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Copycat Puff Pastry Sausage Bean and Cheese Melts

Make your favourite bakery chain snack in the comfort of your own kitchen. Sausage, Bean and Cheese Melts are a timeless classic that the whole family can enjoy as a quick breakfast, lunch or snack.

A person is using a knife to cut a bean and cheese melt in half.

What Makes This Recipe Great!

  • Money-Saving Recipe – If you love a Greggs Bean Melt, you can save some money by creating your own version of a classic treat at home.
  • Easy To Make – With a few simple ingredients you can make these with ease, even if you’re a beginner in the kitchen.
  • Freezer-Friendly – Make your bean and cheese melts ahead of time and freeze before baking. You can bake them straight from frozen.

About This Recipe – In More Detail

With baked beans, gooey melted cheese and delicious sausage, this classic combination is encased in golden puff pastry. These sausage bean and cheese melts will be loved by the whole family.

So, if you’re not from the UK you may be wondering what all the fuss is about. This recipe is a take on a classic pastry treat from a Popular bakery chain called Greggs who are famous for these bean and cheese melts as well as other classic like their Vegan sausage roll and their steak bakes.

I have created a homemade version of a sausage bean and cheese melt that are so easy to make, even if you are a beginner in the kitchen.

To keep all that lovely baked bean flavour in the bean & cheese melts, Rather than drain the bean sauce away, I fry the baked beans with onion to reduce and concentrate the bean sauce and make it thicker so you don’t end up with soggy bakes.

What’s more, is that they can be frozen before baking too. You can prepare them and freeze them, then bake from frozen whenever the craving arises. Great when you’re looking for a comforting breakfast or snack on the go. This recipe is most certainly kid-approved in my little home, they can’t get enough of these!

A hand is holding half a bean and cheese melt up to show the filling. In the background there are more whole ones laid out on a green surface.

Equipment Needed

  • Rolling Pin (optional) – If you haven’t bought ready-rolled pastry, you will need a rolling pin to roll it out.
  • Sharp Knife – To divide the pastry into portions and for slicing the cooked sausages. Use a chopping board too.
  • Baking Tray/Baking Sheet(s) – Lined with baking paper/parchment paper for cooking the sausages and bean and cheese melts on.
  • Frying Pan – To fry the filling and thicken it.
  • Large Mixing Bowl – A large bowl big enough to mix the filling in.
  • Wooden Spoon – To mix everything together and to spoon the filling onto the pastry.
  • Grater – To grate the cheddar cheese.
  • Fork – For crimping the edges of the pastry together, to create a seal.
  • Whisk – For beating the egg.
  • Pastry Brush – To coat the pastry with beaten egg wash.
  • Cooling Rack – Use a wire rack to cool the pastries a little before serving or leave them to cool completely before storing. Using a rack will prevent the bottom of the pastry pockets from becoming soggy.

Ingredients

A labelled photo with all the ingredients needed to make sausage bean and cheese melts.
  • Chipolata Sausages – Chipolata pork sausages are the classic here. They cook quickly and are easy to cut up into small chunks.
  • Olive Oil – We need just a little for cooking the sausages.
  • Ready Rolled Puff Pastry – Puff pastry gives you a nice flaky texture to the cheese melts. I use ready-rolled to make this recipe super easy, but you can also use a block of puff pastry and roll it out yourself.
  • Baked Beans – A can of beans will do, any brand you choose is fine to use.
  • Onion: Finely sliced and fried with the beans, onion serves to gives an extra flavour boost. However, you can choose to omit the onion if you’d prefer.
  • Cheddar Cheese – Use a good quality strong cheddar cheese for the best flavour.
  • Egg – A medium egg should suffice as we only need a little beaten egg for an egg wash. Egg is essential though, if you want a nice golden puff pastry finish to your bean melts.

Additions and Substitutions

Substitutions:

  • Sausages and Beans: If you want to make this super quick, use a can of sausages and baked beans instead of cooking them separately.
  • Sausages: You can use regular pork sausages, frankfurters or create a vegetarian version and use vegetarian sausages instead.
  • Olive Oil: You can use an oil of your choice for cooking the sausages.
  • Cheddar: Replace it in part or whole with some cooking mozzarella (fresh mozzarella may make the end result a little soggy), parmesan or Gruyère cheese.
  • Egg – Instead of egg you can brush the pastry with a little milk instead.

Additions:

  • Bacon: Cooked Bacon bits will go well and add a little extra flavour.
  • Pastry Decorations: If you want to make them extra fancy, cut out some shapes from extra puff pastry and stick them to the top with a little egg wash.

A person is placing a rectangle of puff pastry over the top of the filling on another pastry sheet to create a parcel.

Step-By-Step Guide – How To Make Sausage Bean and Cheese Melts

Step 1: Preparation

  • Preheat Oven: Preheat your oven to 190°C (375°F).

Step 2: Cooking the Filling

  • Cook Sausages: Heat olive oil in a large frying pan. Add chipolata sausages and fry over medium heat, turning frequently until browned and cooked through.
  • Slice Sausages: Remove sausages from the pan, slice them into small pieces, and set aside.
  • Prepare Onion: Finely slice the onion and add it to the frying pan. Fry until soft and transparent.
  • Combine Ingredients: Add baked beans to the pan with onions. Continue frying, stirring regularly, until the mixture thickens and reduces. Once thickened, remove from heat and mix in the sausage pieces evenly. Set aside to cool.
A hand is using a wooden spoon to stir chipolata sausages in a frying pan.
A hand is using a sharp knife to cut cooked chipolata sausages on a wooden board into pieces.
A hand is using a sharp knife to slice onion on a wooden board.
A hand is mixing together sausages onions and baked beans in a frying pan using a wooden spoon.

Step 3: Assembling the Parcels

  • Prepare Cheese: Grate the cheddar cheese and set aside.
  • Roll Pastry: Roll out the puff pastry sheet and divide it into 4 equal pieces. Then, divide each piece in half again.
  • Fill Pastry: Spoon the bean and sausage mixture into the centre of 4 pastry pieces, leaving an edge around the sides.
  • Add Cheese: Sprinkle the grated cheddar cheese over the filling.
  • Seal Parcels: Lightly beat the egg. Brush the exposed edges of the pastry with the egg. Cover each pastry with the remaining pastry rectangles, ensuring the filling is completely covered. Crimp the edges together with a fork to seal the parcels.
  • Prepare for Baking: Place the puff pastry parcels on a lined baking sheet with space between them. Pierce the tops with a fork to allow steam to escape.
A sheet of puff pastry cut into eight pieces.
4 rectangles of puff pastry on a lined baking sheet with sausage and bean piled in the middle with a gap around the edge.
A hand is using a pastry brush to brush the exposed edges of puff pastry with the filling in the middle.
Two hands are placing a rectangle of puff pastry over the filling to seal it inside.
A hand is using a fork to crimp the edges of the puff pastry together to create a seal.
A hand is using a fork to Pierce holes in the tops of the unbaked sausage bean and cheese melts to allow steam to release.

Step 4: Baking

  • Apply Egg Wash: Brush the tops of the puff pastry parcels with beaten egg.
  • Bake: Bake in the preheated oven for about 20 minutes or until the parcels are puffed up and golden brown.
A hand is using a blue pastry brush to brush egg wash on top of the puff pastry parcels.
A hand inside an oven glove is holding a baking sheet with four baked sausage bean and cheese melts on top.

Step 5: Serving

  • Cool and Serve: Once baked, remove the parcels from the oven and transfer them onto a wire rack to cool slightly before serving. Note: The filling will be very hot straight from the oven, so handle with caution.

A person is sprinkling cheddar cheese on top of the filling on pastry which is sat on a lined baking sheet.

FAQ

How long should I fry the chipolata sausages for?

Fry the chipolata sausages over a medium heat, turning them often, until they are browned and cooked through, typically about 10-15 minutes.

How do I know when the pastry parcels are done baking?

The parcels should be puffed up and golden brown when they’re ready. Bake them for about 20 minutes or until they achieve this desired appearance.

Can I prepare the filling in advance and refrigerate it overnight before assembling the parcels?

Yes, you can prepare the filling in advance and refrigerate it. Just make sure to allow it to come to room temperature before assembling the parcels to prevent chilling the pastry.

Can I make smaller or larger pastry parcels?

Absolutely, you can adjust the size of the parcels based on your preference. Just be mindful of the baking time, as smaller parcels may require less time in the oven, while larger ones may need more.


Pro Tips and Guidance

  • Properly Brown Sausages: When frying the chipolata sausages, make sure to brown them evenly on all sides over a medium heat.
  • Sauté Onion Perfectly: Take care not to brown the onion too much while sautéing. Cook until it becomes soft and transparent.
  • Thicken Bean Mixture: Allow the baked bean mixture to simmer until it thickens and reduces down to a thick consistency. This ensures that the filling isn’t too watery, preventing the pastry from becoming soggy during baking.
  • Cool Filling Slightly: Let the bean and sausage mixture cool slightly before spooning it onto the pastry. This prevents the heat from melting the pastry prematurely and makes it easier to handle during assembly.
  • Seal Pastry Edges Securely: Use a fork to crimp the edges of the pastry parcels firmly together. This helps to seal the parcels properly, preventing the filling from leaking out during baking.
  • Ventilate the Parcels: Pierce the tops of the parcels with a fork to create vents before baking. This allows steam to escape, preventing the pastry from becoming too puffy and ensuring even baking.
  • Monitor Baking Closely: Keep an eye on the parcels towards the end of the baking time to prevent them from overcooking. Adjust the baking time if needed.
A sliced sausage bean and cheese melt showing the filling, on a green surface with others in the background.

Storage

Storage:

  • Once baked, the puff pastry sausage parcels can be stored in an airtight container in the fridge for 1-2 days.
  • Ensure the parcels are completely cooled before storing to prevent condensation and sogginess.

Reheating:

  • To reheat, preheat the oven to 180°C (350°F) and place the parcels on a baking sheet.
  • Bake for 10-15 minutes or until heated through and the pastry is crispy again.
  • Alternatively, you can reheat individual portions in the microwave for 1-2 minutes, but the pastry will become less crispy this way.

Freezing:

  • I don’t recommend freezing the parcels once assembled and baked.
  • Freezing can adversely affect the texture and quality of both the cooked pastry and the filling.
  • However, you can freeze the unbaked assembled parcels before baking for up to 1 month for future use.

Baking From Frozen:

  • If you’ve frozen unbaked parcels, you can bake them straight from frozen, but extend the baking time to ensure they are baked and hot all the way through.
  • Do not defrost and refreeze the parcels after they’ve been baked, as this can affect their texture and taste.

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A hand is holding a sliced sausage bean and cheese melt up to show the filling.

Copycat Puff Pastry Sausage Bean and Cheese Melts

5 from 3 votes
A classic British Bakery Treat. These Sausage Bean and Cheese Melts are so easy to make, money saving and can be frozen before baking for whenever you have a craving for a Puff pastry snack.
Print Recipe Pin Rate Save
Course: Breakfast, lunch, Snack
Cuisine: British
Prep Time: 20 minutes
Cook Time: 40 minutes
Total Time: 1 hour
Servings: 4 Melts
Calories: 789kcal

Ingredients
 
 

  • 6 Chipolata Sausages , approx. 190g
  • 1 tsp Olive Oil
  • 1 small Onion
  • 320 g Ready Rolled Puff Pastry
  • 415 g Canned Baked Beans
  • 50 g Cheddar Cheese
  • 1 medium Egg

Instructions

  • Preheat the oven to 190°C (375°F).
  • Heat the oil in a large frying pan and add the chipolata sausages, fry over a medium heat, turning them often until they have browned and cooked through.
  • Remove the sausages from the pan, slice into small pieces using a sharp knife and set aside.
  • Finely slice the onion and add it to the frying pan, fry until the onion is soft and transparent.
  • Once the onion is ready, add the baked beans and continue to fry, stirring regularly.
  • The baked bean juice will begin to thicken and reduce down, once you have a thick mixture, turn off the heat and mix the sausage pieces through the beans, distributing them evenly. Set the mixture aside and allow it to cool.
  • Grate the cheddar cheese and set it aside in a separate bowl.
  • Roll out the puff pastry sheet and, using a sharp knife, divide it into 4 equal pieces. Then, divide each piece in half again.
  • Spoon the bean and sausage mixture into the centre of 4 pieces of pastry, leaving an edge around the sides.
  • Sprinkle each pastry with the grated cheddar cheese.
  • Lightly beat the egg and brush the exposed edges of the pastry with it, using a pastry brush.
  • Cover each pastry with the remaining pastry rectangles, ensuring that the filling is completely covered.
  • Using a fork, crimp the edges together to seal the parcels.
  • Place the puff pastry parcels on a lined baking sheet with space between them to allow for puffing up during baking.
  • Pierce the tops of the parcels with a few pokes of a fork to allow steam to escape.
  • Brush the tops of the puff pastry parcels with beaten egg.
  • Bake in the preheated oven for about 20 minutes or until the parcels are puffed up and golden brown.
  • Once baked, remove the parcels from the oven and transfer them onto a wire rack to cool slightly before serving. (Note: The filling will be very hot straight from the oven, so handle with caution.)

Recipe Notes

  • Brown Sausages Evenly: Fry chipolata sausages over medium heat until uniformly browned on all sides.
  • Sauté Onion Carefully: Cook onion until soft and transparent, avoiding excessive browning.
  • Thicken Bean Mixture: Simmer baked bean mixture until it thickens to prevent a watery filling.
  • Cool Filling: Allow bean and sausage mixture to cool before spooning onto pastry to prevent premature pastry melting.
  • Seal Edges Firmly: Crimp pastry edges securely with a fork to prevent filling leakage during baking.
  • Ventilate Parcels: Pierce tops of parcels with a fork to release steam for even baking and prevent puffiness.
  • Monitor Baking: Keep a close eye on parcels towards the end of baking time to prevent overcooking, adjusting as needed.

Nutrition Estimate

Calories: 789kcal | Carbohydrates: 61g | Protein: 23g | Fat: 51g | Saturated Fat: 16g | Polyunsaturated Fat: 5g | Monounsaturated Fat: 20g | Trans Fat: 0.01g | Cholesterol: 61mg | Sodium: 1336mg | Potassium: 420mg | Fiber: 8g | Sugar: 2g | Vitamin A: 186IU | Vitamin C: 3mg | Calcium: 162mg | Iron: 4mg

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