Name: Grilled Cheese Sausage and Egg Breakfast Casserole Recipe
Prep time: 20 min
Cook time: 40 min
Total time: 1 h
Cuisine: American
Ingredients: Pork Breakfast Sausage: 1 pound Eggs: 18 large, divided Butter: 4 tablespoons, divided Whole Milk: 1 cup, divided Kosher Salt: 1/4 teaspoon Coarse Ground Black Pepper: 1/2 teaspoon Ground Mustard: 1/2 teaspoon Texas Toast: 12 slices American Cheese: 12 slices

Jump to Recipe

There’s something downright magical about a dish that brings everyone to the table first thing in the morning—especially when it’s as comforting and crave-worthy as the Grilled Cheese Sausage and Egg Breakfast Casserole. Imagine gooey layers of golden American cheese and juicy sausage sandwiched between fluffy scrambled eggs and buttery Texas toast, all baked to crispy perfection. It multitasks as the ultimate weekend brunch centerpiece, a holiday breakfast, or an easy meal prep solution for busy weeks. Trust me, once you’ve tasted this casserole, you’ll want to make it again and again.

Grilled Cheese Sausage and Egg Breakfast Casserole Recipe - Recipe Image

Ingredients You’ll Need

This lineup of classic breakfast ingredients is so simple, but each component is essential to the bold flavors and irresistible, melty texture. Every ingredient plays a key role, from adding creamy richness to delivering that signature savory bite and irresistible golden color.

Pork breakfast sausage: Choose your favorite variety—spicy, maple, or classic—for a hearty, savory layer that infuses the whole casserole.
Large eggs: Eighteen eggs might sound like a lot, but they make every bite fluffy and rich (and stretch the casserole to feed a crowd!).
Butter: Adds richness and helps toast the bread beautifully for that golden, crispy top.
Whole milk: Balances the eggs and creates a creamy, custard-like interior.
Kosher salt: A little goes a long way to amplify all the flavors.
Coarse ground black pepper: Gives each bite a gentle heat and classic breakfast flavor.
Ground mustard: Adds a subtle tang and depth that really enhances the eggs and cheese.
Texas toast: Thick-cut bread holds up to all those delicious layers and gets perfectly crisp.
American cheese slices: Melts into gooey perfection, binding everything together with classic grilled cheese flavor.

How to Make Grilled Cheese Sausage and Egg Breakfast Casserole

Step 1: Brown the Sausage

Start by preheating your oven to 375 degrees. In a large pan over medium-high heat, crumble and cook the breakfast sausage until it’s deeply browned and nicely caramelized, about 4–5 minutes. The goal here is to develop all that savory flavor that will carry through the finished Grilled Cheese Sausage and Egg Breakfast Casserole. Drain the fat so things don’t turn greasy, and set the cooked sausage aside for later.

Step 2: Scramble a Layer of Eggs

Return the pan to medium heat and add one tablespoon of butter. While that’s warming, whisk together 10 eggs with 1/4 cup of milk, salt, and pepper. Pour this egg mixture into the skillet and gently scramble until they’re just set—soft and creamy is perfect. This layer of eggs will add luscious texture to the middle of your casserole.

Step 3: Build the Grilled Cheese Layers

Now the fun part begins! Arrange six slices of Texas toast along the bottom of a greased 9×13 pan, making sure the whole bottom is covered. Top each slice with a piece of American cheese. Next, evenly distribute all of your browned sausage over the cheese. Then, spoon on that soft, freshly scrambled egg layer. Top each section with another slice of cheese for double the melty goodness.

Step 4: Add the Egg Custard

For the finishing touch that makes this casserole unbelievably creamy, whisk together the remaining eight eggs, 3/4 cup milk, and the ground mustard in a medium bowl. Carefully pour this mixture evenly over the layered ingredients in the baking dish, letting it seep into every nook and cranny.

Step 5: Top and Butter Up

Lay down the remaining six slices of Texas toast on top, covering the casserole like a giant, griddled sandwich. Melt the last three tablespoons of butter and brush it generously over the top of the bread. This final step ensures a crisp, golden finish reminiscent of your favorite grilled cheese sandwich.

Step 6: Bake to Perfection

Cover the pan tightly with foil and bake at 375 degrees for 20 minutes. Then, remove the foil and bake for another 20 minutes, until the top is a deep golden brown and the custard is set. Let the Grilled Cheese Sausage and Egg Breakfast Casserole cool for at least 5 minutes before slicing—trust me, the anticipation is worth it!

How to Serve Grilled Cheese Sausage and Egg Breakfast Casserole

Garnishes

Chopped fresh chives or green onions are a fantastic way to add a little pop of color and gentle onion freshness on top of your Grilled Cheese Sausage and Egg Breakfast Casserole. A sprinkling of freshly cracked black pepper or a dusting of smoked paprika adds visual flair and subtle flavor, too. If you’re feeling adventurous, a spoonful of your favorite salsa or hot sauce can bring the whole plate to life.

Side Dishes

This casserole is hearty, so light and fresh sides really shine. Try a vibrant fruit salad, citrus wedges, or tomato slices to balance that savory richness. Crispy hash browns, roasted potatoes, or a simple green salad also pair beautifully—making the meal extra filling and colorful without overshadowing the main event.

Creative Ways to Present

Elevate your casserole game by cutting rectangles into sandwich-sized pieces and serving them stacked high, like a breakfast sandwich casserole tower. For brunches, slice into squares and arrange on a platter lined with leafy greens or bright veggies. If you want to go individual, bake the recipe in lightly greased muffin tins for perfectly portioned mini casseroles—kids and grownups alike love the presentation.

Make Ahead and Storage

Storing Leftovers

Leftover Grilled Cheese Sausage and Egg Breakfast Casserole can be stored right in the baking dish, tightly wrapped with foil or plastic wrap, in the refrigerator for up to four days. The flavors intensify as it sits, and it’s just as delicious warmed up for a speedy breakfast or lunch the next day.

Freezing

This casserole freezes surprisingly well. Simply let it cool completely, then cut into portions and wrap each piece tightly in plastic wrap followed by aluminum foil. Arrange in a freezer-safe ZIP bag or airtight container to prevent freezer burn. When properly stored, it can last up to two months and makes those busy mornings a breeze.

Reheating

To reheat, pop individual slices in the microwave for 1–2 minutes, or cover with foil and warm in a 350-degree oven until heated through (about 15–20 minutes). If reheating from frozen, thaw overnight in the fridge for best results. For maximum crispiness, a quick pass under the broiler revives the buttery, golden top of the Grilled Cheese Sausage and Egg Breakfast Casserole.

FAQs

Can I use a different type of cheese instead of American?

Absolutely! While American cheese melts beautifully and gives that classic grilled cheese vibe, you can substitute with cheddar, Swiss, provolone, or even a spicy pepper jack for a twist. Just keep in mind the texture—creamier melting cheeses work best for that ooey-gooey finish.

Can I make this casserole vegetarian?

Definitely—swap the pork sausage for your favorite plant-based breakfast sausage, or use sautéed mushrooms and spinach for an all-veggie version. The Grilled Cheese Sausage and Egg Breakfast Casserole is endlessly adaptable to different diets and preferences.

Can I assemble this the night before?

Yes! You can fully assemble the casserole (just stop before baking), cover tightly, and refrigerate overnight. In the morning, uncover and bake as directed—just add a few extra minutes to account for the chilled ingredients.

What’s the best bread for this recipe?

Thick-sliced Texas toast is classic for its sturdy texture and ability to soak up the custard without getting soggy. You can try brioche or challah if you want a slightly sweeter, richer flavor, but thinner bread isn’t recommended as it might fall apart.

How do I know when it’s fully cooked?

The edges will be golden and crisp, and the center will be set (not jiggly) when gently shaken. If you want to be certain, insert a small knife in the center—it should come out clean and the cheese should be melty and bubbling.

Final Thoughts

If you’re ready to bring people together around the breakfast table, this Grilled Cheese Sausage and Egg Breakfast Casserole will not disappoint. It’s incredibly satisfying and sure to become a family favorite whether for lazy weekends or special brunches. Give it a try—you may just find yourself looking forward to mornings like never before!

Grilled Cheese Sausage and Egg Breakfast Casserole Recipe

★★★★★

4.8 from 11 reviews

Author: lilan
Total Time: 1 hour
Yield: 8 servings
Diet: Vegetarian

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Description

This Grilled Cheese Sausage and Egg Breakfast Casserole is a delicious and hearty dish that’s perfect for feeding a crowd at breakfast or brunch. Layers of fluffy scrambled eggs, savory pork sausage, gooey American cheese, and buttery Texas toast come together in this easy-to-make casserole.

Ingredients

Pork Breakfast Sausage:

1 pound

Eggs:

18 large, divided

Butter:

4 tablespoons, divided

Whole Milk:

1 cup, divided

Kosher Salt:

1/4 teaspoon

Coarse Ground Black Pepper:

1/2 teaspoon

Ground Mustard: