The Ultimate Comfort Food: Your New Favorite Italian Sausage Penne Casserole

Is there anything more satisfying than a bubbling, cheesy, deeply flavorful casserole emerging from the oven? It’s the culinary equivalent of a warm hug. And when that casserole is a hearty, robust Italian Sausage Penne Casserole, it transcends simple comfort food to become the centerpiece of a memorable family dinner, the star of a potluck, or the perfect make-ahead meal for a busy week.

This isn’t just another pasta bake. This Italian Sausage Penne Casserole is a masterclass in texture and taste. It combines al dente penne pasta, richly seasoned Italian sausage, a quick yet incredibly flavorful tomato sauce, and a glorious blanket of melted mozzarella cheese. It’s a dish that feels indulgent and gourmet but is deceptively simple to prepare. Whether you’re a seasoned home cook or just starting your culinary journey, this recipe from Great Grub, Delicious Treats is about to become a staple in your repertoire.

Why This Italian Sausage Penne Casserole Recipe is a Guaranteed Hit

Before we dive into the ingredients and method, let’s talk about what makes this specific Italian Sausage Penne Casserole so special.

• The Perfect Balance of Flavors: The star, undoubtedly, is the Italian sausage. Its inherent blend of fennel, garlic, and red pepper flakes creates a flavor base that is miles ahead of using plain ground meat. It infuses the entire dish with a savory, aromatic depth that is simply irresistible.

• A Symphony of Textures: We consciously cook the penne to al dente. This ensures that during its second bake in the oven, the pasta maintains a pleasant bite and doesn’t turn to mush. Combined with the crumbled, slightly crisp sausage and the gooey, stretchy mozzarella, every forkful is a textural delight.

• Unbeatable Convenience: This is a one-pan meal in spirit. With just a skillet for the sausage and sauce and a pot for the pasta, the cleanup is minimal. Furthermore, the entire Italian Sausage Penne Casserole can be assembled ahead of time and refrigerated until you’re ready to bake, making it the ultimate solution for stress-free entertaining.

• Crowd-Pleasing Versatility: With 8 generous servings, this casserole is built for feeding a crowd. It’s a guaranteed hit with adults and kids alike. Plus, as you’ll see later, it’s a wonderfully adaptable recipe that you can tweak to your family’s preferences.

Deconstructing the Ingredients for the Perfect Casserole

The magic of this Italian Sausage Penne Casserole lies in the quality and synergy of its components. Let’s break down why each ingredient is crucial and explore potential variations.

1. The Hearty Foundation: Pasta and Sausage

• Penne Pasta (16 oz): Penne is the ideal shape for a casserole. Its tubular structure and angled ends are perfect for capturing pockets of sausage and sauce. The ridges on penne rigate are even better, as they help the sauce cling to every inch. Cooking it to al dente is non-negotiable; it’s the key to preventing a mushy final product.

• Italian Sausage (2 lb): This is the flavor engine of the dish. The recipe calls for hot Italian sausage, which adds a pleasant, building heat. However, this is where you can customize:

  • For a Milder Palate: Use sweet or mild Italian sausage.

  • For Maximum Heat: Stick with hot Italian sausage or even add a pinch of red pepper flakes to the sauce.

  • A Mix for Complexity: Using one pound of hot and one pound of sweet sausage is a fantastic way to create a well-rounded heat profile that isn’t overwhelming.

  • Chicken or Turkey Sausage: For a leaner option, high-quality chicken or turkey Italian sausage works beautifully.

2. The Cheesy, Gooey Glory

• Mozzarella Cheese (24 oz): We use a full 1.5 pounds of cheese, and for good reason. Mozzarella provides that iconic, stretchy, milky goodness that makes a casserole so decadent. The recipe incorporates cheese directly into the pasta mixture and layers it throughout, ensuring cheesy perfection in every bite.

  • Pro-Tip: Always shred your own mozzarella from a block. Pre-shredded cheese is coated with anti-caking agents like potato starch or cellulose, which can prevent it from melting as smoothly and seamlessly.

3. The Aromatic Soul: The Sauce

• Onion and Garlic (1 medium onion, 5 cloves garlic): This aromatic duo forms the flavor base of our quick sauce. Sautéing them in the reserved sausage grease is a chef’s secret—it builds layers of flavor that you just can’t get from using a neutral oil.

• Diced Tomatoes (28 oz can): Using high-quality canned diced tomatoes is essential. They provide a bright, tangy acidity that balances the richness of the sausage and cheese. Do not drain them; the tomato juices are part of the sauce.

• Basil and Oregano (1½ tsp each): These classic Italian herbs bring a fresh, earthy dimension. Using dried herbs is perfect here, as their flavor holds up well to the cooking process. If you have fresh herbs on hand, stir in a tablespoon of chopped fresh basil at the very end before assembling for a burst of freshness.

Step-by-Step Guide to Crafting Your Italian Sausage Penne Casserole

Follow these detailed steps for a flawless Italian Sausage Penne Casserole every single time.

Prep Time: 20 minutes
Cook Time: 1 hour
Total Time: 1 hour 20 minutes
Servings: 8

Ingredients

• 16 oz box Penne pasta

• 2 lb Hot Italian Sausage (can use sweet or mild)

• 24 oz mozzarella cheese, shredded (divided)

• 1 medium onion, diced

• 5 cloves garlic, minced

• 28 oz can diced tomatoes

• 1½ tsp dried basil

• 1½ tsp dried oregano

• Salt and pepper, to taste

Instructions

1. Preheat and Prepare: Begin by preheating your oven to 350°F (175°C). This ensures it’s perfectly heated when your casserole is ready to bake. Spray a 3-quart casserole dish (a 9×13-inch baking dish works perfectly) with non-stick spray and set it aside.

2. Brown the Sausage: Remove the sausage from its casings and add it to a large skillet over medium heat. Use a wooden spoon to crumble the sausage as it cooks. Continue cooking until it’s thoroughly browned and no longer pink. This step is crucial for developing flavor, so don’t rush it.

3. Sauté the Aromatics: Carefully drain the excess grease from the skillet, but be sure to reserve about 2 tablespoons. This rendered fat is packed with flavor! Return the 2 tablespoons of grease to the skillet. Add the diced onion and minced garlic and sauté for 4-5 minutes, until the onions have softened and become translucent and the garlic is fragrant.

4. Build the Simple Sauce: Pour the entire can of diced tomatoes (with their juices) into the skillet with the onions and garlic. Add the dried basil, oregano, and a generous pinch of salt and pepper. Stir everything together and let it cook for about 5 minutes over medium heat, allowing the flavors to meld.

5. Simmer for Depth: Add the cooked crumbled sausage back into the skillet. Give it a good stir, then bring the mixture to a gentle boil. Once boiling, reduce the heat to low, cover the skillet, and let it simmer for 20-30 minutes. This simmering time is what transforms the ingredients into a cohesive, deeply flavored sauce. Stir occasionally to prevent sticking.

6. Cook the Pasta: While the sauce is simmering, cook the penne pasta in a large pot of well-salted boiling water. It is absolutely vital to cook the pasta only until it is al dente (typically 1-2 minutes less than the package instructions). Remember, it will continue to cook in the oven. Drain the pasta and return it to the warm pot.

7. The Grand Assembly: This is where the magic happens. Pour the entire sausage and tomato sauce mixture over the drained pasta in the pot. Now, add half of your shredded mozzarella cheese. Stir everything vigorously until the cheese begins to melt and creates a wonderfully creamy sauce that coats every piece of pasta and sausage.

8. Layer and Bake: Transfer half of the pasta mixture into your prepared casserole dish. Sprinkle a layer of cheese over this first layer. Then, add the remaining pasta mixture, and finally, top it all with the remaining cheese. Cover the dish tightly with aluminum foil.

9. Bake to Bubbly Perfection: Place the covered casserole in the preheated oven and bake for 25-30 minutes. The foil trap steam, gently heating the casserole through without drying it out. Then, remove the foil and bake for an additional 5-10 minutes, or until the cheese on top is completely melted, bubbly, and has those irresistible golden-brown spots.

10. Serve and Enjoy! For the best experience, let the casserole rest for 5-10 minutes after pulling it from the oven. This allows the layers to set slightly, making it easier to serve. Dish it up alongside a crisp green salad and some warm, buttery garlic bread to complete the perfect Italian-inspired meal.

Pro-Tips for a Flawless Italian Sausage Penne Casserole

• Don’t Skip the Sausage Fat: Sautéing the onions and garlic in the reserved sausage grease is a flavor power move. It adds a profound savory depth that you simply can’t replicate with olive oil.

• Salt Your Pasta Water: “Salt it like the sea!” This old adage is true. The pasta water should be salty, as this is your primary opportunity to season the pasta itself from within.

• Make-Ahead Magic: This casserole is a meal-prepper’s dream. You can assemble the entire dish, cover it tightly, and refrigerate it for up to 24 hours before baking. When ready to bake, you may need to add 10-15 minutes to the covered baking time since it will be going into the oven cold.

• Freezing Instructions: You can also freeze this Italian Sausage Penne Casserole unbaked. Assemble it in a freezer-safe dish, wrap it tightly in both plastic wrap and foil, and freeze for up to 3 months. Thaw completely in the refrigerator before baking as directed.

Customize Your Casserole: Delicious Variations

The beauty of this Italian Sausage Penne Casserole is its adaptability. Feel free to make it your own!

• Add Some Greens: Stir in a few handfuls of fresh spinach or chopped kale when you add the sauce back to the pasta. The residual heat will wilt it perfectly.

• Vegetable Boost: Add sliced mushrooms, diced bell peppers, or zucchini to the skillet when you sauté the onions for an extra nutrient punch.

• Creamy Twist: For a richer, rosé-style sauce, stir in 1/2 cup of heavy cream or marinara sauce into the tomato and sausage mixture during the final simmer.

• Cheese Lover’s Dream: Incorporate 1/2 cup of freshly grated Parmesan or Romano cheese into the pasta mixture along with the mozzarella for a sharper, more complex cheesy flavor.

The Nutritional Picture

While this Italian Sausage Penne Casserole is a hearty, indulgent dish, it’s helpful to understand its nutritional profile. According to the recipe, one serving contains approximately:

• Calories: 884

• Carbohydrates: 51g

• Protein: 43g

• Fat: 56g

Please note that these values are approximate and can vary based on the specific brands of ingredients you use and any modifications you make.

The Ultimate Comfort Food: Your New Favorite Italian Sausage Penne Casserole

Print Recipe

If you’re looking for a crowd-pleasing, comforting meal, this Italian Sausage Penne Casserole is your go-to. Loaded with savory Italian sausage, tender penne pasta, tangy tomatoes, and gooey mozzarella cheese, it’s like lasagna without the fuss.

• Author: alae

Ingredients

Scale 1x2x3x

• 16 oz penne pasta

• 2 lb hot Italian sausage (or sweet/mild)

• 24 oz shredded mozzarella cheese

• 1 medium onion, diced

• 5 cloves garlic, minced

• 28 oz can diced tomatoes

• 1½ tsp dried basil

• 1½ tsp dried oregano

• Salt and pepper, to taste

• Non-stick cooking spray

Instructions

1. Prep casserole dish & oven:
   Preheat oven to 350°F (175°C) and spray a 3-quart casserole dish with non-stick spray.

2. Cook sausage:
   Remove sausage from casing and crumble into a large skillet. Cook over medium heat until browned. Drain excess grease, reserving 2 tablespoons, and set sausage aside.

3. Sauté vegetables:
   Add reserved grease to skillet. Sauté onion and garlic until onions are translucent.

4. Add tomatoes & seasonings:
   Pour in diced tomatoes. Add basil, oregano, salt, and pepper. Cook over medium heat for 5 minutes.

5. Combine sausage & simmer:
   Return sausage to skillet. Bring mixture to a boil, then cover and simmer on low for 20–30 minutes, stirring occasionally.

6. Cook pasta:
   Prepare penne according to package directions for al dente. Drain, rinse, and return to pot.

7. Mix pasta & sauce:
   Stir sausage mixture into pasta. Add half of the mozzarella and stir until melted.

8. Assemble casserole:
   Place half of the pasta mixture into the prepared casserole dish. Sprinkle with cheese, then add the remaining pasta and top with remaining mozzarella.

9. Bake:
   Cover with foil and bake 30 minutes until heated through. Remove foil and bake a few more minutes for golden, bubbly cheese.

10. Serve:
    Slice and serve hot with salad and garlic bread.

Notes

• Sausage choice: Hot Italian sausage adds a kick; sweet sausage works for a milder flavor.

• Cheese options: Mix mozzarella with provolone or parmesan for extra richness.

• Make ahead: Assemble casserole and refrigerate for up to 24 hours before baking.

• Freezing: Fully cooked and cooled casserole can be frozen in portions for up to 2 months. Reheat covered in the oven.

Nutrition

• Calories: 884 kcal per serving
• Fat: 56 g
• Saturated Fat: 24 g
• Carbohydrates: 51 g
• Protein: 43 g

In Conclusion: Your New Go-To Dinner

This Italian Sausage Penne Casserole is more than just a recipe; it’s a reliable, crowd-pleasing solution for countless dining situations. It delivers the comfort and flavor of a slow-simmered Italian meal with the straightforward ease of a weeknight casserole. The combination of savory sausage, al dente pasta, tangy tomatoes, and copious amounts of melted mozzarella is a proven winner.

So, preheat your oven, grab your skillet, and get ready to create a dish that will have your family and friends asking for seconds and begging for the recipe. This Italian Sausage Penne Casserole is destined to earn a permanent spot in your dinner rotation.