Air Fryer Chili Relleno Casserole
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I make Air Fryer Chili Relleno Casserole when I’m craving that chili relleno flavor but don’t want the hassle. The air fryer crisps the top golden while keeping everything underneath cheesy and rich. Every bite delivers tender chilies, seasoned beef, and melted cheese in perfect layers. It’s easier than the traditional version and tastes just as good.
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I make this for weeknight family dinners, casual gatherings, and potlucks because it feeds a crowd and travels well. It’s perfect for Cinco de Mayo or game day parties too, and it’s a total crowd-pleaser that’s make-ahead friendly. Leftovers stay fresh in the fridge for 4 days or freeze for 2 months.
Ingredients You’ll Need
You’ll need all the ingredients shown in the photograph below.
How to Make Air Fryer Chili Relleno Casserole with Step-By-Step Instructions
Scroll down for the full recipe card containing a full printable recipe and measurements in both US customary and metric units.
Let me walk you through how I make this casserole so you get perfect layers every time.
Prep Your Baking Dish
Grab a 9×13-inch baking dish and spray it with cooking spray to prevent it from sticking. Check that your dish fits inside the air fryer basket before you begin layering everything.
Mix the Egg Topping
In a glass mixing bowl with pour spout, whisk together the eggs, flour, milk, hot sauce, paprika, onion powder, and salt, then set it aside while you work on the other components.
I use a sturdy stainless steel whisk here because it blends the eggs and seasonings fast without any clumps.
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This eBook is a collection of 86 recipes I make again and again in my own kitchen. If you love good food and easy instructions, this book was made for you.
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∙ Cheesy Egg Bites
∙ Broccoli Cheddar Soup
∙ Asparagus Casserole
∙ Crack Chicken Casserole
∙ Coffee Cake
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Cook the Beef and Bean Mixture
In a cast-iron skillet over medium heat, cook the ground beef with the chopped onions until the meat is browned and the onions are soft. Stir in the refried beans and mix everything until it’s well combined and heated through.
Build the First Layer
Layer half of the tortilla chips across the bottom of your greased baking dish. Top with half of the beef mixture, then lay half of the roasted green chilies over that, opening them flat so they cover everything. Sprinkle half of the shredded Monterey Jack cheese over the chilies. If you’d like extra creaminess, add a handful of shredded Oaxaca cheese as well. A box grater with a built-in container makes quick work of shredding cheese when you’re starting with a block.
Add the Second Layer
Repeat the layering with the remaining tortilla chips, beef mixture, and chilies. Pour the egg mixture evenly over the top, then finish with the remaining shredded cheese. I like using a silicone spatula here because it makes it easy to spread the egg mixture evenly over the casserole.
Bake in the Air Fryer
Cover the dish with foil and place it in your air fryer. Bake at 375°F (190°C) for 25 minutes. I use my thick heat-resistant oven gloves when lifting the dish out, because the air fryer basket is way too hot to handle bare-handed.
Remove the foil during the last 5 minutes until the cheese gets golden and slightly brown on top. Let it cool for a few minutes before slicing and serving so the layers set up nicely. Serve and enjoy!
Ingredients
- 8 green chilies whole, baked and peeled
- 1 pound ground beef
- 1 cup onion finely chopped
- 2 cups Monterey jack shredded
- 2 cups corn tortilla chips
- 1 ½ cups refried beans
For the topping:
- 4 eggs beaten
- ¼ cup flour
- 2 teaspoons hot sauce
- ½ cup whole milk
- ¼ teaspoon paprika
- ¼ teaspoon onion powder
- Salt to taste
Instructions
- Grease a 9×13-inch baking dish with cooking spray.
- In a large bowl, whisk together the eggs, flour, milk, hot sauce, paprika, onion powder, and salt. Set aside.4 eggs, ¼ cup flour, 2 teaspoons hot sauce, ½ cup whole milk, ¼ teaspoon paprika, ¼ teaspoon onion powder, Salt
- In a skillet over medium heat, cook the ground beef and chopped onions until the meat is browned and the onions are soft. Stir in the refried beans and mix well.1 pound ground beef, 1 cup onion, 1 ½ cups refried beans
- Layer half of the tortilla chips in the prepared baking dish, followed by half of the meat mixture, half of the chilies (laid open), and half of the shredded cheese. Repeat the layers, finishing with the chilies.8 green chilies, 2 cups corn tortilla chips, 2 cups Monterey jack
- Pour the egg mixture evenly over the top and sprinkle with the remaining cheese.
- Cover with foil and bake in the air fryer at 375°F (190°C) for 25 minutes. Remove the foil during the last 5 minutes to allow the cheese to brown slightly.
- Let the casserole cool for a few minutes before serving. Enjoy!
Notes
- Check your dish size: Make sure your 9×13-inch baking dish actually fits in your air fryer basket before you start assembling everything, or you’ll have to transfer it all to a different pan.
- Whisk out the lumps: Make sure the flour is completely smooth in your egg mixture with no lumps, or you’ll have pockets of dry flour in the finished casserole.
- Drain the beef well: After browning the ground beef, drain off any excess grease before mixing in the refried beans so your casserole doesn’t turn out greasy.
- Open the chilies flat: Lay the roasted green chilies open like you’re butterflying them so they cover more surface area and you get chili flavor in every bite.
- Don’t skip the cooling time: Let the casserole rest for 5 minutes after it comes out of the air fryer so the egg mixture sets up and you can cut clean slices instead of a soupy mess.
- Flash freeze for meal prep: If you’re freezing portions, place them on a baking sheet for 1 hour first before wrapping and bagging so they hold their shape and don’t stick together in the freezer.
Nutrition
DO MORE WITH YOUR
AIR FRYER
This eBook is a collection of 86 recipes I make again and again in my own kitchen. If you love good food and easy instructions, this book was made for you.
Immediate eBook download. No physical book available.
∙ Cheesy Egg Bites
∙ Broccoli Cheddar Soup
∙ Asparagus Casserole
∙ Crack Chicken Casserole
∙ Coffee Cake
...and much more!
Includes ad-free recipes like:
How to Store Leftovers
Let the casserole cool completely before storing. I like to portion it into airtight containers so it’s easy to grab for quick meals, and it keeps well in the fridge for up to 4 days. Reheat individual servings in the microwave for 1–2 minutes, or warm them in the oven at 350°F for 10–15 minutes, or in the air fryer for 5–7 minutes, until hot and melty again.
For longer storage, wrap portions tightly in plastic wrap, then place them in freezer bags and freeze for up to 2 months. Thaw overnight in the fridge before reheating. The texture stays pretty good, though the tortilla chips soften a bit after freezing.
What to Serve With Air Fryer Chili Relleno Casserole
I usually serve the casserole with Mexican rice, a simple side salad with lime vinaigrette, and tortilla chips with salsa or guacamole on the side. Sour cream, pico de gallo, and sliced avocado make perfect toppings when you want something fresh and bright on top.
Black beans, cilantro lime rice, or refried beans work great as sides. If you’re feeding a crowd, add chips and queso, seven-layer dip, or Mexican street corn for a full spread that everyone will love.
More Easy Recipes for You to Try at Home
If you love this casserole, you’ll want to try these other air fryer recipes that are just as hearty and crowd-pleasing.
