Go Back
Italian Sausage Penne Casserole Recipe
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
Cook Time 1 hour
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.