Smoked Poblano Shells and White Cheddar

July 13, 2026

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This Poblano Shells and White Cheddar combines tender shells and diced poblanos in a velvety-smooth white cheddar sauce, all topped with a fiesta breadcrumb topping and kissed with smoke. You can make this mac on your smoker in under an hour, and it beats the box off the store-bought stuff!

Smoked Poblano Shells and White Cheddar

This Poblano Shells and White Cheddar takes classic shells and cheese and turns it into something that will have guests at your cookout begging for the recipe. When we were dating and first married, Todd and I lived on boxed shells and cheese. It’s cheap, fast, and easy to make when you’re just learning. This version takes the simple staple and dials up the flavor. Smoky poblanos, a fiesta breadcrumb topping for crunch, and hand-shredded cheddar and mozzarella instead of a powder packet give this nostalgic dish a much-needed upgrade.

It still comes together fast, but it tastes like something you’d actually serve at a cookout instead of eating while you stand over the stove. Give this one a try and you’ll never look at the boxed stuff the same way again.

Ingredients for Poblano Shells and White Cheddar

You don’t need a bunch of fancy ingredients for this one. Grab yourself a couple poblano peppers from the produce section of the grocery store near the jalapeños. The rest are common ingredients you’ve likely got on hand already. Here’s what you’ll need so you can get started:

1 pound medium shell noodles
2 poblano peppers (stems and seeds removed, and finely diced)
4 cloves garlic (grated)
½ cup salted butter
1 Tablespoon ground mustard powder
⅓ cup all-purpose flour
2 cups half and half
4 ounces cream cheese (softened)
3 cups extra sharp white cheddar (hand-shredded)
1 ½ cups mozzarella cheese (hand-shredded)

Fiesta Breadcrumb Topping

This breadcrumb topping is totally optional, but you won’t regret sprinkling it on top of your shells. The crunch of the breadcrumbs contrasts the silky cheese sauce beautifully, and the Fiesta Rub adds a little kick of heat to complement the poblanos.

To make the panko topping, add the melted butter to a small bowl, then add in the breadcrumbs and Fiesta Rub. Stir everything together with a fork to combine, then set aside until your mac and cheese is ready to smoke.

If heat isn’t your thing, you can also make a sweet BBQ version of this topping using my signature Sweet Rub!

What Temperature for Smoking Mac and Cheese?

When smoking the mac and cheese, you’re really just looking to add smoky flavor and crispy texture. Everything will be cooked before hitting the smoker, so you want to go with a low-and-slow 225 degrees F. You can do this on your favorite smoker (or grill with two-zone heat). This lower temperature gives the wood smoke time to work its magic without breaking down the cheese sauce or overcooking the noodles.

How to Make Smoked Poblano Shells and White Cheddar

These shells are so good your guests will think the recipe is super complicated, but you just need to follow these easy steps:

Set up. Preheat the smoker to 225 degrees F, cook the shells to al dente according to the package instructions, prepare the fiesta topping, and use a sharp knife to finely dice the poblanos.
Cook the poblanos and garlic. Melt ½ cup of salted butter in a 14-inch cast iron skillet over medium heat, then add the diced poblanos and cook for 3 to 4 minutes or until softened. Next, add the grated garlic and cook for 1 to 2 minutes until fragrant.
Make the cheese sauce. Add the ground mustard powder to the peppers, then add the all-purpose flour. Whisk well until no lumps remain, then slowly pour in the half and half while stirring constantly. If you like a saucier mac, add an extra ½ cup. Next, add the softened cream cheese and stir with a wooden spoon until the sauce is smooth and creamy. Finally, stir in the hand-shredded cheeses and stir until the sauce is fully melted and silky.
Add the pasta and topping. Pour in the drained pasta and stir gently until the sauce fully coats all of the noodles. Sprinkle the prepared topping over the top of the shells.
Smoke the mac and cheese. Transfer the skillet to the smoker preheated to 225 degrees F, then close the lid. Smoke for 20 to 30 minutes for a light smoke and crispy, golden topping. If you want heavier smoke and a casserole-style texture, smoke for up to 1 hour.
Serve and enjoy. When your mac is smoked exactly how you like it, remove the skillet to cool for a few minutes. Serve warm with some smoked ribs, chili, or cornbread!

What to Serve with Poblano Shells and White Cheddar

Now that you know how to make this Poblano Shells and White Cheddar, let’s round out the cookout menu with some tasty options:

Storage and Reheating

These shells and white cheddar are super filling, so don’t be surprised if you end up with extra. The good news is leftovers store easily and taste even better the next day! Simply place any remaining shells in a gallon-size zip-top bag or other airtight container, then place in the refrigerator to enjoy for 3 to 4 days. When you’re ready to enjoy more, just reheat slowly over medium-low heat until warmed through. That’s it!

More Smoked Side Dish Recipes

Smoking and grilling meats is fun, but nothing beats putting together a full spread right in your own backyard to feed the people you love. I’ve got dozens of sides you can browse right here on the https://homefrontking.com/, as well as in the Hey Grill Hey App. For now, check out these popular side recipes:

Poblano Shells and White Cheddar Recipe

Give this Poblano Shells and White Cheddar recipe a try this weekend, then make sure to come back so you can drop a rating and comment below! I love hearing how your recipes turn out!

If you’re not already, make sure you’re following me on Instagram and Facebook, and that you’re subscribed to my YouTube channel. Then you can tag @heygrillhey when you post those drool-worthy photos of your shells and cheese so I can cheer you on!

Fiesta Breadcrumb Topping

Preheat the smoker. Set your favorite smoker (or grill with two-zone heat) up at around 225 degrees F with a mild wood like alder or a fruit wood.
Cook the pasta. Bring a large pot of salted water to a boil. Cook 1 pound medium shell noodles for 8 to 9 minutes until just al dente. Drain and set aside.

1 pound medium shell noodles
Cook the poblanos and garlic. Melt ½ cup salted butter in a 14-inch cast iron skillet over medium heat. Add 2 poblano peppers, stemmed, seeded, and finely diced and cook for 3 to 4 minutes until softened and fragrant. Add 4 cloves grated garlic to the skillet and cook for 1 to 2 minutes, or until fragrant.

2 poblano peppers, 4 cloves garlic, ½ cup salted butter
Make the cheese sauce. To the peppers and garlic, stir in 1 Tablespoon ground mustard powder, then add ⅓ cup all-purpose flour. Stir well until no lumps remain. Slowly pour in 2 cups half and half, stirring constantly. For a saucier mac and cheese, add an extra ½ cup. Add 4 ounces softened cream cheese and stir until the sauce is smooth and creamy. Add 3 cups extra sharp white cheddar and 1 ½ cups mozzarella, and stir until fully melted and silky.

⅓ cup all-purpose flour, 1 Tablespoon ground mustard powder, 2 cups half and half, 4 ounces cream cheese, 3 cups extra sharp white cheddar, 1 ½ cups mozzarella cheese
Add the pasta. Pour in the drained pasta and stir gently until the sauce fully coats all of the noodles.
Make the panko topping. In a small bowl, combine 1 cup panko breadcrumbs, ⅓ cup melted butter, and 1 Tablespoon Fiesta Rub. Stir to combine, then sprinkle evenly over the top of the mac and cheese.

1 cup panko breadcrumbs, ⅓ cup salted butter, 1 Tablespoon Hey Grill Hey Fiesta Rub
Smoke the mac and cheese. Transfer the skillet to a smoker preheated to 225 degrees F. Smoke for 20 to 30 minutes. For a light smoke and crispy golden topping, or up to 1 hour for a heavier smoke and casserole-style texture.
Serve and enjoy. When your mac is smoked to your preference, remove the skillet to cool for a few minutes, then serve with your favorite smoked meats, some crusty bread, or any other sides you love with mac and cheese!