Jalapeno Cheddar Sausage Recipe

Prepare casings

If using dried hog casings, soak them in warm water for at least 30 minutes, then flush with cold water until they are pliable and clear of salt. Keep submerged in clean water until ready to stuff.

Chill equipment

Place the bowl of a stand mixer (or mixing bowl), grinder parts, and knife/blade in the freezer for 15–30 minutes so meat and equipment stay cold during processing.

Prepare jalapeños and cheese

Seed and finely dice the jalapeños. If you prefer more heat, reserve some seeds. Cut the cold cheddar into approximately 1/4-inch cubes. Keep cheese chilled in the refrigerator until needed.

Season the pork

Cube the cold ground pork (if not already ground) and set it in the chilled mixer bowl. Evenly sprinkle kosher salt, ground black pepper, granulated sugar, paprika, garlic powder, onion powder, ground coriander, and cure #1 (if using) over the meat. Toss lightly to coat.

Emulsify with ice water

Add the ice water to the seasoned meat. Using a stand mixer with the paddle attachment or by hand, mix on low/medium speed until the mixture becomes sticky and tacky (about 2–4 minutes). This helps the proteins bind and hold the cheese and jalapeño pieces.

Fold in jalapeños and cheese

Remove the bowl from the mixer. Gently fold the diced jalapeños, chopped cilantro (if using), and cold cheddar cubes into the meat mixture by hand until distributed evenly. Avoid overmixing to keep cheese cubes intact.

Load stuffer and prepare casings

Assemble your sausage stuffer or use a sausage stuffing attachment on a grinder. Slip the soaked hog casing onto the stuffing horn, leaving a few inches hanging. Lightly spray the casing interior with water or use water to help slide it on.

Stuff the sausages

Fill the stuffer with the sausage mix and start feeding the mixture into the casing at a steady, moderate pace to avoid air pockets. Aim for links about 6 inches long. Once filled, twist links to separate and tie off ends with kitchen twine if desired. Prick any large visible air pockets with a needle and gently press out air toward the open end.

Dry the surface

Hang or place the stuffed sausages on a baking rack and refrigerate uncovered for 1–2 hours to dry the casing surface slightly. This helps the smoke adhere.

Preheat smoker

Preheat your smoker to 160–180°F (71–82°C) with apple or pecan wood. Place a small pan of water in the smoker to maintain moisture.

Cold smoke (optional for extra flavor)

If you want stronger smoke flavor without cooking, cold-smoke the sausages at 80–90°F (27–32°C) for 2–4 hours before hot smoking. This step is optional and only if you have cold-smoking capability.

Hot smoke to safe temperature

Arrange sausages on smoker racks, leaving space between each link for smoke circulation. Smoke at 225°F (107°C) until the internal temperature reaches 155°F (68°C), about 1–1.5 hours depending on thickness. Monitor with a probe thermometer.

Optional sear

For a crisper casing and extra color, finish sausages on a hot grill or skillet for 1–2 minutes per side after smoking, monitoring so cheese does not burst out.

Rest and serve

Let sausages rest 10 minutes after removing from heat. Slice or serve whole. Serve warm with mustard, pickles, or on a bun.

Refrigerate smoked sausages in an airtight container for up to 7 days (less if no cure used). For longer storage, freeze up to 3 months. If cure #1 was used and sausages reached proper temp, they will keep slightly longer in the fridge.