Traeger Smoked Mac and Cheese Without Velveeta

Smoked Mac and Cheese is a comfort food side dish made with pasta, a blended cottage cheese sauce, sharp cheddar, and Gruyere, cooked low and slow on a pellet grill until golden and gooey on top. It works well for backyard BBQs, holiday spreads, and anytime you're already firing up your Traeger for a main course. The secret is blended cottage cheese in place of Velveeta, which creates a naturally creamy, protein-rich sauce made entirely from real ingredients.

Here in Texas, smoked macaroni and cheese isn't just a fun twist; it's a tradition. We smoke our Thanksgiving dinner every year, and this smoked mac and cheese is always on the table alongside our Traeger Brisket, Traeger Scalloped Potatoes, and Smoked Green Beans. It's a staple on Memorial Day, too.

Most smoked mac and cheese recipes rely on Velveeta or processed cheese to keep the sauce creamy, but that's just not how I like to cook. I wanted a version made with real-food ingredients that still came off the smoker rich, gooey, and crowd-worthy.

Blended cottage cheese ended up being the trick. It gives the sauce body and creaminess without making the dish taste like cottage cheese. It also holds up well for holiday prep, which is a lifesaver when the smoker is already full.

If you've ever pulled smoked mac and cheese off the grill only to find the sauce oily, grainy, or dried out, you're not alone. That usually comes down to the cheese sauce base and smoker temperature. As a nutrition coach, I wanted a real-food fix that still came off the smoker creamy, gooey, and crowd-worthy.

If you are looking for more easy smoker sides, check out reader favorites like Traeger Baked Potatoes, Smoked Baked Beans, Traeger Smoked Queso Without Velveeta, or Traeger Smoked Asparagus.

Ingredients You'll Need

• Cottage Cheese: This is my real-food swap for Velveeta. Use full-fat or 2% cottage cheese and blend it until completely smooth before adding it to the sauce. I do not recommend fat-free cottage cheese because it will not give you the same rich, creamy texture.
• Milk: Whole milk adds richness and helps loosen the sauce so it coats the pasta evenly. Grass-fed whole milk is my favorite here, but any whole milk will work.
• Cheese (Sharp Cheddar + Gruyere): Sharp cheddar gives you that classic mac and cheese flavor, while Gruyere adds a rich, nutty depth that works really well with smoke. For the smoothest sauce, shred the cheese yourself from a block. If you're out of Gruyere, Gouda, Monterey Jack, Havarti, or Fontina can work too.
• Gluten-Free Flour: Helps thicken and stabilize the sauce so it coats the pasta well. I like Bob's Red Mill, but regular all-purpose flour also works if you are not gluten-free.
• Garlic Powder, Paprika, and Mustard Powder: These pantry staples add a ton of flavor. The garlic gives a subtle savory note, paprika brings a little warmth and color, and the mustard powder adds just the right amount of zip.
• Sea Salt and Black Pepper: For seasoning the sauce just right. Taste and adjust as needed!
• Gluten-Free Pasta: I love using elbow macaroni or small shells-something with crevices that holds onto all that cheesy sauce. Jovial's brown rice or cassava pasta are my go-tos. If you tolerate gluten, regular pasta works just fine!

See the recipe card for full information on ingredients and quantities.

How to Make Smoked Mac And Cheese

This is an overview with step-by-step photos. Full ingredients & instructions are in the recipe card below.

Step 1. Heat a large pot of water over high heat. Once the water has come to a boil, add a generous pinch of sea salt and add your pasta to the boiling water. Cook the pasta to al dente according to the package directions. Be sure to reserve some of the pasta water, as you may want to use it to thin the sauce out.

Step 2. While the pasta is cooking, add the cottage cheese, milk, ¾ of the shredded cheddar, ¾ of the shredded gruyere, gluten-free flour, garlic powder, paprika, mustard powder, cayenne pepper, sea salt, and black pepper to the bowl of a food processor. Blend the cottage cheese mixture until it is smooth and creamy. Taste for seasonings and adjust as needed.

Step 3. Once the pasta is done cooking, drain it well and add it to a large bowl. Pour the blended cheese sauce over the cooked pasta and toss to combine. Transfer the pasta to a greased large cast-iron skillet. Spread the pasta mixture evenly across the pan. Top with the remaining grated cheese.

Step 4. Place your cast iron skillet on the grill grates of your Traeger and smoke at 225 degrees for 1 hour.

Holiday Make-Ahead Plan

This is one of my favorite make-ahead smoker sides for Thanksgiving, Memorial Day, and BBQs because you can assemble it the day before and smoke it right before serving.

Here's how you can plan ahead:

This make-ahead method is a game-changer when you're cooking multiple dishes. It frees up space (and mental energy!) so you can actually enjoy the holiday too.

How Long To Smoke Mac And Cheese

At 225°F, smoked mac and cheese takes about 1 hour. That's enough time for the top to turn golden, the edges to bubble, and the pasta to absorb a rich layer of smoke flavor without drying out. A few variables can affect that timing:

You're looking for a lightly golden top with glossy, bubbling edges. If the top looks dark or the sauce looks dry around the edges, pull it.

Storage And Reheating

• Storage: If you've got leftovers (which honestly doesn't happen too often around here), keep them in an airtight container in the fridge for up to 4 days. 
• Reheating: To bring it back to life, warm it in the oven at 325 degrees F until hot and bubbly. If it looks a little dry, stir in a splash of milk before reheating.