Italian Sausage Penne Casserole Recipe

Italian Sausage Penne Casserole Recipe | Cheesy & Delicious

I just whipped up this Italian Sausage Penne Casserole Recipe and I’m telling you it’s one of the coziest, cheesiest, most satisfying meals I’ve had in a while. As soon as I pulled it from the oven, the cheese was gooey and bubbling and the aroma filled my kitchen. It’s one of those recipes that makes you feel like you cooked for a crowd but it’s simple enough for a weeknight dinner.

I love that a handful of basic ingredients turns into something hearty, comforting and full of flavor. If you’re looking for a pasta bake that’s easy, family-friendly, and reliably delicious — this is your winner. You can also enjoy similar creamy pasta flavors in my Creamy Tortellini with Spinach and Mushrooms Recipe or try a lighter twist with Farfalle with Chicken and Roasted Garlic Recipe.

Ingredients

Here’s what you’ll need to make this casserole (about 8 servings total):

• 16 oz box penne pasta – choose a quality semolina pasta so it holds up well after baking.
• 2 lb Italian sausage (hot or mild) – hot gives a nice kick, mild if you prefer gentle flavor. Remove casings before cooking.
• 24 oz shredded mozzarella cheese – freshly shredded for best melt and texture.
• 1 medium onion, chopped – adds sweetness and depth.
• 5 cloves garlic, minced – for aromatic richness.
• 28 oz can diced tomatoes – the base of the sauce, gives acidity and moisture.
• 1½ tsp basil (dried) – adds classic Italian herb flavor.
• 1½ tsp oregano (dried) – complements basil for that traditional Italian seasoning.
• Salt and pepper, to taste – essential for seasoning the sauce and sausage properly.

Note: serves around 8 people

Variations

If you want to tweak this recipe (dietary needs or flavor preferences), here are some easy variation ideas:

• Use mild Italian sausage instead of hot if serving children or spice-sensitive guests.
• Swap the sausage for ground chicken, turkey, or lean beef for a lighter version.
• Mix half mozzarella and half part-skim cheese for a slightly lighter but still cheesy casserole.
• Use dairy-free cheese and plant-based sausage for a full dairy-free version.
• Add vegetables like mushrooms, spinach, zucchini, or bell peppers for more texture and flavor.

Cooking Time

• Prep Time: about 20 minutes
• Cooking Time: around 1 hour
• Total Time: roughly 1 hour 20 minutes

Equipment You Need

• Large pot: for boiling the penne pasta.
• Large skillet: brown sausage and sauté onions and garlic.
• 3-quart casserole dish: ideal for layering and baking the casserole.
• Nonstick spray: prevents sticking and keeps cleanup easy.
• Spatula or wooden spoon: for stirring sauce, pasta, and cheese together.

How to Make Italian Sausage Penne Casserole

Here’s an easy breakdown to help you cook it smoothly.

Step 1: Prep

Preheat your oven to 350°F (175°C). Spray a casserole dish with nonstick spray and set it aside so everything is ready to assemble later.

Step 2: Cook the Sausage

Remove the sausage from its casing and crumble it into a hot skillet. Cook until browned, then drain the extra grease, leaving a little behind to add flavor to the sauce.

Step 3: Sauté Onion and Garlic

In the same pan, add the chopped onion and garlic. Cook over medium heat until softened and fragrant, which builds the flavor base of the sauce.

Step 4: Make the Sauce

Add the diced tomatoes, basil, oregano, salt, and pepper. Stir everything together and let it simmer. Add the sausage back in, then cover and simmer for 20–30 minutes so the flavors develop deeply.

Step 5: Cook the Pasta

Boil the penne in salted water until al dente. Drain the pasta and return it to the pot so it’s ready for mixing with the sauce.

Step 6: Assemble the Casserole

Add the sausage sauce and half the mozzarella to the pasta. Toss until the cheese melts slightly. Layer half in the casserole dish, sprinkle cheese, then add the remaining pasta mixture and top with the rest of the mozzarella.

Step 7: Bake

Cover with foil and bake for 30 minutes. Then uncover and bake another 10–15 minutes until the cheese is golden, bubbly, and irresistible.

Additional Tips for Making This Recipe Better

Here are some personal tips I’ve learned from making it:

• I keep just a small amount of sausage grease — it boosts the sauce flavor beautifully.
• I cook the pasta slightly underdone so it doesn’t become mushy after baking.
• I always use freshly shredded mozzarella; it melts smoother and stretches better.
• I sometimes mix in a pinch of chili flakes when I want a little extra heat.

How to Serve Italian Sausage Penne Casserole

I love serving this dish right out of the oven, topped with fresh basil or parsley for a pop of green. It pairs perfectly with a crisp salad, roasted vegetables, or warm garlic bread. A sprinkle of grated Parmesan and a drizzle of olive oil makes the flavors pop even more.

Nutritional Information

Approximate nutrition per serving:

• Calories: ~884 kcal
• Protein: ~43 g
• Carbohydrates: ~51 g
• Fat: ~56 g

Make Ahead and Storage

Storage

Once cooled, store leftover casserole in an airtight container. It stays fresh in the refrigerator for up to 4 days.

Freezing

After cooling completely, wrap the whole casserole tightly in plastic wrap and foil or store portions in airtight freezer containers. Freeze for up to 3 months.

Reheating

If frozen, thaw overnight in the fridge. Reheat covered in a 325°F oven for about 20 minutes or until hot and bubbly.

Why You’ll Love This Recipe

Here’s why this casserole becomes a repeat favorite:

• Effortless to make: Simple steps and pantry-friendly ingredients make it perfect for busy days.
• Super comforting: Sausage, cheese, and pasta come together for a cozy, satisfying meal.
• Very versatile: You can change the protein, cheese, or veggies based on what you have.
• Feeds a crowd: Makes enough for family dinner, parties, or several days of leftovers.
• Great leftovers: The flavors deepen and taste even better the next day.

Ben Carraoli

Italian Sausage Penne Casserole Recipe

I just whipped up this Italian Sausage Penne Casserole and I’m telling you it’s one of the coziest, cheesiest, most satisfying meals I’ve had in a while. As soon as I pulled it from the oven, the cheese was gooey and bubbling and the aroma filled my kitchen.

Print Recipe Pin Recipe

Prep Time 20 minutes mins

Cook Time 1 hour hr

Servings: 8

Ingredients Method Notes

Ingredients

  

• 16 oz box penne pasta – choose a quality semolina pasta so it holds up well after baking.
• 2 lb Italian sausage hot or mild – hot gives a nice kick, mild if you prefer gentle flavor. Remove casings before cooking.
• 24 oz shredded mozzarella cheese – freshly shredded for best melt and texture.
• 1 medium onion chopped – adds sweetness and depth.
• 5 cloves garlic minced – for aromatic richness.
• 28 oz can diced tomatoes – the base of the sauce gives acidity and moisture.
• 1½ tsp basil dried – adds classic Italian herb flavor.
• 1½ tsp oregano dried – complements basil for that traditional Italian seasoning.
• Salt and pepper to taste – essential for seasoning the sauce and sausage properly.

Method

 

1. Preheat your oven to 350°F (175°C). Spray a casserole dish with nonstick spray and set it aside so everything is ready to assemble later.
2. Remove the sausage from its casing and crumble it into a hot skillet. Cook until browned, then drain the extra grease, leaving a little behind to add flavor to the sauce.
3. In the same pan, add the chopped onion and garlic. Cook over medium heat until softened and fragrant, which builds the flavor base of the sauce.
4. Add the diced tomatoes, basil, oregano, salt, and pepper. Stir everything together and let it simmer. Add the sausage back in, then cover and simmer for 20–30 minutes so the flavors develop deeply.
5. Boil the penne in salted water until al dente. Drain the pasta and return it to the pot so it’s ready for mixing with the sauce.
6. Add the sausage sauce and half the mozzarella to the pasta. Toss until the cheese melts slightly. Layer half in the casserole dish, sprinkle cheese, then add the remaining pasta mixture and top with the rest of the mozzarella.
7. Cover with foil and bake for 30 minutes. Then uncover and bake another 10–15 minutes until the cheese is golden, bubbly, and irresistible.

Notes

• I keep just a small amount of sausage grease — it boosts the sauce flavor beautifully.
• I cook the pasta slightly underdone so it doesn’t become mushy after baking.
• I always use freshly shredded mozzarella; it melts smoother and stretches better.
• I sometimes mix in a pinch of chili flakes when I want a little extra heat.