Creamy Smoked Mac and Cheese With Bacon-Panko Topping

This creamy smoked mac and cheese combines tender pasta, a homemade three-cheese sauce and a crispy bacon-panko topping with just enough wood-fired flavor. It is an easy crowd-pleaser for football parties, backyard cookouts, holiday gatherings and family dinners.

You can prepare it in a smoker, pellet grill or gas grill set up for indirect cooking. The key is to build a creamy sauce before the pan goes outside and use a mild wood flavor that complements the cheese without overpowering it.

Creamy Smoked Mac and Cheese

Prep time: 25 minutes
Smoking time: 45–60 minutes
Total time: Approximately 1 hour 20 minutes
Servings: 8–10

Ingredients

For the Mac and Cheese

• 1 pound elbow macaroni or cavatappi pasta
• 6 tablespoons unsalted butter
• ¼ cup all-purpose flour
• 3 cups whole milk, warmed
• 1 cup half-and-half, warmed
• 4 ounces cream cheese, softened and cubed
• 2 cups freshly shredded sharp cheddar cheese
• 1½ cups freshly shredded smoked Gouda or regular Gouda
• 1 cup freshly shredded Monterey Jack cheese
• 1 teaspoon Dijon mustard
• 1 teaspoon garlic powder
• ½ teaspoon smoked paprika
• ½ teaspoon kosher salt, plus more for the pasta water
• ¼ teaspoon freshly ground black pepper

For the Crispy Topping

• 1 cup panko breadcrumbs
• 2 tablespoons melted butter
• 4 slices bacon, cooked until crisp and crumbled
• 2 tablespoons grated Parmesan cheese
• 1 tablespoon chopped fresh chives or parsley

Equipment

• Smoker or grill capable of indirect cooking
• Deep 12-inch cast-iron skillet or disposable foil pan
• Large saucepan
• Whisk
• Large pot for cooking pasta

How to Make Smoked Mac and Cheese

1. Preheat the Smoker or Grill

Preheat the smoker or pellet grill to 250°F. If using a gas or charcoal grill, create an indirect cooking zone and maintain a steady temperature near 250°F.

Apple, cherry, pecan or another mild cooking wood works well with cheese. Strong smoke can overwhelm the dish, so begin with a restrained amount.

2. Undercook the Pasta Slightly

Bring a large pot of salted water to a boil. Cook the pasta approximately two minutes less than the package’s al dente directions.

Drain the pasta without rinsing it. Slightly undercooking prevents the noodles from becoming too soft while the macaroni finishes on the smoker.

3. Make the Cheese Sauce

Melt six tablespoons of butter in a large saucepan over medium heat. Add the flour and whisk continuously for approximately one minute. The mixture should become smooth and lightly bubbly without turning dark brown.

Slowly add the warm milk while whisking. Add the half-and-half and continue cooking for approximately 4–6 minutes, stirring frequently, until the sauce thickens enough to coat the back of a spoon.

Reduce the heat to low. Add the cream cheese, Dijon mustard, garlic powder, smoked paprika, salt and pepper. Stir until the cream cheese is completely incorporated.

4. Add the Shredded Cheese

Remove the saucepan from direct heat. Add the cheddar, Gouda and Monterey Jack a handful at a time, stirring until each addition melts before adding more.

Freshly shredded cheese generally melts more smoothly than pre-shredded cheese, which may contain anti-caking ingredients.

5. Combine the Pasta and Sauce

Add the drained pasta to the cheese sauce and stir gently until every piece is coated. The mixture should look slightly looser than ordinary finished mac and cheese because it will thicken while smoking.

Transfer the mixture to a lightly buttered cast-iron skillet or foil pan. Spread it into an even layer without pressing down firmly.

6. Prepare the Bacon-Panko Topping

In a small bowl, combine the panko, melted butter, cooked bacon and Parmesan. Sprinkle the mixture evenly over the macaroni and cheese.

Reserve the fresh chives or parsley until after cooking so they retain their color and fresh flavor.

7. Smoke Until Hot and Golden

Place the uncovered skillet on the smoker or on the indirect side of the grill. Close the lid and cook for approximately 45–60 minutes.

The mac and cheese is ready when the sauce is bubbling gently around the edges and the topping is golden. Rotate the pan once if your grill has noticeable hot spots.

Avoid smoking it much longer than necessary. Extended cooking can dry the sauce and create an overpowering smoke flavor.

8. Rest and Serve

Remove the skillet carefully and place it on a heat-safe surface. Allow the mac and cheese to rest for approximately five minutes before serving.

Finish with the chopped chives or parsley and a small amount of additional crumbled bacon if desired.

How to Smoke Mac and Cheese on a Gas Grill

You do not need a dedicated smoker to prepare this recipe. Turn on the burners on one side of the gas grill and leave the other side unlit. Place the skillet over the unlit area and adjust the burners to maintain approximately 250°F.

For additional smoke flavor, use an approved smoker box and wood chips according to the grill manufacturer’s instructions. Never place loose wood chips directly where the manufacturer does not permit them.

How to Keep Smoked Mac and Cheese Creamy

• Undercook the pasta: The noodles continue cooking on the smoker.
• Keep the sauce loose: A sauce that appears slightly thin before smoking will thicken as it cooks.
• Shred your own cheese: It usually melts more smoothly.
• Add cheese away from direct heat: Excessive heat can make the sauce oily or grainy.
• Use indirect cooking: Direct flame can burn the bottom before the center is hot.
• Do not oversmoke it: Remove the pan when the edges bubble and the topping is golden.
• Serve it promptly: Mac and cheese naturally thickens as it cools.

The Best Cheese for Smoked Mac and Cheese

A combination of cheeses creates better flavor and texture than relying on just one. Sharp cheddar provides the familiar mac-and-cheese flavor, Monterey Jack melts smoothly and Gouda adds richness.

Smoked Gouda can deepen the smoky character, but regular Gouda is a good choice if your smoker produces a stronger flavor. You can also replace part of the cheese with Gruyère, mild white cheddar or Colby Jack.

Avoid using only very aged or dry cheese because it may not melt as smoothly.

Can You Make It Without Bacon?

Yes. Leave out the bacon for a meat-free version and add two additional tablespoons of Parmesan to the panko topping. You can also mix chopped roasted jalapeños into the pasta for extra flavor.

Easy Recipe Variations

• Jalapeño mac and cheese: Add one finely chopped roasted jalapeño.
• Buffalo chicken: Fold in cooked shredded chicken and a restrained amount of buffalo sauce.
• Pulled-pork mac and cheese: Add warm smoked pulled pork immediately before serving.
• Lobster mac and cheese: Fold in cooked lobster near the end of smoking.
• Extra-crispy topping: Briefly increase the heat at the end, monitoring closely to prevent burning.
• Meat-free version: Omit the bacon and add extra Parmesan or toasted chopped pecans.

What to Serve With Smoked Mac and Cheese

This recipe works as a substantial side dish with ribs, pulled pork, grilled chicken, sausage or brisket. It can also be served as the main dish with grilled vegetables or a fresh salad.

For game day, place the skillet on a heat-safe serving surface and provide small bowls so guests can help themselves throughout the party. Refrigerate leftovers promptly rather than leaving dairy-based dishes outside for extended periods.

Take Comfort Food Outdoors With Sunzout

A thoughtfully planned outdoor kitchen gives you space to prepare the cheese sauce, smoke the finished dish and serve guests without carrying every ingredient and utensil back and forth from the house.

Sunzout offers customizable outdoor kitchens, built-in grills, smokers, side burners, refrigerators, storage cabinets and other outdoor-cooking appliances. A free 3D design can help you coordinate the cooking equipment, preparation space and storage around the foods you enjoy making.

Sunzout supplies and ships outdoor-kitchen products and ready-to-assemble systems nationwide. Installation and utility connections are completed locally by qualified professionals.

Frequently Asked Questions

What temperature should I use for smoked mac and cheese?

Set the smoker or grill for approximately 250°F using indirect heat. This allows the dish to absorb smoke and heat gradually without quickly burning the bottom.

How long should mac and cheese stay on the smoker?

Approximately 45–60 minutes is usually enough when the pasta and cheese sauce are already warm. Cooking time varies according to the pan, outdoor temperature and smoker.

What wood is best for smoked mac and cheese?

Mild woods such as apple, cherry or pecan complement cheese without dominating it. Use smoke sparingly because dairy absorbs smoky flavors quickly.

Can I prepare smoked mac and cheese in advance?

Yes. Assemble the pasta and sauce in the pan, cover and refrigerate it. Add the panko topping shortly before smoking. A cold pan will require additional cooking time.

Can I use a disposable foil pan?

Yes. A foil pan makes preparation and cleanup easier, especially for parties. Support the pan from underneath when moving it because it may become flexible when hot.

Why did my cheese sauce become grainy?

High heat and adding cheese too quickly can cause the sauce to separate. Remove the sauce from direct heat and add freshly shredded cheese gradually while stirring.