How much food are you going to smoke? This is important because some of the top pellet smokers are relatively large. And if you’re not looking at smoking a lot of meat, you might purchase a unit that’s too big. Conversely, if you buy a unit that’s too small, you are going to be frustrated because you’re going to make some delicious meat just not as much as you need.
I've been wanting a Yoder for the last year and a half. Finally pulled the trigger on a 640 a couple months ago. Absolutely fantastic. I've been a Weber guy forever and this is my first smoker. This defiantly took my food over the top. My 640 has been incredibly accurate with keeping the heat on the grate to the setting I punch in. Just finished my first brisket and it was fantastic. The only way to go!
The flame broiler uses a digitally controlled burn system. Its Digital Control Center lets you set the temperature ranging from 170F to 600F with ease. The desired temperature is set and maintained through an electric auto-start and fan-forced air mechanism. These, in addition, give that flavorful smoky taste to all of your foods. The auger automatically feeds pellets into the smoker, so you can pretty much let it take care of everything.
But as said, there are a few things we don’t like; it’s relatively small, doesn’t have a lot cooking space, and the design feels cramped. At the same time, it’s still relatively heavy at 140 lbs. For the same price, you could choose the Z-Grills Master 700D, which packs almost 25% more surface area on the rack. That doesn’t seem like much but is a significant amount of room. Or you could just spring for the Traeger Pro 22. There have also been reports of poor quality control, and that the temperature control is very inconsistent, often swinging up and down nearly 30 or 40 degrees.
Now, there are different materials that certain pellet grills are made from. Since steel is such a heavy duty and heavy item, some brands have opted in for more cost-efficient materials, such as a stainless-steel lid to remove some of the weight from the pellet grill. With that said, the interior grill gates are as equally important as the exterior. For example, some grill gates are made from an easy to clean porcelain material while some are designed from stainless steel to be more user-friendly and cost-effective. With that said, let’s discuss another important element to consider when it comes to a pellet grill.
I have several smokers I have used over the years. I have dialed in everyone I own over a course of trial and error. They all get great results, but require me to tend them all throughout the cook. I wanted a smoker that I could easily get to the desired temp, maintain the temp, provide good smoke flavor, and have the size to do a small or large cook, and not need me to be tending it throughout the cook. The learning curve on this smoker is super easy if you know all your temps, your first cook will give you the results your looking for. I was a little worried that I was not going to get the smoke flavor with a pellet smoker, but my brisket turned out amazing, very tender, the smoke ring was perfect. When I was searching for a new smoker I was a little shy of the Yoder based on the price, but when you figure in the ability to grill as well this became a better alternative. The quality is top tier, this is built to last a long time. I'm so glad I went with the Yoder YS640 no regrets.
****Update 12/2014: So I finally found something negative to report. Today I was cooking 2 pork butts and a brisket and discovered that this grill does not do well with wind on a brisk day (It was 45 degrees here today). When set at 250 degree, the smoker could barely make it up to 190 degrees. I was able to bypass the problem by throwing a cheap moving blanket over the grill (an $8 fix) but I think it's worth noting.
Pellet grills preheat quickly, so you can start cooking almost immediately, and the pellets are available in a number of woods, for different smoke flavors. The smoke has a subtle wood-fired flavor with less of the acrid flavor that comes from standard wood or charcoal. For the maximum smoke flavor, it’s best to cook at a temperature lower than 250 degrees, while higher temperatures cook faster with less smoke.