Smoked Mac and Cheese Casserole
On May 09, 2025
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Creamy, cheesy pasta, crunchy panko topping, and a smoky finish, this Smoked Mac and Cheese Casserole is a crowd-pleasing entree or side dish.
Smoked Mac and Cheese Casserole
This Smoked Mac and Cheese Casserole takes everything you love about classic mac and cheese and kicks it up with a smoky BBQ twist. I’m talking about a rich, velvety cheese sauce made with four types of cheese, poured over big-boy elbow macaroni, and topped with buttery panko bread crumbs for the perfect crunch. An hour in the smoker adds incredible depth and flavor, while baking everything together just enough to give you creamy, sliceable squares of cheesy, casserole goodness.
It’s easy to prep, feeds a crowd, and goes with just about anything you throw on the smoker. Whether you serve it as a stand-alone dish or pair it with your favorite grilled meats, this mac makes you the hero of any gathering.
Ingredients for Mac and Cheese Casserole
This dish comes together using simple ingredients full of flavors. Take a look at this list of legen-dairy ingredients, so you’ll have what you need when you’re ready to start:
- 2 pounds elbow macaroni noodles (large, or your favorite pasta noodle)
- ¼ cup all-purpose flour
- ¼ cup butter (I recommend unsalted butter because the rub has plenty of salt)
- 1 cup whole milk
- 1 cup heavy cream
- 8 ounces Velveeta (orignal flavor, cubed)
- 8 ounces medium cheddar cheese (shredded)
- 4 ounces sharp cheddar cheese (shredded)
- 4 ounces smoked gouda cheese (shredded)
- 2 eggs (beaten)
- 3-4 teaspoons Hey Grill Hey Beef Rub
If you don’t have any Beef Rub, you can use equal parts Kosher salt, black pepper, paprika, garlic powder, onion powder, and mustard powder. Or, you can pick some up in the Hey Grill Hey Store.
Breadcrumb Topping
- ¼ cup butter (melted)
- 1 cup panko bread crumbs
- 1 Tablespoon Hey Grill Hey Sweet Rub
How to Make Smoked Mac and Cheese Casserole
Creating this cheesy masterpiece is simple enough for a weeknight dinner but impressive enough for your next backyard gathering. Here’s how to bring all these amazing flavors together:
- Preheat the smoker. Set your smoker to 225 degrees F and add a mild wood like pecan, apple, or maple. This low-and-slow cook will infuse all that cheesy goodness with just the right amount of smoke.
- Cook the pasta. Bring a large pot of salted water to a boil. Add the noodles and cook according to the package instructions until al dente (about 6–7 minutes). Drain with a colander, then set aside.
- Make the cheese sauce. In another large pot over medium-low heat, melt the butter. Whisk in the flour to form a roux, then slowly add the milk and cream, whisking constantly until smooth. Add in all the cheeses and the Beef Rub seasoning, and stir until everything melts into a rich, creamy sauce.
- Build the casserole. Remove the cheese sauce from the heat. Stir in the cooked noodles and beaten eggs until everything is fully coated and combined.
- Make the topping. In a medium bowl, stir together the melted butter, panko, and Sweet Rub. Sprinkle evenly over the top of the mac and cheese.
- Smoke the casserole. Transfer everything to a smoker-safe baking dish (if not already in one), and place it on the smoker. Close the lid and smoke for 1 hour at 225 degrees F, or until the casserole is set and the topping is lightly golden.
- Serve and enjoy. Remove from the smoker, slice into squares, and dig in! It’s creamy, smoky, and packed with flavor in every bite. Cover your
Alternative Cooking Methods
While I love the depth of smoky flavor you get from the smoker, there’s more than one way to casserole a mac. Here are a couple alternatives if you don’t have access to a smoker, or just can’t wait for that casserole.
Can I make this in the oven?
You’ll miss out on the smoky notes, but the casserole still bakes up beautifully in a conventional oven. Simply follow the same preparation steps, then bake at 225 degrees F for about an hour until the cheese is bubbly and the topping turns golden brown. Baked macaroni casserole is still a classic.
Can I make it faster?
If you’re short on time, you can increase the temperature to 350 degrees F and reduce the cooking time to about 30 minutes. This higher-temperature approach creates an amazingly crispy, bubbly exterior with those delicious browned edges many people love.
Even when using your smoker at this higher temperature, you’ll still get some smoke flavor, just not quite as pronounced as the low-and-slow method.
Storing and Using Leftovers
This mac and cheese stores easily and actually tastes even better the next day as the flavors continue to develop. Once it cools to room temperature, store it in an airtight container or gallon zip-top bag in the refrigerator for up to 3-4 days. If you’re looking for a creative way to use leftovers, this casserole works perfectly for my Deep-Fried Mac and Cheese Bites.
More Creative Mac and Cheese Recipes
If you think this recipe’s a banger, wait until you see the other mac and cheese-inspired recipes I’ve got in store for you. Check out these favorites from the Hey Grill Hey recipe vault, and remember you can also find them all in the Hey Grill Hey App:
Smoked Mac and Cheese Casserole Recipe
After you make this Smoked Mac and Cheese Casserole to share with the people you love, come back and leave a 5-star review. Did you go low and slow? Hot and fast? A little of both? I wanna hear about it, so be sure to drop a comment below.
Don’t forget to follow along on Instagram, Facebook, and my YouTube channel so you can get more recipes, how-to videos, and BBQ pro tips. No matter where you are on your grilling journey, Hey Grill Hey is here to help you become a Backyard BBQ Hero.
Smoked Mac and Cheese Casserole
Equipment
- 1 Smoker I highly recommend this pellet grill!
Ingredients
- 2 pounds elbow macaroni noodles cooked according to package instructions
- ¼ cup all-purpose flour
- ¼ cup butter
- 1 cup milk whole
- 1 cup heavy cream
- 8 ounces Velveeta original flavor, cubed
- 8 ounces medium cheddar cheese shredded
- 4 ounces sharp cheddar cheese shredded
- 4 ounces smoked gouda cheese shredded
- 2 eggs beaten
- 1 Tablespoon Hey Grill Hey Beef Rub
Breadcrumb Topping
- 1 cup panko bread crumbs
- ¼ cup butter melted
- 1 Tablespoon Hey Grill Hey Sweet Rub
Instructions
- Preheat the smoker. Set your smoker up for 225 degrees F with a mild wood.
- Cook the pasta. Heat water in a pot over high heat until boiling, then add the pasta noodles. Boil for 5-7 minutes, then strain.2 pounds elbow macaroni noodles
- Make the roux. Melt the butter in a heavy-bottom pot over medium-low heat, then whisk in the flour, Add the milk and heavy cream, then add in all the cheeses and the seasoning. Stir until everything is incorporated.¼ cup all-purpose flour, 1 cup milk, 1 cup heavy cream, 8 ounces Velveeta, 8 ounces medium cheddar cheese, 4 ounces sharp cheddar cheese, 4 ounces smoked gouda cheese, 1 Tablespoon Hey Grill Hey Beef Rub, ¼ cup butter
- Add the noodles. Remove the roux from heat, then add the noodles. Add the beaten eggs, then stir until combined.2 eggs
- Prepare the topping. In a medium-size bowl, combine the melted butter, bread crumbs, and Sweet Rub. Mix with a fork until combined, then sprinkle on top.1 cup panko bread crumbs, ¼ cup butter, 1 Tablespoon Hey Grill Hey Sweet Rub
- Smoke the casserole. Place the pot on the grates of your preheated smoker, close the lid, and allow it to smoke for around an hour.
- Serve and enjoy. Remove the mac and cheese from the smoker, serve with your favorite sides, and enjoy!
Notes
- Purchase in the Hey Grill Hey Store here
- Purchase in the Hey Grill Hey Store here
- Make your own following the recipe here
Nutrition
Nutrition information is automatically calculated, so should only be used as an approximation.
