The Best Pulled Pork on a Pellet Grill: Juicy, Smoky, and Unforgettable Every Time!
The smell of slow cooked pork, lightly kissed by wood smoke, always reminds me why pulled pork is a favorite for backyard gatherings and relaxed weekends. Making pulled pork on a pellet grill gives you that classic smoky taste with less fuss and more control over the entire cook. It’s my go-to choice for feeding a hungry crowd, and this method yields meat that’s fall apart tender, packed with flavor, and absolutely crave worthy for everyone—even if you’re not a pitmaster.
One thing I love about this recipe is how forgiving it is. Even when tweaking seasonings or switching up the pellets, the method remains simple and satisfying. Just a little planning and patience and you’ll have juicy pulled pork so good, folks will ask for leftovers—if there are any to spare!
Why Pulled Pork on a Pellet Grill Rocks
- Consistent low and slow heat. Pellet grills keep temperatures rock steady, giving you reliable results right from your first try.
- Flexibility with flavors. Try different wood pellets like hickory, apple, or cherry for unique smoky profiles that suit your taste.
- Easy for beginners and pros. Pellet grills take much of the guesswork out of barbecue, letting you relax and enjoy the process.
- Makes plenty for sharing. A single pork shoulder feeds a crowd, perfect for parties or meal prepping for the week ahead.
What You Need for Pellet Grill Pulled Pork
Here’s what I reach for every time to make juicy and flavorful pulled pork:
- 1 whole pork shoulder (also called pork butt), 7-9 pounds
- 1/4 cup yellow mustard for the slather
- 1/4 cup apple juice or apple cider vinegar for the mop or spritz
- Wood pellets (hickory, apple, or cherry work great for flavor)
- Aluminum foil or butcher paper
- BBQ rub (store bought or homemade, see below)
For a simple homemade pork rub, mix together:
- 1/4 cup brown sugar
- 2 tablespoons paprika
- 1 tablespoon garlic powder
- 1 tablespoon onion powder
- 1 tablespoon kosher salt
- 2 teaspoons black pepper
- 1 teaspoon cayenne (optional, for a hint of heat)
How to Smoke the Best Pulled Pork on a Pellet Grill
1. Prep the Pork Shoulder
Begin by trimming away large flaps of fat but keep most of the fat cap; this helps the pork stay moist. Pat the pork dry with paper towels and slather it with a thin layer of yellow mustard. This not only helps the seasoning stick but also adds a subtle tang. Then, coat every side of the pork generously with the BBQ rub.
2. Fire Up the Pellet Grill
Fill the hopper with your favorite pellets and set your grill to 225°F. Allow it a solid 10-15 minutes to preheat and let the temperature stabilize. The smoke will be rolling in no time, and that’s when the magic starts.
3. Get Smoking
Place the pork shoulder directly on the grill grate, fat side facing up. Close the lid and let it smoke slowly. For most 8-pound shoulders, this stage takes 4-5 hours. Try not to open the lid too often because you’ll lose heat and slow down the process.
4. The Spritz (Optional but Helpful)
After it’s been on the grill for about 2 hours, start spritzing the pork every 45-60 minutes using a spray bottle filled with apple juice or cider vinegar. This keeps the surface moist and helps build up a tasty bark—the seasoned outer crust everybody loves.
5. Wrap When It Hits the Stall
When the pork hits about 160°F internally (usually after 5-6 hours), the meat hits what’s called “the stall.” Moisture on the surface begins to evaporate, which slows down the cooking. At this stage, wrap the pork tightly in two layers of heavy-duty foil or in uncoated butcher paper. Wrapping moves the cook past the stall and keeps everything juicy.
6. Finish Cooking to Perfection
Put the wrapped pork back on the grill. Smoke until it reaches an internal temperature of 195-203°F. I find 203°F creates pull-apart tenderness that makes shredding effortless. Expect this part to take another 3-4 hours, but timing can vary depending on size and conditions.
7. Rest, Then Shred
Once done, let your pork rest while still wrapped in a cooler or switched-off oven for at least 45 minutes, or even up to 2 hours. This crucial step keeps juices locked in. Unwrap, then use gloves or forks to pull the pork apart. Toss out big pieces of fat and bone, then mix the juicy bits together for max flavor in every bite.
Pulled Pork Cooking Tips & Variations
- If you crave a strong smoke hit, pick hickory or oak. For a sweeter and gentler profile, give apple or cherry a shot.
- Cooking for a few people? You can opt for a pork picnic shoulder—it’s slightly leaner but cooks up just as tasty.
- For Carolina-style tang, splash in some spiced vinegar or hot sauce when shredding the pork. It’ll give the pulled pork a punchy finish.
- Got leftovers? Pulled pork freezes beautifully. Pack it into zip-top bags with a little of the cooking juice—reheats quick for tacos, sandwiches, or baked potato toppers.
FAQs About Pulled Pork on a Pellet Grill
Q: What’s the best cut of pork for pulled pork?
Pork shoulder (pork butt or Boston butt) wins every time. It has the right amount of fat to keep things juicy and tender even over many hours of cooking.
Q: How long does pulled pork take on a pellet grill?
For an 8-pound shoulder, budget about 8-12 hours in total, depending on your grill and the weather. Good things come to those who wait.
Q: Should I wrap the pork during cooking?
Wrapping at the stall (about 160°F) keeps the bark from getting too dry and helps retain moisture. Foil traps more steam, while butcher paper lets a bit more smoke in. Choose whichever texture you like better.
Q: Can I use store bought rub?
Yes! There are some fantastic pork rubs at the store. Look for a balance between sweet, savory, and spicy for delicious results.
Q: What’s the best way to serve pulled pork?
Pulled pork goes perfectly piled on soft rolls with coleslaw and barbecue sauce. It’s also great over baked potatoes, in tacos, or just by itself with a fork.
Get Your Pellet Grill Smoking!
If you’ve never tried making pulled pork on a pellet grill, this is the perfect moment to give it a shot. The combination of effortless grilling and unbeatable smoky flavor makes this a technique you’ll return to again and again. Try it and share how your pork turned out or what tasty adjustments made it your own. Enjoy the cook and enjoy the leftovers—if you manage to save any!
For those who want to dig into more barbecue recipes, consider testing pulled chicken, brisket, or even smoked beans next. Pellet grills make it easy to master a whole lineup of smoky crowd pleasers for any event. Happy grilling!