Chili Relleno Casserole Recipe

This hearty and cheesy Chili Relleno Casserole is the kind of meal that feels like a warm hug at the end of a long day. Packed with roasted green chilies, savory ground beef, gooey cheese, and soft layers of tortillas, it delivers all the comforting Tex-Mex flavors you crave—without the hassle of stuffing and frying individual peppers. It’s a fantastic make-ahead dish, perfect for feeding a hungry crowd or transforming a weeknight dinner into something special.

Why You’ll Love This Recipe

• Perfect for Busy Nights: Skip the tedious prep of traditional chili rellenos—this layered casserole is quick to assemble and bakes to perfection.
• Packed with Flavor: Between the mildly spicy green chilies, seasoned beef, melted cheese, and the savory egg topping, every bite is bold and satisfying.
• Comfort Food Classic: It’s cheesy, hearty, and soul-warming—everything a great casserole should be.
• Crowd-Pleaser: Whether it’s a potluck or a family dinner, this one disappears fast. Even picky eaters love it.

Ingredients You’ll Need

Let’s break down what makes this casserole shine. Each ingredient adds its own magic:

• Green Chilies: Use whole roasted chilies, preferably Hatch brand—they bring a mild heat and that distinct smoky-sweet flavor.
• Ground Beef: Provides a savory, meaty layer that pairs beautifully with the spice and cheese.
• Onion: Finely chopped to melt into the beef mixture and add aromatic depth.
• Grated Cheese: Monterey Jack or white cheddar both melt beautifully and bring creamy richness.
• Corn Tortillas: These form the base and middle layers—think of them as the Tex-Mex lasagna sheets.
• Refried Beans: They bulk up the meat mixture and make it ultra comforting and hearty.

Topping:

• Eggs: Acts as the binding layer, giving structure and a slight custardy texture to hold the layers together.
• Flour: Helps thicken the topping and keep everything cohesive.
• Evaporated Milk: Adds creaminess and a touch of richness to the topping.
• Hot Sauce: Adds just a subtle kick—adjust to your heat preference.
• Paprika, Onion Powder, Salt: Seasonings that enhance every layer without overpowering.

Variations

Want to make this your own? Here are some fun and tasty ideas:

• Vegetarian Version: Skip the ground beef and double up on refried beans, or add sautéed mushrooms and zucchini instead.
• Spicy Twist: Add chopped jalapeños or use pepper jack cheese for more heat.
• Breakfast-Style: Swap the beef for chorizo or sausage and serve it with scrambled eggs for a Tex-Mex brunch bake.
• Low-Carb Option: Replace tortillas with thin zucchini or eggplant slices to cut down on carbs.

How to Make Chili Relleno Casserole

Step 1: Prep the Oven and Dish

Preheat your oven to 375°F (190°C) and grease a 9×13-inch baking dish with cooking spray or a bit of oil.

Step 2: Mix the Topping

In a large bowl, whisk together the eggs, flour, evaporated milk, hot sauce, paprika, onion powder, and salt until smooth. Set aside.

Step 3: Cook the Meat Mixture

In a skillet over medium heat, cook the ground beef and chopped onion until browned and tender—about 5-7 minutes. Stir in the refried beans until fully combined.

Step 4: Build the First Layer

Cut your corn tortillas into strips and layer half of them on the bottom of the baking dish. Top with half the green chilies, then half the cheese.

Step 5: Repeat the Layers

Layer the rest of the tortilla strips, followed by the remaining chilies and cheese.

Step 6: Add the Topping and Meat

Pour the egg mixture evenly over the layers in the dish. Then, spoon the beef and bean mixture on top and smooth it out.

Step 7: Finish with Cheese

Sprinkle the remaining cheese all over the top for that gooey, golden finish.

Step 8: Bake

Cover with foil and bake for 45 minutes. Remove the foil during the last 5 minutes to brown the top. Let it rest before slicing.

Pro Tips for Making the Recipe

• Drain Your Green Chilies: Excess moisture can make your casserole soggy. A quick drain on paper towels helps.
• Cheese Matters: Use freshly grated cheese—it melts better and tastes richer than the pre-shredded kind.
• Let it Rest: Letting the casserole sit for 10 minutes before serving helps it set and makes slicing easier.
• Make It Ahead: This dish is even better the next day, so it’s ideal for prepping in advance.

How to Serve

This casserole is delicious on its own, but here are a few ideas to round out the meal:

Toppings:

• A dollop of sour cream
• Chopped cilantro or green onions
• Fresh avocado slices or guacamole
• A spoonful of salsa or pico de gallo

Sides:

• Mexican rice or Spanish rice
• A crisp green salad with lime vinaigrette
• Tortilla chips and salsa on the side

Make Ahead and Storage

Storing Leftovers

Let the casserole cool completely, then cover tightly or transfer to an airtight container. Refrigerate for up to 4 days.

Freezing

This freezes beautifully. Slice into portions, wrap individually, and freeze for up to 2 months. Thaw overnight in the fridge before reheating.

Reheating

Warm in the microwave or cover with foil and bake at 350°F until heated through. Add a sprinkle of fresh cheese on top before reheating for extra yum.

FAQs

Can I make this casserole vegetarian?
Yes! Skip the ground beef and use more beans, or add sautéed vegetables like mushrooms, bell peppers, and zucchini for a hearty vegetarian version.

Can I use flour tortillas instead of corn?
Corn tortillas hold up better and add authentic flavor, but flour tortillas will work in a pinch. Just know they’ll be softer and a bit more doughy.

Is this casserole spicy?
Not overly. The green chilies add mild warmth, and the hot sauce is subtle. If you’re sensitive to heat, reduce or omit the hot sauce entirely.

Can I make this ahead of time?
Absolutely! Assemble the casserole a day in advance, cover, and refrigerate. Bake when you’re ready, adding 5-10 extra minutes if it’s cold from the fridge.

Final Thoughts

This Chili Relleno Casserole is everything you love about Tex-Mex comfort food, with none of the stress. It’s easy, satisfying, and endlessly adaptable. Whether you’re serving it for a casual family dinner or prepping meals for the week, this dish always hits the spot. Try it once and it just might become a regular on your table!

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