This is a layered baked casserole that puts leftover smoked or barbecue-seasoned pulled pork to work inside a moussaka-style structure — eggplant, a spiced meat layer, and a creamy egg-and-cheese topping. It feeds a crowd from ingredients most cooks already have on hand, and it slices cleanly the next day, making it one of the more practical things you can do with a pork surplus.
What makes this version work
Two things matter most here. First, the eggplant has to be properly pre-cooked before it goes into the baking dish. Raw eggplant releases too much water during baking and turns the layers soggy — salt it, let it sit for 20 minutes, pat it dry, then roast or pan-fry it until it’s actually soft and lightly browned. Second, the pulled pork needs to be warmed and mixed with enough tomato-based sauce that it stays moist through the full bake time. Dry shredded pork straight from the fridge will absorb moisture from the other layers and leave the whole dish tasting flat. A couple of spoonfuls of your existing barbecue sauce stirred into the meat before layering solves this without adding any extra shopping.
Smart swaps
- Pulled pork substitute: No smoked pork? Ground pork cooked with a teaspoon of smoked paprika, a splash of Worcestershire sauce, and a tablespoon of tomato paste gets you close. Make sure it reaches 160°F (71°C) internal temperature.
- Eggplant substitute: Zucchini works as a direct swap — slice it thicker than you think you need to, around ½ inch, so it holds up in the layers.
- Topping: If you’re short on the cheese called for, any firm melting cheese does the job — cheddar, Monterey Jack, or even a mix of what’s in the fridge. Skip the garnish — not worth the extra dish.
- Barbecue sauce: A plain tomato sauce with a pinch of smoked paprika and brown sugar substitutes cleanly if you’ve run out of barbecue sauce.
What can go wrong
- Watery bottom layer: Even well-salted eggplant can release liquid if it wasn’t roasted long enough. Make sure it looks dry and slightly shrunken before layering — not just softened.
- Topping sinks into the meat layer: The meat layer needs to be fairly compact and not too saucy before you pour the topping over it. If it’s very wet, let it cool for 10 minutes in the dish first so the topping sits on top rather than mixing in.
- Topping browns too fast before the center sets: Tent loosely with foil after the first 20 minutes if the top is coloring quickly. Remove the foil for the last 10 minutes to let it finish browning.
- Dish falls apart when sliced hot: This is normal. The layers need at least 15–20 minutes of resting time out of the oven before cutting, and it slices much more cleanly after a full overnight rest in the fridge.
- Bland meat layer: Pulled pork that’s been refrigerated for a day or two loses some of its punch. Taste the meat mixture before layering and adjust — a little extra smoked paprika, salt, or a splash of apple cider vinegar can bring it back.
Storage and reheating
Covered in the fridge, this keeps well for up to 4 days — and genuinely tastes better on day two once the layers have settled. To reheat individual portions, use a microwave on medium power in 90-second intervals rather than full blast, which can make the topping rubbery. To reheat the whole dish, cover it with foil and warm it in a 325°F (165°C) oven for about 25 minutes. For freezing, cut into individual portions first, wrap tightly, and freeze for up to 2 months. Thaw overnight in the fridge before reheating — freezing and reheating from frozen tends to make the eggplant layers watery.
Smokey Barbecue Pork Moussaka Recipe
Ingredients
2 pounds ground pork (minced pork)
½ cup BBQ sauce (barbecue sauce) - tomato-based
1 large eggplant (brinjal, aubergine, or guinea squash)
1 large egg
¼ cup cheddar cheese - shredded
½ cup ricotta cheese
1 medium summer squash (yellow zucchini)
1 medium yellow onion - sliced
4 tablespoons cilantro (coriander) - chopped
2 tablespoons olive oil - for sautéing
Instructions
- Slice eggplant into 1/4-inch slices.
- Preheat the oven to 400 degrees Fahrenheit.
- Lightly oil foil covered cookie sheet with olive oil. Arrange eggplant on a cookie sheet and brush with remaining olive oil.
- Place eggplant in the oven and bake for 30 minutes, turning once.
- While eggplant is cooking in a skillet, heat the pulled pork and toss it with your choice of barbecue sauce. Once warmed, leave on low to slowly keep warm, and set aside.
- Chop summer squash into bite-sized pieces and toss with cilantro and onion.
- Once the eggplant is ready, prepare a casserole dish by greasing it lightly with your choice of oil (coconut, olive, etc.); in my case, I used a bit of bacon grease.
- Place a single layer of eggplant slices on the bottom of the pan, reserving a little over half.
- Cover that layer with half of your pulled pork and summer squash.
- Place another layer of eggplant slices on top of the pork, reserving some.
- Cover that again with pulled pork and summer squash.
- Place remaining eggplant slices onto the top of your moussaka.
- Scramble egg with ricotta cheese and pour over the top.
- Sprinkle top with cheddar cheese.
- Bake in 350-degree Fahrenheit oven for 45 minutes or until the top is a nice golden brown colour.
- Allow to cool for 15 to 20 minutes before slicing and serving (we were a bit too eager and did not, which makes it a bit less solid and messy looking).
Nutrition
Common questions
Can I use store-bought pulled pork instead of homemade?
Yes, store-bought pulled pork works fine. Just make sure it’s fully heated through to 160°F (71°C) when you warm it with the sauce before layering, and taste it — many store-bought versions are quite sweet, so you may want to cut back on any added barbecue sauce.
Do I have to salt and drain the eggplant?
It’s strongly recommended. Skipping this step means the eggplant releases water during baking, which makes the layers wet and difficult to slice. Twenty minutes of salting followed by a thorough pat-dry takes little effort and makes a real difference to the final texture.
Can I assemble this the night before and bake it the next day?
Yes, and it’s actually a good approach. Assemble fully, cover tightly, and refrigerate overnight. Add about 10 extra minutes to the bake time since it’s going in cold, and check that the center is hot and the topping is set before pulling it out.
What if I don’t have enough pulled pork — can I stretch it?
You can bulk out the meat layer with a can of drained lentils or finely diced mushrooms mixed into the pork. Both absorb the barbecue flavors well and won’t change the texture of the finished dish noticeably.
My topping didn’t set properly — what happened?
The most common cause is a meat layer that was too wet, which steams the topping from below instead of letting it bake firm. It can also happen if the eggs in the topping weren’t at room temperature when mixed. If it’s still loose after the full bake time, give it an extra 10 minutes uncovered.
Can I make this with ground pork instead of pulled pork?
Absolutely. Brown ground pork thoroughly to 160°F (71°C), drain excess fat, then season it with smoked paprika, garlic, a little tomato paste, and barbecue sauce to replicate the flavor profile. The texture will be slightly finer than pulled pork but the dish works just as well.
More mince recipes to try
- Layered Beef Enchilada Casserole
- Mediterranean Lamb Feta Pie
- Hearty Beef Cauliflower Bake
- Cumberland Sausage Mince Pie
