Cheesy Italian Sausage Pasta Casserole Recipe

Ingredients

• 340 g (12 oz)fusilli pasta
• 454 g (1 lb)bulk Italian sausage, sweet or hot
• 1 mediumonion, diced
• 3 clovesgarlic, minced
• 1green pepper, deseeded and diced
• 227 g (8 oz)cremini mushrooms, quartered
• 1½ tspkosher salt
• ½ tspred pepper flakes
• 2 tspdried basil
• 1½ tspdried oregano
• 3 cans, 425 g (15 oz) eachstrained tomatoes or tomato sauce
• 340 g (3 cups)shredded mozzarella cheese
• 113 g (½ cup, about 4 oz)sliced pepperoni

Instructions

1. 1

   Cook the pasta

   Heat the oven to 175°C (350°F). Grease a 23 x 33 cm (9 x 13-inch) baking dish and set it aside. Boil the pasta in a large pot of salted water according to the packet instructions until al dente. Drain and set aside.

2. 2

   Brown the sausage

   As the pasta cooks, cook the sausage in a large frying pan over medium heat, breaking it into small bite-sized pieces. Cook for 6–8 minutes, until browned and cooked through.

3. 3

   Cook the vegetables

   Add the onion, garlic, green pepper and mushrooms to the sausage. Cook for about 4–6 minutes, until the onion is soft. Stir in the salt, red pepper flakes, basil and oregano, then add the strained tomatoes and mix. Bring to a simmer for 3–4 minutes, then take the pan off the heat.

4. 4

   Layer the casserole

   Pour the meat and vegetable sauce over the cooked pasta in a large bowl. Mix in half of the pepperoni. Spoon half of the pasta mixture into the prepared baking dish and scatter over half of the mozzarella. Add the remaining pasta mixture, then the rest of the cheese, and finish with the remaining pepperoni.

5. 5

   Bake until bubbling

   Cover the dish and bake at 175°C (350°F) for 25 minutes. Uncover and bake for a further 15–20 minutes, until bubbling and the cheese is beginning to brown.

What is a pizza pasta casserole?

This is a baked pasta dish with the flavours associated with Italian-American pizza: tomato, sausage, pepperoni and melted cheese. Rather than sitting on a crust, those toppings are combined with fusilli and baked together.

Fusilli catches the sauce in its twists, while layering the pasta with mozzarella helps give the casserole cheesy bites throughout as well as a melted top.

Nutrition and macros by portion

The nutrition label shows one serving as written: 480 calories, 28g protein, 45g carbs, 22g fat.

The pasta and tomato sauce contribute most of the carbohydrates, while sausage, mozzarella and pepperoni provide much of the fat and protein. Serve a portion with salad or vegetables for a more balanced plate.

Choose the pasta and sausage

Fusilli: its spirals hold onto the tomato sauce and work well in a layered bake. Cook it only to al dente, as it will spend more time in the oven.

Sausage: sweet or hot Italian sausage both suit the recipe. Breaking it into small pieces helps distribute it through the pasta.

Build flavour in the pan

Brown first: cooking the sausage before adding the vegetables gives it colour and lets its flavour carry into the sauce.

Soften the vegetables: cook the onion, garlic, pepper and mushrooms until the onion is soft, then stir in the dried herbs and spices before adding the tomatoes. Let the sauce simmer for 3–4 minutes as directed.

Layer for an even bake

Divide the pasta mixture and mozzarella into two layers rather than putting all the cheese on top. That way, some cheese melts between the pasta as well as browning on the surface.

Mix half the pepperoni into the pasta and reserve the rest for the top. The upper slices will be visible once the casserole is baked.

Check texture and doneness

Pasta: drain it when it is still firm to the bite, not soft, so it holds its shape during baking.

Casserole: after the covered 25-minute bake, uncover it and look for bubbling sauce and cheese that is starting to brown. The recipe gives a further 15–20 minutes for this stage.

Plan the timing and sides

The pasta and sauce are prepared before the casserole goes into the oven, so the layering can be done once both are ready. Allow the full 25 minutes covered, then check the uncovered bake during its 15–20-minute window.

Serve it with a green salad or a simple vegetable side to bring freshness alongside the rich, cheesy pasta.

Recipe notes & tips

• Salt the pasta water before adding the fusilli.
• Break the sausage into small pieces as it cooks so it mixes evenly through the casserole.
• Cut the mushrooms into quarters as specified so they keep some texture in the sauce.
• Let the tomato mixture simmer for the full 3–4 minutes before combining it with the pasta.
• Reserve the second half of the pepperoni for the top of the casserole.

Variations

• Choose hot sausage: use hot Italian sausage for more spice.
• Use tomato sauce: swap the strained tomatoes for tomato sauce as the recipe allows.
• Adjust the heat: leave out the red pepper flakes for a milder casserole.
• Change the pasta: use another short pasta shape that can be cooked al dente.
• Add a side salad: serve with crisp salad leaves for a fresh contrast.

Common mistakes to avoid

• Overcooking the pasta: stop at al dente so it does not turn too soft in the oven.
• Skipping the sausage browning: cook it until browned and cooked through before adding vegetables.
• Adding tomatoes too soon: soften the onion with the other vegetables first, then stir in the seasonings and tomatoes.
• Putting all the cheese on top: split it between the layers as directed for cheese throughout.
• Leaving the dish covered: uncover it for the final 15–20 minutes so the cheese can begin to brown.

How to store

Refrigerate leftovers in a covered container and eat within 3–4 days. Reheat portions until hot throughout, in the microwave or in a covered oven-safe dish.

Frequently asked questions