Cheesy Poblano Layers

This chili relleno casserole transforms the beloved Mexican classic into a simple, crowd-pleasing dish without the fuss of stuffing and frying individual peppers. The layers of roasted chilies, seasoned beef, beans, and cheese come together with a savory egg topping that puffs up beautifully as it bakes.

I first made this casserole for a potluck dinner with neighbors who had just moved from New Mexico. They were homesick for Southwestern flavors, and this dish earned their highest compliment when they asked for seconds and the recipe to take home.

Ingredients

• Whole green chilies preferably poblanos for their smoky depth and perfect mild heat level. Look for ones with firm flesh and smooth skin.
• Ground beef adds hearty protein and savory flavor. Choose 80/20 for best flavor or leaner if preferred.
• Onion creates an aromatic base that sweetens slightly when cooked. Fresh onions with no soft spots will provide the best flavor.
• Monterey jack cheese melts beautifully and has the perfect mild flavor that complements the chilies. Freshly grated melts much better than pre-shredded.
• Corn tortilla chips provide texture and authentic corn flavor in every bite. Select sturdy, thick chips that won't dissolve completely.
• Refried beans create a creamy layer that helps bind everything together. Traditional or vegetarian versions both work wonderfully.
• Eggs form a soufflé like topping that rises while baking. Farm fresh eggs give the best color and flavor.
• Flour helps thicken the egg mixture for perfect consistency. All purpose works perfectly here.
• Milk creates richness in the egg topping. Whole milk produces the best results.
• Seasonings including paprika, onion powder, and hot sauce build layers of flavor throughout the dish.

Step-by-Step Instructions

Prepare Your Oven

Set your oven to 375°F and thoroughly grease your baking dish with butter or cooking spray, making sure to cover the sides to prevent sticking. This temperature creates the perfect environment for the eggs to puff while allowing the cheese to melt without burning.

Create The Egg Topping

Whisk together eggs, flour, milk, hot sauce, and seasonings until completely smooth with no flour lumps remaining. The mixture should be the consistency of a thin pancake batter. This will form a beautiful golden top layer that binds everything together.

Cook The Meat Mixture

Brown the ground beef over medium heat, breaking it into small crumbles as it cooks. Add the onions about halfway through cooking so they soften without burning. Once meat is fully cooked and onions are translucent, stir in the refried beans until thoroughly combined. The mixture should be thick and hold together well.

Layer The Casserole

Start with a base layer of tortilla chips, pressing them slightly into the baking dish. Add half the meat mixture, spreading it evenly with the back of a spoon. Arrange half the chilies in a single layer, then sprinkle with half the cheese. Repeat these layers, finishing with the remaining chilies on top.

Add The Topping

Pour the egg mixture slowly and evenly over the entire casserole, allowing it to seep down between the layers. Sprinkle the remaining cheese on top, which will form a beautiful golden crust during baking.

Bake To Perfection

Cover the dish with foil to prevent the top from browning too quickly. Bake for 40 minutes covered, then remove the foil for the final 5 minutes to allow the cheese to develop a slight golden color. The casserole is done when the egg mixture is set and the edges are bubbling.

Rest Before Serving

Allow the casserole to rest for 10 minutes before cutting. This crucial step allows the layers to set properly so your portions stay intact when served.

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My absolute favorite part of this recipe is the contrast between the charred, slightly smoky poblano peppers and the rich, melty cheese. It reminds me of the first time I tried authentic chiles rellenos at a small family restaurant in Santa Fe, where I watched the grandmother of the family carefully roasting peppers over an open flame.

Make Ahead Tips

This casserole is perfect for planning ahead. You can fully assemble it up to 24 hours before baking—just cover tightly and refrigerate. When ready to cook, let it sit at room temperature for about 30 minutes before baking to ensure even cooking. You might need to add an extra 5-10 minutes to the baking time if it goes into the oven cold.

Perfect Pepper Preparation

The key to outstanding flavor in this casserole is properly preparing your poblano peppers. Roast them under a broiler or over an open flame until the skin blisters and blackens, turning occasionally for even charring. Immediately place them in a paper bag or bowl covered with plastic wrap to steam for 10 minutes. This makes the skins slip off easily while preserving that smoky flavor that makes this dish special.

Serving Suggestions

This versatile casserole works beautifully as the centerpiece of any Mexican inspired meal. Serve with a simple green salad dressed with lime vinaigrette for a perfect contrast to the rich casserole. A side of Mexican rice adds wonderful texture, while fresh pico de gallo brings brightness. For a complete fiesta, offer warm flour tortillas, guacamole, and a variety of hot sauces so guests can customize their plates.

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Recipe FAQs

→ Can I make this chili relleno casserole ahead of time?

Yes! You can assemble the entire casserole the night before, cover it tightly, and refrigerate. When ready to eat, simply bake it fresh according to the instructions, possibly adding 5-10 minutes to the cooking time since it will be cold from the refrigerator.

→ What kind of chilies work best in this casserole?

Poblano peppers are ideal for their smoky flavor and moderate heat. Roast and peel them for the best results. If poblanos aren't available, canned whole green chilies are a convenient alternative that works well.

→ How can I make a vegetarian version?

For a delicious vegetarian adaptation, simply omit the ground beef and either double the refried beans or add sautéed mushrooms, bell peppers, or a meat substitute. The cheese and egg mixture will still provide plenty of protein and flavor.

→ Can I adjust the spice level?

Absolutely! Control the heat by adjusting the amount of hot sauce in the egg mixture or by using pepper jack cheese instead of Monterey jack. For extra spice, add chopped jalapeños or a pinch of cayenne to the meat mixture.

→ What's the best way to reheat leftovers?

For best results, reheat individual portions in a 350°F oven until heated through (about 15-20 minutes) to maintain the texture. Microwaving works too, but might make the casserole slightly softer. The flavors often develop overnight, making leftovers especially delicious.

→ What can I serve with chili relleno casserole?

This hearty dish pairs beautifully with a simple green salad, Mexican rice, or black beans. For serving, offer toppings like fresh salsa, guacamole, sour cream, chopped cilantro, or lime wedges to let everyone customize their portion.