Air Fryer Johnsonville Chili Cheese Smoked Sausage

Air Fryer Johnsonville Chili Cheese Smoked Sausage

Air frying Johnsonville Chili Cheese Smoked Sausage creates a juicy, bold sausage with a crispy casing and a rich, cheesy, chili-flavored interior—all ready in under 10 minutes. This quick and easy method gives you maximum flavor with minimal mess, perfect for sandwiches, platters, or fun weeknight meals.

Why You’ll Love This Recipe

Bold Chili Flavor With Melty Cheese

Each bite delivers spicy chili seasoning and creamy cheddar, sealed inside a perfectly crisped sausage.

Fast, Easy, and No Cleanup

No grill or skillet needed—air fryer cooking means less mess and faster meals.

Great for Sandwiches, Bowls, or Appetizers

Serve whole in buns, slice into mac and cheese, or skewer for party bites.

Cook From Frozen or Fresh

Cooks evenly and crisps beautifully whether starting from fridge or freezer.

Ingredients

• 1 package Johnsonville Chili Cheese Smoked Sausage (fresh or frozen)

Optional:

• Buns or hoagie rolls

• Shredded cheddar, diced onions, jalapeños

• Chili sauce, mustard, or BBQ sauce for topping

Instructions

Step 1: Preheat the Air Fryer

Preheat your air fryer to 375°F (190°C) for 3–4 minutes.

Step 2: Prepare the Sausages

• Remove Johnsonville Chili Cheese Smoked Sausages from packaging.

• If frozen, separate gently—no thawing needed.

• Arrange sausages in a single layer in the air fryer basket or tray with space between each one.

Step 3: Air Fry to Perfection

• Cook at 375°F for 8–10 minutes, flipping halfway through.

• For frozen sausages, cook for 10–12 minutes, flipping after 6 minutes.

• Sausages are ready when the casing is browned and internal temperature reaches 160°F (71°C).

Step 4: Rest & Serve

Let sausages rest for 2–3 minutes before slicing or serving to allow the cheese and juices to settle.

Pro Tips for the Best Results

Use a Meat Thermometer

Confirm internal temperature reaches 160°F to ensure sausages are safely and fully heated.

Flip Carefully

Turn halfway through cooking to achieve even crisping on all sides.

Keep Whole During Cooking

Avoid slicing before air frying to prevent the cheese from leaking out.

Allow Space for Circulation

Do not overcrowd the air fryer basket to ensure crispy, evenly cooked sausages.

What to Serve With Johnsonville Chili Cheese Smoked Sausage

Dipping Sauces

• Chili Sauce or Spicy Mustard – Bold and tangy

• BBQ Sauce – Sweet and smoky balance

• Cheese Sauce – Extra indulgent topping

• Ranch or Jalapeño Ranch – Cool, creamy contrast

Side Dishes

• French Fries or Loaded Tater Tots – Fun and satisfying

• Mac and Cheese – Cheesy comfort food pairing

• Roasted Corn or Bell Peppers – Sweet and savory balance

• Coleslaw or Pickle Spears – Crisp and tangy sides

Creative Serving Ideas

• Chili Cheese Dog: Serve in a bun, topped with shredded cheese, diced onions, and jalapeños

• Nachos: Slice and layer over tortilla chips with cheese and salsa

• Skillet Hash: Chop and mix with potatoes and eggs

• Party Platter: Slice and serve with toothpicks and dipping sauces

Storage & Reheating Instructions

How to Store Leftovers

Cool completely, then refrigerate in an airtight container for up to 4 days.

How to Reheat in the Air Fryer

Reheat sausages at 350°F (177°C) for 3–4 minutes until hot and slightly crisp.

Can You Freeze After Cooking?

Yes—wrap sausages tightly and freeze for up to 2 months. Reheat from frozen at 375°F for 6–7 minutes.

Frequently Asked Questions

Are Johnsonville Chili Cheese Smoked Sausages Fully Cooked?

Yes—these sausages are fully cooked. You only need to heat to an internal temperature of 160°F.

Can I Cook Them From Frozen?

Yes—simply extend the cooking time by 2–3 minutes and flip halfway through.

Should I Use Oil or Spray?

No—these sausages crisp naturally in the air fryer without needing extra oil.

Will the Cheese Leak Out?

If left whole during cooking, most of the cheesy filling stays sealed inside.

Make Johnsonville Chili Cheese Smoked Sausage in the air fryer for bold chili flavor and melty cheddar inside a crisp casing in under 10 minutes. Full instructions, tips, and serving ideas included.