This dish of cheesy potatoes with smoked sausage has been a weeknight lifesaver and a potluck star in my family for years. I first came across the idea during a busy holiday season when I needed something that could be prepped quickly, feed a crowd, and travel well. The combination of tender russet potatoes, a rich cheese sauce, and slices of smoky sausage delivers a balance of creamy texture and savory bite that always brings people to the table.

I remember the first time I served it at a small gathering and the casserole came back empty in minutes. The potatoes hold just enough structure to be forkable while the cheese sauce binds everything together into a silky, irresistible blanket. The smoked sausage adds depth and a hint of spice depending on the variety you choose. It is pure comfort food that works equally well as a side for a holiday spread or as a main when paired with a simple green salad.

Ingredients

• Russet potatoes: 4 cups diced peeled russet potatoes. Russets hold their shape when boiled and briefly undercooked before baking. Look for firm potatoes without sprouts. Dice into roughly 1 inch pieces for even cooking.
• Olive oil: 1 teaspoon for browning the sausage. Extra virgin is fine. It prevents sticking and adds a light fruitiness.
• Smoked sausage: 14 ounce package smoked sausage sliced about 1 4 inch thick. Fully cooked kielbasa or smoked Polish sausage are great choices. Choose a brand you trust for consistent flavor.
• Butter: 4 tablespoons unsalted butter for the roux. Start with unsalted so you can control seasoning.
• All purpose flour: 1 4 cup to thicken the sauce. Measure carefully for a silky texture without lumps.
• Half and half or milk: 2 cups. Half and half yields a richer sauce. Whole milk works well if you prefer a lighter finish.
• Garlic powder: 1 4 teaspoon for background warmth. Fresh garlic will brown in the butter quickly so the powder is a safe choice for smooth sauce.
• Velveeta cheese: 8 ounces cubed. Processed cheese melts smoothly and helps create that glossy, creamy body.
• Sharp cheddar cheese: 1 cup shredded sharp cheddar. Provides tang and depth. Grate it yourself for best melting quality.
• Salt and black pepper: To taste. Start with a quarter teaspoon of salt and a few grinds of pepper and adjust after the cheese melts.

Instructions

Prepare the baking dish and potatoes:Lightly grease a 9 inch square baking dish with a little butter or nonstick spray. Place the diced potatoes in a large pot of cold salted water, bring to a gentle boil, then simmer until just tender when pierced with a fork about 8 to 10 minutes. You want them slightly undercooked so they keep texture after baking. Drain thoroughly to remove excess water and transfer to the prepared dish.Brown the sausage:Heat a large nonstick skillet over medium high heat and add the olive oil. Arrange the sausage slices in a single layer and brown for about 2 minutes per side until the edges caramelize. Remove the browned slices to the baking dish with the potatoes. Browning improves flavor by creating Maillard notes that stand up to the creamy sauce.Make the roux and sauce:Wipe the skillet clean and return to medium heat. Add the butter and let it melt without letting it brown. Stir in the flour and cook for about 1 minute while whisking to remove raw flour taste. Gradually whisk in the half and half and bring to a gentle simmer; the sauce will thicken slightly. Add the garlic powder, then turn the heat to low and stir in the cubed processed cheese a few pieces at a time until fully melted and smooth.Finish the cheese sauce:Stir in half the shredded cheddar until melted and smooth. Taste the sauce and season with salt and pepper. If the sauce is too thick add a tablespoon of milk at a time until it reaches a pourable consistency. Pour the sauce over the potatoes and sausage in the baking dish and sprinkle the remaining cheddar evenly on top for a golden crust.Bake:Preheat the oven to 350 degrees Fahrenheit. Bake the assembled dish uncovered for 25 to 30 minutes until the top is bubbling and the cheese is lightly golden. Let rest five to ten minutes before serving to allow the sauce to set slightly for clean slices.

Storage Tips

Cool leftovers to room temperature for no more than two hours and refrigerate in a shallow airtight container. For best results store slices in a single layer separated by parchment paper. Reheat in an oven preheated to 325 degrees Fahrenheit covered with foil until warmed through about 12 to 15 minutes. Avoid microwaving large portions as the sauce can separate and the texture of the potatoes may become mealy.

Ingredient Substitutions

If you prefer a lighter dish use whole milk instead of half and half and reduce the processed cheese to 4 ounces, supplementing with extra sharp cheddar for flavor. For a gluten free option replace the all purpose flour with an equal amount of rice flour or use a gluten free all purpose blend. Swap smoked turkey sausage for pork sausage to lower saturated fat and retain the smoky flavor.

Serving Suggestions

Serve slices with a crisp green salad dressed in an acidic vinaigrette to cut richness. Steamed green beans or roasted Brussels sprouts add color and texture. For a heartier meal pair with roasted carrots and a simple apple slaw that contrasts the warm creaminess with fresh crunch.

Cultural Background

This casserole style dish is rooted in American comfort food traditions that blend convenience and flavor. Using smoked sausage and processed cheese reflects home cook adaptations made for quick, reliable melting and bold taste. Variations appear across regions with local smoked sausages and cheese styles influencing the final character.

Seasonal Adaptations

In winter add a pinch of smoked paprika or a splash of Dijon mustard to the sauce for warmth. In summer lighten the dish by folding in blanched green beans and using milk with less fat. For holiday tables increase the seasoning and finish with a gratin of panko and melted butter for a crisper top.

Meal Prep Tips

Dice the potatoes and parboil then cool and store in the refrigerator up to two days ahead. Slice and brown the sausage the day before. Assemble the casserole the morning of serving and keep covered in the refrigerator. Allow 10 to 15 extra minutes of bake time when starting from chilled.

Whether you bring it to a family dinner or serve it after a long day, this cheesy combination has a way of making people feel looked after. Make it your own by adjusting salt, swapping cheeses, or trying different smoked sausages until you find the version that feels like home.