Emptying the hopper and purging pellets from the pellet delivery system maintains pellet freshness and prevents moisture damage. This guide explains how to safely empty the hopper on Weber Searwood 600 and Weber Searwood XL 600 pellet grills when changing pellet varieties or preparing for storage.

 

When to Empty the Hopper

• Switching pellet varieties between cooks for different flavour profiles
• Preparing the Weber Searwood for long term storage
• After exposure to moisture or damp conditions
• When pellets have been in the hopper for an extended period without use
• As part of periodic deep cleaning maintenance

 

What You Will Need

• Container or bucket to collect emptied pellets
• Shop vacuum (for removing pellet dust)
• Dry cloth or kitchen paper
• Airtight container for storing emptied pellets

 

Before You Begin

1. Run a full shutdown procedure on the Weber Searwood
2. Allow the Weber Searwood to cool completely
3. Unplug the Weber Searwood from the electrical outlet
4. Prepare a clean, dry container for collecting pellets

 

Step-by-Step: Emptying the Hopper

1. Ensure the Weber Searwood is completely cool and unplugged
2. Open the hopper lid and check the pellet level
3. Place a container or bucket beneath the pellet release opening at the base of the hopper
4. Pull the pellet release handle to empty pellets from the hopper into the container
5. Allow all pellets to flow out of the hopper through the pellet release opening
6. Once pellet flow stops, release the pellet release handle to close the opening
7. Use a shop vacuum to remove remaining pellet dust and small fragments from the hopper interior
8. Wipe the inside of the hopper with a dry cloth or kitchen paper—never use water in the hopper
9. Ensure the hopper interior is completely clean and dry

 

Understanding Pellets in the Auger

After emptying the hopper using the pellet release handle, some pellets will remain in the auger tube between the hopper and the burn pot. These residual pellets:

• Will feed into the burn pot during the next startup
• Are normal and do not require removal for typical pellet changes
• Will mix with new pellets when the hopper is refilled
• Can be left in place for short term storage (a few weeks)

For Long-Term Storage

If preparing the Weber Searwood for long term storage (several months), residual pellets in the auger should be removed:

1. Empty the hopper completely using the pellet release handle
2. Ensure the Weber Searwood has cooled completely and is unplugged
3. Remove the cooking grates, Flavorizer bar, heat diffuser, and heat deflector to access the burn pot
4. Use a shop vacuum to remove any pellets visible in the burn pot area
5. Note: Some pellets will remain in the auger tube and cannot be easily removed without disassembly
6. For extended storage beyond a few months, consult the Owner's Manual for additional storage guidance

 

Refilling the Hopper with Fresh Pellets

1. Ensure the hopper is completely clean and dry
2. Pour fresh Weber All Natural Hardwood Pellets into the hopper
3. Use pellets that have been stored in an airtight container in a dry location
4. Do not overfill the hopper—leave space at the top
5. Close the hopper lid securely
6. Plug the Weber Searwood back into the electrical outlet
7. The Weber Searwood is now ready for use

 

Storing Emptied Pellets

• Transfer emptied pellets to an airtight container immediately
• Store pellets in a dry, indoor location away from moisture
• Do not mix different pellet varieties in the same container unless you intend to use them together
• Label containers with pellet variety and date emptied
• Inspect pellets before reusing—discard pellets that show signs of moisture damage (swelling, crumbling, or clumping)
• Do not reuse pellets that have been exposed to rain or excessive humidity

 

Tips for Best Results

• Always store pellets in sealed, airtight containers to prevent moisture absorption
• Never leave damp or moisture-damaged pellets in the hopper—moisture can cause pellets to swell and jam the auger
• Empty the hopper before long term storage to prevent pellet deterioration
• Use the pellet release handle regularly to keep the hopper clean and prevent pellet dust accumulation
• Check pellets in the hopper periodically for signs of moisture damage
• Keep the hopper lid closed when the Weber Searwood is not in use to prevent moisture entry

 

What Not to Do

• Do not use water or liquid cleaners in the hopper or auger area
• Do not attempt to empty the hopper or perform maintenance while the Weber Searwood is hot
• Do not skip the shutdown procedure before emptying the hopper
• Do not store pellets in damp or humid locations
• Do not reuse pellets that have absorbed moisture or show signs of damage
• Do not mix pellet varieties unless you intend to use them together for flavour blending
• Do not force the pellet release handle if it is stuck—contact Weber Support

 

Troubleshooting Hopper and Pellet Issues

Pellet Release Handle Stuck or Difficult to Operate

• Ensure the Weber Searwood is completely cool and unplugged
• Check for pellet bridging or clumping near the pellet release opening
• Use a dry tool to gently break up clumped pellets near the opening
• Do not force the handle—contact Weber Support if the issue persists

Pellets Not Flowing from Pellet Release Opening

• Check that the pellet release handle is fully pulled to the open position
• Tap the side of the hopper gently to encourage pellet flow
• Check for moisture-damaged pellets that may be clumped or bridged inside the hopper
• Use a dry tool to gently break up bridged pellets

Pellets Clumping or Swelling in Hopper

• This indicates moisture exposure—empty the hopper immediately
• Discard all moisture-damaged pellets
• Clean and dry the hopper thoroughly
• Inspect the hopper lid seal and ensure it closes properly
• Store the Weber Searwood in a covered, dry location

 

Frequently Asked Questions

Q: Do I need to empty the hopper after every cook?

A: No. Empty the hopper only when changing pellet varieties, preparing for long term storage, or if pellets have been exposed to moisture. For regular use, pellets can remain in the hopper if the Weber Searwood is stored in a dry location with the hopper lid closed.

Q: Can I mix different pellet varieties in the hopper?

A: Yes, you can mix different Weber All Natural Hardwood Pellet varieties for flavour blending. However, for consistent, predictable flavour, empty the hopper completely before switching to a new pellet variety.

Q: What happens if pellets get wet in the hopper?

A: Wet pellets can swell, clump, and jam the auger, causing feeding and ignition issues. If pellets are exposed to moisture, empty the hopper immediately, discard the damaged pellets, and clean and dry the hopper thoroughly before refilling with fresh, dry pellets.

Q: How long can pellets stay in the hopper?

A: Pellets can remain in the hopper for several weeks if the Weber Searwood is stored in a dry location with the hopper lid closed. For storage longer than a few months, empty the hopper and store pellets in an airtight container indoors.

Q: Will residual pellets in the auger affect the next cook?

A: A small amount of residual pellets in the auger after emptying the hopper will feed into the burn pot during the next startup and will not significantly affect flavour. For purist flavour changes, these residual pellets will mix with the new pellets and will have minimal impact after the first few minutes of the cook.

Q: How do I know if pellets are damaged by moisture?

A: Moisture-damaged pellets may appear swollen, soft, crumbly, or clumped together. Pellets should be firm, dry, and free-flowing. Discard any pellets that show signs of moisture damage.

Q: Can I vacuum pellets directly from the hopper instead of using the pellet release handle?

A: The pellet release handle is the recommended method for emptying the hopper. A shop vacuum can be used to remove remaining pellet dust and small fragments after using the pellet release handle, but should not be the primary method for emptying large quantities of pellets.