Breakfast Stuffed Puff Pastry Bars

This breakfast stuffed puff pastry creation transforms your morning favorites into a portable, flaky handheld meal. The combination of savory sausage gravy, crispy hash browns, and melty cheese all wrapped in buttery puff pastry creates a hearty breakfast option perfect for busy mornings or weekend brunches with family.

I first made these when hosting a brunch for my in-laws, and they've become our go-to special breakfast ever since. The way the flaky pastry shatters when you bite into it, revealing those perfect breakfast layers inside, makes even ordinary mornings feel special.

Ingredients

• Puff pastry sheets: the store-bought kind works perfectly and saves significant time
• Ground sausage: provides the rich base for the gravy select breakfast sausage with your preferred spice level
• Flour: helps thicken the sausage gravy choose all-purpose for best results
• Milk: creates the creamy consistency in the gravy whole milk produces the richest result
• Frozen shredded hash browns: these crisp up beautifully and add texture look for ones without added seasonings
• Egg and heavy cream: create the egg wash that gives the pastry its golden finish
• Cheese slices: havarti or cheddar both melt beautifully and create that perfect cheese pull
• Turkey bacon: adds smoky flavor without overpowering the dish choose a quality brand for best results
• Shredded cheddar cheese: adds that final layer of cheesy goodness freshly shredded melts better than pre-packaged

Step-by-Step Instructions

Prep the Oven and Pan:

Preheat your oven to 350°F and line your cookie sheet with parchment paper. This temperature allows the pastry to rise properly while cooking the filling thoroughly. The parchment prevents sticking and makes cleanup much easier.

Create the Sausage Gravy:

Cook the ground sausage until completely browned, keeping all the rendered fat in the pan. Reduce heat to medium-low and sprinkle flour directly into the sausage and grease, allowing it to bubble slightly. Stir continuously for about 1 minute to cook out the raw flour taste. Add milk and pepper, stirring until thickened. The consistency should be relatively thick for these bars to prevent sogginess. Transfer to a bowl and set aside.

Prepare the Bacon:

Cook turkey bacon using your preferred method until crisp. The air fryer works wonderfully at 390°F for about 5 minutes, creating perfectly crisp bacon with minimal mess and smell. Once cooked, allow it to cool slightly before crumbling into small pieces. The varied sizes of crumbles provide texture contrast in each bite.

Crisp the Hash Browns:

Heat a small amount of olive oil in a skillet over medium-high heat. Add frozen hash browns and cook until golden and crispy on both sides, approximately 3-4 minutes per side. The crispy texture is crucial as it provides structural integrity to the bars and prevents sogginess. Drain on paper towels if needed.

Create Egg Wash:

Whisk together one egg and heavy cream until completely combined. This creates a rich egg wash that will give your pastry a beautiful golden color and help seal the edges.

Assemble the Layers:

Place one pastry sheet on your prepared cookie sheet. Spread sausage gravy in the center, leaving about an inch border all around. This border is crucial for properly sealing the pastry. Layer hash browns evenly over the gravy, pressing slightly to create a flat surface.

Add the Filling:

Pour approximately half the egg mixture carefully over the hash browns, ensuring it doesn't spill onto the bare pastry border. Brush the border with some egg wash to help with sealing. Place cheese slices in a single layer, followed by bacon crumbles and shredded cheese.

Seal and Finish:

Place the second pastry sheet on top and press edges together firmly. Use a fork to crimp all around the perimeter, ensuring a tight seal. Brush the entire top surface with remaining egg wash for that gorgeous golden finish.

Bake to Perfection:

Bake for 18-23 minutes until the pastry is puffed and golden brown. The filling should be hot throughout and the cheese completely melted. Allow to rest for 5-10 minutes before cutting to let the filling set slightly. This prevents the filling from spilling out when cut.

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The sausage gravy is truly the heart of this recipe. I learned from my grandmother that the key is cooking the flour in the sausage drippings long enough to remove any raw flour taste but not so long that it burns. This technique creates that velvety gravy that holds everything together and infuses flavor throughout the entire dish.

Frequently Asked Questions

→ Can I substitute puff pastry with another dough?

Yes, you can use crescent roll dough or phyllo dough, though the texture will differ. Puff pastry ensures flakiness.

→ Can I use a different meat instead of turkey bacon?

Absolutely! You can use regular bacon, ham, or even a vegetarian alternative like plant-based bacon.

→ How do I prevent puff pastry from becoming soggy?

Cook hash browns until crispy and ensure sausage gravy has a thicker consistency to avoid excess moisture.

→ Can I prepare these bars in advance?

Yes, assemble the bars and refrigerate them uncooked. Bake them fresh when ready to serve.

→ What cheese works best for this dish?

Havarti or cheddar work great, but you can experiment with gouda, mozzarella, or any melty cheese of your choice.

→ How can I make this dish vegetarian?

Replace the sausage with plant-based alternatives and omit or substitute turkey bacon with a vegetarian option.