This easy and creamy Smoked Mac and Cheese is a must-have side dish for holidays and backyard BBQs. Made without Velveeta and packed with flavor, it's got a cheesy crust on the outside and a gooey, creamy center that melts in your mouth. Smoke it low and slow for next-level flavor!
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.
I've played with a bunch of versions over the years, but this one is hands-down the best. Most recipes use Velveeta to get that creamy texture, but I like to avoid ultra-processed ingredients. Instead, I use cottage cheese. It makes the sauce extra creamy, sneaks in some protein, and gives you that luscious texture without all the junk. This dish gets just the right crust from the smoker, but stays rich and gooey inside.
And the best part? You can make it ahead for stress-free holiday prep. If you are looking for more easy smoker sides, check out my Traeger Baked Potatoes, Smoked Baked Beans, Traeger Smoked Queso Without Velveeta, or Traeger Smoked Asparagus.
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Ingredients You'll Need
- Cottage Cheese: This is the secret to that super creamy texture without using Velveeta. It also adds a nice little protein boost. I always go for full-fat or low-fat. I do not recommend using fat-free as it won't add the creaminess we are looking for. Good Culture is my favorite brand because it's made with high-quality ingredients and no weird additives.
- Milk: Whole milk (ideally grass-fed) adds richness to the sauce. It helps everything blend together into that silky, cheesy magic.
- Cheese (Sharp Cheddar + Gruyere): A combo of sharp cheddar and Gruyere gives this mac and cheese the best flavor. The cheddar brings bold, classic vibes, and the Gruyere adds an earthy depth that balances everything out. When I can, I go for raw, grass-fed cheese; it melts beautifully and adds extra richness. If you're out of Gruyere, Gouda works too.
- Gluten-Free Flour: Helps the sauce thicken up. I like using Bob's Red Mill, but if you're not gluten-free, regular flour works just fine here. The cottage cheese blends smoothly, and the flour helps stabilize the sauce so it doesn't separate on the smoker.
- 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.
Substitutions And Variations
- Cheese Swap: Feel free to mix it up depending on what you have on hand. Gouda, Havarti, Monterey Jack, or even a little Fontina can all work great. I still like to keep one bold cheese (like sharp cheddar) in the mix to balance out the meltier, milder ones.
- Add Protein: Want to make it more of a full meal? Stir in some chopped smoked brisket (we do this with leftovers!) or pulled pork. It turns this side dish into a main course really fast, and it's a great way to stretch what you've already got.
- Spicy Version: If you like a little heat, try adding in some diced green chiles. Jalapeños or chipotle powder would be amazing too if you want that smoky-kick combo.
- Breadcrumb Topping: For extra crunch, sprinkle the top with gluten-free breadcrumbs before smoking. You can even toss them with a little butter and paprika for extra flavor.
- No Smoker? No problem. You can still get a delicious baked version by popping it in the oven at 375°F until bubbly and golden brown, usually around 25-30 minutes. It won't have that smoke flavor, but it'll still be cheesy, cozy, and totally worth it.
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.
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Holiday Make-Ahead Plan
This dish has become a staple in our holiday lineup, and one of the reasons I love it so much is that it's easy to make ahead. Whether you're hosting for Thanksgiving, Christmas, or throwing together a backyard Memorial Day spread, this recipe lets you prep in advance and keep things stress-free.
Here's how you can plan ahead:
| Holiday Prep | Timing |
|---|---|
| Boil the pasta and blend the cheese sauce. Assemble everything in your cast-iron skillet. | The day before your big feast (Memorial Day, Thanksgiving, or Christmas). |
| Cover tightly and refrigerate overnight. | Before you head to bed. |
| Let it sit out on the counter while you fire up the smoker. | About an hour before dinner. |
| Smoke at 225°F for 1 hour until hot, gooey, and golden. | Just before the meal hits the table. |
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.
Nadia's Expert Tips And Tricks
- Skip fat-free cottage cheese. You need that little bit of fat to help the sauce stay creamy and rich, especially once it hits the smoker, so stick with full-fat or low-fat.
- Always shred your cheese fresh. I know it's tempting to grab the bagged stuff, but pre-shredded cheese has anti-caking agents that mess with the melt. Freshly shredded cheese gives you that ultra-smooth, gooey texture we're after.
- Cook your pasta just to al dente. It's going to keep cooking a bit in the smoker, so if it's too soft from the start, you'll end up with mush. I usually shave 1-2 minutes off the package directions.
- Choosing the Right Wood: The type of wood you use will change the flavor of this mac and cheese. Hickory or mesquite give you that bold, classic BBQ taste, but they can be strong if you're not careful. Apple, cherry, or pecan are milder and slightly sweet, which works great if you want the cheese to shine without too much smoke. Personally, I lean toward applewood for holidays when this is sitting next to brisket-it's just enough smoke without overpowering the plate.
- How Smoky Do You Want It? If you're new to smoking sides, start with a lighter wood and stick to 60 minutes. If you're like us and love that deeper BBQ flavor, go for 90 minutes with hickory or mesquite. Either way, it's all about finding your balance-creamy cheese and smoky flavor in harmony.
- Double the batch. This dish is made for feeding a crowd. Whether you're hosting Thanksgiving, a summer BBQ, or a potluck with friends, this one always disappears fast. You can easily double it and use a large foil pan if you're cooking for a big group.
What To Serve With Smoked Macaroni And Cheese
This dish doesn't just hold its own; it's a total team player on the table. Whether you're building out your Thanksgiving lineup or pulling together a summer BBQ, here are some of my favorite ways to round out the meal:
- Toppings: You can totally keep it classic, but if you want to level things up, sprinkle some crispy bacon over the top right before serving. A drizzle of hot sauce or even a little fresh sage, which pulls in the fall flavors, works great.
- Holiday Mains: This is one of those sides that goes with just about anything. We always serve it with our Traeger smoked brisket during the holidays, but it also plays well with smoked turkey, smoked ham, smoked boneless chicken thighs or Traeger ribs. Basically, if it came off the smoker or out of the oven, this mac belongs next to it.
- Vegetables: Keep it cozy with something green. Our go-to is smoked green beans, but roasted maple brussels sprouts, or smoked zucchini would balance the richness perfectly. You could also pair it with a harvest salad like my butternut squash and feta salad for a pop of color.
- BBQ Sides: If you're bringing this to a cookout, round things out with classics like potato salad with spring onions, American coleslaw, or elote pasta salad.
- Beverages: Keep it casual with sparkling water or sweet tea, or lean into the comfort food vibes with a crisp hard cider or a chilled glass of wine. This dish is rich, so something light and refreshing works best.
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.
Recipe FAQs
Hickory or applewood are both great choices. Hickory adds bold BBQ flavor, while applewood is milder and sweet.
Yes! You can fully assemble the dish the day before, refrigerate it, and smoke it the next day.
Yes! Blended cottage cheese creates a super smooth sauce and adds extra protein without needing Velveeta or heavy cream.
Elbow macaroni or small shells work best since they hold onto the sauce in every bite.
Don't overcook it. One hour at 225°F is the sweet spot. You can also tent with foil if it looks like it's drying out too quickly.
Absolutely. Any pellet grill or smoker with temperature control will work great for this dish. While it's written as a Traeger-smoked macaroni and cheese recipe, you can easily adapt it to Pit Boss, Camp Chef, or even a traditional offset smoker.
The smoke flavor adds depth you just can't get in the oven! Plus, that slightly crispy top from the smoker is perfection. Out of all the smoked macaroni and cheese recipes I've tried, this version hits that sweet spot between creamy, gooey comfort food and bold smoky flavor, without relying on Velveeta.
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Creamy Smoked Mac and Cheese (No Velveeta)
Ingredients
- 1.25 cups Cottage Cheese
- 1 cup Whole Milk
- 1.5 cups Cheddar Cheese sharp
- ¾ cup Gruyère Cheese
- 1 tablespoons Gluten-Free Flour
- ½ teaspoon Garlic Powder
- ½ teaspoon Smoked Paprika
- ½ teaspoon Mustard Powder
- ¼ teaspoon Cayenne Pepper
- ¼ teaspoon Sea Salt
- ¼ teaspoon Pepper
- 12 oz Gluten-Free Pasta
Instructions
- 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.12 oz Gluten-Free Pasta
- 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.1.25 cups Cottage Cheese, 1 cup Whole Milk, 1.5 cups Cheddar Cheese, ¾ cup Gruyère Cheese, 1 tablespoons Gluten-Free Flour, ½ teaspoon Garlic Powder, ½ teaspoon Smoked Paprika, ½ teaspoon Mustard Powder, ¼ teaspoon Cayenne Pepper, ¼ teaspoon Sea Salt, ¼ teaspoon Pepper
- 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.
- Place your cast iron skillet on the grill grates of your Traeger and smoke at 225 degrees for 1 hour.
Notes
- Skip fat-free cottage cheese. You need that little bit of fat to help the sauce stay creamy and rich, especially once it hits the smoker, so stick with full-fat or low-fat.
- Always shred your cheese fresh. I know it's tempting to grab the bagged stuff, but pre-shredded cheese has anti-caking agents that mess with the melt. Freshly shredded cheese gives you that ultra-smooth, gooey texture we're after.
- Cook your pasta just to al dente. It's going to keep cooking a bit in the smoker, so if it's too soft from the start, you'll end up with mush. I usually shave 1-2 minutes off the package directions.
- Choosing the Right Wood: The type of wood you use will change the flavor of this mac and cheese. Hickory or mesquite give you that bold, classic BBQ taste, but they can be strong if you're not careful. Apple, cherry, or pecan are milder and slightly sweet, which works great if you want the cheese to shine without too much smoke. Personally, I lean toward applewood for holidays when this is sitting next to brisket-it's just enough smoke without overpowering the plate.
- How Smoky Do You Want It? If you're new to smoking sides, start with a lighter wood and stick to 60 minutes. If you're like us and love that deeper BBQ flavor, go for 90 minutes with hickory or mesquite. Either way, it's all about finding your balance-creamy cheese and smoky flavor in harmony.
- Double the batch. This dish is made for feeding a crowd. Whether you're hosting Thanksgiving, a summer BBQ, or a potluck with friends, this one always disappears fast. You can easily double it and use a large foil pan if you're cooking for a big group.
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