From Earthen Pit to Pellet Grill: A Smoker History

Before equipment: the hole in the ground

For most of its history, barbecue needed no gear at all. As the history of barbecue describes, the original American method was a trench dug at the event site, wood burned down to coals inside it, and meat laid across the top. Colonial pit crews carried shovels, not smokers. Above-ground brick and block pits came later, mostly in commercial smokehouses and restaurant yards, and the dug trench still survives wherever a whole-hog crew wants the old result.

Fuel in a bag: the charcoal briquette

The first equipment revolution was not a cooker at all. It was fuel. In 1919, Edward G. Kingsford helped Henry Ford arrange a supply of timberland to feed Ford's auto plants, and the operation's sawmill left mountains of scrap wood. Ford's answer was a process for pressing that waste into blocks of reconstituted char: the charcoal briquette. It launched under Ford's own name and was later renamed Kingsford Charcoal for Edward Kingsford.

The briquette mattered because it made outdoor fire predictable. Lump charcoal burns hot and unevenly depending on the wood; a pressed briquet is uniform, stacks neatly, and burns long. Uniform fuel is what makes repeatable temperature possible, and repeatable temperature is the entire game in smoking. Kingsford remains the leading charcoal maker in the United States, converting more than a million tons of wood waste a year.

1952: a buoy becomes the kettle

After World War II, Americans moved to the suburbs and started cooking on patios, but open braziers fought them constantly: ash in the wind, flare-ups, no way to bank heat. George Stephen, who worked at the Weber Brothers Metal Works, studied the rounded shape of a sheet-metal marine buoy and cut it in half. The bottom half held the coals, the top half became a domed lid, and vents controlled the airflow. His kettle, dated to around 1952 in the company's own telling and placed at 1951 by the Smithsonian, could grill in weather and even indirect-cook with the lid on.

The Weber-Stephen company formed in 1958 to build them, and the kettle became the default charcoal grill of the American backyard. Its real innovation was conceptual: it treated outdoor cooking as an airflow problem, solvable with vents and a lid, the same way a smoker is.

The early 1960s: gas comes to the patio

Gas grills reached the mass market in the early 1960s, with cast-aluminum rectangular designs doing much of the early work; several manufacturers share credit for the form, and the period's records are tangled enough that honest histories hedge on any single inventor. What gas changed was obvious: push-button heat with no chimney, no ash, and no bag. Purists argued then, and argue now, about what flavor the flame leaves behind, which is exactly the argument this site covers in charcoal versus gas versus pellet.

1974: the kamado comes home

Ceramic dome cookers have a much longer pedigree than anything else on this list. Japanese mushikamado rice cookers, clay pots with removable domes, dampers, and draft doors, had been used for centuries, and American servicemen stationed in Japan after World War II started bringing them home. Ed Fisher, a former Navy man, opened a small shop called Pachinko House on Clairmont Road in Atlanta in 1974 and began importing and selling them. He cooked chicken wings out front to draw a crowd, and word of mouth did the rest.

The Big Green Egg line Fisher founded is the best-known descendant, and the design's virtues are thermal: thick ceramic walls hold steady temperature for hours on modest fuel, which makes the kamado a natural smoker as well as a grill. It is the oldest idea in this story and one of the newest arrivals in Western backyards.

1985: the thermostat gets a fire

Joe Traeger, whose family ran a heating business in Mt. Angel, Oregon, spent the early 1980s working on automated heat, building pellet-burning furnaces before turning the idea toward the patio. In 1985 he built his first wood-pellet grill: an auger feeds compressed hardwood pellets into a firepot, a fan drives the burn, and a controller dials the temperature like an oven. The family patented the design, filing US4823684A in October 1987, and sold the concept directly to backyard cooks who wanted smoke without babysitting a fire.

That patent has long since expired, which is the single most important fact in the modern smoker market: once anyone could build a pellet grill, dozens of brands did, prices fell, and controller quality became the differentiator. The set-and-forget school and the tend-the-fire school have been arguing ever since, and both are represented in offset versus pellet for brisket.

The whole lineage in one table

What did not change

Strip the timeline down and every device on it is a box that holds heat above a fire, with some control over air in and air out. The colonial trench had all three parts. So the old skills still transfer completely: reading your thermometer instead of the clock, managing the stall, resting the meat. If you are picking equipment today, the comparisons are less about history than about how much attention you want to pay, and the guides on charcoal versus gas versus pellet smokers and instant-read versus leave-in thermometers cover that decision directly.

Where this history comes from

• National Museum of American History: Weber kettle charcoal grill
• Weber: kettle born from a buoy
• Kingsford: our history
• Big Green Egg: the history of kamado grills
• Big Green Egg UK: Ed Fisher interview
• Google Patents: US4823684A, pellet-fired barbecue
• Statesman Journal: the Joe Traeger timeline