Large-Scale Catering BBQ: Feeding 400 with Pulled Pork, Ribs & Chicken

Large-Scale Catering BBQ: Feeding 400 with Pulled Pork, Ribs & Chicken

Cooking for a few friends or family is one thing, but when you’re responsible for feeding hundreds of hungry mouths, the stakes get higher. Recently, we took on a catering job for about 400 people, and I wanted to share the exact process we used to pull it off without sacrificing flavor.

This wasn’t a competition cook where every bite gets judged. Instead, it was a real-world test of efficiency, planning, and good barbecue fundamentals. The menu centered around pulled pork, ribs, and chicken—three staples that please just about any crowd. With the right gear, rubs, and techniques, we turned out championship-worthy BBQ on a massive scale.

Large-Scale Catering BBQ: Feeding 400 with Pulled Pork, Ribs & Chicken

Let’s break it down step by step.

Pulled Pork: The Workhorse of Catering

When you’re cooking for a crowd, pulled pork is king. It’s affordable, forgiving, and stretches far—perfect for sandwiches or plates. For this cook, we started with whole pork butts. Instead of detailed trimming, I took a no-fuss approach: no slicing, no shaping, no removing of fat. The focus here was speed and flavor.

Seasoning

I seasoned each butt with my go-to Hot BBQ Rub, a versatile blend I use on nearly everything. It’s bold, balanced, and has just the right amount of kick. The trick is to be generous—coat all sides thoroughly. Don’t overthink it; the bark will form beautifully once it hits the smoke.

Smoking Setup

We loaded the butts onto the Old Hickory Double-Wide CTO Smoker, running them fat side up. This way, as the fat renders, it bastes the meat instead of sticking to the grates. The smoker ran at a steady 210–215°F overnight, fueled by Royal Oak Charcoal and kissed with hickory smoke.

Wrapping & Resting

By morning, the smaller butts were tender, but the larger ones needed a boost. I wrapped those in foil around 175–180°F to push them through the stall. This “Texas Crutch” not only sped up the process but also guaranteed I had enough time to rest the meat properly before serving.

Once pulled, I mixed the pork with a splash of Tangy Vinegar BBQ Sauce for brightness and an extra dusting of Hot BBQ Rub. The tang cut through the richness, and the bark pieces added texture and smoke. When catering, that extra pop of flavor ensures every serving tastes like it came fresh off the pit.

Ribs: Bringing Competition Flavor to the Masses

Even though the client wanted mostly pork and chicken, ribs had to make an appearance. After all, people always want a taste of those world-famous Memphis-style ribs. For this cook, we prepped 12 racks of Kroger-branded ribs—an accessible option that still turns out great when treated right.

Prep & Seasoning

Minimal prep was the name of the game: remove the membrane, trim off any hard fat, and move straight into seasoning. For layers of flavor, I used a two-rub method:

Both sides got coated, and then it was straight onto the smoker.

Smoking & Wrapping

The ribs went onto the Recteq 1100 Pellet Grill, holding steady for about two hours. Once they hit the right color, it was time for the wrap. We laid down foil, brushed on Honey Chipotle Rub, and added a generous pour of Butter Bath & Wrap. Ribs went meat side down into the mix, then sealed tight. This ensured tenderness while layering in buttery sweetness with a little heat.

Finishing with Sauce

To finish, I built a sauce blend inspired by my Memphis in May routine:

Once the ribs came out of the wrap, I brushed them with this sauce and put them back on the pit to tack up for about 20 minutes. Before serving, I hit them with a light dusting of Competition Rub for that final pop.

The result? Ribs that had all the hallmarks of a championship box—tender, juicy, and layered with flavor—but scaled up for catering.

Chicken: Quick, Simple, and Crowd-Pleasing

The last protein on the menu was chicken breast. Instead of whole birds or leg quarters, which can be tricky for catering, we went with boneless breasts for consistency and portion control.

Seasoning & Smoking

Each piece was coated with Chicken Rub, a southwestern-style seasoning that’s perfect for poultry. The chicken went onto the smoker for about an hour and a half until it reached 160°F internally.

Finishing Touch

After resting, the chicken was sliced into medallions—easy to serve, easy to eat. To finish, I tossed the slices lightly in Sweet BBQ Sauce. The sauce added flavor and shine without overwhelming the natural smokiness.

This method kept the chicken moist, flavorful, and versatile. It paired just as well with mac & cheese as it did on sandwiches or salads.

Results & Flavor Notes

Cooking on this scale is always about balance—keeping things simple enough to be repeatable, but flavorful enough to stand out. Here’s how everything turned out:

  • Pulled Pork: Tender, juicy, with smoky bark and a vinegar tang. Perfect for sandwiches.
  • Ribs: Sticky, sweet, and smoky with just enough spice to keep things interesting.
  • Chicken: Juicy medallions with a kiss of smoke and a light sauce finish. Easy to portion and serve.

Every bite delivered bold barbecue flavor without the stress of competition-style detail.

Serving & Pairing Ideas

For an event like this, variety is key. Here’s how we served everything:

  • Pulled Pork Sandwiches: On buns with slaw and extra vinegar sauce.
  • Ribs: Sliced into single or double bones for easy plating.
  • Chicken: Served in medallions with a drizzle of sauce—great as a main protein or alongside sides.
  • Classic BBQ sides like potato salad, baked beans, coleslaw, and cornbread rounded out the spread. Sweet tea, lemonade, and cold beer were the perfect pairings.

Storage & Reheating Tips

When cooking for crowds, you often need to hold or reheat meat. Here’s what worked for us:

  • Pulled Pork: Store in foil pans with a little vinegar sauce to keep it moist. Reheat covered at 250°F.
  • Ribs: Wrap in foil with a touch of sauce, then reheat gently until warm.
  • Chicken: Best served fresh, but if needed, store covered in sauce and reheat slowly to prevent drying out.

These tricks ensure your barbecue still tastes fresh even if it’s served hours after cooking.

Equipment Used

Old Hickory Double-Wide CTO Smoker – for pork butts
Recteq 1100 Pellet Grill – for ribs and chicken
Royal Oak Charcoal – fuel for steady smoke

Older post

star
Back to the Recipes