Puff Pastry Sausage Rolls

• These puff pastry sausage rolls are much lower in fat and healthier than the standard sausage roll. This is because the filling is made with lean ground beef and potato and not pork sausage meat.
• Seasoned with Asian spices these are packed with flavour and just about everyone loves them.
• Make them long and enjoy them as an easy meal.
• Cut them shorter and pass them around at casual gatherings, as an easy finger food for a crowd.
• Cut them into dainty bite sized pieces and serve them as appetizers on special occasions.
• Although these take a little longer to make because, the filling has to be cooked and cooled before being wrapped in pastry, it is worth it.
• These can be prepared ahead of time and frozen for later – see our tips for freezing below in our Frequently Asked Questions section.

Ground beef – use a lean beef mince rather than fatty meat because they won’t be greasy.

Potato – Any potato that is suitable for mashing will do, like Desiree, Sebago Russets or Yukon gold.

Curry Powder – My favorite curry powder for this recipe is a brand called Clive of India but, you can use any curry powder that you like.

Just be aware that the recipe has been written for Clive of India curry powder and it’s a mild curry powder.

If you use another curry powder you may need to use more or less of the powder depending on how strong the flavor is.  

Other flavorings: onion, freshly grated ginger, fresh lemon juice, and garam masala.

Puff pastry – I use readymade puff pastry sheets; these are already rolled and are about 26cm (10.5 inches) square.

I use four of these sheets and cut them into half to give me 8 rectangles that are about 26 x 13cm (10.5 x 5 inches) in size.

If you are using puff pastry that is folded in the pack, place the pastry on a floured surface unfold and roll the dough so that is about 5mm (¼ inch) thick.

Then use the above measurements as a guide to get the correct pastry sheet sizes.

Cook the potato by boiling in salted water until tender then drain well. Use a potato masher to mash the potatoes until smooth, put to one side for later.

Meat filling - Fry onion, garlic, and ginger on medium heat until the onions become golden. Reduce the heat and add the Clive of India curry powder, salt, lemon juice, and fry for about one minute.

Add the beef mince, turn the heat to high. Use a spatula to break the mince into small tiny pieces as it cooks.

• Note: If using another curry powder add about 2-3 teaspoons after the onions have browned, then add more after you have added and cooked the beef mince. Mix in a half to 1 teaspoon of curry powder at a time until you are happy with the taste.

Add half a cup of hot water, cover and simmer for 10 minutes or until the mixture is almost dry.

Mix in the garam masala and a squeeze of lemon juice. Taste adding a little more curry powder if you find it lacking in taste.

• Tip: You want the curry flavour to be a little stronger in the meat mixture because, once it gets mixed in with the potato the flavours will even out.

Make the filling – In a large bowl mix the mashed potato and meat mixture together, taste again and season with salt and mix well.  Allow the mixture to cool completely before dividing and making the sausage rolls.

How to make sausage rolls with puff pastry

Defrost the pastry by carefully removing 4 frozen sheets of puff pastry from the pack and placing them in a single layer on the bench. Leave to thaw for 15-20 minutes.

Step 1 - Cut each of the pastry sheets in half to make 8 rectangles that are about 26 x 13cm (10.5 x 5 inches) in size.

Use kitchen scales to divide the filling into eight even portions. Take one portion of filling and place it in the center of one piece of puff pastry.

With clean hands shape the filling into a “log” so that it goes lengthwise down the center of the pastry.

Step 2 - Brush egg wash on one long side of the pastry. Next, roll the pastry around the filling starting with the unwashed edge, and roll it toward the edge with the egg wash to seal.

Gently roll the pastry over so the sealed edge is facing down. Repeat the process to make the rest of the sausage rolls.

Step 3 - Use a shape knife to evenly cut each long piece into six even sections. Place the pieces on a large baking sheet lined with parchment paper, spacing the rolls well apart.

Brush the tops with egg wash and sprinkle with sesame seeds. You can use white or black sesame seeds are a combination of both.

Step 4 - Bake for 15 – 20 minutes or until light golden brown. If your oven has a hot spot turn the tray halfway through cooking to ensure even browning. Allow them to cool for about 10 minutes before serving.

Allow the filling to cool – It’s important to cool the filling completely before adding it to the pastry. If the filling is not cold or at room temperature it can melt the pastry making it difficult to handle and can even ruin the pastry.

Prepare the filling in advance – this filling can be made several days in advance and stored covered in the fridge.

Puff pastry alternative – if you can’t buy puff pastry where you live you can use my homemade rough puff pastry to make the sausage rolls.

• The recipe for rough puff pastry makes 2 sheets of pastry about 33cm (13 inch) square which is enough for half of the filling in this recipe.
• To make things easier on yourself, make the pastry the day before and store covered in the fridge.
• The next day cook the filling and allow it to come to room temperature before making the puff pastry rolls.  
• With this homemade puff pastry, you will need to work with it cold and on a light floured surface to prevent sticking.
• Once you have rolled the rough puff pastry into two 33cm (13 inch) squares, cut each into half to get four 33 x 15cm (13 x 6 inch) rectangles, then add the filling.
• Cut the sausage rolls into your desired lengths and place spaced well apart on a prepared baking sheet lined with parchment paper.
• Brush with egg wash and sprinkle over black or white sesame seeds and bake until golden brown.

Cutting Tips – use a light and gentle sawing action to cut the pastry into rolls and wipe the blade clean between each cut. The best cuts are made using a thin long straight-edge knife blade.

Cutting even size pieces – If you want even size pieces use a ruler to evenly space and mark cutting points in the pastry.

(The following measurements are based on uncut sausage rolls that are 26 cm / 10.5 inches long).

• For 16 big sausage rolls; cut each piece into 2 equal portions about 13 cm (5 inch) long. This size is great if you are going to have it on its own as a meal.
• For 48 party size sausage rolls; cut each piece into 6 equal portions about 4 cm (1.6 inch) lengths. This size is great for serving as a side to my pumpkin soup or to serve as a filling finger food.
• For 64 appetizer sausage rolls; cut each piece into 8 equal portions about 3.5 cm (1.2 inch) lengths. This size is small and a great starter to pass around that won’t over fill people before a big meal.

How to store sausage rolls – These sausage rolls can be stored uncooked and without egg wash in the fridge for up to 2 days. Make sure to cover with plastic to stop the pastry from drying out in the fridge.

When ready to bake place on baking trays, brush with egg wash, and bake as directed in the recipe.

Allow cooked sausage rolls to cool completely then transfer to an airtight container and store in the fridge.

How to reheat cooked sausage rolls – place the sausage rolls on a baking tray and loosely cover with aluminum foil, place in a preheated 180°C (350°F) oven for 10 – 15 minutes or until heated through.

Perfect for parties or as an after-school snack, these easy beef sausage rolls are even more delicious when dipped into homemade tomato ketchup.  These savory mouthfuls will make a complete meal when teamed up with my roast pumpkin and sweet potato soup.