I’ve made my fair share of pasta bakes, but this Italian Sausage Penne Casserole Recipe has become a true family favorite. It’s the kind of comforting, hearty meal I turn to for a satisfying weeknight dinner or a casual get-together with friends.

The combination of spicy sausage, rich tomato sauce, and perfectly melted cheese is simply irresistible. It feels like a warm hug in a casserole dish. You can also enjoy a creamy side like Baked Mushrooms in Parmesan Cream Sauce Recipe alongside it for extra indulgence.

Ingredients

This recipe uses simple, accessible ingredients to create a rich and flavorful casserole. Here’s what you’ll need and a few tips to get the best results.

1 box (16 ounces) dry penne pasta – Penne’s tube shape and ridges are perfect for catching all the delicious sauce.
2 pounds Italian sausage – You can use hot or sweet Italian sausage. I prefer hot sausage as it adds a wonderful kick that complements the rich sauce.
24 ounces mozzarella cheese – Grating your own cheese from a block is a must! Pre-shredded cheese contains anti-caking agents that prevent it from melting as smoothly.
1 medium yellow onion – A chopped yellow onion provides a sweet, aromatic base for the sauce.
5 cloves garlic – Freshly chopped garlic offers a pungent, savory flavor that you just can’t get from a jar.
1 can (28 ounces) diced tomatoes – Canned diced tomatoes are the foundation of the sauce, providing both liquid and texture.
1 1/2 teaspoons basil – Dried basil adds a classic Italian herbal note that is essential for this dish.
1 1/2 teaspoons oregano – Dried oregano brings a peppery, slightly bitter flavor that balances the sweetness of the tomatoes.
Salt, to taste – Use salt to enhance all the other flavors in the dish.
Pepper, to taste – Freshly ground black pepper adds a final touch of spice.

Note: The ingredient quantities provided will yield several generous servings, perfect for a family meal or for having leftovers. You can pair this with a warm bowl of Chicken Potato Soup Recipe for a hearty dinner spread.

Variations

One of the best things about this recipe is how easily you can adapt it to your taste or dietary needs.

Go Dairy-Free: Substitute the mozzarella with your favorite dairy-free shredded cheese alternative. Nutritional yeast can also be sprinkled in the sauce to add a cheesy, nutty flavor.
Change the Protein: Not a fan of sausage? You can easily use ground beef, ground turkey, or even ground chicken instead. For a vegetarian option, try using plant-based sausage crumbles or a mix of roasted vegetables like zucchini and bell peppers.
Boost the Veggies: Add more nutrients and texture by incorporating spinach, mushrooms, or bell peppers. Sauté them with the onions and garlic until tender before adding the tomatoes.
Spice It Up: If you love heat, add a pinch of red pepper flakes to the sauce along with the basil and oregano for an extra kick.

Cooking Time

Prep Time: 20 minutes
Cook Time: 1 hour
Total Time: 1 hour 20 minutes

Equipment You Need

Large Skillet: For browning the sausage and building your delicious tomato sauce.
Large Pot: To cook the penne pasta until it’s perfectly al dente.
3-Quart Casserole Dish: The ideal size for baking the casserole to cheesy, bubbly perfection.
Colander: For draining the cooked pasta and sausage grease effectively.
Knife and Cutting Board: Essential for chopping the onion and garlic.

How to Make Italian Sausage Penne Casserole

This recipe comes together in a few straightforward steps, creating a restaurant-quality meal right in your own kitchen. Following these instructions will lead you to a perfect bake every time.

Prepare for Baking

First, get your oven ready by preheating it to 350°F. While it’s heating up, grab your 3-quart casserole dish and coat it with a non-stick cooking spray. This simple step ensures that your casserole won’t stick, making serving and cleanup much easier later.

Cook the Sausage and Aromatics

Start by removing the Italian sausage from its casings and adding it to a large skillet. Cook it over medium heat, using a spoon to crumble the meat as it browns. Once cooked through, drain the grease, but be sure to reserve about two tablespoons in the skillet.

Build the Sauce

Spoon the reserved sausage grease back into the skillet. Add the chopped onion and garlic, and sauté until the onion becomes soft and translucent. Now, pour in the can of diced tomatoes and stir in the basil, oregano, salt, and pepper to create a flavorful base.

Simmer the Sauce

Add the cooked sausage back into the skillet with the tomato and onion mixture. Bring everything to a gentle boil, then reduce the heat to low. Cover the skillet and let the sauce simmer for 20 to 30 minutes, stirring occasionally, to allow the flavors to meld together.

Cook the Pasta

While your sauce is simmering, cook the penne pasta in a large pot of salted water according to the package directions for al dente. Cooking it al dente is key, as the pasta will continue to cook in the oven. Once done, drain the pasta well and return it to the pot.

Combine and Assemble

Pour the sausage and tomato sauce mixture over the drained pasta in the pot. Add half of the grated mozzarella cheese and stir everything together until the cheese is melted and well combined. This ensures every bite has that cheesy goodness mixed right in.

Bake the Casserole

Transfer half of the pasta and meat mixture into your prepared casserole dish. Sprinkle a layer of cheese over it, then add the remaining pasta mixture on top. Finish by covering the entire casserole with the rest of the mozzarella cheese, cover with foil, and bake for about 30 minutes, or until bubbly.

Additional Tips for Making This Recipe Better

After making this dish many times, I’ve picked up a few tricks that really elevate it.

I always let the sauce simmer for the full 30 minutes, or even a little longer if I have the time. This extra time allows the flavors to deepen, creating a much richer and more complex sauce.
Don’t be shy with the cheese! I sometimes add a sprinkle of Parmesan or Pecorino Romano along with the mozzarella on top for an extra salty, nutty flavor that crisps up beautifully in the oven.
I make sure to undercook the pasta by about 1-2 minutes. Since it will continue to cook in the sauce while baking, this prevents it from becoming mushy and ensures a perfect al dente texture in the final dish.
For a final touch, I remove the foil for the last 5-10 minutes of baking. This allows the cheese on top to get golden brown and slightly crispy, which adds a wonderful texture.

How to Serve Italian Sausage Penne Casserole

This casserole is a complete meal on its own, but it pairs wonderfully with a few simple sides. Serve it hot, straight from the oven, with a simple green salad dressed in a light vinaigrette to cut through the richness of the dish. A side of warm garlic bread is also a classic choice, perfect for soaking up any extra sauce left on the plate. For a beautiful presentation, garnish individual servings with a sprinkle of fresh chopped parsley or basil.

Nutritional Information

Here is an approximate nutritional breakdown per serving. Please note that these values can vary based on the specific ingredients used.

Calories: 1114.6
Protein: 56.4 g
Carbohydrates: 74.9 g
Fat: 66.1 g

Make Ahead and Storage

This casserole is an excellent option for meal prep and is just as delicious the next day.

Make Ahead

You can assemble the entire casserole a day in advance without baking it. Simply cover it tightly with foil and store it in the refrigerator. When you’re ready to eat, you may need to add about 10-15 minutes to the baking time since you’ll be starting with a cold dish.

Storing

Allow any leftovers to cool completely before transferring them to an airtight container. The casserole can be stored in the refrigerator for up to 3-4 days. The flavors often meld together even more overnight, making leftovers a real treat.

Freezing and Reheating

This casserole freezes beautifully. You can freeze it whole or in individual portions for up to 3 months. To reheat, let it thaw in the refrigerator overnight and then bake at 350°F until heated through. You can also reheat individual portions in the microwave.

Why You’ll Love This Recipe

There are so many reasons to make this Italian sausage penne casserole a staple in your meal rotation.

Ultimate Comfort Food: With its hearty sausage, rich tomato sauce, and gooey melted cheese, this dish is the definition of comfort. It’s perfect for a cozy night in or a chilly day.
Perfect for Feeding a Crowd: This recipe makes a generous amount, making it an ideal choice for family dinners, potlucks, or when you have guests over. It’s a guaranteed crowd-pleaser that everyone will enjoy.
Great for Meal Prep: The casserole can be assembled ahead of time and baked later, or you can bake it and enjoy the leftovers for days. It saves time during busy weeks and reheats wonderfully.
Easily Customizable: You can easily swap out the protein, add vegetables, or adjust the spice level to suit your family’s preferences. It’s a versatile base that you can make your own.

Ash Tyrrell