We used to buy our kolbász from a local butcher shop, but they seem to have changed their recipe. We don’t care for it as much, so we decided to try making our own. I refuse to buy mass-produced pre-packaged kielbasa – I really don’t like eating food that contains ingredients I can’t pronounce or identify as edible (what, for instance, is isolated soy product? And why does everything in the universe need to contain corn syrup? But I digress.)
The local grocery store had a good sale on pork last week, so I picked up a 9-1/2 lb. pork butt. It was pretty lean, but we happened to have about 1 lb. of pork jowl in the freezer (doesn’t everybody have pork jowls in the freezer for just such an occasion?)
Our recipe is a combination of different ingredients from many different recipe sources. Here are two of the books we own and refer to often and one particular Web site we like:
- Great Sausage Recipes and Meat Curing by Rytek Kutas (an encyclopedia of all types of sausage making – some parts are geared more to a commercial sausage-making establishment – but I can usually find an answer to a specific question in this book.)
- Charcuterie: The Craft of Salting, Smoking, and Curing by Michael Ruhlman and Brian Polcyn (a bit highfalutin’ – I doubt I’ll be preparing Shrimp, Lobster and Leek Sausage any time soon but, then again, who knows? – overall a good book with a lot of the basics illustrated and very clear instructions.)
- Len Poli’s Sonoma Mountain Sausages Web site (if you can’t find a recipe you like here, it doesn’t exist!)
Our Smoked Hungarian Kolbász recipe:
10 lbs. pork, trimmed of gristle and bone and cubed
For each pound of meat, these are the spices we use initially (we get to taste it later):
- 1/2 teaspoon salt
- 1/4 teaspoon pepper
- 1 teaspoon paprika (sweet Hungarian)
- 1/2 teaspoon dried marjoram
- 1/4 teaspoon dried savory
- 2/3 teaspoon good garlic powder (not garlic salt)
- 1/2 teaspoon yellow mustard seeds
For a 10 lb. batch, we use a total of these ingredients:
- 2 cups powdered milk
- 2 tablespoons sugar
- 1 teaspoon powdered mustard
- 2 cups liquid (we used 1-1/3 cups of water and 2/3 cups chardonnay wine)
Equipment We Use:
- A meat grinder (or you can have the store/butcher coarse grind it for you)
- A meat mixer (totally optional, but your hands will get very, very, very cold – trust me)
- A sausage stuffer (we prefer a manual stuffer)
- A smoker or grill for smoking the kolbász
So let’s get started.
Put your cubed meat into the freezer until partially frozen. This allows the grinder to cut the meat cleanly. Shallow trays or cookie sheets work great. Keep everything very cold from start to finish. We even put the grinder parts in the freezer. Luckily, the weather cooperated and it was cold enough outside to chill our mixer, too. That definitely doesn’t fit in the freezer.
We mix the seasonings, powdered milk and the liquid together, blend well and let sit in the fridge for a while to meld the flavors.
Make sure the casings are well rinsed. Ours were packed in salt to preserve them, so we rinse them out with water (just find an end, put it over the faucet end and run water through the casings to flush out any excess salt). Let soak until you’re ready to stuff the sausage. These are 42mm casings we got from the butcher shop. By the way, casings packed in salt last practically forever.
Please excuse the mess. One small kitchen + one large temporary game processing table because it’s deer season = a total disaster. In spite of the clutter, we’re ready to start processing. Our meat is “crunchy” and the grinder is assembled. Time to grind the meat.
Here’s our pork coming out of the grinder. Looks good so far. Keep the ground meat in the refrigerator (or the freezer if it’s not for too long – you don’t want it frozen solid) until you’re ready to begin mixing. Just keep everything very cold.
Put the ground meat into a mixer or a very large pot or bucket if you’re going to mix it by hand.
Thoroughly mix the seasoning liquid into the meat, while retaining the texture and not “mushing” the meat. This is hard to do when you’re mixing by hand – your hands will be numb from the cold and your arms will hurt from trying to stir with a spoon. We did it that way for years, so I literally feel your pain. If using a mechanical mixer, don’t overmix the meat. We did ours for only about a minute.
Here’s where you get to taste it. Take a small ball and make a patty. Fry in a pan until cooked through and check the seasonings. Don’t try to cook it in a microwave – you won’t get the same flavor as frying it on the stove.
We needed a bit more salt (about another tablespoon), a bit more sugar (about a tablespoon), and a bit more liquid. We mixed the salt and sugar into another 1/4 cup of chardonnay and mixed the meat for just a few more seconds. We’ve learned it’s better to slightly under-season the sausage if you’re not sure.
Here’s what our meat looks like after mixing. Still a lot of texture but the orange from the paprika is pretty evenly disbursed throughout.
Chill the meat until you’re ready to begin stuffing. You can leave it in the fridge overnight if you like (especially if you’ve mixed by hand – you’ll need a break).
Lightly pack the meat into your stuffer. This is a hand-cranked one that holds about five pounds of meat.
Thread the rinsed casing onto the nozzle of the stuffer. Push a tiny bit of meat out to get any air bubbles out of the nozzle and the casing. Tie off the end with a piece of cotton string. (I know the picture looks vaguely “suggestive”, but that’s really what it looks like.)
Casings are pretty sturdy and they will stretch quite a bit. Stuffing is one of those things that you just have to practice.
Stuffing is easier with two people – one to crank and the other to form the sausage. BarBBQ Bill cranks and I make sure the casing is evenly filled (don’t overstuff or the casing can split) and keep as much air out of the sausage as possible. If I get any huge air bubbles in the sausage, I just prick it with a needle or pin.
We’re making “horseshoes” about 20″ long. It also helps to put some water on the table so the sausage glides around and doesn’t stick to the countertop. When they’re long enough, stop cranking the stuffer and tie off the end tightly with another piece of string. Leave the string ends about 4-6″ long, so you can hang these after smoking. Tie another piece of string about an inch or so away from the sausage end (this will be the beginning of the next horseshoe) then cut between the two pieces.
We’re done stuffing. This batch (which was actually 10 lbs. 13 ozs. of meat) yielded six “horseshoes” and a short link about 6″ long. Put them into the refrigerator overnight, uncovered, to blend the flavors and dry the casings slightly.
The next day, we’re ready to smoke them. We have a smoker box in our gas grill – if you don’t have one of those, just make a pouch of heavy-duty aluminum foil, fill with soaked wood chips, poke a few holes in the top, and put it right on the grill. BarBBQ Bill is using a bit of mulberry wood, some pecan chips and some apple chips.

Here’s our kolbász after about an hour. The one on top closest to the smoker box (the warmest spot) is already starting to turn color. The fire bricks act kind of like a pizza stone to absorb the heat and they also protect the sausage if the wood in the smoker box happens to catch on fire (that’s pretty normal).
Another hour and the color is deepening (and the porch smells really, really good). Smoke the kolbász until the internal temperature is 150°F. It took ours a little over three hours to reach that temperature (and it was about 38° outside for reference).
These are done smoking.

Drop the kolbász into an ice bath and bring the temperature down to about 90°.
Then hang at room temperature overnight to cure. For long-term storage, we’ll vacuum seal and freeze them.
These have an incredible aroma of sweet, fruity, nutty woodsmoke and garlic and I just wish you could smell them right now!