Prep Time: 20 minutes
Cook Time: 35 minutes
Total Time: 55 minutes
Active Intensity: Medium-Low (Simple steps, mostly hands-off baking)
Skill Level: Beginner-Friendly
Serves: 6-8 people
Nutritional Information (Per serving, based on 8 servings):
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Calories: ~520 kcal
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Total Fat: 29g
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Saturated Fat: 13g
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Cholesterol: 80mg
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Sodium: 1150mg
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Total Carbohydrates: 38g
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Dietary Fiber: 3g
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Sugars: 6g
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Protein: 28g
Please note: Nutritional values are estimates and can vary based on specific ingredients and brands used.
Ingredients
For the Casserole:
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12 oz (340g) rotini or penne pasta
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1 tablespoon olive oil
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1 lb (450g) mild or hot Italian sausage, casings removed
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1 medium yellow onion, diced
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1 medium green bell pepper, diced
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8 oz (225g) sliced cremini mushrooms
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3 cloves garlic, minced
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1 (24 oz) jar of good-quality marinara sauce (about 3 cups)
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1 (14 oz) can diced tomatoes, drained
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1 teaspoon dried oregano
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½ teaspoon crushed red pepper flakes (optional)
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½ teaspoon black pepper
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4 oz (115g) sliced pepperoni, divided (half for mixing, half for topping)
For the Cheese Layer:
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2 cups (8 oz / 225g) shredded low-moisture mozzarella cheese
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1 cup (4 oz / 115g) shredded sharp cheddar cheese
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½ cup (2 oz / 55g) freshly grated Parmesan cheese
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1 (8 oz / 225g) block of whole milk mozzarella, sliced into ¼-inch rounds (for the top layer)
For Garnish (Optional):
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Fresh basil or parsley, chopped
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Extra grated Parmesan
Equipment
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Large pot for boiling pasta
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Large skillet or Dutch oven
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Colander
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9×13 inch (23×33 cm) baking dish
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Mixing spoon
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Grater (if grating cheese from a block)
Instructions
Step 1: Prep & Preheat
Preheat your oven to 375°F (190°C). Grease your 9×13 inch baking dish lightly with oil or cooking spray. Begin boiling a large pot of salted water for the pasta.
Step 2: Cook the Pasta & Veggies
Cook the pasta according to package directions for al dente (it will soften further in the bake). Drain and set aside.
While the pasta cooks, heat olive oil in your large skillet over medium-high heat. Add the Italian sausage and cook, breaking it up with a spoon, until browned and cooked through (about 5-7 minutes). Use a slotted spoon to remove the sausage, leaving the drippings in the pan.
Add the diced onion, bell pepper, and mushrooms to the skillet. Sauté in the sausage drippings (add a bit more oil if dry) until the vegetables are softened, about 5-6 minutes. Add the minced garlic and cook for 1 more minute until fragrant.
Step 3: Build the Sauce
Return the cooked sausage to the skillet with the vegetables. Stir in the marinara sauce, drained diced tomatoes, dried oregano, red pepper flakes (if using), and black pepper. Reduce heat to low and let the sauce simmer for 5 minutes to allow the flavors to meld.
Step 4: Assemble the Casserole
In the large pot with the drained pasta (or in a very large bowl), combine the savory meat sauce, the cooked pasta, and half of the sliced pepperoni. Stir until everything is evenly coated.
Transfer the entire mixture into your prepared baking dish and spread it into an even layer.
Step 5: The Cheesy Blanket
In a medium bowl, mix the shredded mozzarella, cheddar, and Parmesan cheeses. Sprinkle this cheese blend evenly over the entire surface of the casserole.
Artistically arrange the remaining half of the pepperoni and the slices of fresh mozzarella on top of the shredded cheese.
Step 6: Bake to Perfection
Place the baking dish in the preheated oven and bake, uncovered, for 25-35 minutes, or until the cheese is completely melted, golden, and bubbly around the edges, and the casserole is heated through.
Step 7: Rest & Serve
Once out of the oven, let the casserole rest for 5-10 minutes. This crucial step allows the layers to set slightly, making it easier to scoop and serve without it being too runny.
Garnish with fresh herbs and a sprinkle of extra Parmesan if desired. Serve hot with a simple side salad and garlic bread for the full pizza night experience.
Chef’s Notes & Customizations
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Make-Ahead Magic: Assemble the casserole completely (without baking), cover tightly, and refrigerate for up to 24 hours. Add 5-10 minutes to the baking time when cooking from cold.
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Protein Swaps: Substitute Italian sausage with ground beef, turkey, or chicken. For a vegetarian version, use plant-based crumbles and skip the pepperoni.
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Veggie Variations: This is your “supreme” canvas! Add black olives, diced ham, sautéed jalapeños, or artichoke hearts when you mix in the sauce.
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Storage: Store leftovers in an airtight container in the refrigerator for up to 4 days. Reheat individual portions in the microwave or cover the whole dish with foil and warm in a 350°F (175°C) oven until hot.
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Freezing: Bake, cool completely, and freeze tightly wrapped for up to 2 months. Thaw in the refrigerator overnight before reheating.

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