How to Make Starbucks-Style Double Smoked Bacon at Home

As a Starbucks regular I’m a huge fan of their Double Smoked Bacon Cheddar & Egg breakfast sandwich. The combination of smoky bacon, melted cheddar, egg, and flaky croissant is simply heavenly. However, visiting Starbucks daily can get pricey. After some experimentation, I developed an easy method to replicate Starbucks’ signature double smoked bacon at home for a fraction of the cost.

Why Double Smoked Bacon Is So Good

Traditional bacon is cured, smoked once, and sliced. Double smoked bacon takes things up a notch by smoking the cured pork belly a second time. This extra smoking step adds intense smoky flavor and deep mahogany color. It also renders some fat, making the bacon extra crisp. No wonder it tastes so amazing!

While you can sometimes find double smoked bacon at higher end grocers, it’s surprisingly easy to make your own by double smoking basic smoked bacon. With just a few simple steps, you can level up basic bacon to be worthy of a Starbucks breakfast sandwich.

Ingredients Needed

• Smoked bacon slices – choose a quality applewood or hickory smoked bacon for the best flavor. I like Nueske’s.
• Wood chips – apple, hickory, pecan, or mesquite work well. Soak before using.
• Smoker box or foil pouch

Step 1 – Partially Cook the Bacon

The first step is par-cooking the bacon before the second smoking. This renders some fat and promotes caramelization later.

• Arrange bacon slices in a single layer on a wire rack set over a foil-lined baking sheet.
• Bake at 400°F for 8-12 minutes until bacon just starts to crisp but isn’t fully cooked through.
• Allow to cool slightly. The bacon will stiffen up.

Step 2 – Make a Smoker Pouch

To generate smoke, you’ll need wood chips in a smoker box or foil pouch.

• Take a large sheet of heavy duty aluminum foil. Place 1 cup soaked wood chips in the center.
• Create a sealed pouch by bringing together the foil edges and folding over several times to seal. Poke several holes in the top with a skewer to allow smoke release.

Step 3 – Smoke the Bacon

Now it’s time to smoke the par-cooked bacon for full double smoked flavor.

• Prepare grill or smoker for low heat indirect cooking (180-250°F).
• Place smoker pouch by heat source.
• Lay bacon on cool side of grill and smoke for 45-60 minutes with lid closed.
• Flip bacon halfway through. Wood chips should smolder and release fragrant smoke.
• Remove bacon once it reaches your desired level of doneness. It should be somewhat shrunken and darkened.

Step 4 – Cool and Slice

After smoking, the bacon needs to rest before serving.

• Transfer smoked bacon to a cutting board to cool slightly.
• Once cool enough to handle, slice bacon into pieces.
• Enjoy right away or refrigerate for up to 1 week.

Quick Double Smoked Bacon in the Oven

If you don’t have a grill or smoker, you can also double smoke bacon in the oven using a smoker pouch.

• Follow step 1 to par-cook bacon.
• Add a smoker pouch to a foil lined sheet pan and lay bacon slices around it.
• Bake at 275°F for 45-60 minutes until darkened and shrunken, flipping halfway.

While not as authentic, the oven method infuses smoky flavor too.

Cooking Ideas for Double Smoked Bacon

With homemade double smoked bacon on hand, you can recreate Starbucks sandwiches and more!

• Make copycat sandwiches with bacon, egg, and cheddar on croissants.
• Mix into potato hash with veggies.
• Sprinkle over baked beans.
• Use in bacon cheeseburgers.
• Toss with roasted Brussels sprouts.
• Add to chicken carbonara pasta.

By smoking store-bought bacon twice, you can get insanely delicious results at home. This unique method makes bacon worthy of any gourmet sandwich or meal. Once you try it, you may never go back to regular bacon again!