Breakfast Casserole made with Fresh Milled Flour

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Breakfast casseroles have a magic all their own, transforming humble ingredients into a heartwarming feast that’s perfect any morning. This version, featuring freshly milled flour and savory sausage, invites you to explore a comforting yet adventurous blend of flavors and textures. It’s the best way to start the day with something warm, nourishing, and satisfying — whether it’s Christmas morning with family gathered around the table or one of those busy mornings when you need breakfast ready to go. Made with fresh ground flour, wholesome ingredients, and plenty of essential nutrients, this healthy breakfast casserole proves that comfort food can also be good for you. It’s hearty enough to feed a crowd, simple enough for meal prep, and delicious enough to become a new family favorite. Let this delicious breakfast casserole be a gateway to mornings filled with delicious discovery and simple joy.

What Makes This Recipe Great

Freshly milled flour adds unparalleled texture and flavor.

Unlike store-bought flour, freshly milled flour retains natural oils and a subtle nuttiness that give the casserole a tender crumb and a rich, wholesome character. This ingredient elevates the hearty breakfast from ordinary to something genuinely memorable and artisan.

Robust, savory sausage complements perfectly.

The sausage brings a hearty depth that balances the mildness of eggs and flour beautifully, contributing an aromatic blend of spices that wakes up your taste buds with every bite. It provides a satisfying, meaty element that makes this casserole feel substantial and indulgent.

Versatile and comforting for any occasion.

Whether made for a festive brunch or a quick weekend breakfast, this great recipe serves up a warm, inviting experience. It’s the perfect meal that welcomes discussion, sharing, and the feeling of being cared for through food, perfect for family gatherings or solo moments of comfort.

For more fresh milled recipes, try these mini panettones or this Christmas stollen bread!

Overview of Ingredients

Fresh Milled Flour

Using freshly milled flour gives this casserole its unique texture and slightly nutty flavor. If fresh milling isn’t an option, high-quality whole wheat flour or all-purpose flour can stand in, though the depth of flavor will be less pronounced.

Sausage

Choose a flavorful sausage, such as Italian or breakfast sausage, to infuse the savory breakfast with rich, spiced meatiness. For a lighter option, ground turkey or chicken sausage can be substituted, but the flavor profile will be softer.

Eggs

Eggs are the binding element that lifts this casserole, contributing to its rich, custardy texture. Pasture raised or organic eggs are preferred for their superior flavor and yolk richness.

Cheese

A mix of cheddar cheese or Monterey Jack creates a melty, golden topping that adds a creamy contrast to the savory sausage. You can substitute with mozzarella or gouda depending on your preference for mild or smoky flavor.

Milk

Adding milk enriches the custard base, making it silkier and more indulgent. Whole milk can be swapped with half-and-half or plant-based milk alternatives for a different texture and flavor.

Tips for Success

#1 Use freshly milled flour right away

Freshly milled flour can lose its potency when exposed to air, so use it promptly to capture the full nutty aroma and tenderness it imparts to the casserole. Milling just before mixing ensures the best texture and flavor throughout the dish.

#2 Brown the sausage thoroughly

Don’t rush the browning process; letting the sausage caramelize gently develops deeper, richer flavors that will permeate every bite. Crumble the sausage finely to distribute it evenly, preventing large fatty chunks.

#3 Let the casserole rest before baking

Allow the assembled casserole to sit for 10 to 15 minutes before baking to let the flavors meld and the liquid to soak into the flour and sausage mixture. This step improves the final texture and ensures each bite is perfectly cohesive.

#4 Use a sharp knife for cutting

After baking, a clean cut not only presents beautifully but also preserves the casserole’s structure. A serrated knife or a hot, dry blade works best to avoid tearing or crumbling.

#5 Watch your baking time closely

Oven temperatures and casserole depths vary, so check for doneness around 30-35 minutes. Look for a golden-brown crust and a set center that jiggles slightly but is not wet or runny.

Helpful Tools & Supplies

Whether you’re just dipping your toes into the world of fresh milled flour or you’re a seasoned home baker, I’ve taken the guesswork out of what you truly need. All of these tools and resources are available in my shop, designed to help your journey be smooth and nourishing:

Grain Mills

• NutriMill Classic Grain Mill – My go-to for fine, consistent milling; perfect for sandwich breads and everyday baking.
• NutriMill Harvest Grain Mill – Stone-ground elegance: this model delivers whole-grain flavor with a beautiful appearance.

Mixers

• Ankarsrum Mixer – A powerhouse kitchen companion with multiple speeds and attachments—ideal for kneading bread dough effortlessly.

Baking & Bread Tools

• Bread Bow Knife – Artisan-made with a high-carbon steel blade and cherry wood handle—this knife slices loaves with ease.
• Sourdough Essentials Kit With Starter – Complete starter kit that includes dehydrated sourdough starter, banneton baskets, a dough whisk, scoring lame, and more.

Cookbooks & eBook Bundles

• Everyday Whole Grains Vol. 1 & 2 (printed & digital) – Packed with 70+ recipes built around fresh milled flour, from breads to snacks and desserts.
• The Fresh Breads Bundle – A comprehensive set including eBooks like The Perfect Loaf, the Cookie Jar, bulk baking guides, and a sourdough mini‑course—all centered on fresh milled flour.
• Freshly Milled Made Simple Guide – A video-based guide that walks you through milling and baking basics, making the process feel easy and approachable.

Specialty Items

• Dehydrated Sourdough Starter – Just add water and flour to rehydrate this starter—perfect for bakers without an active sourdough culture.
• I Knead Fresh Flour Mug – A charming, handmade 12 oz ceramic mug—great for coffee breaks during dough rising!

Why These Are Worth It

Every tool in this collection has been personally vetted to support you in baking with fresh milled flour. From the grain mills that make your flour, to mixers that knead dough, to resources that teach you every step—it’s all here to make sure your homemade bread journey is joyful, nourishing, and successful.

➡️ Explore all of these items and more in the Generation Acres Farm Shop — your one-stop spot for fresh milled flour baking essentials

Equipment:

Large Skillet
Mixing Bowls
Casserole Dish (9×13-inch)
Measuring Cups and Spoons
Whisk or Fork
Knife and Cutting Board  

How to Make Breakfast Casserole with Fresh Milled Flour

Ingredients

Biscuit Dough:

• 3 cups freshly milled kamut, einkorn, or soft white wheat flour, finely milled (390 grams)
• 2 teaspoons baking powder
• ½ teaspoon baking soda
• ¾ teaspoon salt
• 5 tablespoons COLD butter, grated with cheese grater (72 grams)
• 1 cup buttermilk (258 grams)

Egg Mixture:

• 1 lb cooked and drained Italian sausage
• 2 cups shredded cheese (140 grams)
• 8 eggs
• 1 ¾ cup milk (435 grams)
• 2 teaspoons dried basil
• 1 ½ teaspoons salt
• ½ teaspoon pepper
• 1 teaspoon garlic powder
• 1 teaspoon onion powder

Directions:

• Grease a 9×13 inch dish and preheat the oven to 350 degrees F.

• Prepare the biscuit dough by combining the dry ingredients in a medium size bowl. Grate in cold butter and mix with your hands until the butter is covered in flour and resembles coarse sand. Rub the flour and butter mixture between your hands to full incorporate. 

• Add buttermilk to the dry ingredients and mix until combined. 

• Knead a few times in the bowl, then press into the bottom of the prepared dish.

• Sprinkle the cheese over top of the biscuit dough, followed by the sausage.

• In a large bowl, mix the eggs, milk, and remaining seasonings.

• Pour the milk mixture over the casserole.

• Bake for 40-50 minutes, until the center is set. 

Recipe Variations

Vegetarian Version:
Replace sausage with  green onions and sautéed mushrooms and bell pepper for a savory, meat-free version that’s equally satisfying.

Spicy Twist:
Add chopped jalapeños or a dash of cayenne pepper to the sausage mixture for a gentle heat that livens the dish.

Herb Infusion:
Mix fresh rosemary, thyme, or sage into the egg custard for an aromatic lift that pairs beautifully with the richness of sausage.

Gluten-Free:
Substitute the fresh milled flour with almond flour or a gluten-free baking blend, adjusting liquid as needed to maintain texture.

Troubleshooting Common Problems with this Recipe

Casserole Is Too Dry
Ensure to use enough liquid in your custard mixture—milk or cream plus eggs—to keep the casserole moist. Avoid overbaking by checking around the 30-minute mark to prevent drying out.

Sausage Is Under-seasoned
Use flavorful, well-seasoned sausage or add your own spices like fennel seeds, sage, or smoked paprika to deepen the taste. Browning the sausage slowly helps develop its full flavor.

Casserole Falls Apart When Sliced
Allow the casserole to rest and cool for at least 10-15 minutes after baking to let it set properly. Using enough eggs and flour as binders is also crucial to maintain the structure.

Cheese Doesn’t Melt Evenly
Use freshly shredded cheese rather than pre-shredded, which contains anti-caking agents. Also, distribute cheese evenly over the casserole to ensure uniform melting.

Freezing & Storing Leftovers

Freezing:
Cool the casserole completely before placing it in an airtight container or wrapping tightly with aluminum foil and plastic wrap. Freeze for up to 2 months. When ready, thaw in the refrigerator overnight before reheating.

Storing:
Keep leftovers in an airtight container in the refrigerator for 3 to 4 days. Reheat gently to preserve moisture and texture.

How To Reheat

Oven Method
Preheat the oven to 350°F (175°C). Place the casserole in an oven-safe dish, cover loosely with foil to prevent drying, and heat for 20-25 minutes until warmed through. Remove foil in the last 5 minutes for a crisp top.

Microwave Method
Place a portion on a microwave-safe plate and cover with a microwave-safe lid or damp paper towel. Heat on medium power for 1-2 minutes, checking to avoid overheating and drying out.

Stovetop Method
Reheat individual slices in a non-stick skillet over medium-low heat, covering with a lid to warm evenly. Add a splash of milk or water to maintain moisture if needed.

Air Fryer Method
Preheat the air fryer to 320°F (160°C). Warm casserole slices for 5-7 minutes, checking to maintain moisture while achieving a lightly crisped top.

Extra FAQs

Can I prepare the casserole the night before?
Yes, you can assemble the casserole the evening before and refrigerate it overnight, then bake it fresh the next morning for convenience and deeper flavor melding.

Is it necessary to use fresh milled flour?
While fresh milled flour adds outstanding flavor and texture, you can substitute with whole wheat or all-purpose flour, though the dish will lack some of its signature depth.

Can I use gluten-free flour?
Yes, gluten-free flour blends can be used, but moisture levels might need adjustment. Experiment with almond or oat flour for similar textures.

What sausage alternatives work best?
Ground turkey or chicken sausage can substitute to vary flavor or accommodate dietary needs, though the richness may differ.