowering
Skipping the roux → It’s essential for smooth, thick sauce
❓ FAQs
Can I make this without a smoker?
Yes! Bake at 350°F for 20–25 minutes uncovered. Add a dash of liquid smoke if desired.
What other cheeses work well?
Fontina, Monterey Jack, or pepper jack for spice. Avoid crumbly cheeses like feta.
Can I add mix-ins like bacon or jalapeños?
Absolutely! Stir them in after the cheese sauce is ready, before baking.
Is this spicy?
Not unless you add hot elements. It’s rich, cheesy, and savory — mild and family-friendly by default.
Smoked Mac and Cheese
Equipment
- 1 Smoker I highly recommend this pellet grill!
Ingredients
- 1 lb elbow macaroni
- 4 tbsp unsalted butter
- 1/4 cup all-purpose flour
- 3 cups whole milk
- 1 cup heavy cream
- 2 cups sharp cheddar cheese shredded
- 1 cup smoked gouda cheese shredded
- 1 cup Monterey Jack cheese shredded
- 1 tsp mustard powder
- 1/2 tsp smoked paprika
- Salt and pepper to taste
- 1/2 cup panko breadcrumbs
- 2 tbsp butter melted
Instructions
- Cook Pasta: Boil macaroni until just shy of al dente. Drain and set aside.
- Make Sauce: Melt butter, whisk in flour, then slowly add milk and cream. Simmer until thick. Stir in seasonings and cheeses.
- Assemble: Mix pasta with cheese sauce. Top with buttery panko breadcrumbs.
- Smoke: Smoke uncovered at 225°F for 45–60 minutes until bubbly and golden.
- Serve: Enjoy hot with optional garnishes.
Video
Notes
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