Healthy Sausage Rolls

Name: Healthy Sausage Rolls
Prep time: 20 min
Cook time: 20 min
Total time: 40 min
Ingredients: 1 kg pork mince (2.2 lb); 4 tbs olive oil; 1 onion (finely chopped); 2 carrots (peeled and finely grated (about 1 cup)); 4 heaped tbsp tomato paste; 1/3 cup Worcestershire sauce; 3 tbsp onion powder; 3 tbsp garlic powder; 2 cups breadcrumbs; 1 tsp salt (or use less, if preferred.); 1/2 tsp pepper; 2 eggs; 4 sheets puff pastry (thawed at room temperature. Or swap for filo pastry or Mountain Bread (see notes).); 1 egg yolk (lightly beaten); 2 tbsp sesame seeds (or poppy seeds, for decorating)

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Kids will love these healthy sausage rolls made with pork mince and veggies! Encased in flaky puff pastry and filled with healthier ingredients, they make a classic Australian snack that can be enjoyed as a party food, in lunchboxes, or for an easy lunch or dinner. Delicious hot or cold, make them in batches to store in the freezer for busy weekdays!

mini sausage rolls on a white board with tomato sauce

Why you’ll love this recipe

Healthy. Made with lean pork mince, grated carrot and spices, homemade sausage rolls make a much healthier option than the store-bought version. And the recipe can be tweaked to be even healthier (see my tips below)!
Freezer-friendly. Perfect for batch cooking and eating later.
Great for serving at parties.
Meal prep friendly. The filling can be prepared ahead of time and the sausage rolls can be stored cooked or un-cooked in the fridge or freezer, ready to add to the oven when required.
Perfect for lunchboxes, easy family dinners or a quick lunch on the go.
Bulk recipe. This recipe makes 40 mini sausage rolls and can easily be doubled for parties or entertaining.

Ingredients you will need

all ingredients for healthy sausage rolls laid out on a table

** This post contains tips and instructions to achieve the best possible results. The photo above is a great guide for when you are in the supermarket, but for full ingredient quantities and methods, please scroll down to the detailed recipe card below!

Pork mince/ground pork forms the filling for the sausage rolls. Real pork mince is used instead of sausage mince, which can be laden with fat as well as other questionable ingredients and additives. Use lean pork mince for less fat content.
Carrots are used to add some vegetables, but you can also add equal quantities of grated zucchini, chopped spinach or a combination of all three. Note: if you do use zucchini, squeeze any excess liquid out before adding it to the mixture to prevent a soggy pastry base.
Breadcrumbs. Regular, store-bought breadcrumbs are used to help bind the filling ingredients. Gluten-free breadcrumbs can be used, if required.
Puff pastry. Store-bought, frozen sheets of puff pastry are used here. But you can also make your own if preferred! Place the pastry sheets on the bench to thaw while you prepare the pork filling. It needs to be thawed and soft so that it will wrap around the filling without breaking. Filo pastry can also be used. Or, in Australia, Mountain Bread can be substituted for puff pastry for a healthier option. *In Australia, puff pastry comes in individual sheets that are 25cm x 25cm (10 x 10 “) squares. They need to be sliced in half so that there are eight 25 x 12.5cm pieces.
Spices. I use garlic and onion powder, as well as salt and pepper. But you can also use some fresh or dried herbs if you have them. They taste great with some added dried rosemary or thyme, or freshly chopped basil.

Step by step guide

Homemade sausage rolls are super quick and easy to make.

Mix the filling
Cut the pastry to size.
Divide the filling between the prepared pastry sheets.
Brush with egg and top with sesame or poppy seeds.
Cut to size.
Bake until puffy and golden.

pork and sausage roll ingredients in a glass bowl

sausage roll filling mixture in a glass bowl

Place all of the filling ingredients together in a large bowl and mix everything together with your hands, until completely combined. **Using a spoon won’t mix everything together as fully as using your hands. If you don’t want to touch the meat, I recommend using food handling gloves.

rectangles of puff pastry laid out on a wooden board

sausage roll filling shaped over puff pastry

Divide the mixture into eight equal portions and then shape the mixture along the middle of each piece of sliced puff pastry.

Roll the puff pastry from the long end, to enclose the filling. You can seal the edges with a little egg wash, or just pinch the ends to form a seal.

a pastry brush spreading egg mixture over puff pastry rolls

a hand sprinkling sesame seeds over sausage rolls

Placing the sausage rolls seam side down, brush the tops with a little egg yolk and sprinkle with sesame seeds.

a long sausage roll being sliced into smaller pieces

uncooked sausage rolls on a baking tray lined with paper

Cut them to your desired size (40 pieces for mini sausage rolls, 16 for large sausage rolls) and place them onto a baking tray lined with baking paper. Ensure there is a little space between each sausage roll.

finished pork sausage rolls on a baking tray

sausage rolls on a tray with tomato sauce

Bake for around 15-20 minutes, until the pastry is puffed and golden and the middle is completely cooked through. When they are ready, all you need is a big bowl of tomato sauce (ketchup) to dunk them in! Or use homemade tomato sauce for a healthier option.

Full ingredient list and instructions are found in the recipe card below.

Expert tips

While this recipe uses puff pastry, in Australia you can also use Mountain Bread which significantly reduces the calories and fat content. Filo pastry can also be used. 5-6 sheets of Mountain Bread are required, and you can use the whole sheet rather than slicing them in half. Divide the mixture between the mountain bread sheets and wrap around the filling to enclose. Use a little egg wash to seal. The baking times are the same as the puff pastry version. The casing does not stay as crisp as puff pastry, but is much healthier. To re-heat, use an air fryer, oven or sandwich press to ensure the coating goes crisp again.
To make them gluten-free, swap the regular breadcrumbs and puff pastry for gluten-free.
Storage. Cooked sausage rolls can be stored in an airtight container in the fridge for 2-3 days. They can also be frozen, either cooked or un-cooked, for up to 3 months. Layer the sausage rolls between sheets of baking paper to prevent sticking.
Reheating sausage rolls. Pre-heat your oven to 180 C/356F and place them on a baking tray. Cook the sausage rolls for 8-10 minutes, or until heated through. Alternatively, you can use an air fryer to reheat them. Place the sausage rolls into the air fryer basket and heat at 160 C/320F for around 5-8 minutes, or until heated through.
To make ahead. The sausage rolls are best assembled, cut into pieces and then frozen or refrigerated un-baked. Place them into a good quality airtight container lined with baking paper in between each layer. Brush them with the egg just before baking. Bake from frozen for around 35-40 minutes, or from the fridge as per the instructions in the recipe card below. *Un-cooked sausage rolls will keep in the fridge for 1-2 days before cooking and can be frozen for 3 months.
Sausage rolls can be eaten hot or cold. If placing them into lunchboxes to eat later, store them with an ice-pack to keep them cool.

FAQs

How do you know when pork sausage rolls are cooked through?

Pork should always be 75 C/165F before it is safe to consume. Due to the size of the sausage rolls and the time they take in the oven to get the pastry golden and flaky, the pork filling will be cooked through by the time they come out.

How long do cooked sausage rolls last?

Cooked sausage rolls will last around 2-3 days when stored in the fridge in an airtight container, or up to 3 months when frozen.

Can I cook sausage rolls in the air fryer?

Yes! Place the un-cooked sausage rolls in the air fryer basket, ensuring that they are not touching (you may need to cook in batches). Follow the same recipe steps below to prepare the sausage rolls. Then, cook them in the air fryer at 200C/400F for around 10-15 minutes, or until puffed, golden and completely cooked through.

sausage rolls spread out on a baking tray with a dish of tomato sauce

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Update Notes: This recipe was originally published in December 2018, but was re-published with new information and photos in August 2021.

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