Chili Relleno Casserole Bake

This Chili Relleno Casserole instantly became a favorite in my kitchen for weeknight dinners and big family gatherings alike. I love how it transforms all the classic flavors of a stuffed chili into a cozy, crowd-pleasing bake perfect for sharing.

When I first layered this casserole for my sister’s birthday brunch I was amazed by how every bite delivered that perfect balance of creamy cheesy spicy and savory. Now it is a go-to any time comfort is in order.

Ingredients

• Ground beef: Provides heartiness and protein, use freshly ground with good marbling for best flavor
• Finely chopped onion: Builds a savory foundation, pick yellow or white onions for subtle sweetness
• Refried beans: Add creaminess and keep the layers moist, look for authentic brands or make your own
• Roasted green chilies: Bring a smoky mild heat, Hatch chilies are extra special if you can find them
• Monterey Jack or white cheddar cheese: Melts beautifully and adds that essential rich tang, choose blocks and shred yourself for best melting
• Corn tortillas: Create structure and subtle corn flavor, use fresh tortillas from a local shop if possible
• Large eggs: Bind everything together, always use fresh eggs for the creamiest texture
• All-purpose flour: Helps set the custard, go for unbleached if you can
• Evaporated milk: Creates a silky lush custard layer, opt for full-fat for best results
• Hot sauce: Lets you control the spice, find your favorite for a bit of kick
• Paprika: Boosts the chili flavor, choose a smoked paprika for added depth
• Onion powder: Enhances the savory notes, try granulated for great blending
• Salt: Pulls all the flavors forward, use kosher salt for balanced seasoning

Instructions

Prepare the Oven and Baking Dish:

Preheat your oven to 375 degrees Fahrenheit or 190 degrees Celsius and generously grease a 9 by 13 inch dish with butter or oil to prevent sticking and encourage golden edges

Whisk the Egg Mixture:

In a medium bowl whisk the eggs with flour evaporated milk your chosen amount of hot sauce paprika onion powder and salt continue whisking until completely smooth with no lumps visible then set aside

Cook the Beef and Beans:

In a large skillet over medium heat cook the ground beef and finely chopped onion together allow them to cook stirring often breaking apart the beef until it is fully browned and the onions are soft this usually takes about five to seven minutes stir in the refried beans and mix thoroughly until evenly combined and heated through

Start the First Layer:

Scatter half of your sliced corn tortillas over the bottom of the prepared dish making sure they overlap slightly to cover well

Add Chilies and Cheese:

Lay half of the roasted chilies over the tortillas arranging them evenly sprinkle half of your shredded cheese over the chilies

Repeat the Layers:

Repeat with the remaining tortillas chilies and most of the cheese reserving a small handful for the top

Pour Egg Custard Over:

Slowly pour the egg mixture all over the layered ingredients moving in a circular pattern to ensure even coverage and soak each corner

Top with Beef and Beans:

Dollop the beef and bean mixture over the top in even spoonfuls then use a spatula to gently spread it across the casserole in a smooth even layer

Finish with Cheese:

Sprinkle the reserved cheese evenly across the surface pressing lightly if needed so it adheres well

Bake and Rest:

Cover tightly with foil and bake on the middle rack for forty five minutes then remove the foil and bake for an additional five minutes so the cheese bubbles and browns slightly allow to rest for ten minutes before slicing to help it set

I always use thick roasted Hatch chilies if I see them in the market since their smoky flavor takes the casserole to another level. My husband says the cheese layer is his favorite and the golden bubbling top never fails to draw everyone to the kitchen.

Storage tips

Once cooled slice into servings and store in airtight containers in the fridge for up to three days. This casserole reheats beautifully in the oven or microwave. For longer storage wrap tightly and freeze for up to one month then thaw overnight in the fridge before reheating.

Ingredient Substitutions

If you do not eat beef substitute with ground turkey cooked mushrooms or even black beans for a vegetarian twist. Both Monterey Jack and white cheddar melt excellently but pepper jack adds extra zing. Flour tortillas work in a pinch if corn is unavailable though the flavor will change.

Serving Suggestions

Serve hot with a spoonful of salsa sour cream or diced avocado. It is terrific alongside a crisp salad simple rice or charred corn. I like to offer extra hot sauce so guests can customize their heat.

Cultural Note

Chili Relleno is a beloved classic in Mexican cuisine traditionally made with stuffed battered and fried peppers. This casserole was inspired by my favorite mom and pop Mexican diner’s homestyle version—a comforting shortcut that preserves all the savory goodness but with an easier assembly and no frying mess.

Seasonal Adaptations

When summer peppers are in abundance roast and peel your own chilies for ultra-fresh flavor. Top with juicy sliced tomatoes and cilantro for a summer vibe. In winter serve as a brunch dish with poached eggs or a citrusy salad.

Success Stories

My neighbor tried this for their holiday potluck and said it disappeared before anything else. One friend called it her new favorite meal prep recipe because each square heats up so perfectly later in the week.

Freezer Meal Conversion

Before baking assemble the casserole and cover well with foil then freeze. On baking day add about ten minutes to the cook time straight from the freezer. This has saved many busy weeknights when I needed a hearty meal fast.

So many casseroles come and go in my kitchen but this one always lands on the repeat list. If you want a dish that brings people together and leaves everyone reaching for another slice this Chili Relleno Casserole is a true keeper.

Recipe FAQs

→ What cheese works best for this casserole?

Monterey Jack or white cheddar give the smoothest melt and rich flavor. Blend them for extra depth.

→ Can I use fresh chilies instead of canned?

Yes, roast and peel fresh Hatch or Anaheim peppers for an even more vibrant flavor and texture.

→ Is corn tortilla substitution possible?

Flour tortillas can be used, but corn offers a classic texture and helps soak up the egg mixture beautifully.

→ How can I add extra heat?

Increase hot sauce to taste or include diced jalapeños in the beef layer for an added kick.

→ Can I prepare ahead of time?

Assemble and refrigerate up to one day ahead, then bake just before serving for best results.