How to Smoke Sausage on a Pellet Grill: A Step-By-Step Guide

Smoking sausage on a pellet grill is one of the best ways to infuse juicy, flavorful sausages with that perfect smoky aroma and taste. Whether you prefer mild breakfast sausage or spicy Italian links, smoking sausage on a pellet grill helps to take the flavor to the next level.

In this comprehensive guide, we will walk through the entire process of smoking sausage on a pellet grill, from start to finish. We will cover pellet grill setup, choosing the right sausage, using the proper wood pellets, step-by-step instructions, and tips for maximizing flavor. Follow along to learn how to make the most delicious smoked sausage you’ve ever tasted!

Benefits of Smoking Sausage on a Pellet Grill

First let’s discuss why smoking sausage on a pellet grill is such a great cooking method

• Enhanced flavor – The smoke imparted by the pellet grill gives the sausage a wonderful smoky flavor that you just can’t achieve with other cooking methods.

• Moist and juicy – Pellet grills cook “low and slow,” allowing the sausage to retain moisture and juiciness.

• Perfect doneness – Pellet grills give you precise temperature control, making it easy to smoke sausage to the ideal doneness without overcooking

• Convenience – Pellet grills are very easy to use. Once you set the temperature, they provide consistent, even heat without having to constantly adjust the settings.

• Versatility – You can smoke all types of sausage, from breakfast links to bratwurst, kielbasa, chorizo, and more.

Pellet Grill Setup

To start. you need to properly set up your pellet grill

• Fill the hopper – Make sure you have enough wood pellets in the pellet hopper to smoke for a few hours. Avoid overfilling.

• Preheat – Turn on your pellet grill, set it to 225°F, and let it preheat for 10-15 minutes before adding the sausage.

• Use a drip pan – Place a foil drip pan under the grates to make cleanup easier. The pan will catch any drippings.

• No direct heat – If your grill has multiple levels, smoke the sausage on the top grate, away from direct heat.

Once your pellet grill is preheated and setup, you’re ready to prep and add the sausage.

Choosing the Right Sausage

You can smoke just about any type of raw, uncooked sausage on a pellet grill. Here are some top varieties to consider:

• Pork – Smoked pork sausage is probably the most common. This includes breakfast links, Italian sausage, brats, chorizo, kielbasa, etc.

• Chicken – Chicken sausage is leaner and will take on a nice smoky flavor.

• Beef – Beef sausages like smoked kielbasa can be delicious.

• Turkey – Turkey sausages are a healthier, low-fat option.

• Vegan – You can even smoke vegan sausage varieties made from soy, seitan, etc.

For the most flavor and moisture, choose raw sausages without a casing. The smoke will penetrate better. You can also remove sausage from the casing before smoking.

Using the Right Wood Pellets

Your wood pellet choice has a major impact on the aroma and flavor of the smoked sausage. Here are some top options:

• Hickory – Provides a classic, robust, bacon-like smoky flavor.

• Apple – Imparts a sweeter, fruity smoke flavor.

• Maple – Also gives a slightly sweet, woodsy smoke taste.

• Mesquite – Strong, earthy smoke flavor that works well with beef.

• Cherry – Light and delicately sweet smoked flavor.

Use 100% flavor wood pellets, not blends with filler woods like oak or alder. Stay away from strong mesquite if you want a milder sausage smoke.

Step-By-Step Instructions

Now, let’s walk through the full process of smoking sausage on your pellet grill:

1. Prepare the Sausage

• Remove sausage from packaging and peel off casing if desired.

• Apply any dry rubs, seasoning blends, marinades, etc. Refrigerate 30-60 mins to allow flavors to penetrate.

• If using casing on, prick sausages several times with a fork to prevent bursting.

2. Preheat the Pellet Grill

• Turn on grill, open lid, fill hopper with desired pellets.

• Set temperature to 225°F and preheat for 10-15 minutes until it stabilizes.

3. Add the Sausage

• Place sausages directly on greased grill grates, evenly spaced apart.

• Avoid overcrowding. Use upper racks if needed to fit all sausages.

• Insert a probe thermometer into thickest sausage to monitor temp.

4. Smoke the Sausage

• Close lid and smoke sausages at 225°F for 1-2 hours until 160°F internal temp.

• If flare ups occur, move sausages to a cooler area temporarily.

• For more smoke, add more pellets to the hopper during smoking.

5. Rest and Serve

• When done, remove sausages from grill and let rest 5 minutes.

• Serve sausages warm by themselves or use in your favorite recipes.

• Slice open and add toppings/condiments if desired. Enjoy!

Smoking Sausage Tips

Follow these tips for the highest quality smoked sausage:

• Choose the freshest sausage possible, ideally raw and uncured.

• Apply rubs/marinades before smoking to maximize flavor.

• Use wood pellets tailored to the type of sausage for optimal aroma.

• Maintain a consistent, low temperature between 225-250°F.

• Insert a probe thermometer to accurately monitor internal temp.

• Avoid flare ups by moving sausage temporarily if needed.

• Let sausage rest 5 minutes before slicing to retain juices.

• Refrigerate leftovers within 2 hours and use within 3-4 days.

FAQs

Let’s answer some common questions about smoking sausage on pellet grills:

What’s the best sausage to smoke?

Pork sausages like kielbasa, chorizo, and brats work very well. Chicken, turkey, and beef sausage also smoke nicely. Go for raw, uncured sausage without casings.

What temperature should I smoke sausage at?

Aim for 225-250°F to get that ideal low and slow smoke. Higher temps risk overcooking the sausage.

How long does it take to smoke sausage?

1-2 hours is typical for smoking sausage to 160°F internal temp. Thicker sausages may take a bit longer.

What wood pellets are best for smoking sausage?

For sausage, sweeter fruit woods like apple and cherry or robust hickory are ideal options. Avoid heavy mesquite smoke.

Can I use liquid smoke instead?

You can, but the flavor will not be as complex or authentic. Smoking over real wood smoke is ideal.

Enjoy Your Delicious Smoked Sausages

There you have it! Follow this complete guide to learn how to smoke flavorful, juicy sausages on your pellet grill. The beauty of pellet grills is how easy they make it to infuse sausages with smoky perfection.

Be sure to choose high-quality sausages, apply seasoning, use complementary wood pellets, and stick to low, controlled temperatures. Monitor with a meat thermometer for best results. In no time, you’ll be serving up spectacular smoked sausages to delight family and friends.

So fire up that pellet grill and get ready to become the neighborhood sausage smoking master! Delicious smoked kielbasa, brats, chorizo, and more are just a few hours of smoky bliss away.