Pellet Grill Pulled Pork Recipe: Smoke-Infused Tenderness Overnight

There’s nothing like the aroma of tender pulled pork slowly smoking on a pellet grill. This method delivers that perfect balance of smokiness and juiciness without constant attention.

I’ve refined this technique over years of competition BBQ, ensuring the meat falls apart with just the right amount of bark. The overnight cook lets the flavors develop deeply while keeping the pork impossibly moist.

Ingredients for Pellet Grill Pulled Pork

Simple ingredients yield competition-level pulled pork with deep smoky flavor and tender texture.

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The pork shoulder quality is non-negotiable. Bone-in, well-marbled cuts from Costco or a trusted butcher deliver the best results. Avoid pre-trimmed cuts—the fat cap renders down beautifully during the long cook. For pellets, Traeger or Pit Boss brands offer consistent burn rates. Hickory provides robust smoke, while applewood adds a sweeter note (worth experimenting with both).

Out of brown sugar? Maple syrup or honey can substitute in the rub (use half the volume). No apple cider vinegar? White vinegar works for spritzing, though the flavor profile shifts slightly. For the BBQ sauce, Stubb’s or Sweet Baby Ray’s are reliable choices. The beer can be any variety—dark beers add richness, but even a light lager contributes moisture.

Store uncooked pork in the fridge for up to 3 days or freeze for 6 months. Pellets keep indefinitely in a sealed container away from moisture. Once cooked, pulled pork stays fresh for 4-5 days refrigerated or 3 months frozen. Reheat gently with a splash of liquid to maintain moisture.

Step-by-Step Instructions for Pellet Grill Pulled Pork

Here’s the method. Straightforward, tested, works every time.

Step 1: Prepare and Apply the Dry Rub

Pat the 4 lb Pork Shoulder dry with paper towels, then coat all sides with 0.25 cup Yellow Mustard. This acts as a binder for the rub. In a bowl, combine 0.5 cup Brown Sugar, 2 tbsp Kosher Salt, 2 tbsp Black Pepper, 1 tbsp Paprika, 1 tbsp Garlic Powder, 1 tbsp Onion Powder, and 0.5 tsp Cayenne Pepper.

Massage the rub into the pork shoulder, ensuring an even coat on all surfaces. The mustard helps the spices adhere and creates a flavorful crust. Let the seasoned pork rest at room temperature for 30 minutes while you prepare the grill.

Step 2: Set Up the Pellet Grill for Low and Slow

Fill your pellet grill with 20 lb Pellet Grill Wood Pellets—hickory or applewood works best here. Preheat the grill to 225°F using the smoke setting. This temperature ensures a slow cook that breaks down the collagen in the pork, resulting in tender, fall-apart meat.

Once the grill reaches temperature, place the pork shoulder directly on the grates, fat-side up. The fat cap will render down during cooking, basting the meat and adding moisture. Close the lid and maintain the temperature at 225°F throughout the cook.

Step 3: Smoke and Spritz for Moisture

Smoke the pork shoulder undisturbed for 4-5 hours. After this time, check the pork and begin spritzing every 45-60 minutes with a mixture of 0.5 cup Apple Cider Vinegar and 1 cup Beer or Apple Juice. This keeps the exterior moist and adds a tangy layer of flavor.

Continue smoking until the internal temperature reaches 165-170°F. At this point, the pork may stall as the moisture evaporates. Wrap the pork shoulder in aluminum foil with 0.5 cup Butter to push through the stall and add richness.

Step 4: Finish and Rest the Pork

Return the wrapped pork to the grill and cook until the internal temperature reaches 200-205°F. This usually takes an additional 3-4 hours, depending on the size of the pork shoulder. The pork is done when a probe slides in effortlessly, like butter.

Remove the pork from the grill and let it rest, wrapped, for at least 1 hour. This resting period allows the juices to redistribute, ensuring every bite is moist and flavorful. Unwrap, shred with forks, and mix in 2 cups BBQ Sauce to taste before serving.

Health Benefits of These Flavors

Lean Protein Source

This dish delivers 40g of protein per 4oz serving, supporting muscle repair and growth. The slow cooking process preserves these nutrients better than high-heat methods. I notice my energy levels stay steady after eating a portion. 💪

Rich in B Vitamins

Pork shoulder is packed with B12, B6, and niacin, essential for metabolism and nervous system health. These nutrients help convert food into energy your body can use efficiently throughout the day.

Iron Boost

You’ll get about 15% of your daily iron needs from a single serving. The iron in pork is heme iron, which your body absorbs more easily than plant-based iron. This helps prevent fatigue and supports oxygen transport.

Collagen Benefits

The long cooking time breaks down collagen into gelatin, which supports joint health and digestion. This is why the meat becomes so tender – and why it’s so good for your connective tissues.

Low in Saturated Fat

When trimmed properly, pork shoulder contains less saturated fat than you might expect. The fat cap renders out during cooking, leaving you with about 7g per serving. This makes it a heart-healthier option than many cuts. 💛

Zinc Powerhouse

Each serving provides 25% of your daily zinc needs. This mineral is crucial for immune function and wound healing. I always feel like I’m giving my body a boost when I make this for my family.