Smoked Sausage Gouda Mac-n-Cheese

This Smoked Sausage Gouda Mac & Cheese takes classic comfort food up a notch with smoky sausage, creamy Gouda sauce, and a golden pretzel crumb topping. Slow-smoked for rich flavor and finished under the broiler for crunch, it’s hearty, cheesy, and just the right amount of indulgent. The contrast of smoky cheese sauce with the crunchy pretzel topping makes this dish the ultimate game day crowd-pleaser.

Yield: 8-10

Author: Tamra Mentzer

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Smoked Sausage Gouda Mac & Cheese

This Smoked Sausage Gouda Mac & Cheese takes classic comfort food up a notch with smoky sausage, creamy Gouda sauce, and a golden pretzel crumb topping. Slow-smoked for rich flavor and finished under the broiler for crunch, it’s hearty, cheesy, and just the right amount of indulgent. The contrast of smoky cheese sauce with the crunchy pretzel topping makes this dish the ultimate game day crowd-pleaser.

Ingredients

• 1 lb mild Italian sausage
• Garlic salt, black pepper, red pepper flakes (to taste)
• 3 Tbsp butter
• ¼ cup all-purpose flour
• 2 ½ cups half-and-half
• 12 oz Gouda cheese (shredded)
• 4 oz sharp cheddar (shredded)
• 4 oz pepper jack (shredded)
• 1 lb box macaroni (cellentini)
• ½ cup crushed honey mustard & onion pretzels
• ½ cup Panko breadcrumbs
• 3 Tbsp melted butter

Instructions

1. Cook the pasta - Bring a large pot of salted water to a boil. Cook pasta until just al dente. Drain and set aside.
2. Brown the sausage - In a large skillet or Dutch oven, cook sausage over medium-high heat with garlic salt, black pepper, and red pepper flakes until browned and fully cooked. Remove sausage to a plate, leaving drippings in the pan.

Make the roux and cheese sauce (same pan)

1. Lower heat to medium. Add butter to the sausage pan.
2. Once melted, whisk in flour. Cook 1–2 minutes, whisking constantly, until smooth and slightly golden.
3. Slowly add the half-and-half: start with about ¼–½ cup, whisk until smooth, then continue adding in small amounts while whisking. This prevents clumps and makes a silky base. Once the roux is loosened, add the rest in a steady stream.
4. Whisk until thickened enough to coat the back of a spoon (about 5 minutes).
5. Remove from heat. Stir in Gouda, cheddar, and pepper jack until melted and creamy. Adjust seasoning as needed.

Assemble

1. Fold in cooked pasta and browned sausage until evenly coated in cheese sauce. Transfer to a cast iron skillet or oven-safe dish.

Smoking Method

1. Smoke at 225°F for 90 minutes–2 hours until bubbly and infused with smoke.

Add topping & broil

1. In a small bowl, mix pretzels, Panko, and melted butter.
2. Sprinkle evenly over the smoked mac and cheese.
3. Place under the broiler for 1–2 minutes max — just until golden brown and crisp. Watch closely the entire time so it doesn’t burn.

Oven Method

1. If not smoking, bake uncovered at 350°F for 30 minutes. Add topping before baking.