BBQ Pork Casserole Recipe: Smoky Layers With Crispy Cheese Crown

I’m sharing my secret BBQ pork casserole recipe that combines tender pulled pork, tangy BBQ sauce, and creamy comfort food elements into one satisfying dish. 🔥 This comforting casserole is perfect for weeknight dinners or feeding a crowd.

With simple ingredients and straightforward instructions, you’ll achieve a golden-brown crust and a rich, flavorful interior. Let’s get started!

Ingredients for Bbq Pork Casserole

Simple ingredients for a comforting casserole. No fuss, just good food.

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The pork shoulder is key here. Costco and Sam’s Club often have great deals on larger cuts. Look for a shoulder with good marbling—it’ll be more tender. If you can’t find boneless, just remove the bone yourself. For the BBQ sauce, Stubb’s and KC Masterpiece are solid choices. Get the good stuff for best flavor.

No cream of mushroom? Make your own with sautéed mushrooms and a roux. Or swap for cream of chicken if that’s what you’ve got. The hash browns can be O’Brien style (with onions and peppers) if you want extra flavor. For cheese, sharp cheddar gives a nice kick, but mild works too. You can also mix in some Monterey Jack for extra creaminess.

This reheats beautifully—keeps for 3-4 days in the fridge. Freeze individual portions for up to 3 months. When reheating, add a splash of milk if it’s gotten too thick. The top layer might get a bit crispy when reheated—don’t worry, it’s still delicious. Just cover with foil if it gets too brown.

Step-by-Step Instructions for BBQ Pork Casserole

Here’s the method to create this comforting casserole – straightforward and delicious.

🔥 Step 1: Prepare the Pork Shoulder

Preheat your oven to 300°F. Place the 2 lb Pork Shoulder in a large Dutch oven or oven-safe pot. Add 1 whole Onion, diced, and 3 cloves Garlic Cloves, minced, around the pork. Sprinkle 1 tsp Smoked Paprika, 0.5 tsp Black Pepper, and 0.5 tsp Salt evenly over the pork. Cover the pot and transfer it to the preheated oven. Braise for 3-4 hours until the pork is tender and easily shreds with a fork.

Once done, remove the pot from the oven and let it cool slightly. Shred the pork using two forks and mix it with the juices and cooked onions. The mixture should be moist and flavorful, with the pork shreds coated in the rich braising liquid.

🥘 Step 2: Assemble the Casserole

In a large mixing bowl, combine 1 cup Sour Cream and 1 can Cream of Mushroom Soup. Mix until smooth and well combined. Add the shredded pork mixture to this bowl and stir until the pork is evenly coated with the creamy sauce.

In a greased 9×13 inch baking dish, spread half of the 1 bag Frozen Hash Browns evenly across the bottom. Top with the pork and sauce mixture, followed by 1 cup BBQ Sauce spread evenly. Sprinkle 1 cup Shredded Cheddar Cheese over the BBQ sauce. Repeat the layers, starting with the remaining hash browns, then top with the remaining 1 cup Shredded Cheddar Cheese.

🔥 Step 3: Bake the Casserole

Drizzle the 2 tbsp melted Butter over the top layer of hash browns. Cover the dish with aluminum foil and bake in a preheated oven at 375°F for 45 minutes. Remove the foil and continue baking for an additional 15-20 minutes, or until the top is golden brown and the casserole is bubbly around the edges.

Remove from the oven and let it rest for 10-15 minutes before serving. The casserole should be hot, with a crispy top layer and a creamy, cheesy interior. Serve warm, garnished with additional chopped onions or chives if desired.

Pro Cooking Tips for Great bbq pork casserole

Mastering Temperature Control

For perfect BBQ pork, temperature control is crucial. I start by braising the 2 lb pork shoulder at 300°F for 3-4 hours until it’s tender and easily shreds. This low-and-slow method ensures the meat stays moist and develops deep flavor.

Layering for Success

The key to a great casserole is in the layering. I start with a base of frozen hash browns, which provides a crispy texture contrast to the tender pork. Then I add the shredded pork mixture coated in BBQ sauce and sour cream sauce, followed by another layer of hash browns on top. The double layer of cheese—sharp cheddar works best—adds richness and helps create that golden-brown crust.

The Importance of Resting

After baking, I let the casserole rest for 10-15 minutes before serving. This resting period allows the layers to set, making it easier to serve neat portions. It also lets the flavors meld together, enhancing the overall taste. The top layer will be crispy while the inside remains creamy and hot.

Equipment Matters

Using the right baking dish makes a difference. I prefer a 9×13 inch ceramic or glass baking dish as it distributes heat evenly and retains it well. For the pork shoulder, a large Dutch oven is ideal for braising. If you don’t have one, any heavy oven-safe pot will work.

Enhancing Flavor

To take this dish to the next level, I add smoked paprika to the pork rub, giving it that authentic BBQ flavor. You can also experiment with different types of BBQ sauce—whether you prefer sweet, tangy, or spicy will change the character of the dish. Adding fresh herbs like chopped scallions or parsley just before serving adds a fresh contrast to the rich casserole. 🔥

Make-Ahead Tips

This casserole is perfect for making ahead. You can assemble it up to a day in advance and store it in the refrigerator. When you’re ready to bake, just add a few extra minutes to the cooking time. You can also freeze individual portions for up to 3 months—just thaw overnight in the fridge and reheat.