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Smoked Sausage and Potato Casserole

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Smoked Sausage and Potato Casserole is an all-time favorite comfort food. This hearty dish combines the flavors of smoked sausage and creamy, cheesy potatoes. It’s easy to prepare and guarantees to leave your family and guests asking for seconds.

Freshly baked cheesy sausage and potato casserole in a pan.

My family loves sausage and potato recipes! John really likes our sausage and potatoes skillet recipe because it’s packed with chicken apple sausage and plenty of fresh veggies.

When we have extra sweet potatoes, our sausage and sweet potato hash is one the menu!

Today, it’s my cheesy smoked sausage and potato casserole. This dish is full of flavorful smoked sausage, tender russet potatoes, and the creamiest Velveeta cheese sauce.

To make this dish last for a few days, we like to serve it with some veggie packed side dishes.

One of our favorites is sautéed fresh green beans. I pan-fry these green beans in cast iron then top them with garlic and crispy bacon.

Another great side dish is our roasted brussels sprouts recipe. These brussels sprouts are drizzled with a little olive oil, sprinkled with salt and pepper, then roasted until golden brown. Yum!

This sautéed broccoli may be my favorite pairing! Broccoli florets are cooked until brown and crispy. Then, I toss in some garlic and lemon juice for a bright, flavorful finish.

There are so many side dish options that taste good with this sausage and potato casserole. Choose your favorite!

How to Make Smoked Sausage and Potato Casserole

(These instructions include step-by-step photos but don’t include the exact amounts of each ingredient. For that information, you’ll want to scroll to the recipe card further down the page.)

  1. Place the diced potatoes into a large pot of salted water, and bring to a boil. Cook the potatoes until they’re fork tender but not quite soft enough for mashed potatoes.
  2. Drain the potatoes, and return to the same pan used to prepare them. While the potatoes cook, brown the sausage.
  3. Heat a large skillet over medium heat, and add the diced sausage. Stir often, and cook until the sausage begins to carmelize. Let it brown to your liking then transfer to the pan of potatoes.
Diced potatoes in a pan of water.
Cooked smoked sausage pieces in a skillet.
  1. In another medium pan or skillet, warm the Velveeta cheese, butter, milk, garlic powder, onion powder, salt, and pepper. Stir frequently until the mixture is smooth and creamy.
  2. Pour the warm cheese sauce over the potatoes and sausage, and gently stir to coat.
Butter, Velveeta, milk, and spices in a pan.
Melted cheese sauce poured into a pan of sausage and potatoes.
  1. Spray a casserole dish or baking dish with non-stick cooking spray, and transfer the mixture to the dish.
  2. Sprinkle with shredded cheese, if using. Bake at 400°F for 15-20 minutes or until the sauce begins to bubble around the edges.
Shredded cheese sprinkled over cheese, sausage and potatoes.
Top down view of a smoked sausage and potato bake.

Substitutions and Variations

  • Protein: Swap the smoked sausage with turkey sausage, chicken sausage, or kielbasa.
  • Paprika: Add a sprinkle paprika for flavor and a pop of golden brown color.
  • Veggies: Add a cup or two of steamed broccoli, sautéed mushrooms, or sweet peas.
  • Cheese Sauce: Skip the Velveeta and make a homemade cheese sauce with flour, butter, and your favorite cheese.
  • Cheese: Sprinkle your favorite flavor of shredded cheese over the top of the casserole. Some options are sharp cheddar cheese, mozzarella, and pepper jack.

Storage

Refrigerator: Store leftovers in an airtight container in the refrigerator for up to 4 days.

Reheating: Reheat on the stovetop over low heat until warmed through. Or, heat in the microwave on half power until the casserole reaches the desired temperature.

Freezer: Since our smoked sausage casserole uses Velveeta, we don’t recommend freezing it. It doesn’t hold up well, and the cheese sauce has an unappealing texture once thawed.

Tips

  • Make sure to cook the cheese sauce on low or low-medium heat and stir it frequently. This sauce can scorch easily, so it’s best to keep a close eye on it.
  • Don’t over bake the casserole. The cheese sauce can scorch in the oven, too. You want to bake it just until it begins to bubble around the edges.
  • The sauce becomes very thick as it cools. When reheating, add a few splashes of milk or half and half to loosen it up if needed.

Frequently Asked Questions

I love to use russet potatoes because they’re starchy and hold up well to the thick cheese sauce. They soak up some of the sauce and still have the texture of potatoes without being mushy.

Some other options are red potatoes and yukon gold potatoes. Neither are as starchy as russets, so they’re going to be softer in texture.

Yes, hash browns will work. There are a couple of things to keep in mind.

You’ll want to thaw them first. Make sure they’re completely thawed and remove any excess moisture.

Depending on the type of hash browns used, you may need more or less than the amount of potatoes listed in the recipe.

Sure! Slice the sausage into circles if that’s what you prefer. I love to cut it into bite-sized pieces so it’s about the same size as the potatoes.

It makes it easier to fit the ingredients into the baking pan and to stir in the cheese sauce.

Prepare the casserole all the way up to the point of baking. Cover it tightly in plastic wrap, and refrigerate for up to 1 day.

When you’re ready to bake the casserole, remove the plastic wrap and bake in a preheated oven as written in the instructions.

Note: The sauce becomes very thick as it cools, so it may take a few minutes longer to bake after it’s been in the refrigerator. Keep a very close eye on it so the sauce doesn’t burn.

Yes, absolutely! This recipe easily doubles, but you’ll want to use two pans, a 9×13-inch pan, or a large aluminum baking pan.

Close up view of cheesy potatoes and sausage in a pan.

Smoked Sausage and Potato Casserole

5 from 1 vote
Print Pin
Author: Kim
Prep Time: 20 minutes
Cook Time: 40 minutes
Total Time: 1 hour
Servings: 10 Servings

Ingredients

  • 4 cups potatoes, diced in ½-inch cubes
  • 14 ounces smoked sausage, cut into bite-sized pieces
  • 16 ounces Velveeta, cut into small cubes
  • ½ cup unsalted butter
  • ½ cup milk
  • 1 teaspoon salt, or adjust to taste
  • ½ teaspoon garlic powder
  • ¼ teaspoon onion powder
  • ¼ teaspoon ground black pepper
  • ½ cup sharp cheddar cheese, shredded (optional)

Instructions
 

  • Preheat the oven to 400°F, and grease an 11×7-inch or 9×9-inch pan with cooking spray.
  • Place the potatoes into a large pot of salted water and bring to a boil. Cook until the potatoes are fork tender but not so soft that they're mashable. Drain, and return to the pan (off the burner/remove from heat).
    4 cups potatoes
  • While the potatoes boil, cook the sausage. Place a medium skillet over medium heat, and cook the sausage until browned and carmelized to your liking. Stir frequently to prevent burning. Transfer the sausage to the pan of drained potatoes.
    14 ounces smoked sausage
  • In a medium pan over low heat, melt the Velveeta, butter, milk, salt, garlic powder, onion powder, and pepper. Stir often to keep the sauce from scorching. Once melted and creamy, pour the sauce over the potatoes and sausage and stir gently to coat.
    16 ounces Velveeta
    ½ cup unsalted butter
    ½ cup milk
    1 teaspoon salt
    ½ teaspoon garlic powder
    ¼ teaspoon onion powder
    ¼ teaspoon ground black pepper
  • Transfer to the prepared baking dish, and top with shredded cheese if using. Bake for 15-20 minutes or until the sauce bubbles around the edges.
    ½ cup sharp cheddar cheese
  • Serve warm! Scroll up and see the post for tips, substitutions, answers to frequently asked questions, and storage information.

Suggested Equipment

Notes

*The calories listed are an approximation based on the ingredients in the recipe card and a serving size of 1/2 cup of casserole. Actual calories will vary.
*For more information, tips, and answers to frequently asked questions, please refer to the post.
*This casserole is very hearty, so we serve it in smaller servings alongside a vegetable side dish.

Nutrition

Serving: 0.5cupCalories: 397kcalCarbohydrates: 22gProtein: 17gFat: 27gSaturated Fat: 14gPolyunsaturated Fat: 2gMonounsaturated Fat: 8gTrans Fat: 0.4gCholesterol: 79mgSodium: 1337mgPotassium: 614mgFiber: 2gSugar: 5gVitamin A: 807IUVitamin C: 17mgCalcium: 332mgIron: 1mg
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