Spray a 5 or 6 quart slow cooker with non stick cooking spray.: The cool surface glistens when properly greased, and that thin film prevents the custard and tater tots from stubbornly sticking to the insert. Rubbing a little extra spray around the edges helps the casserole release cleanly, and it also encourages the edges to brown evenly. One mistake to avoid is skimping on the spray which can lead to tearing when you serve, so be generous and coat bottoms and sides thoroughly.
Crumble and brown breakfast sausage in a medium skillet until cooked through.: As the sausage hits the hot pan you will hear a steady sizzle and smell savory, meaty aromas that deepen as it browns. Crumbling it small ensures even distribution through the casserole; large chunks leave gaps in texture. Cook until no pink remains and the pieces are nicely browned, which concentrates flavor. A common error is overcrowding the pan, which causes steaming rather than browning, so brown in batches if needed to get that golden sear.
Whisk eggs in a medium bowl and add them to the slow cooker.: The beaten eggs should be smooth, with a uniform pale gold color. When poured into the warm, greased insert they settle and begin to mingle with the air around them. Whisking until even, but not foamy, helps the final custard set with a fine, tender texture. Avoid over whisking which traps air and can create a spongy set instead of a silky one.
Add heavy cream, pimientos, ground mustard, onion, and half of cheese to slow cooker. Whisk to combine.: When you add the heavy cream the mixture takes on a richer sheen and the aroma softens. Fold in the diced pimiento , a dusting of ground mustard , diced onion , and half the grated cheddar cheese so the flavors and textures are distributed. Whisking here ensures pockets of melted cheese are integrated rather than forming a single layer. A misstep I often see is adding un drained pimiento which can make the custard watery, so drain them well first.
Add frozen tater tots and browned sausage to slow cooker. Stir to combine and evenly coat.: When the cold, frozen tater tots hit the warm custard they glint frost like little moons, and stirring brings the browned sausage in so every bite will have a bit of meat. Coat the tots thoroughly so they are surrounded by custard, this helps them cook through and become tender inside while the tops crisp. A pitfall is stirring too vigorously, which can cause uneven distribution; gently fold to keep the structure intact.
Cover and cook on high for 150 to 180 minutes, rotating insert halfway through. Check to make sure eggs are set.: During the long, slow cook you will notice a gentle bubbling and a custard aroma spreading. The interior should feel set and not jiggly when you gently nudge it, while the edges may pull away slightly from the cooker walls. Rotating the insert halfway promotes even browning and heat distribution, especially if your slow cooker runs hot in the back. Avoid opening the lid too often, as heat loss prolongs cooking and can affect the final set.
Sprinkle remaining cheese on top, cover with lid until cheese has melted.: Once the casserole is set, add the reserved grated cheddar cheese across the surface and cover briefly. The residual heat will melt the cheese into glossy ribbons that seal in moisture and add a golden finish. You want the cheese just melted, not overcooked to a rubbery stage, so watch closely. A common mistake is leaving the lid off too long and melting unevenly; cover to concentrate the heat and get an even melt.
Sprinkle with sliced green onions or chives.: The final touch of sliced green onion or chives adds a bright scent and a fresh, oniony pop against the rich base. Scatter them just before serving so they stay crisp and colorful. If you add them too early they will wilt and lose their visual and flavor contrast, so reserve them for the finish.