First things first – let’s cook the sausage. Heat a skillet over medium-high heat, and add the bulk pork sausage. Break the sausage apart with a wooden spoon as it cooks, ensuring it turns brown and is no longer pink. This process usually takes about 5-7 minutes. Once the sausage is fully browned, drain any excess grease. This step helps ensure your casserole isn’t greasy and that the sausage flavor really shines through.
Now it’s time to start building the casserole layers. Lightly spray the inside of your 6-quart slow cooker with cooking spray to prevent anything from sticking. Begin by placing half of the thawed Potatoes O’Brien (or hash browns if you’re using those) in the bottom of the Crock Pot. These potatoes serve as a delicious and crispy base for the casserole.
Next, layer half of the browned sausage on top of the potatoes. The sausage brings a savory, flavorful punch that pairs beautifully with the potatoes. Follow this with half of the grated cheddar cheese, which will melt beautifully throughout the casserole.
Repeat these layers with the remaining potatoes, sausage, and cheese, finishing with the last layer of cheese on top. This ensures that the cheese gets a chance to melt and become golden and bubbly by the time your casserole is done cooking.
In a large mixing bowl, whisk together the eggs, milk, seasoned salt (or regular salt), and pepper. This egg mixture will help bind all the layers together, creating a custard-like texture once it’s cooked. Pour the egg mixture evenly over the layered ingredients in your slow cooker. Make sure the eggs are distributed evenly, covering all the layers.
Once everything is layered and the egg mixture has been poured over, cover the Crock Pot with its lid. Set your slow cooker to LOW and let it cook for 4 to 5 hours. The eggs should be fully set, and the casserole should have a nice, firm texture. The slow cooking method allows all the flavors to meld together while keeping the potatoes tender and the cheese wonderfully melted.
After 4 hours, check the casserole to ensure the eggs are fully cooked through. You can do this by gently inserting a toothpick into the center. If it comes out clean or with just a few moist crumbs, your casserole is ready. If not, cover and continue to cook for an additional 30 minutes to an hour, checking every so often until the eggs are set.
Once your Crock Pot Breakfast Casserole is done cooking, turn off the slow cooker and remove the lid. Let the casserole cool uncovered for about 30 minutes on a cooling rack. This resting period helps the casserole firm up a bit more, making it easier to slice. Plus, it gives the flavors time to settle, making each bite even more delicious.