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Zuppa Toscana Casserole

Zuppa Toscana Casserole

This recipe transforms the classic Zuppa Toscana soup into a hearty, sliceable casserole. It combines spicy Italian sausage, crisp bacon, tender potatoes, and earthy kale in a rich, creamy sauce, baked until golden-brown. This comforting dish is a complete meal, perfect for a satisfying weeknight dinner or feeding a crowd.
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Prep Time 15 minutes
Cook Time 1 hour
Total Time 1 hour 15 minutes
Servings: 6 servings
Calories: 924
Ingredients Equipment Method Notes

Ingredients
  

Ingredients
  • 8 oz bacon, cooked crisp & crumbled (reserve 1/4 cup bacon grease)
  • 1 lb ground Italian sausage, cooked, crumbled & drained
  • 7 cups thinly sliced russet potatoes
  • 1 small white onion, peeled & diced
  • 2 tbsp garlic paste
  • 6 packed cups washed and chopped kale leaves (stems removed)
  • 1/2 cup flour
  • 4 cups chicken broth
  • 1 - 1 1/2 cups heavy whipping cream
  • 1 large egg, beaten & tempered
  • salt & pepper to taste
  • 1 1/2 cups shredded Parmesan cheese, divided

Equipment

  • 9x13" baking dish
  • large skillet
  • mandoline slicer (optional)
  • wire rack

Method
 

Instructions
  1. Preheat your oven to 400°F. Spread the thinly sliced potatoes in a 9x13" baking dish. Sprinkle the cooked Italian sausage and crumbled bacon evenly over the potatoes.
  2. In a large skillet, add the reserved bacon grease and set it over medium heat.
  3. Add the diced onion and garlic paste to the skillet. Sauté for a couple of minutes until the onion softens. Toss in the chopped kale and stir until it wilts.
  4. Sprinkle the flour over the vegetable mixture and stir continuously for about 60 seconds to cook out the raw flour taste.
  5. Gradually pour in the chicken broth while whisking constantly to prevent clumps. Let the mixture simmer for a few minutes until it begins to thicken, then stir in the heavy cream.
  6. Temper the egg by transferring a tablespoon of the hot cream mixture into the beaten egg and stirring quickly. Repeat two more times. Then, pour the warmed egg mixture back into the skillet, whisking to combine fully.
  7. Stir in half of the shredded Parmesan cheese (3/4 cup) until it melts. Season with salt and pepper. Pour the sauce mixture evenly over the potatoes, sausage, and bacon in the baking dish.
  8. Cover the dish tightly with aluminum foil and bake for 50-60 minutes. Remove the foil and sprinkle the remaining Parmesan cheese over the top.
  9. Place the uncovered dish back in the oven and bake for another 25-30 minutes, or until the top is bubbly and golden brown.
  10. Remove the casserole from the oven and let it rest on a wire rack for at least 10 minutes to allow the sauce to set before serving.

Notes

For the best results, slice potatoes thinly and uniformly, preferably with a mandoline. Tempering the egg is a crucial step to prevent it from scrambling and ensures a smooth sauce. Letting the casserole rest for at least 10 minutes after baking is essential for the sauce to set properly.