How to Smoke a Pork Butt on a Pellet Grill

Every grillmaster from Dallas to Memphis knows smoked pulled pork is about as good as it gets. There’s something about the tender meat that pairs perfectly with a smoky, succulent BBQ sauce. 

While there are plenty of great cuts of pork to consider, the cut above the rest when it comes to smoking has got to be pork butt. Also known as Boston Butt, this cut comes from, you guessed it: the pig’s butt muscle. Pulled pork from a pork butt is ideal for smoking because of the tight tissue structure. 

So, now that you know why this choice cut of meat is best, let’s dig in and learn how to smoke pork butt on a pellet grill. Follow these steps, and you’ll smoke pork butt on a pellet grill perfectly every time. 

Step 1 – Select Your Rump

Before you start smoking, you need to make sure you’re working with a choice cut. BBQ Champs Academy suggests picking a pork butt that is:

  • Bright pink
  • Coarsely grained
  • Marbled
  • Capped with firm, white fat

Step 2 – Trim the Fat 

Now that you have your rump ready, it’s time to trim. Take a sharp knife and trim off some of the excess fat around the perimeter of your pork butt. Be careful not to remove all of it, though, as some of that fat will add flavor to the roast as it cooks. 

Step 3 – Season 

Pick your poison and season your pork butt to your heart’s content. Rubs, herbs, or even  a simple dash of salt and pepper will do. This step is more about giving an under-layer of flavor to the meat. Ultimately, the BBQ sauce you use is going to do most of the heavy lifting.  

But don’t hold back. Be generous as you season your pork butt thoroughly. This will ensure every bite is flavorful. 

Step 4 – Choose the Right Wood 

All wood pellets will work in your pellet grill, but not all wood pellets burn the same way. You may be surprised to learn that different woods burn smokier or drier. They also imbue different flavors on your meat. 

While there is no single best wood pellet for smoking, some of the best wood pellets for pork include: 

  • Apple 
  • Cherry 
  • Hickory 
  • Pecan 

We recommend trying different pellets with each smoke that you do and selecting your favorite. 

Step 5 – Heat Your Grill 

This one is easy with the right pellet grill. Simply set your grill’s temperature to 225 degrees Fahrenheit, close the lid, and wait. Once it’s properly pre-heated, simply drop in your pork butt and re-close the lid. 

Burning wood pellets for pellet grill smoker

Step 6 – Cook 

Cook time is a tricky thing. How long to smoke pork butt on a pellet grill largely depends on how large a roast you have. 

Rather than giving you a ballpark, we can instead suggest that you use a meat thermometer. This will tell you exactly when your pork butt is done. Simply inject it into the meat. Once the thermometer reads between 195 and 205 degrees Fahrenheit on the meat’s internal temperature, you’re good to go. 

If you feel like the meat has stalled cooking and won’t get past 150 degrees Fahrenheit, don’t fret. You can wrap it in aluminum foil to help speed up the cook. Once the meat stalls at 150, it’s no longer absorbing smoke, so there’s no risk of ruining your flavor. 

Step 7 – Rest 

Like any other grilled meat, it’s important to let your cooked pork butt rest while wrapped.  That’s because cutting into it too soon will release all of the juices and flavor that are stored inside. Set it aside after it comes out of the pellet smoker. 

Letting the meat rest, covered, for about an hour will trap the juices. This will ensure moist, fork-tender bites through and through. 

Smoke Your Next Pork Butt with HALO 

A perfectly smoked pork butt on a pellet grill demands a perfect pellet smoker. And at HALO, we have just that. We have everything you need to find the best way to smoke pork butt on a pellet grill. Shop our Pellet Grills and Accessories today. 


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