This Cheesy Potatoes with Smoked Sausage has been a go-to for cold evenings and busy weeknights when everyone wants something comforting and hands-off. I first put this combination together one winter when I had leftover smoked sausage and a bag of russet potatoes on hand; the result was so indulgent and simple that it immediately made it into our regular rotation. The dish delivers a luscious, velvety sauce made with butter, flour, half-and-half and Velveeta, balanced by the bite of sharp cheddar and the smoky, savory rounds of sausage. Texture is everything here: tender but slightly firm potatoes that keep their shape, and a creamy sauce that clings to each piece.

What makes this particular version special is the approach to timing and layering. I prefer par-boiling the potatoes so they hold up to a final bake without turning to mush, and browning the smoked sausage gives extra caramelized flavor. The cheese blend—processed cheese for silkiness and sharp cheddar for flavor—creates that perfect nostalgic gooey pull. We serve it as a hearty side for large family dinners or as a main when paired with a simple green salad. Leftovers reheat beautifully, so it’s also a smart choice for meal prep or potlucks.

Ingredients

• Russet potatoes: 4 cups diced, peeled russets (about 2 to 3 medium potatoes). Choose firm potatoes without green spots; russets break down less than waxy varieties and develop a fluffy interior after boiling.
• Olive oil: 1 teaspoon for browning sausage. A neutral olive oil works well; it helps the sausage caramelize without adding competing flavors.
• Smoked sausage: 1 (14-ounce) package, sliced into 1/4-inch rounds. I like kielbasa or smoked andouille for pronounced smoke notes; fully cooked smoked sausage adds instant depth.
• Butter: 4 tablespoons to form the base of the white sauce. Unsalted butter gives you control over final seasoning.
• 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 richer sauce; 2% milk keeps it lighter but still creamy.
• Garlic powder: 1/4 teaspoon for background savoriness—adds complexity without dominating.
• Velveeta cheese: 8 ounces, cubed. The processed cheese melts smoothly and creates that silky texture you want in a cheesy bake.
• Sharp cheddar cheese: 1 cup shredded, divided. Use a good-quality cheddar (8-ounce block shredded fresh) for the best flavor and melting behavior.
• Salt and pepper: To taste. Start conservatively since smoked sausage can be salty; adjust after tasting the sauce.

Instructions

Prepare and par-boil the potatoes: Lightly grease a 9-inch square baking dish. Place diced potatoes in a pot large enough to hold them in a single layer with water covering by about 1 inch; add 1 teaspoon of salt and bring to a boil. Boil until just tender when pierced with a fork—about 8 to 10 minutes depending on dice size. You want them a little undercooked since they finish in the oven. Drain well and transfer to the prepared baking dish. Brown the sausage: Heat a large nonstick skillet over medium-high heat, add 1 teaspoon olive oil, and sauté the sliced smoked sausage until it develops brown edges and a bit of crispness, about 4 to 6 minutes. Remove and add to the potatoes in the baking dish so the sausage juices mingle with the warm spuds. Make the roux and sauce: Wipe the skillet clean, then melt 4 tablespoons butter over medium heat. Sprinkle in 1/4 cup all-purpose flour and stir constantly for 1 minute to cook off the raw flour taste. Gradually whisk in 2 cups half-and-half, bring to a gentle simmer and add 1/4 teaspoon garlic powder. Reduce heat to low and stir in 8 ounces cubed processed cheese until fully melted and smooth. Add half (about 1/2 cup) of the shredded sharp cheddar and stir until melted; season with salt and pepper to taste. Assemble and bake: Pour the cheese sauce evenly over the potatoes and smoked sausage in the dish. Sprinkle the remaining shredded cheddar on top. Bake in a preheated 350°F oven for 25 to 30 minutes, until bubbling and lightly browned on top. Remove from oven and let rest for 5 minutes before serving—this helps the sauce set slightly and makes it easier to serve.

Storage Tips

Let leftovers cool to near room temperature (no more than two hours), then transfer to an airtight container and refrigerate for up to 4 days. For longer storage, freeze in a foil-lined baking dish or freezer-safe container for up to 3 months; wrap tightly to prevent freezer burn. To reheat from frozen, thaw overnight in the refrigerator, then bake at 350°F until simmering—about 20 to 30 minutes depending on depth. For refrigerated leftovers, reheat in a 325°F oven for 15 to 20 minutes covered, then uncover for the last 5 minutes so the top regains some texture.

Ingredient Substitutions

If you prefer a lighter sauce, substitute whole milk for half-and-half—expect a slightly thinner texture. For a stronger smoky flavor, use smoked gouda in place of Velveeta and reduce additional salt. To make this gluten-free, use 1/4 cup gluten-free all-purpose flour or 2 tablespoons cornstarch whisked into a little cold milk before adding; cornstarch produces a slightly glossier sauce. Vegetarian option: replace smoked sausage with grilled mushrooms and smoked paprika, and use plant-based processed cheese to mimic the silky texture.

Serving Suggestions

Serve slices from the 9-inch square dish alongside a crisp green salad dressed with lemon vinaigrette to balance richness. For heartier meals, pair with roasted Brussels sprouts or steamed green beans and pickled red onions for acidity. Garnish with chopped chives or parsley and a sprinkle of smoked paprika for color and aroma. This casserole also works well at brunch—add a side of scrambled eggs and fruit for a complete spread.

Cultural Background

This layered potato-and-sausage dish reflects the American tradition of hearty casseroles that stretch simple ingredients into satisfying family meals. Smoked sausage has Central and Eastern European roots—kielbasa and smoked links arrived with immigrants and became staples in comfort cooking. The use of processed cheese for smoothness is a mid-20th-century American technique that prioritizes meltability and convenience; when paired with sharp cheddar and fresh seasoning, it creates a modern comfort classic that families have adapted for decades.

Seasonal Adaptations

In winter, boost the comfort factor with roasted root vegetables folded into the bake; in summer, lighten it with a splash of lemon in the dressing for an accompanying salad and swap half the cheese for fresh mozzarella. For holiday tables, add sliced smoked turkey sausage and chopped roasted red pepper for color. During grilling season, brown the sausage on the grill or use smoked grilled kielbasa for an outdoor twist.

Meal Prep Tips

To save time, par-boil the diced potatoes the night before and refrigerate in an airtight container. Brown the sausage and shred the cheddar ahead of time; when ready to serve, assemble and bake for the full 25 to 30 minutes. If transporting to a potluck, bake covered and finish uncovered for the last 10 minutes at the host’s oven to recreate the crisp top. Portion into individual foil dishes for single-serving reheats at work or school lunches.

There’s something deeply satisfying about lifting a spoonful of creamy potatoes and smoky sausage straight from the baking dish—this is the kind of food that invites conversation and second helpings. Try it once and I bet it will become one of those easy, reliable dishes you reach for again and again.