A Guide to Easy & Delicious Burgers Stuffed with Smoked Chilli Rustic

In Recipes by Greg

A smoky twist on a BBQ classic. Juicy beef burgers stuffed with melting centre of Smoked Chilli Rustic for a smoky, spicy kick.
We’ve taken the humble burger up a notch with the bold flavour of our Smoked Chilli Rustic. Infused with Ancho, Chipotle and numex mix flakes from South Devon Chilli Farm, this cheese adds a subtle heat and deep savoury note that pairs beautifully with flame-grilled beef. It’s BBQ indulgence with a grown-up kick — simple, satisfying, and seriously good. You can also try adding a variety of chutneys to the mix.
Why Smoked Chilli Rustic Makes the Ultimate BBQ Burger Cheese
Sharpham Smoked Chilli Rustic is the hero of this recipe — and it deserves its own spotlight. This naturally smoked, semi-hard cheese is infused with Ancho, Chipotle and Numex chilli flakes, giving it a deep, savoury warmth without overpowering the beef. When stuffed inside a burger, it melts into a rich, smoky centre that elevates even the simplest BBQ.
What makes a Great Stuffed Burger?
Stuffed burgers are trending because they deliver:
A molten cheese centre
Extra moisture and richness
A gourmet twist on a classic BBQ favourite
By using high‑fat beef mince and a quality melting cheese like Smoked Chilli Rustic, you create a burger that stays juicy, flavourful and indulgent.
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Prep Time 25 minutes
Cook Time 15 minutes
Total Time 40 minutes
Servings 4 people

Ingredients
  

For the Patties:

  • 500 g beef mince ideally 15–20% fat
  • 1 small onion finely grated or chopped
  • 1 tsp dijon mustard
  • salt & pepper
  • 1 egg optional, helps bind
  • splash of Worcestershire sauce optional, adds a bit of kick.

For Stuffed Option:

  • 150 g Smoked Chilli Rustic grated or thinly sliced

For Assembly:

  • 4 brioche buns
  • lettuce leaves
  • tomato thiny sliced
  • red onion thiny sliced

Optional Sauces:

  • Sharpham Smokey Red Pepper Relish,
  • Sharpham Caramelised Red Onion, Rosemary and Thyme Marmalade
  • Scotch Bonnet Chilli Jam.

Instructions
 

Make the Beef Patty Mix:

  • In a large bowl, combine beef, onion, mustard, seasoning, and egg if using. Mix gently — avoid overworking to keep the burgers tender.
  • Shape the Patties:
  • Divide the mix into 4 equal parts.

Stuffed Option:

  • o Flatten each portion into two thin discs.
  • o Place some grated/sliced Smoked Chilli Rustic in the centre of one, cover with the second disc, and seal the edges well.
  • o Chill for 10–15 minutes before cooking to help them hold shape.

BBQ Grill the Burgers:

  • BBQ grill over medium-high heat for 4–5 minutes per side, depending on thickness. If not stuffed, add cheese slices in the last 2 minutes to melt on top. For extra cheesiness, you can add slices to the stuffed burgers.

Assembly and sauce options:

  • Toast the buns on the grill for 1 minute. Build burgers with salad, pickles, and any sauces you like — we love a smoky mayo, you can make this by adding a spoonful or our smoked red pepper relish to mayo and mix well or the teams favourite try the caramelized red onion, rosemary and thyme marmalade with this cheese. Or looking for a super chilli kick, add the Scorch Bonnet Chilli Jam

Notes

Best Sides for Smoked Chilli Rustic Burgers

  • Grilled corn with chilli butter
  • Smoky paprika potato wedges
  • Charred peppers and onions
  • A crisp slaw with lime and coriander

🍺 Drinks Pairings

  • A hoppy IPA to cut through the richness
  • A smoky porter or stout
  • A chilled rosé for a lighter pairing
  • Ssndridge BartonWine 

🍟 Topping Ideas

  • Caramelised onions
  • Pickled jalapeños
  • Crispy bacon
  • Avocado slices
  • Sharpham Smokey Red Pepper Relish
  • Sharpham Caramelised Red Onion, Rosemary & Thyme Marmalade
  • Sharpham Scotch Bonnet Chilli Jam (for heat lovers)

Why Choose Sharpham Cheese for BBQ Season?

Sharpham’s cheeses are handcrafted in Devon using traditional methods, making them ideal for summer cooking and outdoor dining.

FAQS

Can you stuff burgers with any cheese?

You can, but semi-hard cheeses like Smoked Chilli Rustic melt beautifully while still holding their flavour. Soft cheeses can leak, and hard cheeses may not melt as smoothly.

How do you stop stuffed burgers from falling apart?

Chill them before cooking, seal the edges well, and avoid flipping too often. A higher‑fat mince also helps the patties stay juicy and cohesive.

Can I cook these burgers in a pan instead of on the BBQ?

Absolutely. A cast‑iron pan works brilliantly — you’ll still get a great crust and a molten cheese centre.

What’s the best sauce for a smoked chilli burger?

Smoky, sweet or spicy sauces pair best. Try Sharpham’s Smokey Red Pepper Relish or Scotch Bonnet Chilli Jam for a bold kick.

Is Smoked Chilli Rustic vegetarian?

Yes, all Sharpham cheese is vegetarian. 
Keywords Sharpham Rustic, Smoked Chilli