How to Cook Frozen Burgers on Pit Boss Pellet Grill (3 Super Simple Steps)

Don’t be ashamed of those frozen patties in your freezer!

We all have to choose convenience sometimes!

Plus it is easy to grill burger patties from frozen.

I do this all the time as a midweek meal instead of making my own from scratch

However your frozen hamburger can turn to mush if you don’t do this right

So make sure you follow my steps

Frozen Burgers Are so Damn Convenient

Frozen burgers are widely accessible in any supermarket.

They are also an easy contender for a hot grill in your favorite burger recipes.

Frozen burger patties can be kept for long periods so you don’t have to worry that your burger meat has spoiled.

Choose as per your favorite burger seasoning like Cajun or BBQ.

Check the meat content is above 90% for a preferred flavor you would expect from a freshly made one.

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Why Is Grilling on a Pit Boss Our Preferred Method of Cooking?

What are the benefits of grilling from frozen on a Pit Boss?

  • It adds a depth of smoky flavor to the meat
  • Easy tools to monitor throughout the cooking process

What You Need for Declious Burgers

  • 4-ounce burgers (frozen) per serving 
  • Burger buns as per serving
  • Slice of cheese as per serving (I used classic American cheese)
  • Olive oil or cooking spray of your choice
  • Kosher salt 
  • Black pepper
  • Store-bought barbecue sauce
  • 1 fresh salad tomato 
  • Iceberg lettuce 
frozen-burgers-on-pellet-grill-1

Aioli Ingredients 

  • 2 egg yolks
  • 2 crushed garlic cloves
  • Bit of salt
  • 1 cup extra virgin olive oil
  • 1 tsp lemon juice
  • 1 tsp cold water
  • 1 tsp Dijon mustard
  • Dash of Worcestershire sauce

Equipment

  • Pit Boss Pellet Grill
  • Smoker chips
  • Meat thermometer
  • Mixing bowl
  • Paper towel
  • Sharp knife
  • Foil
  • Spatula 
  • BBQ Brush
  • Food processer 
  • Plastic wrap
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What Are the Differences Between Frozen Burgers & Fresh Burgers?

So what is the difference when it comes to cooking burgers frozen or fresh?

Other than obviously the temperature there are some key differences.

  • Frozen burgers will have a higher fat content than fresh
  • Frozen burgers will take longer to grill than fresh
  • Frozen burgers should not be left pink in the middle but fresh burgers can
  • Frozen burgers tend to be seasoned with herbs, spices, and even veg
  •  Fresh burgers are usually ground chuck beef

Want More Burger Recipes?

Get the best burger recipes here

Smoked Burgers

Beer Can Burgers

Brisket Burgers

Cedar Plank Burgers

Why Don’t We Defrost the Burgers?

So why don’t we just defrost the meat before grilling?

Apart from time-saving, we won’t defrost because it will change the texture of the meat. 

Thawing frozen patties will make them mushy.

You also wouldn’t be able to get a good sear from residual moisture in the protein. 

There is a likelihood that the inside would still contain frozen meat.

Frozen meat will cook unevenly and risk food poisoning. 

Do I Still Season Frozen Burgers?

Do I still season my frozen patties?

Yes! 

We should bask the burgers while they are cooking with seasoning and a condiment of your choice.

Adding this provides seasoning for extra flavor.

It can also introduce moisture and evade the chance of a dry burger. 

Although the timings are going to be different.

Start basking halfway through the cooking process. (10 minutes)

How Do I Prepare Frozen Burgers?

A perfect burger needs little prep time!

Follow the recommended instructions on your frozen burger packaging.

Mix up your condiment with the seasoning of your choice.

Get your Pit Boss Pellet Grill ready as per the instructions below.

What Temperature Should I Be Cooking Frozen Burgers on a Pit Boss?

What temperature should I set the Pit Boss for my frozen hamburger patties?

First, you should check as per the manufacturer’s instructions on the packaging.

You will likely be grilling hot and fast with direct heat at around 300°F-325°F

This high temperature will help evaporate excess water and form a tasty outer crust. 

What Internal Temperature Should the Burgers Be Before Eating?

What internal temp do the burgers need to be before eating?

A careful measure of the internal temperature is important for any meal… Especially when it comes to the meat that was frozen.

Use temperature probes for an accurate reading.

Insert the probes into the thickest part of your biggest pattie! (You might have to wait until they have cooked a little first)

The required internal temperature is 165°F before consumption. 

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What Is the General Cooking Time for Frozen Burgers on a Pit Boss?

The cooking time for an entire burger should be around 15-20 minutes.

What if I Don’t Have a Pit Boss Pellet Grill?

What if you don’t have a Pit Boss electric pellet smoker?

A charcoal smoker, gas grill, or charcoal grill works but is just not as efficient or accurate.

Making the Aioli

Freshly made mayonnaise with garlic is a perfect accompaniment to the beefy flavor.

Don’t be disheartened, it minimal effort with a food processor!

– Combine the garlic, salt, yolks, and mustard in a food processor on the lowest setting.

– With a slow and steady stream, add the oil into the mix and wait until it forms into a thick consistency. 

– Transfer to a bowl.

– Fold in the lemon juice and water.

Cover with plastic wrap and refrigerate until use. 

Frozen Beef Burgers With Homemade Aioli on a Pit Boss Pellet Grill

I want this recipe to inspire you, even when you are using frozen ingredients.

The Pit Boss pellet grill’s functionality makes it a tasty dream.

The hardest part is prying the frozen patties to throw on those cooking grates!

As ever, be creative in your seasonings and condiments. 

I enjoy basking the burgers with simple BBQ sauce, salt, and black pepper.

You could also add paprika for a smoky kick!

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Our Method for Smoked Frozen Burgers on a Pit Boss Pellet Grill

Step 1: Preperation of Ingredients & Pit Boss 

– Slice your tomatoes, lettuce & hamburger buns.

Mix the BBQ sauce, salt, pepper, and oil into a bowl.

– Gather and prepare the Aioli ingredients.

– Load your chosen type of wood chips, prime, and set the Pit Boss to temperature settings of 325°F and wait until up to temp.

– Lightly cover the Pit Boss cooking grate with oil.

Step 2: Grilling the Frozen Burgers & Making the Aioli

– Place your frozen burgers on the Pit Boss.

– Monitor them during the cooking process and bask with the sauce mixture every 2 minutes. 

– Flip the patties after 10 minutes or when you can see a crust has formed on the underside.

Bask the other side every 2 minutes.

– Remove when the probe reaches 165°F.

Rest for 5 minutes in tin foil with the cheese on top.

Step 3: Making the Aioli 

Make the aioli as per the instructions above while the burgers finish cooking and rest.

Step 4: Building the Ultimate Burger & Enjoy

– Build your burger with the bun, lettuce, tomato, and aioli.

– Enjoy!

Frozen Burgers on Pit Boss

Frozen hamburger patties are widely available and are easy and delicious to prepare on a Pit Boss.
Prep Time5 mins
Cook Time15 mins
Total Time20 mins
Course: Appetizer, Dinner, lunch, main, Main Course, Side Dish
Cuisine: American, Barbecue, bbq, dinner, grill, lunch
Servings: 4 servings
Calories: 267kcal
Author: Charlie
Cost: 20

Equipment

  • Pit Boss Pellet Grill
  • Smoker chips
  • Meat thermometer
  • Mixing bowl
  • Paper towel
  • Sharp knife
  • Foil
  • Spatula
  • BBQ brush
  • Food processer
  • Plastic wrap

Ingredients

  • spray of your choice
  • Kosher salt
  • Black pepper
  • Store-bought barbecue sauce
  • 1 fresh salad tomato
  • Iceberg lettuce

Aioli Ingredients

  • 2 egg yolks
  • 2 crushed garlic cloves
  • Bit of salt
  • 1 cup extra virgin olive oil
  • 1 tsp lemon juice
  • 1 tsp cold water
  • 1 tsp Dijon mustard
  • Dash of Worcestershire sauce

Instructions

Making the Aioli

  • Combine the garlic, salt, yolks, and mustard in a food processor on the lowest setting.
  • With a slow and steady stream, add the oil into the mix and wait until it forms into a thick consistency.
  • Transfer to a bowl.
  • Fold in the lemon juice and water.
  • Cover with plastic wrap and refrigerate until use.

Frozen Beef Burgers With Homemade Aioli on a Pit Boss Pellet Grill

  • I enjoy basking the burgers with simple BBQ sauce, salt, and black pepper.
  • You could also add paprika for a smoky kick!

Step 1: Preperation of Ingredients & Pit Boss

  • Slice your tomatoes, lettuce & hamburger buns.
  • Mix the BBQ sauce, salt, pepper, and oil into a bowl.
  • Gather and prepare the Aioli ingredients.
  • Load your chosen type of wood chips, prime, and set the Pit Boss to temperature settings of 325°F and wait until up to temp.
  • Lightly cover the Pit Boss cooking grate with oil.

Step 2: Grilling the Frozen Burgers & Making the Aioli

  • Place your frozen burgers on the Pit Boss.
  • Monitor them during the cooking process and bask with the sauce mixture every 2 minutes.
  • Flip the patties after 10 minutes or when you can see a crust has formed on the underside.
  • Bask the other side every 2 minutes.
  • Remove when the probe reaches 165°F.
  • Rest for 5 minutes in tin foil with the cheese on top.

Step 3: Making the Aioli

  • Make the aioli as per the instructions above while the burgers finish cooking and rest.

Step 4: Building the Ultimate Burger & Enjoy

  • Build your burger with the bun, lettuce, tomato, and aioli.
  • Enjoy!

Smoke On!

Charlie

Author: Charlie Reeves
Hi, I’m Charlie, I am head taste tester at Simply Meat Smoking! I love it grilling, smoking, and getting out in the yard with the kids! The family also love to test all my recipes (especially my EXTRA CRISPY pulled pork, smoky pork loin, and ANY SEAFOOD I grill)

You will usually find me playing with the kids, perfecting my brisket bark, or sipping beers with boys around the fire. Can’t wait to share all my delicious smoking and grilling adventures with you!

You can read more on our About Us page.

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