The origins of barbecue in the United States are diverse and have collectively contributed to its prominence in American food culture. One notable origin is Central Texas Barbecue, which began in small towns in the geographic area where German and Czech butchers smoked meat, particularly cuts that were less desirable as fresh items. Sausage making, influenced by European traditions, was integral to these establishments with recipes being passed down through generations. Smoking sausages added flavor and extended their shelf life, making it a convenient ready-to-eat item for customers.
The contribution of meat markets to the barbecue scene, at least in the Southern part of the United States, was influenced by Jim Crow laws that enforced racial segregation in such places as restaurants where minorities were forced to use separate entrances, eat in designated locations, or were served only takeout. Meat markets did not have these same restrictions, so people would go into them and purchase smoked meats, including sausages, get some bread or tortillas, cheese and other items to make a meal. Over time, these smoked products, especially sausage, served in this manner gained popularity with a wider audience and became a foundation for our love affair with this style of food.
Sausage ultimately gained fame as part of the Texas Trinity, alongside brisket and pork spareribs, forming the core of Texas Barbecue. In the 20th century, ordering one-, two-, or three-meat plates or buying meat by the pound on butcher paper became common. Sausage, being the least expensive of these proteins, was often added to catering meals to keep costs low.
How the sausage is made
Sausage manufacturing is both an art and science. Its roots began as a way to use trimmings from beef and pork carcasses by grinding or chopping them with added seasonings then stuffing into natural casings before smoking. Although these steps seem to be straightforward, each one requires great skill, knowledge, and experience to produce consistently great sausage.
Historically, the sausage maker was the most skilled expert whose experience led to creating masterpieces that differentiated one establishment from another.
As barbecue restaurants became standalone entities where raw materials were sourced to cook onsite, sausage became a commodity that was purchased rather than was made. This allowed restaurants to focus on the more difficult and longer tasks of cooking and smoking briskets, pork shoulders and other items. Sausage, for the most part, simply had to be reheated, sliced, and served, and in some ways, became relegated to being the least important part of the protein menu.
Source: ©CAVAN - STOCK.ADOBE.COMSausage crafting
While there remained a handful barbecue restaurants that always made their own sausage, more recently there has been a resurgence of eateries where manufacturing sausage is done in-house. This probably coincides with the development of what is referred to as craft barbecue, and the desire to make dining experiences memorable. These restaurants pay special attention to each item including sides and desserts bringing a level of culinary expertise and social media photography worthiness to everything they do. Some of these pitmasters have culinary training and others call on their ethnic backgrounds to infuse Asian and Hispanic flavors and ingredients. All foods have been influenced, but manufacturing sausage in-house with attention to adding unique ingredients and flavors has been taken to a new level.
Some examples of these craft sausages include Hurtado Barbecue’s Wagyu All Beef, Eaker Barbecue’s House Made Hill Country Sausage and House Made Jalapeño and Cheddar Sausage, Stiles Switch Sausage of the Month for May 2025, The Beef Merguez Sausage, “all-beef sausage inspired by original recipes dating back to the 12th Century” that includes cumin, coriander, paprika, cayenne, cinnamon, garlic, and fennel along with fresh cilantro and mint. These examples showcase products that the forefathers of barbecue with their humble roots would never have dreamed of.
Ensuring safety
As with all food preparation, following food safety guidelines and regulations are important. With sausage being a non-intact product, it is important to ensure that minimum cooking temperatures and times are met, and if products are to be chilled before serving, that proper chill down temperatures are followed. Restaurants must remember that although making sausages for their customers is perfectly acceptable from a regulatory standpoint, these products cannot be sold to other restaurants for their use without following appropriate inspection requirements.
With the popularity of online ordering, many of the barbecue restaurants ship their products, including sausage, around the country. Kansas City’s Fiorella’s Jack Stack Barbecue has mail order options for its barbecue sausage in one to seven 1-lb packs. Kreuz Market ships a Mixed Sausage Box that includes a combination of 25 of the Original Sausage and Jalapeño Cheese Sausage. Snow’s BBQ offers both their Original Sausage and Jalapeño Sausage as part of their way of ensuring that people who cannot make the trip to Lexington, Texas, can enjoy their highly demanded products, too.
While some might debate whether these are officially sausages, their uniqueness and similarities to sausage are worth noting. Elgin, Texas-based Southside Market & BBQ has a Sausage Slammer that is a “house-made pork sausage stuffed with a cheddar-filled jalapeño half and then wrapped in bacon.” Hutchins Barbeque, in Frisco and McKinney, has a Texas Twinkie that is a “jalapeño stuffed with brisket and cream cheese and wrapped in premium thick-cut bacon.”
Smoked sausage has become a staple in today’s barbecue world, evolving from its humble beginnings to a celebrated culinary delight that allows pitmasters to showcase their expertise in creating unique flavors. Sausage has firmly established itself as a beloved component of modern barbecue culture. Its rich history, coupled with innovative approaches by contemporary pitmasters, has elevated this humble food item to new heights. As barbecue enthusiasts continue to seek out unique and flavorful experiences, smoked sausage remains a versatile and cherished option.
Whether enjoyed at a local barbecue establishment or ordered online for a taste of regional specialties, smoked sausage embodies the spirit of creativity and tradition that defines today’s barbecue world. The future of smoked sausage looks bright, promising even more delicious and inventive creations for generations to come.
