Green Chile Cheddar Recipe

Roast and prep chiles

If using fresh green chiles (Anaheim, Hatch), roast over a gas flame or under a broiler until blistered and charred on all sides. Place in a bowl and cover tightly with plastic wrap for 10 minutes to steam. Peel skins, remove seeds if desired for milder heat, and finely chop. Measure out 3 cups packed.

Prep casings

If using natural hog casings, rinse and soak in warm water for 30 minutes, then flush through with running water to remove salt. Keep casings in water until ready to use. If using collagen casings, follow package rehydration instructions.

Chill meat and equipment

Cut ground pork into chunks if needed and keep refrigerated until very cold. Chill the bowl and mixing tools briefly—cold meat and equipment help the sausage bind and keep cheese from melting while mixing.

In a large mixing bowl, combine the ground pork and additional pork fat (if using). Add the minced garlic, kosher salt, black pepper, ground cumin, smoked paprika, dried oregano, and crushed red pepper flakes.

Add the chopped roasted green chiles and shredded sharp cheddar to the meat mixture. Sprinkle the 3 tablespoons cold water over the mixture (this helps distribute seasoning and improves texture). Using clean hands or a sturdy spoon, gently but thoroughly mix until ingredients are evenly distributed and the mixture becomes slightly tacky, about 2–3 minutes. Avoid overworking to keep the finished sausage tender.

Taste-and-adjust: Take a small 1/2 teaspoon of the mixture and cook it in a skillet until fully cooked. Cool briefly and taste for seasoning, heat and salt. Adjust salt, pepper, or red pepper flakes in the main mixture if needed.

Set up your sausage stuffer or a funnel attachment on a stand mixer or manual stuffer. Slide the soaked casing onto the nozzle, leaving a few inches hanging, and tie a small knot at the end or hold it closed.

Fill the stuffer with the sausage mix, keeping it cool. Feed the meat into the casing with even pressure to avoid air pockets, forming a continuous tube. As the casing fills, guide it onto a tray. Avoid overstuffing—casing should be firm but not stretched thin.

When you reach the desired length, twist the sausage into links (about 4–6 inches per link) by pinching and twisting in alternating directions every 4–6 inches. Prick any large visible air bubbles with a sterile needle to release trapped air.

Refrigerate for immediate cooking (fresh sausage)

If you plan to cook and serve within 24–48 hours, refrigerate the linked sausages on a tray covered loosely with plastic wrap. To cook: heat a skillet over medium heat with 1 tablespoon olive oil. Add links and brown on all sides, about 3–4 minutes per side, then reduce heat and cover, cooking an additional 6–8 minutes or until internal temperature reaches 160°F (71°C). Rest 5 minutes before serving. Optionally sprinkle with extra shredded cheddar and chopped cilantro before serving.

Light smoking (optional)

For added flavor, cold-smoke or hot-smoke sausages at 175–200°F (80–95°C) for 1–2 hours until they reach 145°F internally, then finish by poaching or baking to bring internal temp to 160°F (71°C).

To cure and store (requires cure and food-safety steps)

If you intend to make shelf-stable cured sausages, follow a tested curing recipe that includes curing salts (Prague Powder #1 or #2 as appropriate), controlled fermentation cultures, humidity and temperature control. This recipe is for fresh sausage; do not attempt long curing without proper curing agents and process. Store fresh sausages refrigerated up to 3 days or frozen up to 3 months.

To serve as a snack, slice cooked links into 1/2-inch rounds, drizzle lightly with a little olive oil if desired, and sprinkle with extra shredded cheddar and chopped cilantro. Serve warm with mustard, pickles, or a simple roll.