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A scoop of cheesy Baked Ziti with meat sauce being lifted from a baking dish, creating a perfect cheese pull.

Hearty Italian Sausage Penne Casserole

A rich and comforting baked pasta dish featuring savory Italian sausage, tender penne, a robust tomato sauce, and a creamy, cheesy topping. Perfect for a satisfying family dinner.
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Prep Time 20 minutes
Cook Time 50 minutes
Total Time 1 hour 10 minutes
Servings: 6 servings
Course: Main Course
Cuisine: Italian
Calories: 780
Ingredients Equipment Method Notes

Ingredients
  

For the Pasta & Sauce
  • 1 lb penne pasta
  • 1 tbsp olive oil
  • 1.5 lbs bulk Italian sausage mild or hot
  • 1 large onion chopped
  • 4 cloves garlic minced
  • 1 28 oz can crushed tomatoes
  • 1 6 oz can tomato paste
  • 1/2 cup chicken or vegetable broth
  • 1 tsp dried oregano
  • 1/2 tsp dried basil
  • 1/4 tsp red pepper flakes optional, for heat
  • 1 tsp salt or to taste
  • 1/2 tsp black pepper or to taste
For the Cheese Topping
  • 15 oz ricotta cheese
  • 1 cup shredded mozzarella cheese divided
  • 1/2 cup grated Parmesan cheese divided
  • 1 large egg
  • 1/4 cup fresh parsley chopped
  • 1/4 tsp salt
  • 1/8 tsp black pepper

Equipment

  • Large Skillet or Dutch Oven
  • Large Pot
  • 9x13 inch baking dish
  • Mixing bowls
  • Grater (optional, for cheese)

Method
 

Prepare for Baking
  1. Preheat your oven to 375°F (190°C). Lightly grease a 9x13 inch baking dish.
Cook Pasta
  1. Bring a large pot of salted water to a rolling boil. Add the penne pasta and cook according to package directions until al dente (firm to the bite). Drain well and set aside.
Brown Sausage & Sauté Aromatics
  1. While the pasta cooks, heat the olive oil in a large skillet or Dutch oven over medium-high heat. Add the bulk Italian sausage, breaking it apart with a spoon as it cooks. Brown the sausage evenly, then drain any excess fat.
  2. Add the chopped onion to the skillet with the sausage and cook until softened, about 5-7 minutes. Stir in the minced garlic and cook for another minute until fragrant.
Simmer Sauce
  1. Stir in the tomato paste and cook for 1 minute to deepen its flavor. Pour in the crushed tomatoes and chicken or vegetable broth. Add the dried oregano, dried basil, red pepper flakes (if using), 1 tsp salt, and 1/2 tsp black pepper. Bring the sauce to a simmer, then reduce the heat to low and let it cook for 10-15 minutes, stirring occasionally, allowing the flavors to meld.
Prepare Ricotta Mixture
  1. In a medium bowl, combine the ricotta cheese, 1/2 cup of the shredded mozzarella, 1/4 cup of the grated Parmesan, the large egg, chopped fresh parsley, 1/4 tsp salt, and 1/8 tsp black pepper. Mix thoroughly until all ingredients are well combined.
Combine & Layer Casserole
  1. Add the drained penne pasta to the skillet with the sausage and tomato sauce. Toss gently to ensure the pasta is evenly coated with the sauce.
  2. Spread half of the pasta mixture evenly into the prepared 9x13 inch baking dish.
  3. Dollop half of the ricotta cheese mixture over the pasta layer.
  4. Sprinkle with the remaining 1/2 cup shredded mozzarella and 1/4 cup grated Parmesan cheese.
  5. Repeat the layers: add the remaining pasta mixture, then dollop the remaining ricotta mixture on top.
Bake & Serve
  1. Cover the baking dish loosely with aluminum foil and bake for 20 minutes.
  2. Remove the foil and continue baking for another 10-15 minutes, or until the casserole is bubbly around the edges and the cheese topping is melted and lightly golden brown.
  3. Let the casserole stand for 5-10 minutes before serving to allow it to set and cool slightly. Garnish with extra fresh parsley if desired.

Notes

This casserole is fantastic for meal prepping! You can assemble it a day ahead, cover tightly, and refrigerate. Add 10-15 minutes to the covered baking time if baking from cold. Leftovers store well in an airtight container in the refrigerator for up to 3-4 days. You can also freeze individual portions for convenient future meals. To freeze, assemble the casserole in a freezer-safe dish (without baking), cover tightly, and freeze for up to 3 months. Thaw overnight in the fridge before baking, or bake from frozen (this will significantly increase baking time).