Smoked Pork Loin Recipe Pellet Grill: Low and Slow to Juicy Succulence

My first whiff of hickory smoke still takes me back to those family cookouts. This method marries that nostalgia with French precision for juicy, tender pork loin every time.

Pellet grills make it foolproof—set the temperature, let the smoke work its magic, and trust the process. The result is meat so succulent it falls apart at the touch of a fork.

Ingredients for Smoked Pork Loin Recipe Pellet Grill

Simple rub, quality pork, and hickory smoke create that perfect cookout nostalgia.

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The pork loin is the hero here. Bone-in or boneless both work, but boneless is easier to slice evenly. Aim for a 3-4 lb roast with a nice fat cap—this keeps it juicy during the long smoke. Costco and Sam’s Club have great options, or ask your butcher for a center-cut piece. Let it sit at room temp for about 30 minutes before seasoning (worth the extra minute).

No hickory pellets? Apple or cherry wood gives a sweeter, milder smoke. Swap garlic powder for fresh minced garlic (3 cloves), but the dry version spreads more evenly. Dijon can be replaced with yellow mustard at half the quantity. If you’re out of brown sugar, maple syrup works in a pinch—just brush it on instead of mixing into the rub.

Store uncooked pork in the fridge for up to 3 days, or freeze for 6 months. Leftovers? Wrap tightly and refrigerate for 4-5 days—reheat gently in a skillet with a splash of broth to keep it moist (don’t skip this part).

Step-by-Step Instructions for Smoked Pork Loin on Pellet Grill

Here’s the method I use to get fall-apart tender meat with a perfect bark every time.

Step 1: Create the Dry Rub and Prep the Pork Loin

In a small bowl, combine the 2 tbsp Kosher Salt, 1.5 tbsp Coarsely Ground Black Pepper, 1 tbsp Garlic Powder, 1 tbsp Onion Powder, 1 tbsp Smoked Paprika, and 1 tsp Dried Thyme. I rub the thyme between my fingers first to release its oils.

Pat the 3 lb Pork Loin completely dry with paper towels. This ensures the rub adheres properly and helps form that beautiful crust. Then, brush the entire surface with the 0.25 cup Dijon Mustard—it acts as a binder for the spices and adds a subtle tang.

Coat the pork loin evenly with the dry rub mixture, pressing it into the meat so it sticks. Don’t be shy; you want a generous layer. Let it sit at room temperature for 30 minutes while you prep the grill.

Step 2: Set Up the Pellet Grill and Add Smoke Flavor

Load your pellet grill with the 2 cups Hickory Wood Pellets. I prefer hickory for pork because it gives a robust, slightly sweet smoke flavor that complements the meat perfectly. Set the grill to 225°F and let it preheat for 10-15 minutes to stabilize the temperature.

Once the grill is ready, place the pork loin directly on the grates, fat-side up. The fat will render down during cooking, basting the meat and adding moisture. Close the lid and let the grill do its work—resist the urge to peek, as every time you open it, you lose heat and smoke.

Step 3: Smoke Low and Slow with Occasional Spritzing

Smoke the pork loin undisturbed for 2 hours. After that, I like to spritz it every 45 minutes with a mixture of the 2 tbsp Apple Cider Vinegar and 2 tbsp Olive Oil. Just combine them in a spray bottle and give the pork a light mist. This keeps the surface moist and helps build that sticky, flavorful bark.

Continue smoking until the internal temperature reaches 145°F in the thickest part of the loin. This usually takes about 3-4 hours total, depending on your grill and the size of the pork loin. Use a reliable meat thermometer—guessing can lead to dry or undercooked meat.

Step 4: Rest and Slice for Maximum Juiciness

Once the pork loin hits 145°F, remove it from the grill and transfer it to a cutting board. Tent it loosely with foil and let it rest for 15 minutes. This is non-negotiable; resting allows the juices to redistribute, so every slice stays moist and flavorful.

While it rests, mix the 1 tbsp Brown Sugar with a little of the leftover dry rub and sprinkle it over the top if you want extra caramelization. Slice the pork loin against the grain into ½-inch thick pieces. The meat should be tender and juicy, with a beautiful smoke ring and a crust that crackles slightly with each cut.

Creative Variations of These Flavors

Apple Wood Sweetness

Swap the Hickory Wood Pellets for apple wood to create a milder, sweeter smoke profile. This pairs especially well with a 1 tbsp maple syrup addition to the Dijon mustard binder. I love this for spring cookouts when I want a lighter touch. 🌸

Spicy Coffee Rub

Add 1 tbsp finely ground coffee and 1 tsp cayenne pepper to your dry rub for a bold, smoky heat. The coffee deepens the crust color while adding complexity. I discovered this blend at a local BBQ competition and it’s been my go-to for impressing guests.

Herb-Crusted Version

Mix 1 tbsp fresh rosemary and 1 tbsp fresh sage (finely chopped) into your rub. I forage these herbs along coastal rides—their piney aroma pairs beautifully with pork. Brush with olive oil before applying the rub for better adherence.

Asian-Inspired Glaze

Replace the Dijon with a glaze of ¼ cup hoisin sauce and 1 tbsp soy sauce. Spritz with the apple cider vinegar mix every 30 minutes during the last hour. This creates a sticky, umami-rich crust that reminds me of my French technique training with global flavors.

Brown Sugar Crust

Increase the Brown Sugar to 3 tbsp in your rub for a sweeter, caramelized bark. Mix it with 1 tsp cinnamon for warmth. The sugar will create a beautiful, glossy finish that looks as good as it tastes. 💛

Beer-Braised Finish

During the last 30 minutes of smoking, place the pork in a foil pan with ½ cup dark beer. The steam keeps it moist while adding malty depth. I use a local craft stout from our coastal breweries—it’s a game-changer for depth of flavor.