How Long Does It Take to Cook Polish Sausage on the Grill? A Complete Guide

Polish sausage, also known as kielbasa, is a staple at cookouts and backyard barbecues With its smoky, garlicky flavor, this sausage is always a crowd-pleaser But figuring out exactly how long to grill kielbasa can be tricky. Undercook it and the sausage will be raw inside; overcook it and you’ll end up with a dried-out, tough sausage. So how long should you grill Polish sausage to get it perfectly cooked from the inside out? In this complete guide, we’ll walk through everything you need to know to grill Polish sausage to juicy, smoky perfection.

What is Polish Sausage?

Polish sausage or kielbasa originated in Poland. It’s made from a mixture of pork and sometimes beef or other meats along with garlic, spices, and curing salts. The sausages are then smoked, giving them their characteristic smoky flavor.

There are a few main types of kielbasa:

• Kielbasa zwyczajna The most common smoked Polish sausage in the US It’s made from pork and uses marjoram and garlic as main seasonings.

• Biała kiełbasa: A fresh, unsmoked sausage that’s white in color. It’s made from pork and/or veal.

• Kabanosy: A thin, dry sausage seasoned with caraway seeds.

• Krakowska: Smoked, dried sausage flavored with garlic and peppercorns.

For grilling, the smoked kielbasa varieties like kielbasa zwyczajna are the most common.

Factors That Affect Grilling Time

Several factors impact how long it takes to cook Polish sausage on the grill:

1. Thickness

Thicker sausages take longer to cook than thinner links. A good rule of thumb is to allow 5-7 minutes per inch of thickness for raw sausage. Smoked sausage that is pre-cooked may take less time.

2. Temperature

Cooking over high heat around 400-450°F will grill sausage faster than lower temperatures around 300°F. Control the grill’s temperature by adjusting the heat level and monitoring it with a grill thermometer.

3. Direct vs. Indirect Heat

Cooking directly over the heat source will grill sausage quicker than indirect, off-heat cooking. Use direct heat to get color on the outside, then move to indirect heat to finish cooking through.

4. Pre-cooked vs. Raw

Smoked Polish sausage that is already cooked just needs to be heated through on the grill. Raw sausages must be cooked fully to an internal temperature of 160°F.

5. Cut vs. Whole

Cut sausage pieces or patties will grill faster than whole sausages. Smaller pieces have more surface area for browning.

Taking these factors into account will help you gauge the right grilling time for your kielbasa.

How to Tell When Polish Sausage is Done

There are a few ways to test if your Polish sausage is fully grilled:

• Internal temperature: Use an instant read thermometer to check for an internal temperature of 160°F. Insert the probe into the thickest part of the sausage.

• Firm texture: Fully-cooked sausages will have a firm, juicy texture when squeezed. Raw sausage will still feel soft.

• Browning: Look for nicely browned, crisped exterior and grill marks. Cut into a sausage to check that the interior is no longer pink.

• Smoky aroma: Polish sausage is done when you can smell the savory, smoky aroma.

Checking temperature and visual cues will ensure your kielbasa is cooked through without overdoing it.

How Long to Grill Smoked Polish Sausage

For smoked kielbasa that is already fully cooked, grilling time is short—the goal is just to heat it through and add flavorful browning. Follow these guidelines:

Whole Smoked Links

• Grill for 8-12 minutes total
• 4-6 minutes per side
• Use direct heat the entire time

Cut Smoked Slices

• Grill for 4-5 minutes total
• 2-3 minutes per side
• Direct heat

Flip the sausages once halfway through to brown both sides. Add a splash of beer or water to the grill to help steam and heat the sausages if needed.

How Long to Grill Raw Polish Sausage

Raw kielbasa needs to fully cook on the grill before serving. Follow these time guidelines:

Thin Raw Links or Patties

• 1⁄2 inch thick or less
• 8-12 minutes total
• 4-6 minutes per side
• Direct heat

Thick Raw Links

• 1 inch thick or more
• 14-18 minutes total
• 7-9 minutes per side
• Use 2/3 direct, 1/3 indirect heat

Use a two-zone fire to sear over direct heat before moving to indirect heat to finish cooking. Rotate or flip sausages every 2-3 minutes for even browning.

Grilling Tips for Polish Sausage

To get perfect grilled kielbasa, keep these tips in mind:

• Bring sausage to room temperature before grilling for more even cooking.

• Use a grill basket to easily turn and move multiple sausages.

• Cut slits in sausages before grilling to allow steam to escape and prevent “exploding.”

• Brush or spray the grill grate with oil before adding sausages to prevent sticking.

• Sear over direct heat then move to indirect heat on a two-zone grill to finish cooking.

• Use a digital thermometer to check the internal temperature for doneness.

• Let sausage rest 5 minutes before serving to allow juices to redistribute.

With the right technique, you can achieve juicy, browned Polish sausage with wonderful smoky flavor. Reference the guidelines in this article to determine the ideal grilling time based on the thickness, preparation, and grill temperature. In no time, you’ll be an expert at making perfectly cooked kielbasa worthy of any cookout spread. Serve it up on a bun with all the fixings, or slice it up to top tacos, nachos, pizza and more. However you enjoy it, this versatile sausage is sure to satisfy.