Burton boss Jimmy Floyd Hasselbaink’s hopes of a famous victory over one of his former clubs ended in heartbreak as Middlesbrough grabbed a 2-1 extra-time victory at the Pirelli Stadium.
Christian Stuani was the hero for Aitor Karanka’s side after they had trailed at the break to a George Friend own goal.
Stuani levelled the scores in the 70th minute and struck again in the second period of extra-time to take his side into the third round.
Former England defender Jonathan Woodgate started in a line-up that showed seven changes from the side that went down at home to Bristol City.
Just as the Teessiders seemed to be taking control, they found themselves trailing to a scrappy goal in the 24th minute.
Matt Palmer’s free-kick fell loose in the area and, as Woodgate slid in, the ball squirmed into the net off Friend.
Burton’s resistance was finally broken in the 70th minute when Stuani escaped his marker to slide home a Tomas Kalas cross from six yards.
Stuani grabbed the winner for Boro in the 110th minute, the Uruguayan providing a crisp finish inside the near post.
Burton Albion: Matthews, Naylor (El Khayati 101), O’Connor, Cansdell-Sherriff, Binnom-Williams, Akins (Edwards 75), Weir, Butcher, Reilly, Palmer, Joachim (Thiele 83). Unused substitutes: McLaughlin, Beavon, McCrory, Duffy.
Middlesbrough: Mejias, Stephens (Fabbrini 46), Gibson, Woodgate (Nsue 98), Kalas, Forshaw, Reach (Downing 65), Leadbitter, Friend, Garcia, Stuani. Unused substitutes: Konstantopoulos, Ayala, Clayton, Husband.