Mastering the Art of Smoking a Pork Butt on a Pellet Grill

For barbecue enthusiasts, smoking a juicy, flavorful pork butt is a rite of passage. While traditional offset smokers require constant monitoring and adjustments, pellet grills make achieving pork perfection easier than ever. Their precise temperature control, set-it-and-forget-it convenience, and smoky wood flavor have made them a favorite for cooking pork butts.

In this comprehensive guide we’ll walk through every step needed to smoke a mouthwatering pork butt on your pellet grill. From choosing the right cut to nailing the prep temps, timelines, and techniques, you’ll gain the skills to churn out insanely succulent pulled pork every time. Let’s get smoking!

Choosing the Perfect Pork Butt

The first step is selecting a high-quality pork shoulder to smoke, Here’s what to look for

Bone-in or boneless – Bone-in adds flavor but takes longer. Boneless cooks faster. Choose based on timeline.
Boston butt or picnic – The Boston butt comes from higher on the shoulder. More uniform shape.
8-10 lbs – Go big! Allows for plenty of succulent meat after trimming.
Even shape – Pick a roast with consistent thickness for even cooking.
Good marbling – Opt for nice white fat marbling throughout for moisture and flavor.
Untreated – Avoid enhanced or pre-brined pork. Choose fresh for better smoke absorption.

Finding a nicely marbled, untrimmed bone-in pork butt from a trusted butcher is your best bet for maximum flavor.

Prepping the Pork Butt for the Smoker

Proper prep is crucial for even cooking and good bark development:

Trim excess fat – Leave about 1⁄4 inch. Too much fat prevents smoke absorption.
Score the fat cap – Cutting slits helps render fat and develops bark.
Apply binder – Coat with mustard, olive oil, or yogurt to help rub adhere.
Generously season – Use a sweet or savory rub. Apply to all sides and massage in.
Refrigerate overnight – Dries out the exterior for better bark when smoked.

Choose a rub that complements, not overwhelms the pork. Aim for a balance of sweetness, salt, spice, and savory flavors.

Setting Up Your Pellet Grill for Success

Dialing in your pellet grill is key for low and slow smoking:

Pellet choice – Opt for a milder wood pellet like apple or cherry. Avoid mesquite.
Temperature – Set the grill to 200-225°F for proper low and slow cooking.
Placement – Put the pork butt on the main grate, not the upper rack.
Use a probe thermometer – Monitor the internal temp of the meat throughout the smoke.
Add a water pan – The water pan provides extra moisture as the pork cooks low and slow.
Leave the lid closed – Don’t peek or you’ll lose precious heat and smoke!

Maintaining a steady, consistent temperature is crucial for tender, fall-apart meat.

Estimate Your Cook Time

Cooking a pork butt low and slow takes patience. Here’s what to expect:

8-10 lb bone-in – Estimate 1-1.5 hours per lb, so 8-15 hours total.
5-8 lb boneless – Estimate 45-60 minutes per lb, so 6-10 hours total.
The stall – Be ready for the internal temp to stall around 150-170°F. Just wait it out.
Cook by temp, not time – Rely on a meat thermometer, not just a timer.
Rest time – Plan for at least 30-60 minutes of wrapped resting time before pulling.

There are many variables, so use these time estimates as a loose guide. The internal temp is what matters most.

Monitoring Temperature and Doneness

Tracking the internal temperature is vital for pork butt success:

Target temp – Take the pork butt to 195-205°F for shreddable, succulent meat.
Use a probe thermometer – Monitor the temp in multiple spots.
Expect a stall – Don’t panic if the temp stalls around 150-170°F. Just wait it out.
Watch the temps – Be vigilant as you near the target temp range. It can spike quickly.
Test for doneness – The meat should probe like softened butter when done.

Pulling the pork butt off at precisely the right moment means the difference between incredible pulled pork and an overcooked disaster. Don’t rush it!

Step-By-Step Smoking Instructions

Follow this process for foolproof smoked pork butt:

Choose an 8-10 lb untrimmed, bone-in pork butt. Remove excess fat.
Score the fat cap. Apply mustard binder and liberally season. Refrigerate overnight.
Set up pellet grill for 225°F with apple pellets. Add water pan.
Place seasoned pork butt on main grate fat-side up and insert probes.
Smoke at 225°F for 8-10 hours until internal temp reaches 160°F.
Wrap pork butt tightly in foil and return to grill.
Continue smoking until internal temp hits 205°F, about 5 more hours.
Rest wrapped pork butt for 30-60 minutes before pulling.
Pull pork and serve! Enjoy your masterpiece.

Stick to these instructions and you’ll achieve competition-worthy pork butt every time.

Handling Leftovers

Got leftovers? Here are some delicious ways to use up pulled pork:

Pile it on sandwiches or tacos
Toss with barbecue sauce and bake into casseroles
Mix into baked beans, soups, mac and cheese, etc.
Stuff into omelets, burritos, or frittatas
Top salads, nachos, baked potatoes, or pizza

With endless possibilities, you’ll never waste a single leftover strand of precious pulled pork. Get creative!

Pork Butt Smoking Tips and Tricks

Ready to take your pork butt smoking skills to the next level? Try these tips:

Inject flavor – Injecting a marinade adds moisture and flavor throughout.
Spritz – Spraying with juice, cider, or broth adds flavor and moisture during smoking.
Try new wood – Mix up wood pellet flavors like hickory, pecan, etc.
Wrap early – Wrapping the pork butt earlier, like at 165°F, speeds up cooking.
Skip wrapping – Go wrap-free for an intense smoky bark, but longer cook.
Crank the heat – Finish at a higher temp like 275°F to power through any stall.

Don’t be afraid to experiment once you’ve got the basics dialed in. There’s always more to learn with smoking pork butt!

With the right tools, techniques and patience, your pellet grill can churn out insanely juicy and flavorful pulled pork worthy of any elite barbecue joint. Just remember to take it low and slow. Happy smoking!

Smoked Pork Butt On A Pit Boss | Pulled Pork On A Pellet Grill

FAQ

How long to smoke pork butt at 225?

5 pork butt (also called Boston butt, picnic, pork shoulder, etc.) will require about 14 hours of total cook time if you run your smoker low and slow at about 225°F (107°C). Smoke the meat until it reaches 185°F (85°C) for slicing or about 207°F (97°C) for pulling (pulled pork).

When should I wrap my pork butt?

Temperature-wise, wrap your pork butt when it reaches between 150 and 170°F (65 to 76°C). The easiest way to check the temperature is to use a leave-in thermometer. You’ll want to stick it into the thickest part of the pork away from the bone (if applicable), as this heats up faster.

How to make the best pulled pork in a pellet smoker?

Set temperature to 225°F, close lid, and preheat pellet grill 10 to 15 minutes. Place pork, fat cap side up, on grill grate, close lid, and grill, basting with apple juice mixture every hour, until a meat thermometer inserted into thickest portion of pork registers 150°F to 155°F, 5 1/2 to 6 1/2 hours.

How do you smoke a pork butt on a pellet grill?

Smoke the pork butt at 275 degrees. Place the pork butt on the lower grate of your pellet grill and add a temperature probe to left or right of the shoulder bone so it sits in the middle of the meat. Let the butt smoke for 3-4 hours or until the temperature is 160 degrees. Do not open the smoker.

How do you smoke pork ribs on a pellet grill?

Smoke the pork butt Place the pork butt on the lower grate of your pellet grill and add a temperature probe to left or right of the shoulder bone so it sits in the middle of the meat. Smoke the pork butt at 275 degrees for 3-4 hours or until the temperature is 160 degrees.

How do you smoke a pork butt?

Smoke the pork butt. Place your seasoned roast on the smoker fat side up, preferably in the middle of the grate avoiding any direct hot spots. Close the lid and smoke the pork until it reaches an internal temperature of at least 195 degrees F. You can cook to 201 degrees F if you like softer pork.

How long do you cook a pork butt on a pellet grill?

Let the meat stand at room temperature while you prepare your grill. Just placed onto the pellet grill. Plan on anywhere from 7-10 hours or roughly 1 hour per pound of meat. This is a very rough estimate, as each pork butt cooks differently. So, we advise going into this with an open mind.