Smoked Johnsonville Dr Pepper® Inspired Sausage Mac & Cheese with Fire-Roasted Jalapenos

Just because this is mac and cheese, don’t mistake it for a side dish. This is the main event. This is a smoked sausage, barbecue-lover’s dream mac and cheese, built to hold center stage. In the South, Dr Pepper® in barbecue isn’t a gimmick — it’s tradition. That sweet, caramelized depth plays perfectly with smoke, and when you take Johnsonville Dr Pepper® Inspired Sausage and give it even more wood-fired flavor, you’re layering familiar Southern barbecue notes into every bite.

Then comes the trifecta. Heat from fire-roasted jalapenos. Rich, creamy melt from cheddar and American cheese. And that big, smoky, slightly sweet punch from the sausage. Each one hits differently, but together they turn a comfort food classic into something bold enough to headline your cookout.

Directions

Preheat your smoker to 225°. Place the Johnsonville Dr Pepper® Inspired Sausage directly on the grates and smoke for 60-75 minutes, until heated through (160°) and lightly bronzed with good smoke color. Remove and let cool for 10-15 minutes, then slice on a bias into 1/4 inch coins. Set aside. Turn the smoker up to 350°
Bring a large pot of water to a boil. Season aggressively with kosher salt until it tastes like the ocean. Cook the elbow macaroni just to al dente, about 2-3 minutes shy of package directions. As soon as it isn't crunchy, take it out. Drain and set aside, reserving one cup of the pasta cooking water.
In a large, heavy-bottomed pot or Dutch oven, melt the butter over medium heat. Add the flour and whisk continuously to form a roux. Cook for 2-3 minutes, stirring constantly, until the mixture is lightly golden and smells slightly nutty but not browned.
Slowly pour in the warmed milk, about 1 cup at a time, whisking continuously to prevent lumps. Once all the milk is incorporated, continue cooking at a low simmer and stirring until the sauce thickens enough to coat the back of a spoon, about 6-8 minutes.
Reduce the heat to low. Add the garlic powder, kosher salt, and black pepper. Stir to combine.
Add the 2 cups shredded medium cheddar and the 2 cups torn American cheese. Stir continuously until fully melted and smooth. The American cheese gives you that silky texture; the cheddar brings the flavor. Taste and add more seasoning as needed.
Fold in the cooked macaroni, sliced smoked sausage, and chopped fire-roasted jalapenos. Stir until everything is evenly coated and distributed.
Transfer the mixture to a lightly buttered, deep 9x13-inch baking dish. Sprinkle the remaining 1 cup shredded cheddar evenly over the top.
Bake at 350° for 20-25 minutes, until bubbling around the edges and the top is melted and lightly golden. If you want extra color, broil for 1-2 minutes at the end, watching closely.
Let rest for 10 minutes before serving so it sets up properly.