This Cheesy Potatoes with Smoked Sausage has been a weeknight savior in my kitchen for years. I first put these flavors together one chilly evening when I had a pack of smoked sausage and a bag of russets staring back at me. The result was instantly addictive: tender potato cubes coated in a velvety cheese sauce punctuated by the smoky, savory bite of browned sausage. It quickly graduated from last-minute dinner to a staple whenever friends come over or when I want something that feels like a warm hug on a plate.

What makes this dish special is the balance of textures and comfort: the potatoes are cooked until just tender so they keep a tender-yet-firm bite after baking, while the cheese sauce binds everything together into a creamy, glossy finish. The smoked sausage adds both flavor and a little chew that prevents the dish from becoming one-note. I love making it in a 9-inch square baking dish because it crisps gently at the edges and reheats perfectly. When my family sits down to this, there’s always a rush to claim the crispy corners.

Ingredients

• Russet potatoes: 4 cups diced, peeled. Choose medium-large russets for a starchy texture that becomes creamy without falling apart; peel for the classic silky bite.
• Olive oil: 1 teaspoon to brown the sausage. Use a light-tasting olive oil or a neutral oil if you prefer a cleaner flavor.
• Smoked sausage: 1 (14-ounce) package, sliced. I like kielbasa-style smoked sausage for its smoky profile; look for high-quality brands with short ingredient lists.
• Butter: 4 tablespoons to build the roux. Salted or unsalted both work—if using salted, reduce added salt at the end.
• All-purpose flour: 1/4 cup to thicken the sauce. Measure by spooning into the cup and leveling for accuracy.
• Half-and-half or milk: 2 cups. Half-and-half yields a silkier sauce; whole milk is a lighter, perfectly acceptable swap.
• Garlic powder: 1/4 teaspoon for subtle aromatic depth without overwhelming the cheese.
• Velveeta cheese: 8 ounces, cubed. This melts into a glossy, stable sauce; cubing helps it incorporate quickly.
• Sharp cheddar: 1 cup, shredded. Adds bite and a classic cheddar flavor—freshly shredded melts more smoothly than pre-shredded blends.
• Salt and pepper: To taste. Season only after tasting the sauce since processed cheeses can be salty.

Instructions

Prep the baking dish and potatoes: Lightly grease a 9-inch square baking dish with a little butter or nonstick spray. Bring a pot of salted water to a simmer, add the diced potatoes and cook until they are just tender—about 8 to 10 minutes. You want them slightly undercooked so they hold their shape in the oven. Drain thoroughly to remove excess water and transfer to the prepared dish. Brown the sausage: Heat a large nonstick skillet over medium-high heat. Add 1 teaspoon olive oil and the sliced smoked sausage. Sear until the slices are golden-brown on both sides, about 4 to 5 minutes, stirring occasionally. The browning adds Maillard flavor that lifts the entire dish. Remove the sausage with a slotted spoon and add it to the potatoes. Make the roux and sauce: Wipe the skillet clean and return to medium heat. Melt 4 tablespoons butter, then whisk in 1/4 cup all-purpose flour and cook for about 1 minute to remove the raw flour taste. Gradually whisk in 2 cups half-and-half (or milk) and bring to a gentle simmer, whisking constantly to avoid lumps. Add 1/4 teaspoon garlic powder. Reduce heat to low and stir in cubed 8 ounces Velveeta until fully melted, then fold in half the shredded cheddar (about 1/2 cup) until smooth. Taste and season with salt and pepper as needed. Assemble and bake: Pour the hot cheese sauce evenly over the potatoes and sausage in the baking dish. Sprinkle the remaining 1/2 cup shredded sharp cheddar on top. Bake in a preheated 350°F oven for 25 to 30 minutes, until bubbling and slightly golden at the edges. An additional 3–5 minutes under the broiler will create a golden crust if desired—watch carefully. Rest and serve: Allow the dish to rest for 5 to 7 minutes after removing from the oven; this helps the sauce set slightly so portions hold together. Serve warm straight from the baking dish.

Storage Tips

Cool leftovers to room temperature before covering and refrigerating in an airtight container; they will keep for 3 to 4 days. For freezing, portion into freezer-safe containers and label with the date—frozen portions keep well for up to 3 months. Reheat gently in a 350°F oven covered with foil for 15–20 minutes for single portions, removing foil the last 5 minutes to restore surface texture. Microwaving works for quick meals but may yield a softer texture; add a splash of milk when reheating to restore creaminess.

Ingredient Substitutions

If you don’t have Velveeta, substitute 8 ounces of a melty processed cheese alternative and increase shredded cheddar to 1 1/2 cups to maintain flavor. For a lighter version, use 2 cups whole milk plus 2 tablespoons cornstarch whisked in with the milk to thicken (add cornstarch slurry to cold milk first). For a gluten-free variant, replace all-purpose flour with a 1:1 gluten-free flour blend or 2 tablespoons cornstarch dissolved in the cold milk before heating. Swap smoked sausage for kielbasa turkey sausage or plant-based smoked slices to change the protein profile and reduce saturated fat.

Serving Suggestions

Serve as a hearty side alongside roasted green beans, a crisp simple salad with a vinegar-based dressing, or braised greens to cut through the richness. For a complete plate, add a green vegetable and a tart condiment such as pickled red onions or mustard on the side. Garnish with chopped chives or parsley and a light sprinkle of smoked paprika to highlight the sausage’s flavor. This dish also shines as a main at casual gatherings—offer crusty bread and a crisp coleslaw for contrast.

Cultural Background

Combining potatoes with smoked sausage is a tradition found in many northern and central European cuisines, where preserved meats and root vegetables were pantry essentials. The use of a creamy cheese sauce is a modern American adaptation that leans into comfort-cooking traditions. This particular assembly—cubed potatoes, smoked sausage, and a cheese binder—reflects Midwestern potlucks and homey casseroles that prioritize simplicity, satiety and crowd-friendly flavors.

Seasonal Adaptations

In winter, boost comfort by stirring in roasted garlic or caramelized onions before baking. For spring and summer, lighten the dish with half milk and half low-fat yogurt added off-heat for tang, and top with sliced scallions and halved cherry tomatoes after baking. During the holidays, add a pinch of nutmeg to the sauce for warmth or fold in roasted Brussels sprouts to stretch the dish and add seasonal greens.

Meal Prep Tips

Assemble the casserole up to the point of baking and refrigerate for up to 24 hours; allow it to come to room temperature for 20 minutes before popping in a 350°F oven—you may need to add 5–10 minutes to baking time. Alternatively, make the sauce and cook the sausage ahead, store separately from the potatoes, and combine shortly before baking to preserve texture. Use portioned, oven-safe containers for grab-and-go reheating during busy weeks.

We end every meal with a little extra chatter about who gets the crispy corners next time. I hope these techniques and small tricks help you produce consistent, creamy results that your family will ask for again and again.