How to Smoke Sausage

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How to Smoke Sausage – The savory, smoky goodness of perfectly smoked sausages will kick your taste buds into overdrive. Incredibly juicy and impossibly flavorful, this is a must-have for your sausage-smoking recipes repertoire.

A delicious smoked sausage on a toasted bun, featuring a juicy and flavorful sausage with melted cheese, caramelized onions, and a drizzle of tangy mustard. The sandwich is served with a side of golden-brown fries.

Smoked sausages recipes are one of my absolute favorite smoker meals, not just because their taste is mind-blowing. Unbelievably easy, literally no prep work (other than firing up your grill or smoker), and less smoking time than most meats make them almost too good to be true. 🤯

Plus, there is just so much you can do with smoked sausage. It’s terrific as a main course because it pairs well with just about any side dish. But make plenty of extras because it’s the perfect meat all week long, like jambalayas, chili, breakfast tacos, pizza, and pasta.

Different Types of Sausage for Smoking

So, you may wonder what kind of sausage is best for smoking. Truth be told, just about any raw sausage will taste amazing when smoked. Pre-cooked sausage tends to overcook and doesn’t benefit much from smoking. Here are a few of my favorites:

Italian Sausage (mild or spicy, they both taste great)
Bratwurst (Flavored bratwursts like jalapeno cheddar are amazing smoked!)
Chorizo
Chicken or Turkey Sausage
Kielbasa
All Beef Hot Dogs (Maybe not technically a sausage, but still delicious.)
Pork Sausage
Sausage Links (may cook faster than regular sausage)

Recipe Ingredients

Sausage – The only ingredient you need for this recipe! I used somewhere between 1-2 pounds, but if your grill or smoker is big enough, you can do more.

A plump sausage sizzling in a smoker, surrounded by aromatic wisps of smoke. The sausage is being slow-cooked to perfection, its savory juices infusing with the wood-fired flavor, promising a mouthwatering and smoky delight.

Pellet Grill Smoker Instructions

Preheat your smoker to 225-250°F (107-121°C).
Prep Sausage – Remove sausage from the fridge and score, if desired. (Since mine was too soft, I did not score it.)
Load Smoker – Once the smoker has reached the desired temperature, place the sausages directly on the grates. Leave room between each sausage so the smoke circulates.
Add Water – Fill a metal or aluminum pan with water and place it on the lower rack of the smoker. You can also set it on the same rack as the sausages but as far away as possible away from them. The water pan adds moisture to the cooking environment and stabilizes the temperature inside the smoker.
Close the smoker’s lid and smoke for about 1½-2½ hours. Check the temperature with an instant-read thermometer. It’s ready when the sausage reaches a safe internal temperature of 160°F (71°C). Optionally, turn them once during the cooking process.
Serve – Remove the sausages, let them rest for a few minutes, and serve. They’re great on hot dog buns, baguettes, or with your main course. Enjoy!

Gas Grill Instructions

Prep Grill – Place 3-4 cups of wood chips in a small aluminum pan; then pour apple juice or water in to cover the wood chips. Let the wood sit in the liquid for about 30 minutes to prevent the wood from burning during the smoking process and add flavor.
Make Smoker Packet – Wrap 2-3 cups of the wet wood chunks in aluminum foil and tightly seal them into a packet. Make tiny holes on one side of the foil packet with a knife to create your own smoke box. (Or use a smoke box😉)
Light Grill – Set up the gas grill for indirect cooking. Light up one or two burners to high heat and leave the other unlit (preferably on the far end).
Create Smoke – Next, place the smoke box next to the high heat so it can start smoking fast. Lower the gas temperature to medium-high heat as soon as it starts to smoke. Set the grill temperature to 225-250°F (107-121°C).
Add Humidity – Fill a metal or aluminum water pan with water and place it on the unlit side of the grill. As I mentioned, the water pan serves multiple purposes, including adding moisture to the cooking environment and stabilizing the temperature inside the smoker.
Load Grill – Place the sausage directly on the grates on the unlit side. Cook slowly to get the delicious smoky flavors.
Close the grill and smoke for about 1½-2½ hours or until the sausage reaches a safe internal temperature of 160°F (71°C). Optionally, turn once during the cooking process.
Serve – Remove the sausages, let them rest for a few minutes, and then serve. Enjoy!

Serving up delectable smoked sausage with relish and diced onions

Recipe Variations

Sausage Bar: A fun way to serve smoked sausages is to set up a toppings bar with all your favorite sauces and extras. I like to include ketchup, mustard, mayo, BBQ sauce, sauerkraut, chili, cheese, diced onions, and pickled jalapenos. 🌭
Sausage Pasta: Slice up cooked, smoked sausage and toss it into your favorite pasta and a creamy Alfredo or tangy tomato sauce. Add some spinach or broccoli for extra color and nutrients. 🍝
Breakfast Casserole: Slice these sausages up after cooking them and add them to omelets or a breakfast casserole. It’s quick, easy, and delicious. 🍳

Tips and Tricks

If using a pellet grill, hickory, apple, cherry wood chips, or a mixed blend delivers delicious smoked sausage. All of these varieties are beautiful flavor enhancers. 🤩
It’s super important that you keep an eye on the smoker’s internal temperature using a thermometer. Smoking low and slow is the key to a juicy sausage.
Pay close attention to the water pan to ensure it doesn’t run dry. Add more water as needed. This will keep your sausages nice and juicy too. 👌
Remember, the cooking time will vary for different types and sizes of the sausages you’re smoking. Typically, they take 1-3 hours to smoke fully. Using a meat thermometer ensures they reach a safe internal temperature of 160°F (71°C) before serving.

Make-Ahead Instructions

Feel free to make smoked sausages 3-5 days ahead of time. They keep great in the fridge in an airtight container. You can also freeze them for up to 3 months. Thaw them in the refrigerator a day before reheating and serving them.

Serving and Storage Instructions

Serve smoked sausages hot off the grill as a main course. Or you can toss them in a different dish, like creamy pasta. Mmm! Store leftover smoked sausage in the fridge for 3-5 days in an airtight container. To reheat, pop them on the grill or in a frying pan over medium heat.

FAQs

What makes a high-quality sausage?

Look for meaty sausages with plenty of fatty marbling (the whitish spots you can see through the casings). Check with your local butcher for fresh, locally sourced sausages. These are often tastier and have fewer additives, such as preservatives.

How do I prevent the sausage from splitting open while smoking?

To prevent sausages from splitting open while smoking, make small slits in the sausage casing before. That allows steam to escape and minimize the risk of splitting.

Can I smoke vegetarian or vegan sausages?

Yes, you can smoke plant-based sausages (tofu, tempeh, seitan, or vegetables). They’re usually pre-cooked, so they will take less time to smoke. 😋

What’s the best internal temperature for smoked sausages?

The consensus is 160℉ (71℃), but many feel safer if the internal temperature reaches 165℉ (73℉). Do what makes you feel safest.

What Goes With Smoked Sausages

Everything! Just about, anyway. 😉 grilled squash, grilled tomatoes, and grilled onions all go beautifully with sausage. Grilled potato wedges and grilled bread are also great options. 💞

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Conclusion

I know you’re going to love these juicy sausages with smoke flavor. Made them already? Let me know how they turned out (and how you served them) in the comment section below! 😁