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Costco Copycat Mac and Cheese Recipe
Ash Tyrrell

Costco Copycat Mac and Cheese Recipe

I've been chasing that creamy, gooey Costco mac and cheese flavor for years, and I finally cracked it. I skipped the alfredo-sauce shortcut everyone else uses and built my own cheese sauce from scratch instead. Once I pulled this out of the oven, bubbling and golden on top, I knew I'd nailed it
Prep Time 20 minutes
Cook Time 15 minutes
Servings: 8

Ingredients
  

  • 1 lb cavatappi pasta – the corkscrew shape holds sauce better than plain elbow macaroni
  • 1 tablespoon olive oil – tossed with drained pasta so it doesn't clump while you make the sauce
  • 1/2 cup salted butter – the base of your roux don't swap for margarine if you want real flavor
  • 1/2 cup all-purpose flour – thickens the sauce into a silky béchamel
  • 1 cup cream – adds richness heavy cream works best here
  • 3 cups milk – whole milk gives the creamiest texture
  • 3 1/2 cups white cheddar cheese grated and divided – the main flavor backbone of the sauce
  • 2 cups Gruyere cheese grated and divided – melts beautifully and adds that nutty depth
  • 3/4 cup Romano cheese grated and divided – brings a sharp, salty kick
  • 1/2 cup Parmesan cheese grated and divided – rounds out the flavor with a nutty finish
  • 1/2 cup medium cheddar cheese grated – sprinkled on top mostly for that golden color
  • 1/2 tablespoon salt – balances all that rich cheese
  • 1/2 teaspoon pepper – just enough for a little warmth
  • 1/4 teaspoon paprika – adds subtle color and smokiness
  • 1/4 teaspoon garlic powder – gives the sauce that signature Costco-style savoriness

Method
 

  1. I start by preheating my oven to 325°F so it's ready to go the moment my baking dish is assembled. While that heats up, I grate all five cheeses and divide each one into fourths, which makes layering so much easier later. Getting this done early keeps the rest of the process moving quickly.
  2. I bring a big pot of salted water to a boil and cook the cavatappi about one minute short of the package's al dente time. Since the pasta finishes cooking in the oven, slightly underdone noodles turn out perfect instead of mushy. I drain it well and toss it with olive oil so it doesn't stick together while I finish the sauce.
  3. In a large saucepan, I melt the butter over medium heat, then whisk in the flour until it looks like wet sand, cooking it for about a minute. This roux is what gives the sauce its thick, velvety base, so I don't rush this step or let it scorch.
  4. Next, I slowly pour in the cream and one cup of milk, whisking constantly until smooth. Then I add the remaining milk and keep whisking over medium heat for three to four minutes until the sauce visibly thickens. Patience here means no lumps later.
  5. I stir in the salt, pepper, paprika, and garlic powder, then add a quarter of each grated cheese except the medium cheddar, which I'm saving for the topping. Once that melts smoothly, I stir in another quarter of cheese until it's fully incorporated into the sauce.
  6. I pour the cheese sauce over the cooked pasta and stir everything together. Then I add half of that mixture into my baking dish, sprinkle a quarter of the remaining cheese over top, add the rest of the pasta, and finish with another cheese layer plus the reserved medium cheddar on top.
  7. Finally, I slide the dish into the oven, uncovered, for about 15 minutes until the cheese is fully melted and bubbling around the edges. I like to broil it for the last minute if I want a slightly golden top, then I serve it immediately while it's still gooey

Notes

  • I always grate my own cheese instead of buying pre-shredded bags, because it melts so much smoother into the sauce.
  • I slightly undercook my pasta on purpose since it keeps cooking in the oven and I don't want mushy noodles.
  • I whisk constantly while adding the milk so my sauce never turns lumpy or grainy.
  • I like adding a pinch of cayenne if I want a subtle kick for the adults at the table.
  • I sometimes top mine with buttered panko breadcrumbs for a bit of crunch against all that creaminess.