This Cheesy Potatoes with Smoked Sausage has been a go-to for chilly evenings and casual family gatherings. I first made this version when I had leftover smoked sausage from a summer cookout and a bag of russet potatoes begging to be used. The combination of tender potatoes, a silky cheese sauce made with Velveeta and sharp cheddar, and the smoky bite of browned sausage created a dish that disappeared faster than I could plate it. It’s the kind of comfort food that makes the kitchen smell like home and invites everyone to linger at the table. What makes this dish special is the balance between creaminess and texture. The potatoes are parboiled so they finish perfectly in the oven without turning to mush, and the sausage is quickly browned to develop caramelized edges that stand up to the cheese sauce. The sauce itself is built like a classic béchamel but finished with processed cheese for that smooth, melt-in-your-mouth quality and enriched with sharp cheddar for complexity. Serve it straight from a 9-inch square baking dish and watch it go. I’ve served this at potlucks and midweek dinners, and the feedback is always enthusiastic. Picky eaters love the cheesy component, and adults appreciate the smoky sausage. It’s forgiving, adaptable, and reliable — everything I want in a quick dinner solution.

Ingredients

• Russet potatoes (4 cups, diced): Use firm, starchy russets for the best texture. Peel and dice into roughly 1/2-inch cubes so they cook evenly; they should be slightly undercooked after boiling to avoid collapsing in the oven.
• Olive oil (1 teaspoon): For browning the smoked sausage; a neutral oil or avocado oil also works well.
• Smoked sausage (1 14-ounce package, sliced): Choose a smoked kielbasa or ring sausage with good flavor. I prefer a hardwood-smoked sausage for a deeper smoky note.
• Butter (4 tablespoons): Unsalted is ideal so you can control seasoning; butter adds richness to the sauce and helps the flour cook properly.
• All-purpose flour (1/4 cup): The thickening base for the sauce. Use gluten-free flour if needed and adjust cooking time slightly to remove any raw flour taste.
• Half-and-half or milk (2 cups): Half-and-half yields a silkier, richer sauce; whole milk is fine if you want to lighten it a touch.
• Garlic powder (1/4 teaspoon): Subtle aromatics that complement the sausage without overpowering the cheese.
• Velveeta (8 ounces, cubed): This processed cheese melts evenly and gives the sauce a velvety texture. Cut into cubes so it melts quickly and uniformly.
• Sharp cheddar cheese (1 cup, shredded): Adds bite and depth; freshly shredded melts best and avoids the anti-caking agents found in pre-shredded cheese.
• Salt and pepper: Season to taste. Start with 1/2 teaspoon salt and 1/4 teaspoon black pepper, then adjust after tasting the sauce.

Instructions

Prepare the baking dish: Lightly grease a 9-inch square baking dish with a little butter or nonstick spray so the casserole slides out easily for serving. Preheating the oven to 350°F (177°C) before assembly saves time later. Parboil the potatoes: Place the diced, peeled potatoes in a pot and cover with cold water by about 1 inch. Add a generous pinch of salt and bring to a boil over high heat. Boil until just tender when pierced with a fork, about 6 to 8 minutes depending on cube size. You want them slightly undercooked so they keep their shape during baking. Drain thoroughly to remove excess water and transfer the potatoes to the prepared baking dish. Brown the sausage: Heat a large nonstick skillet over medium-high heat and add 1 teaspoon olive oil. Add the sliced smoked sausage in a single layer and cook until the edges are nicely browned and caramelized, 4 to 6 minutes, stirring occasionally. Browning develops flavor and prevents the sausage from releasing too much liquid into the casserole. Remove the sausage and add it to the potatoes in the baking dish. Make the cheese sauce: Wipe the skillet clean, reduce heat to medium, and add 4 tablespoons butter. Once melted, sprinkle in 1/4 cup all-purpose flour and cook, stirring constantly, for about 1 minute to form a roux and remove the raw flour taste. Gradually whisk in 2 cups half-and-half or milk and bring to a gentle simmer; simmer until slightly thickened, about 2 to 3 minutes. Add 1/4 teaspoon garlic powder, reduce heat to low, and stir in 8 ounces cubed Velveeta until fully melted and smooth. Stir in half of the shredded cheddar (about 1/2 cup) until melted, then remove from heat and taste for seasoning — add salt and pepper as needed. Assemble and bake: Pour the cheese sauce evenly over the potatoes and sausage in the baking dish, stirring lightly to distribute. Sprinkle the remaining 1/2 cup shredded sharp cheddar over the top for a golden, cheesy crust. Bake in a preheated 350°F (177°C) oven for 25 to 30 minutes, or until the casserole is bubbling and the top is lightly browned. Let rest 5 minutes before serving to let the sauce set slightly.

Storage Tips

Cool the casserole to near room temperature before refrigerating in shallow, airtight containers to speed cooling and preserve texture. Refrigerate for up to 4 days. For longer storage, wrap the entire baking dish with plastic wrap and foil or transfer to a freezer-safe container; freeze for up to 3 months. To reheat from frozen, remove plastic, cover loosely with foil, and bake at 350°F (177°C) for 45 to 60 minutes, until heated through and bubbling. For single servings, reheat in a microwave on medium power in 30-second intervals until hot, stirring to redistribute sauce.

Ingredient Substitutions

If you need to lighten the dish, use whole milk instead of half-and-half and swap half the butter for a neutral oil; the texture will be slightly thinner but still creamy. For a dairy-free version, use a store-bought dairy-free cheese sauce and dairy-free cheese alternatives, noting that texture and meltability will differ. For a vegetarian option, replace smoked sausage with smoked mushroom sausage or seasoned tempeh. Swap Velveeta for 8 ounces of cream cheese plus an additional 1/2 cup finely shredded cheddar for a more natural but slightly less silky sauce. If gluten-free, replace 1/4 cup all-purpose flour with a certified gluten-free flour blend at a 1:1 ratio.

Serving Suggestions

Serve this alongside roast chicken, pork chops, or a fresh green salad to cut through the richness. Garnish with freshly chopped chives or parsley for color and a mild onion-lift. For a heartier meal, serve with steamed green beans and crusty bread. It’s also excellent alongside baked ham for holiday meals or as a centerpiece for casual buffet-style dinners.

Cultural Background

This style of casserole is rooted in American comfort food traditions where simple, filling ingredients are combined into one-dish meals. Combining potatoes and sausage has regional variations across the United States, especially in Midwestern and Southern cooking, where smoked sausages and creamy casseroles are staples at family gatherings. The use of processed melting cheese reflects mid-20th-century American convenience-cooking trends that prized meltability and silky textures.

Seasonal Adaptations

In winter, add roasted root vegetables such as parsnips or carrots for depth and warmth. In summer, lighten the dish by adding a cup of fresh corn kernels and swapping half the potatoes for diced summer squash, which shortens baking time. For autumn, stir in a handful of sautéed apples and a pinch of smoked paprika to accentuate the smoky sausage and add seasonal sweetness.

Meal Prep Tips

Assemble the casserole up to the baking step and cover tightly for refrigerating up to 24 hours; bring it to room temperature for 20 minutes before baking and add a few extra minutes to the baking time if starting cold. For portable meal prep, portion into individual ramekins, cover, and either refrigerate for up to 4 days or freeze. Label containers with baking instructions and date. Use shallow containers for faster reheating and even texture.

This Cheesy Potatoes with Smoked Sausage dish is warm, nostalgic, and surprisingly versatile. Whether you’re feeding a crowd or meal prepping for the week, it offers satisfying flavors and dependable results. I hope it becomes a staple in your kitchen, too — feel free to tweak the sausage, cheese blend, and seasonings to make it your own.