No-Fry Chili Relleno Casserole

This cheesy chili relleno casserole gives you all the smoky pepper and gooey cheese flavor of the classic dish without a drop of hot oil.

Layers of roasted poblano strips, two kinds of cheese, and a simple egg custard bake into a puffy, golden casserole that cuts into neat squares. It’s my go-to when I want a big comforting dinner that takes about 20 minutes of actual hands-on time.

What Makes This Baked Version So Good

The roasted poblanos bring a mild, smoky heat that softens into the custard, and the combination of Monterey Jack and cheddar gives you that stretchy, browned top without the mess of frying.

The egg and flour mixture sets around the peppers like a fluffy omelet, holding the whole thing together. Leftovers reheat beautifully, which means lunch is already sorted.

Ingredients

• 6 large poblano peppers: look for firm, glossy peppers with no soft spots
• 2 cups shredded Monterey Jack cheese: a mild melter that gets wonderfully stretchy
• 1 cup shredded sharp cheddar cheese: adds a little tang and helps the top brown
• 6 large eggs: bring them to room temperature if you have time
• 1 cup whole milk: 2% works, but whole milk gives a richer custard
• ¼ cup all-purpose flour: just enough to set the custard
• ½ tsp fine sea salt
• ¼ tsp black pepper
• ½ cup mild red salsa or tomato sauce (optional): spooned on top before baking for extra color and moisture
• Fresh cilantro, for serving

Variations / Substitutions

• Add a protein layer: stir 1 cup cooked, crumbled chorizo or seasoned ground beef with a few tablespoons of salsa, then spread it between the pepper and cheese layers for a heartier casserole.
• Use canned green chiles: swap the fresh poblanos for two 7‑oz cans of whole green chiles, drained and patted very dry. The casserole will be milder and the assembly faster, though you lose that fresh charred flavor.
• Dairy‑free: use your favorite plant‑based shredded cheese and unsweetened oat milk. The custard will still set and puff.
• Amp up the heat: leave a few seeds in the poblanos or add a thinly sliced jalapeño between the layers.
• Change the cheese: a mix of Oaxaca and queso fresco makes it extra authentic, or try pepper jack for a spicy kick.

For the traditional fried version, check out my Classic Chili Rellenos recipe.

How to Make Chili Relleno Casserole

Step 1: Char and Peel the Poblanos

Set the 6 poblano peppers directly over a gas flame or place them on a foil‑lined baking sheet under the broiler. Roast, turning every few minutes, for 10 to 12 minutes, until the skins are blistered and blackened all over.

Immediately transfer the hot peppers to a bowl and cover tightly with plastic wrap or a plate. Let them steam for 10 minutes; this loosens the skins. Rub off the charred skin with your fingers or a paper towel, then slit each pepper open, remove the stem and seeds, and slice into wide strips. Blot the strips dry with paper towels.

Step 2: Layer the Casserole

Preheat the oven to 375°F (190°C) and lightly grease a 9×13‑inch baking dish. Arrange half of the pepper strips in an even layer across the bottom, then sprinkle with 1 cup of the Monterey Jack and ½ cup of the cheddar. Repeat with the remaining peppers and both cheeses.

At this point the dish should have two distinct pepper‑cheese layers. Don’t pack everything down; a little air between the strips helps the custard seep through and puff up.

Step 3: Whisk the Egg Custard and Pour

In a large bowl, whisk the 6 eggs, 1 cup milk, ¼ cup flour, ½ teaspoon salt, and ¼ teaspoon pepper until mostly smooth. A few tiny flour streaks are fine; overmixing can make the baked custard a little rubbery.

Pour the egg mixture evenly over the layered casserole. If you’re using the salsa or tomato sauce, spoon the ½ cup in small dollops over the top and gently swirl it into the custard with a knife tip. The liquid will look thin and separated at first, but it all comes together as it bakes.

Step 4: Bake, Rest, and Serve

Slide the dish into the oven and bake for 35 to 40 minutes. The casserole is done when the top is puffed, deeply golden in spots, and a knife inserted near the center comes out clean.

Move the dish to a wire rack and let it rest for 5 to 10 minutes. The custard firms up during this short wait, making clean slices possible. Scatter fresh cilantro over the top, cut into squares, and serve warm.

A Few Things That Help This Casserole Shine

• Roast your own poblanos if you can. The char from a flame or broiler adds a smoky depth that jarred peppers just don’t have.
• If you’re short on time, two 7‑oz cans of whole green chiles work. Open them, drain well, and pat the chiles completely dry so the casserole doesn’t turn watery.
• Don’t rush the rest after baking. The custard will slump and ooze if you cut in too soon, so give it at least 5 minutes on the counter.
• For cleaner slices, run a thin spatula around the edges before cutting, and use a sharp chef’s knife.

Bake times by dish size (at 375°F):

Storing Leftover Casserole

Refrigerate leftover squares in an airtight container for up to 4 days. Reheating individual portions in the microwave for 1 to 2 minutes works fine, but the oven restores the crisp top best: warm at 350°F (175°C) for 10 to 15 minutes.

What to Serve With Chili Relleno Casserole

A scoop of quick Mexican rice and a side of black beans turn this into a full plate. A simple avocado and tomato salad with lime dressing cuts through the richness. Warm corn tortillas on the side are never a bad idea.

Frequently Asked Questions

Can I use canned green chiles?

Yes, two 7‑oz cans of whole green chiles, drained and patted very dry, substitute well for fresh poblanos. The flavor will be milder and the texture softer.

Can I make this casserole ahead of time?

Assemble the unbaked casserole (through Step 3), cover, and refrigerate overnight. Bake the next day, adding 5 to 10 minutes to the bake time since it starts cold.

Is this dish spicy?

Poblanos are generally mild, and removing the seeds and veins keeps the heat low. If you want more kick, leave a few seeds in or add a pinch of cayenne to the egg mixture.

Can I freeze the baked casserole?

Wrap cooled portions tightly and freeze for up to 2 months. Thaw overnight in the refrigerator, then reheat in a 350°F oven until warm through.

Chili Relleno Casserole Recipe

Print Recipe Pin Recipe

Prep Time 20 minutes mins

Cook Time 40 minutes mins

Total Time 1 hour hr

Servings: 6 servings

Calories: 320

Ingredients Method Notes

Ingredients

  

• 6 large poblano peppers
• 2 cups shredded Monterey Jack cheese
• 1 cup shredded sharp cheddar cheese
• 6 large eggs
• 1 cup whole milk
• ¼ cup all-purpose flour
• ½ tsp fine sea salt
• ¼ tsp black pepper
• ½ cup mild red salsa or tomato sauce (optional)
• Fresh cilantro, for serving

Method

 

1. Char poblano peppers under broiler or over gas flame for 10 to 12 minutes, turning until skin is blackened. Steam in a covered bowl for 10 minutes, then rub off skin, remove seeds and stems, and slice into strips.
2. Preheat oven to 375°F (190°C). Grease a 9×13‑inch baking dish. Layer half the pepper strips, 1 cup Monterey Jack, and ½ cup cheddar. Repeat with remaining peppers and cheeses.
3. In a bowl, whisk eggs, milk, flour, salt, and pepper until mostly smooth. Pour evenly over the casserole. Dollop salsa on top and gently swirl, if using.
4. Bake 35 to 40 minutes until puffed and golden. Rest 5 to 10 minutes, then garnish with cilantro, slice, and serve.

Notes

Let the casserole sit for at least 5 minutes after baking so the custard sets. If you slice it straight from the oven, the pieces may fall apart.