Italian Sausage Penne Casserole Recipe

I just pulled this gorgeous Italian Sausage Penne Casserole Recipe out of the oven, and let me tell you, it’s everything I hoped it would be. The first time I made this recipe, I was looking for something hearty and comforting that could feed my whole family without too much fuss.

The combination of perfectly cooked penne, creamy ricotta, melted mozzarella, and that rich sausage sauce creates pure comfort food magic. This has become my go-to recipe for busy weeknights and family gatherings alike.

Ingredients

This recipe creates layers of flavor that work beautifully together:

• 1 pound penne pasta (or ziti, rigatoni) – I prefer penne because the tubes hold onto the sauce perfectly
• 1.5 pounds mild Italian fennel sausage – Buy bulk sausage if available to save time removing casings
• 1/4 cup extra virgin olive oil – Don’t skimp on quality here, it makes a difference in the sauce
• 1 medium onion, diced – Yellow onions work best for their sweetness when cooked
• 4 cloves garlic, sliced – Fresh garlic only, please, the pre-minced stuff just isn’t the same
• 1/2 teaspoon crushed red pepper flakes – Optional, but adds a nice warmth
• 1/2 cup dry white wine – I use whatever I’m drinking with dinner
• 2 (28-ounce) cans crushed plum tomatoes – San Marzano tomatoes are worth the extra cost
• 1 pound whole milk ricotta – Full-fat ricotta gives the creamiest texture
• 1 pound shredded mozzarella cheese, divided – Freshly shredded melts so much better than pre-shredded
• 1/2 cup grated Pecorino Romano – This adds a sharp, salty kick that complements the creamy cheeses
• Salt and freshly ground black pepper to taste
• 2 tablespoons kosher salt for pasta water

Note: This recipe serves 8 moderate portions or 4-6 large servings, perfect for feeding a family with leftovers.

Variations

Make this recipe work for your dietary needs and preferences:

• Dairy-Free Version: Substitute cashew ricotta and dairy-free mozzarella, though the texture will be slightly different. Use nutritional yeast instead of Pecorino Romano for that cheesy flavor.
• Vegetarian Option: Replace Italian sausage with a mixture of sautéed mushrooms, bell peppers, and zucchini. Add extra herbs like basil and oregano for more flavor depth.
• Spicy Kick: Use hot Italian sausage and increase red pepper flakes to 1 teaspoon. Add diced jalapeños to the sauce for extra heat.
• Herb Enhancement: Stir in fresh basil leaves, chopped parsley, or oregano before baking. Fresh herbs really brighten up the rich sauce.
• Protein Boost: Add cooked ground beef along with the sausage, or throw in some pepperoni slices for a pizza-inspired twist.

Cooking Time

Prep Time: 15 minutes
Cooking Time: 45 minutes
Total Time: 1 hour

Equipment You Need

• Large high-walled pan or Dutch oven – Essential for making the sauce and browning the sausage properly
• Large pot for boiling pasta – You need plenty of room for the pasta to move around
• Large mixing bowl – For combining pasta with sauce and cheeses
• 9×13 inch baking dish – A 10×15 inch dish works even better if you have one
• Wooden spoon – Perfect for breaking up sausage and stirring sauce
• Colander – For draining the pasta
• Sharp knife – For dicing onions and slicing garlic
• Cheese grater – If you’re grating your own cheese (highly recommended)

How to Make Italian Sausage Penne Casserole?

Creating this comforting casserole involves building layers of flavor that come together beautifully in the oven. The key is developing a rich sauce first, then combining it with perfectly cooked pasta and creamy cheeses. 

Prepare the Base

Start by dicing your onion and slicing the garlic cloves. I like to prep all my vegetables before I start cooking so everything flows smoothly. Heat the olive oil in your large pan over medium heat and add the diced onion. Cook for about 5 minutes until the onion becomes soft and translucent. This creates the aromatic foundation for your sauce, so don’t rush this step.

Brown the Sausage

Add the Italian sausage to the pan with the onions, breaking it up with your wooden spoon as it cooks. If you’re using sausage links, remove them from their casings first – just slice down the side and the meat will come right out. Cook the sausage for 7-10 minutes, stirring frequently to ensure even browning. You want nice golden-brown bits throughout, as these add incredible depth to the final sauce. Make sure the sausage is completely cooked through before moving to the next step.

Build the Sauce

Create a little space in your pan and add the sliced garlic, cooking for about 3 minutes until fragrant and golden. Add the red pepper flakes and cook for just 30 seconds more – any longer and they might become bitter. Turn the heat to high and add the white wine, scraping up any browned bits from the bottom of the pan with your wooden spoon. These bits are pure flavor gold, so make sure to incorporate them into the sauce.

Simmer and Season

Once most of the wine evaporates (about 2 minutes), reduce heat to medium and add the crushed tomatoes. Bring the sauce to a gentle simmer and season with salt and pepper to taste. Let this simmer on low heat while you prepare the pasta. The longer it simmers, the more the flavors meld together. At this point, preheat your oven to 375°F and position the rack in the middle level.

Cook the Pasta

Bring a large pot of water to boil and add 2 tablespoons of kosher salt – it should taste like seawater. Add the penne and cook until 2 minutes less than the package directions for al dente. This is crucial because the pasta will continue cooking in the oven, and you don’t want it to become mushy. The pasta should still have a slight bite when you drain it. Reserve about 1 cup of pasta water before draining, just in case you need to loosen the mixture.

Assemble the Casserole

In your largest bowl, combine the undercooked pasta with 4 cups of the sausage sauce. Add the ricotta, 3/4 of the mozzarella, and all the Pecorino Romano. Mix everything together gently but thoroughly – you want every piece of pasta coated with cheese and sauce. The mixture should be creamy and well-combined. If it seems too thick, add a splash of reserved pasta water.

Layer and Bake

Spread a thick layer of the remaining sausage sauce on the bottom of your baking dish – this prevents sticking and adds extra flavor. Pour in the pasta mixture and spread it evenly. Top with the remaining sauce and sprinkle with the rest of the mozzarella cheese. Bake for 25 minutes until the top is golden brown and the cheese is bubbly. For extra color, broil for 1-2 minutes, but watch carefully to prevent burning.

Additional Tips for Making this Recipe Better

• I always undercook my pasta more than the recipe suggests – better too firm than too soft, since it continues cooking in the oven. Trust me on this one, mushy baked pasta is nobody’s friend.
• When I brown the sausage, I resist the urge to stir it too much at first. Letting it sit and develop those beautiful brown bits makes all the difference in flavor depth.
• I’ve learned to taste the sauce multiple times during cooking and adjust seasoning as needed. The canned tomatoes can vary in acidity, so sometimes I add a pinch of sugar to balance things out.
• Using a 10×15 inch baking dish instead of 9×13 gives me better ratios and those crispy edges we all fight over. If you only have the smaller dish, just expect it to be a bit deeper.
• I always let the casserole rest for at least 10 minutes after baking – this helps it set up and makes serving so much cleaner. I know it’s tempting to dive right in, but patience pays off here.

How to Serve Italian Sausage Penne Casserole?

This hearty casserole shines brightest when paired with fresh, crisp accompaniments that balance its rich flavors. Serve generous portions alongside a simple green salad dressed with lemon vinaigrette to cut through the creamy cheese.

Garlic bread is always a hit, but I particularly love serving it with sautéed broccoli rabe or roasted vegetables. For presentation, let each portion settle on the plate for a minute before adding a sprinkle of fresh basil or parsley on top. 

Nutritional Information

Each serving provides substantial nutrition for a satisfying meal:

• Calories: Approximately 870 calories per serving, making this a filling main course option
• Protein: About 47 grams of protein from the sausage, cheeses, and pasta for muscle maintenance
• Carbohydrates: Around 55 grams of carbs from the pasta and tomatoes for energy
• Fat: Approximately 51 grams of fat, primarily from cheese and sausage, providing satiety and flavor

Make Ahead and Storage

Make Ahead: You can assemble this entire casserole up to 24 hours before baking. Simply cover tightly with plastic wrap and refrigerate. Add an extra 10-15 minutes to the baking time if cooking from cold.

Storing: Leftover casserole keeps beautifully in the refrigerator for up to 4 days in a covered container. The flavors actually improve overnight as everything melds together even more.

Freezing: This casserole freezes wonderfully for up to 3 months. I recommend freezing it before baking for best results, though you can freeze leftovers too. Thaw completely in the refrigerator before reheating.

Reheating: Cover with foil and reheat in a 350°F oven for 20-30 minutes until heated through. For single servings, the microwave works fine, though the texture won’t be quite as good as oven reheating.

Why You’ll Love This Recipe?

This Italian sausage penne casserole hits all the right notes for comfort food lovers and busy home cooks alike.

• Incredibly Easy Preparation – Despite tasting like you spent hours in the kitchen, this recipe comes together in about an hour with straightforward steps. Most of the work happens while things are simmering or baking, giving you time to prep side dishes or clean up.
• Perfect for Meal Planning – This recipe makes generous portions and tastes even better as leftovers, making it ideal for meal prep or feeding a crowd. One batch easily provides several dinners for a family or makes an impressive dish for potluck gatherings.
• Endlessly Adaptable – The base recipe works beautifully with different proteins, vegetables, or cheese combinations, so you can customize it based on dietary needs or what’s in your refrigerator. It’s forgiving enough that substitutions rarely fail.
• Freezer-Friendly Convenience – Make a double batch and freeze one for those nights when cooking feels impossible. Having this comfort food ready to pop in the oven is like having a warm hug waiting in your freezer.
• Guaranteed Crowd Pleaser – I’ve never served this to anyone who didn’t ask for the recipe. The combination of pasta, cheese, and savory sausage appeals to both adults and kids, making it perfect for family dinners or entertaining guests.