Easy Cheesy Italian Sausage Penne Casserole
Honestly, this dish found me on a Tuesday night when the fridge was sad and my patience was shorter than the grocery list. I’m all about easy weeknight dinners and leaning on budget-friendly recipes when life gets loud and the kids (and my stomach) demand something fast, comforting, and not takeout. To be real, this casserole feels like a warm, cheesy blanket—exactly what I reach for when the sky goes gray and I want something that tastes like a hug.
I remember the first time I tried a baked penne with sausage. I used the wrong kind of sausage (oops — rookie move), and the whole thing was greasy and floppy. Lesson learned: pick the right sausage and don’t skip the draining step. Now I make this with spicy chicken or turkey Italian-style sausage — full of heat and herbs but without anything that doesn’t belong in my pantry — and it’s been a winner ever since. The scent of garlic and basil bubbling in the skillet makes the whole house stop and stare. The kids wander in asking, “Is it dinner time yet?” like it’s a Pavlovian response to melty cheese.
This casserole ticks a lot of boxes. It’s one of those quick family meals that’s also a sneaky nod to high protein meals, thanks to the generous sausage. It’s not delicate restaurant food — it’s the kind of dinner that gets plates licked and forks fighting. You can prep it while you answer emails, and it handles the oven time like a champ, freeing you up for the collapse-on-the-couch moment you crave. If you like one-pot comfort, you might also enjoy a riff that leans on smoked sausage and potatoes, like this cozy smoked sausage and hashbrown casserole I stumbled upon that doubled as inspiration the first winter I tried sausage-baked dishes.
Picture this: afternoon light slanting through the kitchen window, the aroma of garlic sizzling, and the distant sound of a sitcom laugh track from the living room. The casserole bubbles, the top browns, and you know you did something right—even if you spilled a little pasta water down the stove (hi, that was me last month). Give yourself permission to be messy. It’s part of the charm. This dish is forgiving, sturdy, and honest — like my favorite hoodie.
Why You’ll Love This Recipe
- It’s the epitome of easy weeknight dinners — minimal hands-on time, maximum comfort.
- Leftovers are even better. Reheated, it’s still cheesy, still saucy, and perfectly portable for work lunches as a meal prep win.
- High on protein without being fussy — yes, this counts as one of those high protein meals that doesn’t taste like health food.
- Picky eaters usually ask for seconds. There’s something about baked cheese that heals most kitchen feuds.
- It’s budget-friendly recipes at heart: pantry staples and a couple of affordable proteins make a feast.
- Feels like a hug in a bowl. Honestly. The kind that comes with melted mozzarella and a side of “I made this for you.”
What Makes This Recipe Special?
There are plenty of baked pastas, but what I love here is the balance. The spicy Italian-style turkey or chicken sausage gives the casserole personality without overpowering the tomatoes. A slow simmer helps the garlic and onion soften into the sauce so every forkful has a little sweetness, a little bite, and a lot of cheesy goodness.
This recipe is forgiving of improvisation. No fresh basil? Toss in dried oregano and a splash of good olive oil. Want it heartier? Add roasted vegetables or spinach. Want to make it kid-friendlier? Use mild sausage and a sprinkle of extra mozzarella. My favorite trick: crisp the sausage a touch extra to get those little caramelized bites throughout the pasta. It creates texture and tiny flavor explosions.
I’ve had kitchen disasters with this one — like the time I forgot to drain the grease and the casserole was like an oily blanket. Not cute. So I learned to drain, then return to the pan for the sauté. You live, you learn, you eat better the next night.
Ingredients
- 16 oz penne pasta — I use regular penne; rigatoni works too if you want bigger bites. The hollow centers trap sauce.
- 2 lb spicy chicken or turkey Italian-style sausage (casings removed) — swap in mild if kids are sensitive. This replaces pork sausage and keeps the flavor full-bodied and savory.
- 24 oz shredded mozzarella cheese — whole-milk mozzarella melts like a dream. Pre-shredded works, but grating from a block gives better melt and no anti-caking powder.
- 1 medium onion, diced — sweetens and builds the sauce base.
- 5 cloves garlic, minced — garlic is non-negotiable here. It’s the soul of the sauce.
- 28 oz can diced tomatoes — use fire-roasted for a deeper flavor, or plain for a clean tomato profile.
- 1–2 tsp dried basil and 1 tsp dried oregano — or handfuls of fresh basil if you’re lucky.
- Salt and pepper to taste — taste before you salt; the sausage might already be salted.
- Non-stick spray for the casserole dish — makes cleanup less dramatic.
Why each ingredient matters:
- The penne shape is about texture and sauce delivery. It holds sauce without getting mushy.
- The turkey/chicken sausage provides the herb-and-spice profile without pork — but it still gives that classic sausage bite.
- Mozzarella gives the gooey, stretching cheese factor we all pretend is effortless.
- Onion and garlic are small investments for huge returns in flavor.
Brand notes and substitutions:
- I like store-brand penne for budget nights and name brand for company dinners.
- No mozzarella? Blend cheddar and provolone for a slightly sharper finish.
- If you have a tomato-phobic teenager, puree the diced tomatoes into a smoother sauce.
Don’t do this: don’t skip draining the sausage. Please don’t throw the whole greasy pan into the casserole. That’s how I learned to respect the skillet.
How to Make It Step-by-Step
Step 1 — Preheat and prep
Preheat your oven to 350°F (175°C). Spray a 9×13 casserole dish with non-stick spray. I always spray twice; there’s nothing worse than lovingly baking something only to have half of it glue to the dish like a sticky betrayal.
Step 2 — Brown the sausage
Heat a large skillet over medium heat. Add the sausage (remove casings if using links), breaking it apart with a wooden spoon. Brown it until it’s fully cooked and has little browned bits. Push it through a sieve and drain any excess grease — this is a non-negotiable. Return the meat to the skillet. The sizzle and little crackles make me feel like a dinner rockstar, even if I’m just wearing my laundry-day tee.
Step 3 — Sauté onion and garlic
In that same skillet, add the diced onion. Sauté until translucent and slightly golden — about 4–6 minutes. Add the minced garlic and cook for about 30 seconds until fragrant. The smell here is my personal “I’ve got dinner” signal. Watch the garlic; it will go from heavenly to burned in seconds if you blink.
Step 4 — Build the sauce
Stir in the diced tomatoes, dried basil, oregano, and a generous pinch of salt and pepper. Let everything simmer gently for about 20 minutes, stirring now and then. You want the sauce to reduce slightly and thicken. If it’s looking too watery, turn up the heat for a few minutes; if it looks dry, add a splash of pasta cooking water or a little chicken broth.
Step 5 — Cook the penne
While the sauce simmers, cook the penne according to package instructions until just al dente. Time it so it finishes right when your sauce is ready; nobody likes mushy pasta in a proud casserole. Drain the pasta and reserve about ½ cup of pasta water — magic for rescuing sauce later.
Step 6 — Combine pasta, meat, and half the cheese
In a large bowl or the pot you used for pasta, combine the cooked penne, sausage-tomato sauce, and half of the shredded mozzarella. Stir until everything is evenly coated. If the sauce seems tight, add a dash of the reserved pasta water to loosen it. I sometimes add a drizzle of olive oil here for silkiness.
Step 7 — Layer and bake
Spread half of the mixture into the prepared casserole dish, then add the rest. Top with the remaining mozzarella in an even layer. Cover the dish with foil and bake for 30 minutes. The kitchen will fill with a bubbling, cheesy perfume that is borderline illegal.
Step 8 — Finish and serve
Remove the foil for the last 5–10 minutes of baking to let the top brown a little. Let the casserole rest for 5–10 minutes before serving so it sets and doesn’t slither off your plate. That first scoop should have a little resistance and a lot of cheese pull. Trust me.
I once forgot the resting time and burned my tongue on a molten cheese river. Learned my lesson. Let it sit.
For more cozy sausage comfort (soup vibes), I sometimes switch gears and make a one-pot version inspired by a creamy Italian sausage gnocchi soup that’s perfect for chilly nights.
Tips for Best Results
- Brown the sausage well for flavor — those caramelized bits are everything.
- Drain the grease. I say it again because I once didn’t and learned the hard, soggy way.
- Don’t overcook the pasta. Bite to check; you want al dente because it will continue cooking in the oven.
- Use fresh garlic if you can. Minced jar garlic is fine, but fresh gives the best aroma.
- Let the casserole rest after baking. That 10 minutes makes the difference between a firm scoop and a sloppy mess.
Small tweaks, big payoff: a sprinkle of red pepper flakes at the end gives a pleasant kick, and a handful of chopped fresh basil brightens the whole dish.
Ingredient Substitutions & Variations
- Meat swaps: Use ground beef, ground turkey, or chicken sausage. All work, but pick one seasoned for Italian flavors.
- Cheese changes: Mix mozzarella with provolone for a richer bite. For a lighter option, use part-skim mozzarella.
- Veg add-ins: Stir in chopped spinach, mushrooms, or roasted bell peppers into the sauce for extra veggies.
- Low-carb twist: Swap penne for short-cut spiralized veggies or a low-carb pasta, though texture will change.
- Make it creamy: Stir in ½ cup ricotta into the pasta mixture for a creamier texture.
Pro tip: if you want to bump protein further for high protein meals or high macro meals, fold in some cooked lentils or chickpeas — weird but effective. For those on no prep healthy lunches runs, slice portions and freeze for a quick microwave reheat.
I once tried this with a cheddar top and it tasted like a childhood dream—utterly nostalgic. If you want more comfort-casserole inspiration (fries included), check out this indulgent cheeseburger French fry casserole that’s a carb-forward cousin to this dish.
Directions
Preheat the oven to 350°F (175°C) and spray a casserole dish with non-stick spray. In a large skillet, brown the chicken or turkey Italian-style sausage over medium heat until fully cooked, then drain excess grease. Sauté diced onions and minced garlic in the same skillet until translucent, then stir in the diced tomatoes, basil, oregano, salt, and pepper; simmer for about 20 minutes. Cook the penne pasta according to package instructions; combine the pasta with the sausage mixture and half the mozzarella. Layer the mixture in the casserole dish, top with the remaining cheese, cover with foil, and bake for 30 minutes until bubbly. Remove foil and bake an additional 5–10 minutes to brown the top, then rest 5–10 minutes before serving.
Pairing Ideas (Drinks, Sides, etc.)
This casserole loves company. A simple green salad with a vinaigrette cuts through the cheese beautifully. For bread, I’m partial to garlic bread or a rustic baguette to mop up sauce. If you want drinks: a sparkling water with lemon is refreshing, and a robust iced tea keeps things casually classic.
For dessert, something light like lemon bars or a scoop of vanilla ice cream is perfect. Pair it with a rom-com and some fuzzy socks for peak comfort.
How to Store and Reheat Leftovers
Cool the casserole entirely before covering it tightly with foil or transferring to an airtight container. Refrigerate for up to 4 days. Reheat single portions in the microwave for 2–3 minutes, stirring halfway through, or reheat a full dish in a 350°F oven for 20–25 minutes until heated through.
If the leftovers seem dry, add a splash of water or milk before reheating. I once nuked a slice straight from fridge to plate and it was sad — reheat gently.
Make-Ahead and Freezer Tips
Make the casserole up to the point of baking, then cover and refrigerate for up to 24 hours before baking. For freezing, bake fully, cool, portion into freezer-safe containers, and freeze for up to 3 months. Reheat from frozen in a 350°F oven (covered) for 35–45 minutes, then uncovered 10 minutes to refresh the top.
Label everything. Nothing ruins your week like finding mystery casserole in the back of the freezer and wondering if it expired during the Obama administration. (Okay, slight exaggeration. But label it.)
Common Mistakes to Avoid
- Not draining the sausage — lesson learned the greasy way.
- Overcooking the pasta — results in a mushy casserole.
- Skipping the rest time — molten cheese is delicious but painful.
- Using only pre-shredded cheese — it can be drier and less melty.
- Forgetting to season — taste and adjust before baking.
If you follow these, your casserole will reward you with gooey, saucy happiness.
Frequently Asked Questions (FAQ)
Q: Can I use a different pasta shape?
A: Yes. Rigatoni, ziti, or penne work best because they hold sauce. Long pastas aren’t ideal for baking.
Q: Can I make this vegetarian?
A: Substitute the sausage with crumbled tempeh, cooked lentils, or a plant-based sausage alternative and add extra veggies.
Q: Is it freezer-friendly?
A: Yes. Bake first or freeze before baking. See the Make-Ahead section for details.
Q: How spicy is this?
A: That depends on your sausage. Use mild Italian-style sausage or a mix if you’re feeding heat-sensitive eaters.
Cooking Tools You’ll Need
- Large skillet for browning and sauce
- Large pot for cooking pasta
- 9×13 casserole dish
- Wooden spoon or spatula
- Colander for draining pasta
- Cheese grater (if shredding your own)
- Aluminum foil for baking
Final Thoughts
This casserole is an honest, imperfect, delicious standby in my kitchen. It has rescued more evenings than I can count: nights when I forgot to grocery shop, nights when everyone came over unannounced, nights that felt like they needed a little extra warmth. It’s adaptable, forgiving, and pretty much roommate-friendly. Make it as written for a classic finish, or mess around with add-ins and swaps until it’s yours.
Cooking doesn’t have to be flawless. Sometimes the best meals come out of scrappy pantry raids and last-minute improvisation. If you enjoyed this recipe, don’t forget to save it on Pinterest or share it with a friend!
Conclusion
If you want more versions or a little inspiration, I always peek at recipes like Italian Sausage Penne Casserole – Great Grub, Delicious Treats for presentation ideas and seasoning tweaks, and Easy Baked Penne with Sausage – Salt & Lavender for different cheese combinations that might spark your next casserole twist.
If you enjoyed this recipe, don’t forget to save it on Pinterest or share it with a friend!
Easy Cheesy Italian Sausage Penne Casserole
Ingredients
Pasta and Sauce Base
- 16 oz penne pasta Regular penne; rigatoni works too.
- 28 oz can diced tomatoes Use fire-roasted for a deeper flavor.
- 1-2 tsp dried basil Or handfuls of fresh basil if available.
- 1 tsp dried oregano Or fresh if you prefer.
- Salt to taste Salt and pepper Taste before adding salt.
- Pepper to taste Salt and pepper Taste before adding pepper.
Meat and Vegetables
- 2 lb spicy chicken or turkey Italian-style sausage Remove casings before cooking.
- 1 medium onion, diced Builds the sauce base.
- 5 cloves garlic, minced Non-negotiable.
Cheese
- 24 oz shredded mozzarella cheese Whole-milk mozzarella melts best.
Additional Ingredients
- Non-stick spray Non-stick spray for casserole dish Makes cleanup easier.
Instructions
Preparation
- Preheat your oven to 350°F (175°C). Spray a 9x13 casserole dish with non-stick spray.
- Heat a large skillet over medium heat. Add the sausage, breaking it apart with a spoon. Brown until fully cooked and drain excess grease.
- In the same skillet, add the diced onion and sauté until translucent for about 4–6 minutes. Then add the minced garlic and cook for about 30 seconds until fragrant.
Building the Casserole
- Stir in the diced tomatoes, basil, oregano, salt, and pepper. Let it simmer gently for about 20 minutes.
- While the sauce simmers, cook the penne according to package instructions until just al dente. Drain the pasta, reserving about ½ cup of pasta water.
- Combine the cooked penne, sausage-tomato sauce, and half the mozzarella in a large bowl. Mix until evenly coated.
- Spread half of the mixture into the prepared casserole dish, then add the rest. Top with the remaining mozzarella.
Baking
- Cover the dish with foil and bake for 30 minutes. Remove the foil during the last 5–10 minutes of baking to allow the top to brown.
- Let the casserole rest for 5–10 minutes before serving.
