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A 45-degree angle shot of a cheesy kielbasa and potato casserole in a white dish, showing the gooey, melted cheddar and seared sausage chunks.

Kielbasa Potato Casserole: The Ultimate Cheesy & Comforting Bake

This Kielbasa Potato Casserole is the ultimate comfort food, featuring tender Yukon Gold potatoes, seared smoked sausage, and a rich, velvety cheddar cheese sauce. It's baked until golden brown and bubbly for a perfect weeknight dinner.
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Prep Time 20 minutes
Cook Time 40 minutes
Total Time 1 hour
Servings: 8 servings
Course: Dinner, Main Course
Cuisine: American
Calories: 680
Ingredients Equipment Method Notes

Ingredients
  

  • 2 lbs Yukon Gold Potatoes, peeled and cut into 1-inch chunks Approx 900g
  • 14 oz Polish Kielbasa, sliced into ½-inch rounds Approx 400g
  • 1 tbsp Olive Oil 15ml
  • 4 tbsp Unsalted Butter 57g
  • 1/4 cup All-Purpose Flour 30g
  • 2.5 cups Whole Milk, warmed 600ml
  • 8 oz Sharp Cheddar Cheese, freshly grated and divided 225g
  • 1 tsp Salt 5g
  • 1/2 tsp Black Pepper 2g
  • 1/2 tsp Garlic Powder 2g
  • 1/2 tsp Paprika 2g
  • 2 tbsp Fresh Parsley, finely chopped For garnish

Equipment

  • 1 9x13 inch (23x33 cm) baking dish Ceramic or glass is preferred.
  • 1 Large Skillet
  • 1 Saucepan
  • 1 Large pot

Method
 

  1. Preheat oven to 375°F (190°C). Place potato chunks in a large pot, cover with cold salted water, and bring to a boil. Cook for 8-10 minutes until just fork-tender. Drain well.
  2. While potatoes boil, heat olive oil in a large skillet over medium-high heat. Add kielbasa slices and sear for 2-3 minutes per side, until a deep golden-brown crust forms. Remove from skillet and set aside.
  3. In a saucepan, melt butter over medium heat. Whisk in flour and cook for 1 minute. Gradually whisk in the warm milk until smooth. Cook, stirring, for 5-7 minutes until thickened. Remove from heat and stir in seasonings and three-quarters of the grated cheddar until fully melted.
  4. In a large bowl, combine the drained potatoes and seared kielbasa. Pour the cheese sauce over and stir to combine. Transfer to a 9x13 inch baking dish.
  5. Sprinkle the remaining cheese over the top. Bake for 25-30 minutes, or until the top is golden brown and the edges are bubbling.
  6. Let the casserole rest for 10 minutes before serving. Garnish with fresh parsley and a sprinkle of black pepper.

Notes

Shred Your Own Cheese: This is the most important tip for a gooey, non-greasy casserole. Pre-shredded cheeses have additives that prevent a smooth melt.
Don't Over-Boil the Potatoes: You want them just tender enough to pierce with a fork, but still firm. They will finish cooking in the oven.
Warm Your Milk: Adding warm milk to the roux helps create a lump-free sauce. Cold milk can cause the butter in the roux to seize.
Let It Rest: Giving the casserole 10 minutes to rest after it comes out of the oven is crucial. It allows the molten cheese sauce to set.