How Much Pulled Pork for 40 People (Raw & Cooked)
Prices checked Oct 2026, average US grocery prices. Portions follow common catering rules of thumb; safe temperatures follow USDA. How we calculate
Pulled pork for 40 people takes about 20 lbs of raw pork butt, typically three butts, which suits an overnight smoke that finishes by late morning. One person can run the smoker while others set up. A second cooker, if you can borrow one, removes single-smoker risk.
Raw vs Cooked Pulled Pork for 40 People
| Per person | For 40 guests | Metric | |
|---|---|---|---|
| Raw bone-in pork butt to buy | 0.5 lb | 20 lbs | 9.1 kg |
| Cooked pulled pork | about 4.4 oz | 11 lbs | 5.0 kg |
| Sandwiches (4 oz each) | 1+ | about 44 | — |
| Pork butts | — | 3 × about 6.7 lbs | 3.0 kg each |
Buy by raw weight. If pulled pork is one of two meats, 0.33 lb raw per person is enough; for big eaters, use 0.75 lb.
Plan for Exactly 40 Guests
| Smoker space | 3 butts: one 18-inch smoker on both grates |
|---|---|
| Cook time | about 10 hours at 225°F (cook time depends on each butt, not on how many), plus a 1-hour rest |
| Start time | light the smoker about 11 hours before serving, so usually the night before |
| Thawing if frozen | 2 days in the fridge per butt (USDA: about 1 day per 4–5 lbs) |
| Holding pans | 3 half-size foil pans with lids for about 11 lbs of cooked meat |
| Drinks cooler | 3 × 48-quart coolers for 100 cans, plus 6 × 10-lb bags of ice |
| Serving help | 2 cooking, 2 on serving and refills |
Complete Shopping List for 40
| Item | Quantity | Est. cost |
|---|---|---|
| Pulled Pork (bone-in pork butt (shoulder), raw weight) | 20 lbs (9.1 kg) | $50 |
| Charcoal for a long smoke | 21.5 lbs (2 bags of 16 lbs) | $32 |
| Buns, one per sandwich | 44 (6 packs of 8) | $17 |
| Drinks, mixed (2.5 per person) | 100 | $110 |
| Potato salad (0.3 lb per person) | 12 lbs (5.4 kg) | $30 |
| Coleslaw (0.3 lb per person) | 12 lbs (5.4 kg) | $30 |
| Plates, napkins, cutlery, condiments | 45 plates, 90 napkins | $20 |
| Estimated total | $7.22 per guest | $289 |
Cooked yield: about 11 lbs (5.0 kg) of pulled pork. A pork butt loses roughly 45% of its raw weight to fat, water and bone.
Gear for This Cook
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Adjust for Your Crowd
The numbers above assume adults with pulled pork as the main dish and two sides. Scale them for your event:
| Situation | Multiplier | Pulled Pork for 40 |
|---|---|---|
| Main dish, no other meats | ×1 | 20 lbs (9.1 kg) |
| Served with one other meat | ×0.6 | 12 lbs (5.4 kg) |
| Served with two other meats | ×0.4 | 8 lbs (3.6 kg) |
| Self-serve buffet | ×1.2 | 24 lbs (11 kg) |
Cooking Details
Target temperature: 195–205°F, then rest 30–60 minutes before pulling
Cook time: about 1.5 hours per pound of each butt at 225°F
Food safety: don't leave cooked meat out more than 2 hours, or 1 hour above 90°F (USDA). Keep hot food above 140°F.
Want to change drinks, sides and sauces, or download a PDF shopping list?
Open Full BBQ Calculator →FAQ
How much pulled pork for 40 people?
Buy 20 lbs (9.1 kg) of raw bone-in pork butt for 40 people. After smoking it yields about 11 lbs of pulled pork, roughly 4.4 oz per person.
How many pork butts for 40 people?
3 pork butts of about 6.7 lbs each. Smaller butts cook faster and more evenly than one very large one.
What does pulled pork for 40 people cost?
The meat costs about $50 at average US grocery prices ($2.50/lb). With charcoal, drinks, two sides and supplies, budget about $289 in total, or $7.22 per guest.