Pulled pork is a classic barbecue dish that should result in tender, fall-apart meat after hours of slow cooking. However, it can be frustrating when your pulled pork comes out tough and chewy instead of melt-in-your-mouth tender. There are a few common reasons why your pulled pork may not turn out as tender as you hoped. Read on to learn why pulled pork can turn out tough and how to fix it next time.
Overcooking
One of the most common reasons pulled pork comes out tough is overcooking. While pulled pork does require hours of low and slow cooking, it is possible to cook it for too long. Once the pork reaches an internal temperature of 190-205°F and the connective tissue has broken down, it is fully cooked.
If you continue cooking the pork beyond this point, the meat fibers will tighten and the pork will become tough and dry. Always use a meat thermometer to check the internal temp rather than relying on cooking times. Once the pork hits 200-205°F, remove it from the heat. It will continue to cook and tenderize as it rests.
Not Cooking Long Enough
On the flip side, undercooking is another cause of tough pulled pork. Pork shoulder contains a lot of connective tissue that needs ample time to break down and tenderize the meat. If the pork is not cooked for long enough, this connective tissue will remain intact, leading to chewy pork.
Be sure to cook the pork for at least 1-1.5 hours per pound. An 8-10 lb pork shoulder will likely need 8-12+ hours of cooking time to fully tenderize. Use a meat thermometer to check for an internal temp of at least 190°F, ideally 200-205°F when done. The pork should shred easily when poked with a fork at this point.
Not Cooking at a Low Enough Temperature
To break down the connective tissue in pork shoulder, it needs to be cooked “low and slow” at a low temperature – ideally between 225-275°F. Cooking at higher temperatures will cause the meat to tighten before the collagen has fully broken down.
Make sure to maintain your smoker or oven at 225-275°F for the entire cook time. Use an oven or grill thermometer to monitor the temperature if needed. The lower temperature range will result in more tender meat.
Using the Wrong Cut of Pork
Pulled pork is best made using pork shoulder, also called Boston butt or pork butt. This cut comes from the upper part of the front leg/shoulder and contains a good amount of fat and connective tissue.
If you use a leaner, more tender cut like pork loin or tenderloin, it will likely come out tough when cooked for a long time. Be sure to select a bone-in or boneless pork shoulder/butt for best results.
Not Enough Fat Cap
The fat cap on the pork shoulder helps keep the meat moist and tender as it cooks. Removing too much fat will result in drier, tougher meat. Leave a 1/4 to 1/2 inch layer of fat intact when preparing the pork shoulder.
As the pork cooks low and slow, the fat will melt and baste the meat. If your cut of pork had minimal fat marbling, you may need to add moisture in the form of spritzing or wrapping to prevent it from drying out.
Cooking at Too High of a Temperature
Just like oven temperature, keeping your smoker or grill at too high of a heat can also lead to tough pork. To properly break down connective tissue, pulled pork needs to cook low and slow between 225-275°F.
Cooking faster at a higher heat will not allow enough time for the collagen to fully dissolve. Make sure to keep temperatures low, only increasing heat at the very end if you want to crisp or char the outside of the pork slightly.
Not Letting Meat Rest
It’s important to let pulled pork rest for at least 30 minutes (preferably 1 hour) before pulling or slicing into it. This allows the juices to redistribute throughout the meat.
Cutting into pork too soon can cause the juices to leak out, resulting in drier, tougher meat. Tent the pork with foil and let it rest after cooking and before pulling to maximize moisture.
Pulling the Pork Too Early
Impatience is another common culprit behind tough pulled pork. You need to wait until the meat is completely tender before pulling it. If shredded too early, the pork will seem stringy and tough.
The pork should be so tender that it practically falls apart on its own. Use a fork to test the tenderness. If it’s not shredding easily, continue cooking until the meat reaches 205°F internally before attempting to pull it again.
Not Using a Meat Thermometer
Relying on cooking times alone instead of using a meat thermometer is a recipe for disaster. Each piece of pork may cook slightly faster or slower depending on shape, bone-in vs boneless, etc.
The only way to accurately determine doneness for tender pulled pork is to insert a meat thermometer to check the internal temp. Cook until it reaches at least 190°F, ideally 200-205°F. This ensures the connective tissue has broken down.
Smothering While Cooking
While moisture is important for tender pulled pork, too much braising liquid can also cause the meat to steam and toughen up. Smothering the pork in liquid the entire time can prevent the pork bark from forming and drying out the exterior.
Use a spray bottle to spritz moisture instead of submerging pork in liquid. Add only about 1 cup of broth/liquid to foil when wrapping to prevent steaming. Unwrap and let the exterior dry out and crisp up at the end.
Not Letting Bark Form
The delicious outer crust or bark that forms on smoked/barbecued meats adds texture and flavor. If the bark doesn’t properly set, the pork can taste mushy and soft instead of tender. Avoid steaming and let the exterior dry out to form the bark.
You can wrap the pork in foil to power through the stall, but be sure to uncover it toward the end of cooking to let the bark set. Spritz to add moisture rather than fully braising the pork.
Cooking in the Oven Only
While the oven can be used to cook pulled pork, you may miss out on the crust or bark formation. Oven roasting alone can lead to a softer texture. Combining cooking methods leads to the best results.
Try searing the pork first to form a crust, then transferring to a low oven to finish cooking. You can also smoke the pork on a grill before finishing in the oven. This gives you the benefits of both cooking methods.
Not Properly Seasoning
In addition to proper methods, seasoning is key for flavorful pulled pork. Under-seasoned pork can taste bland and boring. Over-seasoning can also cause the texture to become unpleasantly dry and tough.
Use a balanced dry rub with salt, sugar, and spices. 1-2 tablespoons per pound is usually sufficient. Season overnight or at least a few hours prior to cooking if possible. Let the seasoning penetrate for maximum flavor.
What to Do if Your Pulled Pork is Tough
If you’ve checked all the boxes but your pulled pork still comes out tough, don’t panic. You have a few options to try and salvage it.
– Shred the pork and return it to a 300°F oven in some bbq sauce or broth until tender, at least 30 minutes.
– Chop the pork into small pieces or dice it up to make carnitas or tacos where small pieces work better.
– Use the pork in soups, stews, or chili where it can further braise and tenderize.
– Chop or shred the pork and crisp it up in a skillet to use for nachos, pizza topping, sandwiches, etc.
How to Prevent Tough Pulled Pork Next Time
Now that you know some of the potential causes behind tough pulled pork, here are a few tips to ensure tender meat on your next attempt:
– Use a pork shoulder/butt and trim off minimal fat cap
– Apply a dry rub at least a few hours before cooking
– Maintain a low temperature (225-275°F) the entire time
– Use a meat thermometer and cook until 200-205°F
– Let the meat rest for at least 30 minutes before pulling
– Check for tenderness and wait until pork shreds easily before pulling
– Avoid smothering the pork completely while cooking
– Unwrap and let the bark set at the end
With the right cut, seasoning, temperature, and patience, your next pulled pork is sure to be fall-apart tender. Just remember – low and slow is key when barbecueing.
Tips for Moist and Tender Pulled Pork
In addition to being tender, you also want your pulled pork to come out juicy and moist. Here are some extra tips:
– Inject the pork shoulder with a marinade using an injection needle before cooking. This adds extra moisture directly into the meat.
– Spritz the pork with apple juice, vinegar, broth or water every 1-2 hours while cooking to keep the exterior from drying out.
– Wrap the pork shoulder tightly in foil when internal temp reaches 165°F until 205°F to power through the stall (the temperature plateau where meat stops rising). Add 1 cup of liquid to the foil packet.
– Chop and mix the pulled pork with bbq sauce, broth, or the pork juices collected at the bottom of the pan before serving to add back moisture.
– Let pulled pork rest in a cooler wrapped in towels for 1-2 hours after cooking. This allows the juices to reabsorb back into the meat.
Sample Pulled Pork Cooking Timeline
To see a step-by-step timeline for cooking perfect pulled pork, follow these guidelines:
– The Night Before: Pat dry pork shoulder and rub generously with dry rub. Refrigerate overnight uncovered.
– Prep Day: Remove pork from fridge and let sit at room temperature for 1 hour before cooking.
– 0-3 Hours: Cook pork uncovered at 225-250°F to form initial bark and smoke flavor. Spritz hourly with apple juice/vinegar.
– 3-6 Hours: Wrap pork tightly in foil once bark has set and internal temp reaches 165°F. Add 1 cup broth to foil packet.
– 6-12+ Hours: Continue cooking wrapped pork until internal temp of 200-205°F.
– Resting: Remove pork from heat and let rest still wrapped for 1-2 hours.
– Pulling: Unwrap pork and carefully shred and chop meat using two forks.
– Mixing: Toss pulled pork with bbq sauce and/or pork juices to moisten and serve.
Conclusion
Perfectly cooked pulled pork should be fall-apart tender with moist, juicy meat that soaks up your favorite barbeque sauce. To achieve this, low and slow cooking is key along with the right cut of pork, proper seasoning, and a little patience. Monitor internal temperatures and allow ample resting time for delicious pulled pork every time. With a few simple tweaks, you can salvage or prevent tough pulled pork results on your next attempt.