Delicious Smoked Meatloaf

This smoked meatloaf transforms a classic comfort food into a flavor-packed showstopper with rich, smoky undertones that perfectly complement the savory meat. The low and slow cooking method ensures a juicy, tender result that will have everyone asking for seconds.

I developed this recipe after getting my first pellet grill and now my family refuses to eat meatloaf prepared any other way. The transformation from ordinary to extraordinary happens magically while you relax and enjoy the amazing aromas filling your backyard.

Ingredients

• Ground beef 85/15: Provides the perfect fat content for juicy meatloaf without becoming greasy
• Italian breadcrumbs: Add texture and help bind while contributing subtle herbs
• Whole milk: Soaks into breadcrumbs creating tenderness throughout
• Yellow onion: Provides essential aromatic flavor and moisture
• Chili sauce: Offers tangy sweetness that balances the smoke
• Eggs: Work as crucial binders holding everything together perfectly
• Worcestershire sauce: Delivers umami depth and complexity
• Italian seasoning: Blends multiple herbs for classic flavor profile
• BBQ sauce: Creates a caramelized glaze when exposed to smoke

Step-by-Step Instructions

Prepare The Smoker:

Turn your pellet grill to the smoke setting and allow it to preheat while you prepare the meatloaf. This initial step gets your cooking environment ready with the perfect temperature and smoky atmosphere.

Mix The Meatloaf:

In a large bowl combine ground beef, breadcrumbs, milk, onion, chili sauce, beaten eggs, Worcestershire sauce, Italian seasoning, garlic powder, Kosher salt, and fresh cracked pepper. Use your hands to gently incorporate all ingredients until just combined. Overmixing will result in a dense, tough meatloaf, so stop once everything is evenly distributed.

Form The Loaf:

Shape the meat mixture into a uniform loaf approximately 9 inches long by 5 inches wide by 3 inches high. Place it on a parchment-lined pizza pan, wire rack, or grill pan that will allow smoke circulation while containing any drippings.

Initial Smoke Phase:

Place the formed meatloaf in your preheated pellet grill and allow it to smoke for 10 minutes. This initial exposure to pure smoke without high heat helps develop that wonderful outer bark and sets the foundation for flavor.

Prepare The Glaze:

While the meatloaf is in its initial smoke phase, mix BBQ sauce and chili sauce in a small bowl until thoroughly combined. This tangy sweet glaze will caramelize beautifully during the cooking process.

Low And Slow Cooking:

Increase your grill temperature to 250 degrees and continue cooking for approximately 4 hours. Every 30 minutes, brush the meatloaf with glaze, building up layers of flavor. The magic happens during this extended cooking time as smoke permeates the meat.

Monitor Temperature:

After about 2 hours, insert a meat probe thermometer into the thickest part of the meatloaf and continue cooking until the internal temperature reaches 160 degrees. This ensures food safety while maintaining moisture.

Rest Before Serving:

Once the meatloaf reaches temperature, remove it from the smoker and allow it to rest for at least 10 minutes. This critical resting period allows juices to redistribute throughout the meat for maximum tenderness when sliced.

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My secret weapon in this recipe is the layered glazing approach. My grandfather taught me this technique of multiple thin coats rather than one thick coating. Each layer caramelizes slightly before the next application, creating an incredibly complex flavor and beautiful lacquered appearance that makes this meatloaf truly special.

Make-Ahead Options

This smoked meatloaf is perfect for meal prep. You can mix and shape the meatloaf up to 24 hours before smoking. Simply cover tightly with plastic wrap and refrigerate. Remove from the refrigerator about 30 minutes before smoking to take the chill off. This advance preparation actually improves the flavor as the seasonings have more time to permeate the meat.

Serving Suggestions

While this meatloaf is delicious on its own, it truly shines as the centerpiece of a complete meal. Pair it with creamy mashed potatoes to contrast the smoky flavors, or roasted vegetables that have caramelized edges to complement the meatloaf's exterior. For a lighter option, a crisp green salad with a tangy vinaigrette balances the richness perfectly. Leftover meatloaf makes incredible sandwiches when sliced thin and served cold on good bread with a bit of mayo.

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Troubleshooting Tips

If your meatloaf seems too wet during mixing, add a few more tablespoons of breadcrumbs. Conversely, if it feels too dry, incorporate an additional splash of milk. Weather conditions can impact your smoking time significantly. On humid days, expect longer cooking times, while dry conditions might speed up the process. Always rely on internal temperature rather than time. If your meatloaf develops too much exterior color before reaching the proper internal temperature, wrap it loosely in foil to prevent burning while allowing it to finish cooking properly.

Frequently Asked Questions

→ What temperature should smoked meatloaf reach internally?

Smoked meatloaf should reach an internal temperature of 160°F to ensure it's fully cooked while remaining juicy. Use a meat probe after a couple hours of cooking to monitor the temperature accurately.

→ How often should I apply the BBQ glaze?

The BBQ glaze should be applied every 30 minutes throughout the cooking process, using about 1/4 cup each time until all the glaze is used. This creates a delicious caramelized crust.

→ Can I use a different type of grill if I don't have a pellet grill?

Yes, you can adapt this for other smokers or grills with indirect heat. For gas or charcoal grills, set up for indirect cooking and add wood chips for smoke. Maintain a similar temperature (250°F) and cooking time.

→ Why do you mix milk with the breadcrumbs?

Mixing milk with breadcrumbs creates a panade, which adds moisture and tenderness to the meatloaf. This prevents it from becoming dry during the long smoking process and improves the overall texture.

→ What sides pair well with smoked meatloaf?

Smoked meatloaf pairs excellently with air fryer green beans and herb roasted baby potatoes as mentioned in the recipe. Other great options include mashed potatoes, corn on the cob, coleslaw, or a simple green salad.

→ Can I prepare the meatloaf mixture ahead of time?

Yes, you can prepare the meatloaf mixture up to 24 hours ahead and refrigerate it covered. This actually allows the flavors to meld together better. Just bring it closer to room temperature before smoking.