1. Build Quality and Materials: How to Get More than You Pay For.

Build quality is directly connected to how much you will enjoy your grill. Lightweight materials might save money on the initial purchase, but they’ll wear out faster and make it difficult for your grill to maintain consistent temperatures — both of which will cost more money on the back end. Build and material features that indicate a high-quality pellet grill include:

• Heavy Gauge Steel – A lower gauge number indicates a thicker sheet of metal, with construction grade — or 10-gauge — steel being a marker of a high-quality cooking chamber and 14-gauge steel suitable for other grill parts. Lower-quality steel and aluminum grills will have a considerably shorter lifespan and struggle with temperature regulation.
• Welded Joints – A grill that is welded is much stronger than a grill that has been put together with screws so that it can be shipped in a smaller package. Welded pellet grills also reduce the possibility of leaks and rust and require less maintenance as they contain fewer areas that are susceptible to wear and tear.

2. True Versatility: Don’t Fall for the “Temperature Range” Trap

Pellet grills are known for their versatility, but not all models are created equal. Most grills will give you an expected temperature range because everyone knows that a good pellet grill should go low enough for smoking (around 200°F) and high enough for searing (above 500°F). However, pay attention to how the heat is delivered because temperature range isn’t the only marker of versatility, and a quality pellet grill will offer a variety of ways to transfer heat to your food through:

• Open Flame – If you want steaks and burgers with a perfect crust, look for a pellet grill that offers over-the-flame grilling. There should be the option to cook without blocking the fire with a heat diffuser, as a grill that can achieve searing temperatures but doesn’t expose your food to flame is still just an oven, and you’ll likely be unsatisfied with the results.
• Branded Accessories – A brand that is confident in its grill’s versatility will also spread its commitment to quality across the entire range of accessories. A cast iron griddle or pizza oven shouldn’t feel like it was an afterthought that sits on top of the grates. It should slide perfectly into place, efficiently use the grill’s heat source, and work seamlessly with little modification to the grill.

3. Cooking Space: More is Better Than Not Enough

We never hear, “I wish I had bought a smaller grill,” but we hear the opposite all the time. Cooking space matters more than you might think, especially if you plan to entertain or cook for a crowd. Even if you’re just grilling for your family, having the extra space to cook various foods in multiple heat zones, like chicken, veggies, and other side dishes, can make your grilling more enjoyable and less stressful.

More cooking space also allows for more airflow. When smoking food, airflow is crucial because you want that flavor to pass over every inch of your food. Food that is pushed together disrupts airflow and will not have as much smoke flavor.

Think about how you’ll use your grill. Are you a weekend warrior who loves smoking multiple racks of ribs or briskets? Or do you simply want enough room to flip steaks for two? Either way, erring on the side of more space gives you the flexibility to expand your menu when inspiration strikes. It’s better to have it and not need it than to need it and not have it!

4. Warranty and Support: Find Out Who is Really There For You

A solid warranty says a lot about a brand’s confidence in its product, and they tend to vary broadly. We’ve seen manufacturers offer everything from no warranty to a ten-year warranty. But even seemingly comprehensive warranties can get convoluted, so you’ll want to be on the lookout for some specific warranty features:

• Cooking Chamber Warranty – This will likely correspond with the quality level of materials. If the cooking chamber warranty is less than five years, you can reasonably assume it will be susceptible to rusting out. And once the integrity of your cooking chamber breaks down, it’s time to start shopping for a new smoker again.
• Component Warranty – You’ll want to ensure that key components like the fire pot, auger, and electronics are warranted for at least three years. Unlike the cooking chamber, these can typically be easily replaced to extend the life of your grill.

Equally important is customer support. Do a little research to see how responsive the company is to issues. Call or visit the store you’re considering buying from and ask about the grill. Call or email the manufacturer and ask questions. You’ll find out quickly who will be there for you when you need them. Reliable support can make all the difference if you ever encounter a problem, especially when you are mid-cook with a crowd waiting for food!

And in this information age, see what online resources are available both from the manufacturer and third parties. Check YouTube reviews and roundup reviews from quality publications, as well as online resource pages like blog articles, instructional videos and recipes that are offered by manufacturers.

Best Place to Start: The Yoder Smokers YS640S

Now, take the above criteria and try them out on the grill that was named:

• Field & Stream’s Best Smoker of 2024
• Food & Wine’s Best Professional Grade Grill of 2024
• Wall Street Journal’s Best Luxury Grill of 2024
• Popular Mechanic’s Best Overall Pellet Grill of 2024

That grill is the Yoder Smokers YS640S. We think you should definitely check it out, and we also encourage you to see how other grills you’re considering stack up relative to our outlined criteria. And if at all possible, find a local retailer where you can find different grills on display so that you can see how they look and feel first-hand.

Final Thoughts

Buying a pellet grill doesn’t have to be overwhelming. Focus on quality materials, versatile temperature control, efficient pellet usage, features that match your style, and a reliable warranty. With these tips in mind, you’ll find a grill that suits your needs and keeps you cooking up incredible meals for years to come.

Remember, we’re always here to chat if you have questions. Chat online at www.ATBBQ.com or call us at 316.440.3950.

Happy grilling!