This chili stuffed casserole layers corn tortillas, mild green chiles, seasoned beef, refried beans, and melted cheese into one big, bubbling dish.
It tastes like a cross between enchiladas and chile rellenos, but you assemble it in a single 9×13 pan with no stuffing or frying. A simple egg and milk custard binds the layers so the casserole slices neatly.
Table of Contents
Why This Chili Stuffed Casserole Recipe Works
Corn tortilla strips act like noodles in a lasagna, soaking up the egg custard and green chile juices while keeping some texture. Each layer adds a different flavor and keeps the dish from tasting one note.
Mild green chiles bring smoky, gentle heat that does not overwhelm the beef and beans. Paprika, onion powder, and hot sauce season the custard so the flavor reaches every layer.
Monterey Jack melts smoothly and stays creamy, while the refried beans add body and make the dish filling enough to serve as a full dinner with just a salad.
Ingredients for Chili Stuffed Casserole
- 1 can (27 ounces) whole green chiles, drained
- 1 1/2 pounds ground beef
- 1 medium yellow onion, finely chopped
- 1 pound Monterey Jack or white cheddar cheese, shredded
- 12 corn tortillas, cut into 1 inch wide strips
- 16 ounces refried beans
- 4 large eggs, beaten well
- 1/4 cup all purpose flour
- 1/2 cup evaporated milk
- 2 teaspoons hot sauce
- 1/4 teaspoon paprika
- 1/4 teaspoon onion powder
- 1/2 teaspoon kosher salt
Green chiles. Whole chiles lay flat in layers. Slit them open lengthwise and remove any seeds for a milder dish.
Ground beef. Cook the beef with the onion until browned, and drain any excess fat so the dish does not turn greasy.
Corn tortillas. Cut the tortillas into strips so they layer evenly. Warm them briefly if they crack when you cut them.
Refried beans. Stir the beans into the beef while it is still warm so they spread easily over the top.
Egg custard. The eggs, flour, and evaporated milk bake into a light custard that holds the layers together.
How to Make Chili Stuffed Casserole
1. Heat the oven Heat the oven to 375 degrees F and grease a 9×13 inch baking dish with cooking spray.
2. Whisk the custard In a large bowl, whisk the eggs, flour, evaporated milk, hot sauce, paprika, onion powder, and kosher salt until smooth.
3. Brown the beef Cook the ground beef and onion in a large skillet over medium heat for 6 to 8 minutes, breaking up the meat, until no pink remains and it reaches 160 degrees F.
4. Add the beans Drain any fat, then stir in the refried beans until well combined and warm.
5. Layer the base Arrange half of the tortilla strips in a single layer across the bottom of the dish.
6. Add chiles and cheese Cover the tortillas with half of the green chiles, then sprinkle with a third of the cheese.
7. Repeat the layers Repeat with the remaining tortilla strips, green chiles, and another third of the cheese.
8. Pour the custard Pour the egg mixture evenly over the layers.
9. Top with the beef Spoon the beef and bean mixture over the custard and sprinkle with the remaining cheese.
10. Bake Cover tightly with foil and bake for 40 minutes, then uncover and bake for 5 to 10 minutes more, until bubbly and the center reaches 165 degrees F. Rest for 10 minutes before cutting.
How to Serve Chili Stuffed Casserole
Cut the casserole into squares and top each portion with sour cream, chopped cilantro, and sliced avocado. Serve it alongside cilantro lime rice and warm chile cheese cornbread, with a scoop of homemade taco meat for extra protein. A pitcher of strawberry pineapple mojito makes a bright drink for adults.
How to Store and Reheat Chili Stuffed Casserole
Cool the casserole and refrigerate it in an airtight container for up to 3 days. Reheat portions in the microwave for 1 to 2 minutes, or bake covered at 350 degrees F for 15 to 20 minutes, until they reach 165 degrees F. Do not freeze it, since the egg custard turns watery after thawing.
Tips and Variations for Chili Stuffed Casserole
Drain the chiles well. Pat them dry with paper towels so the dish does not bake up watery.
Shred your own cheese. Block cheese melts more smoothly than pre shredded cheese.
Warm the tortillas. A quick 15 seconds in the microwave keeps them from cracking when you cut them.
Adjust the heat. Add diced jalapenos to the beef or serve with extra hot sauce for more spice.
Make it meatless. Skip the beef and add a second can of black beans and a cup of corn.
Check the center. The center should reach 165 degrees F, and the custard should look set.
Rest before slicing. Ten minutes lets the layers set so the squares hold together.
Cook beef safely. Cook the beef to 160 degrees F, and read the Purdue Extension guide to storing leftovers for general advice on chilling leftovers.
Frequently Asked Questions About Chili Stuffed Casserole
Can I make chili stuffed casserole ahead of time?
Yes. Assemble it, cover, and refrigerate for up to 1 day. Add 10 minutes to the covered baking time when it goes into the oven cold.
What are the layers in chili stuffed casserole?
It has corn tortilla strips, green chiles, and cheese in two layers, then an egg custard, then a beef and bean filling with a final cheese topping.
Can I freeze chili stuffed casserole?
It is not recommended, because the egg custard becomes watery after thawing. Refrigerate leftovers for up to 3 days instead.
Can I use flour tortillas?
Corn tortillas hold their shape better, but flour tortillas work. Cut them into strips and expect a softer texture.
What size can of chiles should I buy?
Use one 27 ounce can of whole green chiles, or about seven 4 ounce cans if you cannot find the large size.
Chili Stuffed Casserole with Green Chiles and Corn Tortillas
Equipment
- 9×13 inch baking dish
- Large skillet
- Aluminum foil
- Mixing bowl
Ingredients
Main Ingredients
- 27 oz whole green chiles canned, drained and patted dry
- 1 ½ lb ground beef
- 1 medium yellow onion finely chopped
- 1 lb Monterey Jack or white cheddar cheese shredded
- 12 corn tortillas cut into 1 inch strips
- 16 oz refried beans
- 4 large eggs beaten well
- ¼ cup all purpose flour
- ½ cup evaporated milk
- 2 tsp hot sauce
- ¼ tsp paprika
- ¼ tsp onion powder
- ½ tsp kosher salt
Instructions
Cooking
- Make the custard. Heat the oven to 375 degrees F. Whisk the eggs, flour, evaporated milk, hot sauce, paprika, onion powder, and salt.
- Cook the filling. Brown the beef and onion for 6 to 8 minutes to 160 degrees F, drain, and stir in the refried beans.
- Layer. In a greased 9×13 dish, layer half the tortilla strips, half the chiles, and a third of the cheese, then repeat.
- Add custard and beef. Pour the custard over the layers, spoon on the beef mixture, and top with the remaining cheese.
- Bake. Cover with foil and bake for 40 minutes, uncover, and bake 5 to 10 minutes more until the center reaches 165 degrees F.
- Rest. Let it stand for 10 minutes before cutting.
