Hearty Sausage Gravy Casserole

Finding a comforting dinner that satisfies the whole family can feel like an impossible task, especially during those busy weeknights when you’re juggling homework help, after-school activities, and what feels like a million other things. After all, most classic comfort foods take hours to prepare, and sometimes you just don’t have that kind of time on your hands.

That’s where this Hearty Sausage Gravy Casserole comes to the rescue: it’s filling and delicious, takes minimal prep time, and combines all the cozy flavors of a home-cooked meal into one simple dish that’ll have everyone asking for seconds.

What Kind of Sausage Should I Use?

For this casserole, breakfast sausage is the way to go, and you’ve got some tasty options to choose from.

Regular pork breakfast sausage works great here, but you can also use maple-flavored breakfast sausage if you want a hint of sweetness, or hot breakfast sausage if you like a bit of kick.

The most important thing is to use bulk breakfast sausage (the kind that comes unformed, like ground meat) rather than links or patties, since you’ll need to break it up while cooking.

If your store only has breakfast sausage in casings, no worries – just remove the meat from the casings before cooking.

Options for Substitutions

Need to make some changes to this casserole? Here are some handy swaps that work well:

• Hash browns: If you can’t find frozen hash browns, you can grate fresh potatoes – just squeeze out the excess moisture with a clean kitchen towel first. You could also use tater tots or even cubed potatoes that you’ve par-boiled for 5 minutes.
• Breakfast sausage: Regular ground pork works great – just add some extra seasonings like sage and thyme. Turkey sausage is a lighter option, though the gravy might be a bit less rich.
• Full-fat milk: While full-fat milk makes the creamiest gravy, you can use 2% milk. I wouldn’t go lower fat than that, as the gravy might turn out too thin. Half-and-half works too if you want it extra creamy.
• Cheddar cheese: Feel free to switch up the cheese – Colby Jack, Monterey Jack, or a mix of cheeses all work well. Just avoid pre-shredded cheese as it doesn’t melt as smoothly.
• Plain flour: For the gravy, you need to stick with regular flour – this is one ingredient that’s best not to substitute as it’s key for the right texture.

Watch Out for These Mistakes While Cooking

The biggest challenge when making sausage gravy casserole is ending up with a lumpy or pasty gravy – to prevent this, make sure to gradually whisk in the milk while the flour-coated sausage is still hot, and keep stirring until the mixture is smooth.

Another common mistake is using cold eggs straight from the fridge, which can lead to uneven cooking – instead, let your eggs come to room temperature for about 30 minutes before whisking them with milk, and they’ll cook more evenly throughout the casserole.

Hash browns can become soggy if you don’t properly drain them first, so take the extra time to pat them dry with paper towels before combining them with butter and seasonings.

For the best texture and flavor, avoid overcooking the casserole – it’s ready when the eggs are set but still slightly jiggly in the center, as they’ll continue cooking for a few minutes after you take it out of the oven.

What to Serve With Sausage Gravy Casserole?

Since this breakfast casserole is already packed with protein and carbs, I like to balance it out with some lighter sides.

Fresh fruit is always a winner – try a simple mixed berry bowl or some citrus segments to cut through the richness of the gravy.

A side of crispy bacon or breakfast sausage links might seem like overkill, but hey, it’s breakfast – go big or go home!

For something green, sautéed spinach or roasted asparagus pairs surprisingly well with the savory flavors of the casserole, and they add some nice color to your plate too.

Storage Instructions

Keep Fresh: This hearty casserole will stay good in the fridge for up to 3 days when stored in an airtight container. It’s actually one of those dishes that tastes even better the next day, as all the flavors have time to mingle together!

Freeze: You can freeze this casserole either before or after baking. Just wrap it tightly in plastic wrap and aluminum foil, and it’ll keep in the freezer for up to 2 months. If freezing unbaked, thaw completely in the fridge overnight before cooking.

Reheat: To warm up leftover portions, cover with foil and pop them in the oven at 350°F for about 20-25 minutes, or until heated through. You can also microwave individual portions for 1-2 minutes, though the texture might not be quite as nice as oven reheating.

Make Ahead: This casserole is perfect for preparing the night before! Just assemble everything, cover tightly, and store in the fridge overnight. The next morning, let it sit at room temperature for 30 minutes before baking. You might need to add an extra 5-10 minutes to the baking time.

 

How to Know When the Sausage Gravy Casserole is Done

You’ll know your casserole is ready when the eggs are completely set and the top has a light golden color, which typically takes about 45-50 minutes of baking.

To test if it’s done, insert a knife into the center – it should come out clean without any runny egg mixture. The cheese on top should be fully melted and just starting to get spots of golden brown, and when you gently shake the dish, you shouldn’t see any liquid movement in the center.

If you notice any jiggling or wet spots in the middle, give it another 5-10 minutes in the oven, checking frequently to prevent overcooking.

Hearty Sausage Gravy Casserole FAQ

Why are my hash browns still crunchy in the casserole?

The key to getting perfectly tender hash browns in this casserole is making sure they’re completely thawed before using them. I always spread my frozen hash browns on a paper towel-lined baking sheet and let them sit at room temperature for about 30 minutes.

This helps remove excess moisture and ensures they’ll cook evenly in the casserole.

How do I prevent my eggs from curdling in the casserole?

The secret to smooth, creamy eggs in this casserole is to whisk them really well with the milk before adding them to the dish.

I also make sure my sausage gravy has cooled slightly before combining it with the eggs. This prevents the hot gravy from starting to cook the eggs before they go in the oven.

Is it normal for the gravy to look lumpy when I first add the milk?

Yes, it’s totally normal for the gravy to look lumpy right after you add the milk to the flour and sausage mixture.

Keep whisking steadily over medium heat, and within a few minutes, the lumps will smooth out. I like to use a whisk instead of a spoon for this step – it really helps break up those flour clumps quickly.

Preparation Time	15-20 Minutes
Cooking Time	45-55 Minutes
Total Time	60-75 Minutes
Level of Difficulty	Easy
Servings	6 Servings
Equipment	9×13″ baking pan, mixing bowl, large skillet

Estimated Nutrition

Estimated nutrition for the whole recipe (without optional ingredients):

• Calories: 4500-4800
• Protein: 220-250 g
• Fat: 300-330 g
• Carbohydrates: 300-320 g

Ingredients

For the hash browns:

• 32 oz thawed southern-style frozen hash browns
• 4 tablespoons butter
• 1½ teaspoons seasoned salt
• ½ teaspoon black pepper

For the sausage gravy:

• 1 pound breakfast sausage
• 1/3 cup plain flour
• ½ teaspoon garlic powder
• 1 teaspoon onion powder
• 3 cups full-fat milk

For the scrambled eggs:

• 12 large eggs
• ½ cup full-fat milk
• Salt and pepper to taste

For the topping:

• 2 cups grated cheddar cheese

Step 1: Prepare and Bake the Hash Browns

• 32 oz thawed southern-style frozen hash browns
• 1½ teaspoons seasoned salt
• ½ teaspoon black pepper
• 4 tablespoons butter

Preheat the oven to 400°F.

Spread hash browns evenly across the bottom of the 9×13″ baking pan.

Sprinkle with seasoned salt and pepper, then drizzle with melted butter.

Bake the hash browns for 25 minutes.

Remove from the oven, stir the potatoes, and spread them out in an even layer again.

Return to the oven and bake for an additional 10 minutes until they are golden and crispy.

Step 2: Prepare the Sausage Gravy

• 1 pound breakfast sausage
• 1/3 cup plain flour
• ½ teaspoon garlic powder
• 1 teaspoon onion powder
• 3 cups full-fat milk

While the potatoes are baking, brown the sausage in a large skillet over medium heat.

Once the sausage is browned, mix in garlic powder, onion powder, and flour.

Stir well to ensure the flour coats everything and cook for a minute or two to eliminate the raw flour taste.

Gradually stir in the milk and continue cooking over medium heat until the gravy starts to bubble and thicken.

Once thickened, remove from heat and set aside.

Step 3: Cook the Scrambled Eggs

• ½ cup full-fat milk
• 12 large eggs
• Salt and pepper to taste

Beat together milk and eggs in a bowl until well combined.

Cook in a large skillet over medium-low heat, stirring gently, until they reach a soft scramble stage—they should be mostly cooked but still slightly creamy.

Season with salt and pepper to taste, then remove from heat.

Step 4: Assemble the Casserole

• 2 cups grated cheddar cheese

Once the hash browns are fully baked, layer the scrambled eggs over them evenly.

Pour the prepared sausage gravy over the eggs and potatoes, making sure everything is covered.

Distribute shredded cheese evenly over the top of the casserole.

Step 5: Final Bake and Serve

Place the assembled casserole back into the oven.

Bake for 10-15 minutes or until the gravy is bubbly and the cheese is fully melted and golden.

Once done, remove from the oven and let it cool slightly before serving.

Enjoy the hearty breakfast casserole hot from the oven!