Smoked Mac and Cheese
This smoked mac and cheese delivers everything comfort food should be — ultra-creamy, deeply smoky, and finished with a golden panko crust. Built on a from-scratch roux with a blend of sharp cheddar, smoked gouda, and gruyere, this recipe works on any smoker at 225°F for 1–2 hours.
Equipment
- 12-inch cast iron skillet or a disposable aluminum half-pan
- Smoker pellet, offset, or charcoal — any type works
- Large pot for boiling pasta
- Whisk for building the roux
- Box grater for shredding cheese — do not use pre-shredded
- Wooden spoon for stirring sauce
Ingredients
Pasta
- 1 lb elbow macaroni cooked al dente — about 1 minute less than package directions
Cheese Sauce
- 4 tbsp unsalted butter
- 1/4 cup all-purpose flour
- 1 tsp dry mustard powder
- 2 cups whole milk
- 1 cup heavy cream or half-and-half
- 4 oz cream cheese full fat, cut into cubes, room temperature
- 2 cups sharp cheddar freshly shredded from block
- 1 cup smoked gouda freshly shredded from block
- 1 cup gruyere freshly shredded from block
- 1 tsp kosher salt plus more to taste
- 1/2 tsp black pepper
Panko Topping
- 1 cup panko breadcrumbs
- 2 tbsp unsalted butter melted
- 1 tsp BBQ dry rub your favorite blend
Instructions
- Preheat your smoker to 225°F. Load with mild wood — apple, cherry, or pecan work best for this recipe.
- Bring a large pot of salted water to a boil. Cook the elbow macaroni until just al dente — about 1 minute less than the package directions. The noodles will continue to soften in the smoker. Drain and set aside.
- In a 12-inch cast iron skillet over medium heat, melt 4 tablespoons of butter. Whisk in the flour and cook for 1–2 minutes until the roux is smooth and just starting to turn golden. Whisk in the mustard powder.
- Slowly pour in the whole milk and heavy cream while whisking constantly. Bring to a gentle simmer, whisking until the sauce thickens, about 3–4 minutes.
- Reduce heat to low. Add the cream cheese cubes and whisk until fully melted and smooth. Add the shredded sharp cheddar, smoked gouda, and gruyere in three additions, whisking well between each addition. Season with salt and pepper.
- Remove the skillet from heat. Fold in the cooked macaroni noodles, stirring gently until every noodle is coated in cheese sauce.
- In a small bowl, combine the panko breadcrumbs, 2 tablespoons melted butter, and BBQ dry rub. Sprinkle evenly over the top of the mac and cheese.
- Place the cast iron skillet in the preheated smoker. Smoke at 225°F for 60–90 minutes, until the top is golden brown and the cheese sauce is bubbling around the edges. Stir once at the 30-minute mark for even smoke distribution. Serve hot directly from the skillet.
Notes
Cheese tip: Always shred your own cheese from a block. Pre-shredded cheese contains anti-caking agents that prevent smooth melting and can cause a grainy sauce.
Temperature is critical: Keep your smoker at exactly 225°F. Higher temps will dry out the macaroni noodles and cause the cheese sauce to break.
Wood selection: Stick to mild woods — apple, cherry, or pecan. Mesquite and heavy hickory are too strong for a dairy-based dish.