Cheesy Loaded Meatloaf Casserole

Ingredients

• 454 g (1 pound)lean ground beef (90/10 works well)
• 15 ml (1 Tbsp)dried onion flakes
• 5 ml (1 tsp)Italian seasoning
• 60 ml (1/4 cup)Sweet Baby Ray’s BBQ Sauce
• 1egg
• 10 ml (2 tsp)chilli powder
• 3.75 ml (3/4 tsp)kosher salt
• 907 g (2 pounds)Russet potatoes, peeled and halved
• 28 g (2 Tbsp)butter
• 160 ml (2/3 cup)milk
• 70 g (1/2 cup)crumbled bacon
• 20 g (1/3 cup)crispy fried onions
• 57 g (1/2 cup)shredded cheddar cheese
• to tastesalt and black pepper

Instructions

1. 1

   Mix the beef

   In a mixing bowl, combine the ground beef, onion flakes, Italian seasoning, BBQ sauce, egg, chilli powder and kosher salt.

2. 2

   Shape the meatloaf

   Spread the mixture in the base of a 18 × 8 cm (7 × 3 inch) pot-in-pot dish. Press it into an even layer using your hands or the back of a spoon.

3. 3

   Set up the pot

   Pour 355 ml (1 ½ cups) of water into the Instant Pot. Put the dish on a trivet with handles and lower it into the pot. Set a second trivet above the meatloaf dish and arrange the halved potatoes on it.

4. 4

   Pressure cook

   Cover the Instant Pot and secure the lid, with the valve set to sealing. Select manual or pressure cook for 25 minutes. When the time is up, leave the pot for 10 minutes, then move the valve to venting and remove the lid.

5. 5

   Mash the potatoes

   Use tongs to transfer the potatoes to a medium bowl and add the butter. Mash, then stir in the milk and bacon. Season the potatoes with salt and pepper to taste.

6. 6

   Add the topping

   Spread the mashed potatoes over the meatloaf, then scatter the fried onions and cheese on top. Use the air fryer lid for about 2–3 minutes at 204°C (400°F) to melt the cheese, or broil in the oven for about 5 minutes.

7. 7

   Serve the casserole

   Serve and enjoy.

What is loaded meatloaf casserole?

Meatloaf is a familiar home-cooked dish, especially in the United States, where versions are often seasoned and served with a sauce. This casserole turns it into a layered meal, pairing barbecue-seasoned beef with mashed potato and a crisp, cheesy finish.

The Instant Pot method cooks the meat and potatoes together: the beef sits in a small dish, while the potatoes cook above it. Bacon, fried onions and cheddar bring savoury flavour and contrasting textures to the soft layers.

Nutrition and macros by portion

The nutrition label shows one serving as written: 435 calories, 26g protein, 37g carbs, 20g fat.

The potatoes and BBQ sauce provide most of the carbohydrates, while the beef and bacon contribute protein and the butter, cheese and meat supply much of the fat. Serve it with green vegetables or salad to add freshness and round out the plate.

The beef layer

Even mixing: combine the beef, egg, seasoning and BBQ sauce just until evenly blended. Press it into a flat layer so it cooks consistently in the small dish.

Lean mince: 90/10 beef keeps the mixture relatively lean while still providing enough fat for a tender result. The egg helps bind the meatloaf layer.

Cooking potatoes above the meat

Pot-in-pot setup: the water goes into the base of the Instant Pot, not into the meatloaf dish. The lower trivet supports the dish, and the second trivet holds the potatoes above it.

Safe lowering: use the trivet handles to lower the dish into the pot, and take care when lifting it out after cooking. The pot and its contents will be hot.

Getting smooth mashed potatoes

Mash while hot: transfer the cooked potatoes to a bowl and mash them with the butter before stirring in the milk. This makes it easier to incorporate the butter and milk evenly.

Add gradually: stir in the milk until the potatoes reach a spreadable consistency. Fold in the bacon, then season to taste before layering the mash over the meatloaf.

The crisp, cheesy finish

Topping order: spread the mash over the beef first, then add the crispy fried onions and cheddar. This keeps the onions on top, where they can retain some crunch as the cheese melts.

Short finish: use the air fryer lid at 204°C for about 2–3 minutes, or broil in the oven for about 5 minutes. Keep an eye on the topping so the cheese melts without the onions scorching.

Serving the casserole

This is a substantial dish with meat, potato and rich toppings in each portion. A green salad or steamed green vegetables make a fresh, simple accompaniment.

Let the casserole settle briefly after adding the topping, then serve with a spoon so each portion keeps its layers together.

Recipe notes & tips

• Cut the potatoes into similarly sized halves so they cook at the same pace.
• Press the beef mixture into an even layer to help it cook consistently.
• Use the trivet handles to lower and lift the hot dish carefully.
• Mash the potatoes before stirring in the milk so you can control their texture.
• Watch the topping closely under the air fryer lid or grill, as the fried onions can brown quickly.

Variations

• Smokier topping: use a smoky BBQ sauce for a deeper barbecue flavour.
• Extra cheese: add a little more cheddar over the potatoes before melting.
• Herby mash: stir chopped chives into the potatoes with the bacon.
• More vegetables: serve with steamed green beans or broccoli alongside.
• Peppery finish: add freshly ground black pepper to the mashed potatoes before spreading.

Common mistakes to avoid

• Uneven beef layer: press the mixture flat so it cooks more evenly.
• Water in the dish: pour the water into the Instant Pot base, not over the meatloaf.
• Unsteady trivet: check that the dish and upper trivet sit securely before adding the potatoes.
• Watery mash: add the milk gradually and stop when the potatoes are spreadable.
• Burnt onions: keep an eye on the topping during the short high-heat finish.

How to store

Refrigerate leftovers in a covered container for up to 3 days. Reheat portions in the microwave or in a covered oven-safe dish until hot throughout; the fried onions may soften after storage.

Frequently asked questions