How Many Sausages for 40 People (Links, Pounds & Packs)
Prices checked Oct 2026, average US grocery prices. Portions follow common catering rules of thumb; safe temperatures follow USDA. How we calculate
A 40-person event with sausages is efficient and crowd-pleasing — 80 links grill in 4 rounds of 20. At this party size, a chafing dish or large covered roasting pan keeps finished batches hot while you grill the rest. Offer 2–3 varieties and label them clearly so guests with preferences can self-select.
Brats vs Hot Dogs for 40 People
| Type | Links per lb | For 40 guests | Packs to buy |
|---|---|---|---|
| Bratwurst / Italian | about 5 | 80 links, 16 lbs | 16 packs of 5 |
| Standard hot dogs | about 8–10 | 80 hot dogs, 8 lbs | 10 packs of 8 |
| Mix: 1 brat + 1 hot dog | — | 40 brats + 40 hot dogs | 8 brat packs, 5 hot dog packs |
Brats are heavier and more filling than hot dogs, so a mix of one of each per person works well for mixed ages.
Plan for Exactly 40 Guests
| Grill loads | 4 loads of about 25 links on a 22-inch kettle, 15 minutes each |
|---|---|
| Grills to serve in ~45 min | 2 kettle-size grills |
| Optional beer bath | 4 foil pans of beer and onions to hold cooked links warm |
| Holding pans | 3 half-size foil pans with lids for about 14 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 |
|---|---|---|
| Sausages (bratwurst or Italian links, about 5 per lb) | 16 lbs (7.3 kg) | $80 |
| Charcoal | 20 lbs (2 bags of 16 lbs) | $30 |
| Buns, one per link | 80 (10 packs of 8) | $28 |
| 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 | $8.20 per guest | $328 |
Links: 80 brats or Italian sausages. Most come 5 to a 19-oz pack, about 5 links per pound.
Gear for This Cook
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Adjust for Your Crowd
The numbers above assume adults with sausages as the main dish and two sides. Scale them for your event:
| Situation | Multiplier | Sausages for 40 |
|---|---|---|
| Main dish, no other meats | ×1 | 16 lbs (7.3 kg) |
| Served with one other meat | ×0.6 | 9.6 lbs (4.4 kg) |
| Served with two other meats | ×0.4 | 6.4 lbs (2.9 kg) |
| Self-serve buffet | ×1.2 | 19.2 lbs (8.7 kg) |
Cooking Details
Target temperature: 160°F internal for fresh pork or beef links
Cook time: 12–15 minutes over medium heat, turning often
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?
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How many sausages for 40 people?
Plan 80 sausage links for 40 people, 2 per person. For brats that is about 16 lbs (7.3 kg), or 16 packs of 5.
How many links are in a pound of sausage?
Bratwurst and Italian sausage run about 5 links per pound. Standard hot dogs are 8–10 per pound.
What does sausages for 40 people cost?
The meat costs about $80 at average US grocery prices ($5.00/lb). With charcoal, drinks, two sides and supplies, budget about $328 in total, or $8.20 per guest.