Nothing says comfort food quite like a hearty pan of Barbecued Beans & Meatballs fresh from the oven. This classic casserole combines tender homemade meatballs, smoky sausage, and a rich baked bean mixture into one satisfying dish that’s perfect for potlucks, backyard cookouts, family reunions, and game day gatherings. Slow baking allows the flavors to blend together while creating a thick, savory barbecue-style sauce that coats every bite. If you’re looking for an easy make-ahead casserole that feeds a crowd and tastes even better the next day, this barbecued beans and meatballs recipe is sure to become a family favorite.
Make the Meatballs
Prepare the Oven:
Preheat the oven to 375°F (190°C). Lightly grease two jelly roll pans or large rimmed baking sheets.
Mix the Meatball Base:
In a large mixing bowl, combine the beaten eggs, milk, and instant minced onion. Let the mixture stand for 5 minutes so the onion can soften. Stir in the bread crumbs, salt, and black pepper until combined.
Shape & Bake:
Add the ground beef and gently mix until just combined. Using wet hands, form the mixture into approximately 48 meatballs, about 2 inches each. Arrange them on the prepared pans without overcrowding. Bake uncovered for 20 minutes, then carefully drain away any excess grease.
Prepare the Bean Mixture
Cook the Sauce:
In a large Dutch oven, combine the pork and beans, tomatoes, corn, tomato sauce, Pioneer Golden Light Brown Sugar, light molasses, and prepared mustard. Bring the mixture to a gentle boil over medium heat, stirring occasionally.
Assemble the Casseroles:
Cut each smoked sausage into thirds. Divide the cooked meatballs and sausage pieces evenly between two 3-quart casserole dishes. Pour half of the bean mixture over each casserole and stir gently to combine.
Bake:
Bake uncovered for 1½ hours, stirring every 30 minutes to ensure even cooking and prevent sticking. The sauce should become thick and bubbly.
Finish with Cheese:
Sprinkle the shredded American cheese evenly over both casseroles. Return to the oven for 2 to 3 minutes, or until the cheese has completely melted. Serve hot with cornbread, biscuits, or a crisp green salad.
This casserole is an excellent make-ahead meal. Assemble it a day in advance, refrigerate, and bake just before serving. Leftovers can be refrigerated for up to four days and often develop an even richer flavor after resting overnight. For food safety, cook ground beef to an internal temperature of 160°F (71°C).
Pioneer Golden Light Brown Sugar gives the barbecue-style sauce a rich, mellow sweetness that balances the acidity of the tomatoes and the tanginess of the mustard. Combined with molasses, it creates a deeper, more complex flavor while helping the sauce thicken as it bakes. Rather than making the dish sweet, the sugar enhances the smoky, savory ingredients and gives the casserole its signature homemade barbecue flavor.
