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Kielbasa Sausage Cheesy Potato Casserole

Kielbasa sausage cheesy potato casserole with smoky seared kielbasa, tender Yukon Gold slices, and a thick cheddar cheese sauce baked until bubbling and deeply golden at 375°F (190°C). Layers of potatoes and onions are smothered in creamy sauce, then finished with extra sharp cheddar for a crisp, melty top.
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Prep Time 25 minutes
Cook Time 1 hour 5 minutes
Resting 10 minutes
Total Time 1 hour 40 minutes
Servings: 8 servings
Course: Dinner
Cuisine: American
Calories: 650
Ingredients Equipment Method Notes

Ingredients
  

Casserole
  • 1.5 lb kielbasa sausage Sliced into ½-inch rounds.
  • 2 lb Yukon Gold potatoes Peeled and thinly sliced.
  • 1 yellow onion Thinly sliced.
  • 3 garlic cloves Minced.
  • 2 tbsp butter For searing and sautéing.
  • 1 tsp smoked paprika For seasoning layers.
  • 0.5 tsp garlic powder For seasoning layers.
  • 0.5 tsp onion powder For seasoning layers.
  • 0.25 salt To taste.
  • 0.25 black pepper To taste.
Cheese Sauce
  • 2 tbsp butter For the roux.
  • 2 tbsp all-purpose flour For thickening.
  • 1.5 cup whole milk Added slowly to prevent lumps.
  • 0.5 cup sour cream Stir in off heat for smoothness.
  • 2 cup sharp cheddar cheese Shredded; melted into the sauce.
  • 0.5 tsp mustard powder For flavor depth.
  • 0.25 salt To taste.
  • 0.25 black pepper To taste.
Topping
  • 1 cup sharp cheddar cheese Additional shredded cheddar for the top.
  • 2 tbsp fresh parsley Chopped garnish.

Equipment

  • 1 cast iron skillet
  • 1 sheet pan
  • 1 Dutch oven
  • 1 stand mixer

Method
 

Prep and bake
  1. Preheat the oven to 375°F (190°C) and grease a 9×13-inch baking dish with butter or cooking spray.
  2. In a large skillet over medium-high heat, melt 2 tbsp butter, add the kielbasa rounds, and sear 2–3 minutes per side until golden-brown edges form; remove to a plate.
  3. In the same skillet, add the sliced onion and cook over medium heat for 5–6 minutes until softened and lightly caramelized.
  4. Add the minced garlic to the onions and cook 1 minute more, then remove and set aside.
  5. Layer half the sliced potatoes in the bottom of the prepared baking dish in a slightly overlapping pattern, then season with smoked paprika, garlic powder, onion powder, salt, and black pepper.
  6. Scatter half the sautéed onion and garlic mixture over the potatoes, add half the kielbasa rounds, and pour half the cheese sauce evenly over everything.
  7. Repeat with the remaining potatoes, onion mixture, and kielbasa, then pour the remaining cheese sauce over the top so the potatoes are coated.
  8. Cover the dish tightly with aluminum foil and bake for 45 minutes.
  9. Remove the foil, scatter the remaining 1 cup shredded cheddar over the top, and bake uncovered for an additional 20–25 minutes until the cheese is deeply golden, bubbling, and the potatoes are fork-tender.
  10. Let the casserole rest for 10 minutes before serving, then garnish with fresh chopped parsley and serve straight from the dish.
Make the cheddar cheese sauce
  1. In a medium saucepan over medium heat, melt 2 tbsp butter and whisk in the flour; cook for 1 minute until golden and nutty-smelling.
  2. Slowly pour in the whole milk while whisking continuously to avoid lumps.
  3. Cook for 3–4 minutes until thick enough to coat the back of a spoon.
  4. Remove the saucepan from heat and stir in the sour cream, shredded cheddar, mustard powder, salt, and black pepper until fully melted and smooth.

Notes

For the smoothest sauce, whisk the milk in slowly and keep the heat at medium so the roux thickens without scorching. Store leftovers covered in the refrigerator for up to 4 days; reheat in a 350°F (175°C) oven until hot and bubbling. Freezing is not recommended because the potatoes and dairy can change texture after thawing. For a lighter option, use reduced-fat cheddar and light sour cream while keeping the same thickening method.