Smoked Burgers Recipe

Why Smoked Burgers Beat Regular Grilled Burgers

A regular grilled burger takes about 8 minutes. A smoked burger takes over an hour. Is it worth the extra time? Absolutely.

When you smoke a burger at 225F, the smoke has time to penetrate deep into the meat. You get a visible smoke ring and a flavor that no amount of liquid smoke or seasoning can replicate. Then you hit it with a high heat sear to get that crust on the outside. It is the best of both worlds: deep smoky flavor with a crispy, caramelized exterior.

I serve these at every cookout now. People who say they do not care about burgers suddenly want seconds. The reverse sear method turns a simple burger into something that competes with steakhouse quality.

The Meat (80/20 Is Non Negotiable)

Fat is flavor. Fat is moisture. Fat is what makes a burger juicy. Do not buy 90/10 or 93/7 ground beef for smoked burgers. The long cook time at low temperature will render out moisture and you need that fat content to keep the patty from drying out.

80/20 ground chuck is the standard. If your butcher offers a custom blend with some brisket trimmings mixed in, even better. The brisket adds more beefy flavor and additional fat.

Do not add anything to the meat. No eggs, no breadcrumbs, no Worcestershire sauce. That turns it into a meatloaf patty. A great burger is just beef, salt, and pepper. Maybe garlic powder if you are feeling fancy. The beef should be the star.

Forming the Patties

Make them thick. 3/4 inch minimum. Thin patties overcook during the smoke phase and turn into hockey pucks by the time you sear them. A thicker patty gives you a better gradient: smoky crust on the outside, juicy and pink (if that is how you like it) in the center.

The thumb dimple in the center is not optional. Ground beef contracts as it cooks and tries to form a sphere. Without the dimple, your burger puffs up in the middle and does not sit flat on the bun. Press a shallow indent into the center of each patty and it will cook flat.

Handle the meat as little as possible. Overworking ground beef makes it tough. Form the patties gently and stop fiddling with them once they are shaped.

The Reverse Sear Method

This is the technique that makes smoked burgers special. You cook low first, then sear hot.

Phase one: 225F for 45 minutes to an hour. The burger slowly comes up to temperature while absorbing smoke. Pull the burgers when they hit 125 to 130F internal.

Phase two: crank the grill to 400F or higher. Most pellet grills take 10 to 15 minutes to reach this temperature. Some people pull the burgers off during the transition. I leave them on because the rising heat does not hurt anything.

Once the grill is hot, sear each side for 2 to 3 minutes. This is where the crust happens. Add cheese during the last minute, close the lid, and let it melt. The sear locks in the juices and gives you that satisfying crunch when you bite through the crust.

Topping Ideas

Classic: sharp cheddar, lettuce, tomato, onion, pickles, ketchup and mustard. Nothing wrong with the classics.

Smoked gouda and caramelized onions. The smoky cheese doubles down on the smoke from the grill. Phenomenal combination.

Pepper jack with jalapenos and a chipotle mayo. If you like heat, this is the move.

Blue cheese and bacon. Bold, rich, and indulgent. Crumble the blue cheese on during the sear so it gets soft but does not fully melt.

Keep the bun simple. Brioche or potato rolls. Toast them on the grill for 30 seconds. A toasted bun holds up to the juices and adds a little crunch.

Troubleshooting

Burgers are dry

Either your beef was too lean or you overcooked them. Use 80/20 and pull at the right internal temperature. Remember that the sear phase adds another 5 to 10 degrees of carryover. If you want a medium burger (145F final), pull them at 135F before the sear.

No smoke flavor

Make sure you are starting at 225F, not higher. The lower the temperature, the more smoke your pellet grill produces. Also check that your pellets are fresh and your fire pot is clean. A dirty fire pot smolders instead of burning cleanly. Our maintenance guide covers how to keep your fire pot in good shape.

Patties fell apart on the grill

The meat was overworked or the patties were too thin. Form them gently and make sure they are at least 3/4 inch thick. Also, do not flip them during the smoke phase. Only flip during the high heat sear when the crust has formed.

Instructions

1. Divide the ground beef into 4 to 6 portions, about 1/3 to 1/2 lb each. Form into patties about 3/4 inch thick. Press a shallow dimple into the center of each patty with your thumb. This prevents the burger from puffing up into a ball during cooking.
2. Season both sides of each patty generously with salt, pepper, garlic powder, and onion powder. Let them sit at room temperature for 15 minutes while the grill heats up.
3. Set your pellet grill to 225F with hickory or oak wood pellets. Place the patties directly on the grate with space between each one.
4. Smoke at 225F for 45 minutes to 1 hour, until the internal temperature reaches 125-130F. The burgers will have a deep smoke ring and mahogany color on the outside.
5. Crank the grill to 400F or higher for the sear. Once it reaches temperature, sear the patties for 2 to 3 minutes per side. Add cheese during the last minute of searing and close the lid to melt it.
6. Pull the burgers when the internal temperature reaches 160F for well done, 145F for medium, or 135F for medium-rare. Rest for 3 to 5 minutes on a plate.
7. Toast the buns on the grill for 30 seconds while the burgers rest. Assemble with your toppings and serve immediately.