Best Smoked Mac and Cheese Recipe (NO Velveeta Needed)
BEST Smoked Mac and Cheese Recipe (NO Velveeta Needed) is a medium American recipe that serves 6. 1325 calories per serving. Recipe by Chiles and Smoke on YouTube.
Prep: 12 min | Cook: 1 hr 24 min | Total: 1 hr 56 min
Cost: $84.32 total, $14.05 per serving
Ingredients
- 2 cups Sharp Cheddar Cheese (shredded)
- 2 cups Chipotle Gouda Cheese (shredded; adds smoky heat)
- 2 cups Pepper Jack Cheese (shredded; melty and mildly spicy)
- 0.5 cup Unsalted Butter (cut into slivers for quick melt)
- 0.5 cup All-Purpose Flour (for roux)
- 2 cups Whole Milk (minimum 2% fat, warmed)
- 2 cups Heavy Cream (for extra richness)
- 1 tablespoon Dijon Mustard (adds subtle tang)
- 2 tablespoons Sedona Sugar-Free BBQ Seasoning (Southwest flavor profile; can substitute regular BBQ rub)
- 0.5 cup Hatch Chilies (diced; optional for heat)
- 6 pieces Bacon Strips (cooked crisp, chopped)
- 1 pound Elbow Macaroni (cooked al dente, drained)
- 1 cup Extra Shredded Cheese for Topping (any melty cheese; optional)
- 0.5 cup Panko Breadcrumbs (optional crunchy topping)
- 1 teaspoon Salt (for pasta water)
Instructions
Shred the Cheeses
Shred the sharp cheddar, chipotle Gouda, and pepper jack cheeses into uniform pieces and set aside in a large bowl.
Time: PT5M
Cook the Pasta
Bring a large pot of salted water to a boil, add the elbow macaroni, and cook al dente (about 8‑9 minutes). Drain and set aside.
Time: PT10M
Temperature: 212°F
Make the Roux
In the wide-bottom saucepan, melt the unsalted butter over medium heat. Once melted, whisk in the flour and cook, stirring constantly, for about 2 minutes to eliminate raw flour taste.
Time: PT5M
Temperature: Medium
Add Milk and Cream
Slowly pour the warmed milk and heavy cream into the roux while whisking continuously. Continue whisking until the mixture thickens and becomes smooth.
Time: PT7M
Temperature: Low (170‑180°F)
Season the Sauce
Stir in the Dijon mustard and Sedona sugar‑free BBQ seasoning. Mix well and keep the sauce on low heat.
Time: PT2M
Temperature: Low (170‑180°F)
Incorporate the Cheeses
Add the shredded cheeses a handful at a time, whisking gently after each addition until fully melted and the sauce is glossy.
Time: PT8M
Temperature: Low (160‑170°F)
Add Chilies and Bacon
Stir in the diced Hatch chilies and chopped cooked bacon. Heat just until everything is warmed through.
Time: PT2M
Temperature: Low
Combine Pasta and Sauce
Transfer the cooked macaroni to the foil pan and pour the cheese sauce over it, mixing gently to coat evenly.
Time: PT3M
Smoke the Mac and Cheese
Preheat the smoker to 250°F. Place the foil pan inside and smoke for 45 minutes, checking once halfway through.
Time: PT45M
Temperature: 250°F
Broil for a Crispy Top
Remove the pan from the smoker, sprinkle the extra shredded cheese (and optional panko) over the surface, and place under the broiler until golden brown, about 5 minutes.
Time: PT5M
Temperature: High broil
Rest and Serve
Let the mac and cheese rest for 5 minutes before serving so the sauce sets slightly.
Time: PT5M
Nutrition Facts
- Calories
- 1325
- Protein
- 60 g
- Carbohydrates
- 33 g
- Fat
- 80 g
- Fiber
- 3 g
Dietary info: Contains dairy, Contains gluten, Contains pork, Not vegan, Can be made vegetarian by omitting bacon
Allergens: Dairy, Gluten, Pork
Ingredient Substitutions
- Instead of Sharp Cheddar Cheese: Colby cheese, Aged cheddar
- Instead of Chipotle Gouda Cheese: Smoked mozzarella, Regular Gouda
- Instead of Pepper Jack Cheese: Monterey Jack, Havarti
- Instead of Unsalted Butter: Salted butter (reduce added salt)
- Instead of All-Purpose Flour: Whole wheat flour (will affect texture)
- Instead of Whole Milk: 2% milk, Whole milk only
- Instead of Heavy Cream: Half-and-half (less rich)
- Instead of Dijon Mustard: Mustard powder (1 tsp)
- Instead of Sedona Sugar-Free BBQ Seasoning: Regular BBQ rub, Smoked paprika
- Instead of Hatch Chilies: Jalapeño, Anaheim peppers
- Instead of Bacon Strips: Turkey bacon, omit for vegetarian version
- Instead of Elbow Macaroni: Shells, cavatappi
- Instead of Extra Shredded Cheese for Topping: More pepper jack, Mozzarella
- Instead of Panko Breadcrumbs: Regular breadcrumbs, crushed cornflakes
- Instead of Salt: Kosher salt
Equipment Needed
- Wide-Bottom Saucepan
- Gravy Whisk
- Measuring Cups
- Regular Whisk
- Large Pot for Pasta
- Colander
- Foil Pan (13x9 inch)
- Smoker
- Broiler (oven setting)
- Spatula or Wooden Spoon
Critical Steps — Do Not Skip
- Making a smooth roux without lumps.
- Maintaining low temperature while melting cheese to prevent sauce breakage.
- Smoking at a steady 250°F for the correct duration to infuse smoke without drying out the sauce.
Chef Tips from the Video
- Use a combination of a hard cheese for flavor and a melty cheese for stretch; at least 2 cups of melty cheese are essential.
- For extra depth, toast the chipotle Gouda briefly before shredding.
- If you don’t have a smoker, use a charcoal grill with a foil pan and add wood chips for indirect smoke.
Troubleshooting
Cheese sauce becomes grainy or separates.
Lower the heat immediately, whisk vigorously, and add a splash of warm milk to bring it back together.
Mac and cheese is too dry after smoking.
Add a few tablespoons of milk or cream before the final broil, and cover loosely with foil during the first half of smoking.
Smoke flavor is weak.
Increase smoker temperature slightly (to 260°F) or extend smoking time by 10‑15 minutes, ensuring the sauce does not over‑cook.
Storage
Refrigerator: Store leftovers in an airtight container for up to 3 days. Reheat gently on the stove with a splash of milk.
Freezer: Freeze in a freezer‑safe container for up to 2 months. Thaw overnight in the fridge and reheat, adding extra milk if needed.
Room temperature: Do not store at room temperature for more than 2 hours due to dairy content.
Make-Ahead Tips
- Prepare the cheese sauce up to step 6 and refrigerate; reheat gently before adding chilies and bacon.
- Cook the pasta al dente, toss with a little oil, and store in the fridge for up to 24 hours.
- Assemble the dish, cover tightly, and smoke later; the sauce will stay creamy.
Frequently Asked Questions
What is the cultural significance and history of smoked mac and cheese in American Southern cuisine?
Smoked mac and cheese blends the classic comfort food of creamy macaroni and cheese with the barbecue traditions of the American South. The addition of smoke infuses the dish with the same deep, woody flavors found in smoked ribs and brisket, making it a popular crowd‑pleaser at cook‑outs and holiday gatherings.
What are the traditional regional variations of mac and cheese in Southern cuisine?
In the South, mac and cheese often features sharp cheddar or Colby as the base, with additions like smoked gouda, pepper jack, or even jalapeños for heat. Some regions fold in crumbled pork sausage or use a breadcrumb topping, while others keep it simple with just cheese and butter.
How is mac and cheese traditionally served in Southern barbecue gatherings?
It is typically served as a side dish alongside smoked meats, placed in a cast‑iron skillet or foil pan, and finished under a broiler or on the grill to create a crispy, golden crust. The dish is often kept warm in a smoker or low oven until guests are ready to eat.
What occasions or celebrations is smoked mac and cheese traditionally associated with in Southern culture?
Smoked mac and cheese is a staple at backyard barbecues, Fourth of July picnics, family reunions, and holiday feasts such as Thanksgiving and Christmas, where it complements the rich, smoky flavors of the main meat dishes.
What makes smoked mac and cheese special or unique in American comfort food cuisine?
The combination of a velvety cheese sauce with a subtle smoke infusion creates a layered flavor profile that is both familiar and unexpected. The smoky aroma adds depth without overwhelming the creamy texture, setting it apart from ordinary baked mac and cheese.
What are the most common mistakes to avoid when making smoked mac and cheese?
Common errors include overheating the cheese sauce, which causes it to separate; smoking at too high a temperature, which dries out the sauce; and not seasoning the pasta water, leading to bland mac. Keep the smoker at 250°F and maintain low heat while melting cheese.
Why does this smoked mac and cheese recipe use a low‑temperature smoker instead of a high‑heat bake?
Low‑temperature smoking (around 250°F) allows the cheese sauce to stay creamy while the smoke penetrates the dish slowly. High heat would bake the pasta too quickly, creating a dry, cakey texture and losing the desired smokiness.
Can I make smoked mac and cheese ahead of time and how should I store it?
Yes. Assemble the mac and cheese, cover tightly, and refrigerate for up to 24 hours. When ready, bring it to room temperature, then smoke as directed. Leftovers can be stored in the refrigerator for 3 days or frozen for up to 2 months.
What texture and appearance should I look for when the smoked mac and cheese is done?
The sauce should be glossy and still slightly fluid underneath the crust, while the top should be golden‑brown and crispy from the broiler. The edges may show a thin, caramelized layer, indicating the perfect balance of creaminess and smoke.
What does the YouTube channel Chiles and Smoke specialize in?
The YouTube channel Chiles and Smoke specializes in Southern‑style barbecue, smoked dishes, and hearty comfort foods with a focus on bold flavors, chili heat, and creative twists on classic recipes.
How does the YouTube channel Chiles and Smoke's approach to smoked comfort food differ from other barbecue channels?
Chiles and Smoke blends traditional smoking techniques with a strong emphasis on chili varieties and spice rubs, often incorporating fresh chilies, hot sauces, and unique cheese combinations, whereas many other channels focus primarily on meat‑centric smoking.
Last updated: September 1, 2026
