Italian Sausage Baked Mostaccioli

If you ask me, baked pasta is one of those dinners that just makes sense.

This hearty casserole combines Italian sausage with penne in a rich marinara sauce, layered with creamy ricotta and topped with melted mozzarella. The sausage brings a savory, slightly spicy flavor that fills every bite.

It’s the kind of dish where everything gets mixed together in a baking dish and comes out bubbly and golden. Fresh basil and Parmesan add a finishing touch that makes it taste like you spent hours in the kitchen.

It’s a comforting meal that feeds a crowd, perfect for busy weeknights or when you need something the whole family will eat.

What Kind of Italian Sausage Should I Use?

You can use either sweet or hot Italian sausage for this baked mostaccioli, depending on your preference. Sweet Italian sausage gives you a milder, more family-friendly flavor, while hot sausage adds a nice kick that pairs well with the red pepper flakes already in the recipe. If you can’t decide, try using half sweet and half hot for a balanced flavor. Most grocery stores sell Italian sausage in links or in bulk form, and either works great here – just remove the casings from the links before cooking if that’s what you grab.

Options for Substitutions

This baked pasta dish is pretty forgiving when it comes to swaps:

• Italian sausage: Ground beef, ground turkey, or even crumbled chicken sausage work great here. Season with Italian herbs if using plain ground meat to get that sausage flavor.
• Penne: While the recipe calls for penne, mostaccioli is actually the traditional choice (they’re very similar). You can also use rigatoni, ziti, or any tube-shaped pasta that holds sauce well.
• Ricotta: Cottage cheese makes a good substitute – just drain any excess liquid first. You can also use a mix of cream cheese and sour cream for a creamier texture.
• Mozzarella: Low-moisture mozzarella is best for baking, but you can use provolone or a mix of Italian cheeses. Fresh mozzarella works too, just pat it dry to avoid excess moisture.
• Marinara sauce: Any tomato-based pasta sauce works fine. You can even use crushed tomatoes with added Italian seasoning if that’s what you have.
• Fresh basil: Dried basil can work in a pinch – use about 1 tablespoon. Add it to the sauce while cooking rather than as a garnish.

Watch Out for These Mistakes While Baking

The biggest mistake when making baked mostaccioli is overcooking the pasta during the initial boil – since it bakes for another 30-40 minutes in the oven, you want to undercook it by about 2 minutes so it doesn’t turn mushy.

Another common error is not draining the sausage after browning, which can make your casserole greasy, so be sure to tilt the pot and spoon out excess fat before adding the onions and garlic.

To prevent a dry casserole, make sure your pasta is well-coated with sauce before transferring it to the baking dish, and if the mixture looks too thick, add a splash of pasta water to loosen it up.

Finally, resist the urge to skip the 10-minute cooling time after baking – this resting period allows the cheese to set and makes serving clean, neat portions much easier.

What to Serve With Baked Mostaccioli?

A simple green salad with Italian dressing is my go-to side for baked mostaccioli – it cuts through all that cheesy richness perfectly. I like to throw together some romaine, cherry tomatoes, red onion, and a sprinkle of parmesan with a tangy vinaigrette. Garlic bread is another must-have because you’ll want something to scoop up any extra sauce and cheese from your plate. If you’re feeding a crowd, roasted vegetables like zucchini, bell peppers, or broccoli make a great addition and add some color to your table without being too heavy.

Storage Instructions

Store: Leftover baked mostaccioli keeps really well in the fridge for up to 4 days. Just cover the baking dish tightly with foil or transfer portions to airtight containers. The flavors actually get even better the next day as everything melds together!

Freeze: This pasta bake is perfect for freezing. You can freeze the whole thing before or after baking for up to 3 months. If freezing unbaked, cover it tightly with plastic wrap and then foil. If it’s already baked, let it cool completely first, then wrap well and freeze in portions or the whole dish.

Reheat: To reheat from the fridge, cover with foil and warm in a 350°F oven for about 20 minutes until heated through. From frozen, thaw overnight in the fridge first, or bake covered at 350°F for about 45 minutes. You can also reheat individual portions in the microwave for 2-3 minutes.

Estimated Nutrition

Estimated nutrition for the whole recipe (without optional ingredients):

• Calories: 3500-3800
• Protein: 155-175 g
• Fat: 170-190 g
• Carbohydrates: 330-360 g

Ingredients

For the meat sauce:

• 3 tbsp olive oil
• 1 lb italian sausage (removed from casings and crumbled into 1/2-inch pieces)
• 1 onion (finely diced into 1/4-inch pieces)
• 4 garlic cloves
• 1/4 tsp pepper flakes
• 24 oz marinara sauce (I like Rao’s Homemade for the best flavor shortcut)
• 1/2 tsp salt
• 1/2 tsp black pepper
• 1/2 tsp dried oregano

For the pasta:

• 1 lb penne (cooked 2 minutes less than al dente to prevent sogginess)

For the cheese mixture:

• 1 3/4 cups ricotta
• 1 egg (lightly beaten to help bind the cheese layer)
• 2 oz parmesan
• 10 oz mozzarella (shredded from a block for better melting and stretch)

For the garnish:

• 12 basil leaves (chiffonade cut into thin ribbons)

Step 1: Prepare Mise en Place and Preheat

• 1 onion, finely diced
• 4 garlic cloves, minced
• 10 oz mozzarella, shredded
• 2 oz parmesan, grated
• 1 egg, lightly beaten

Preheat your oven to 375°F.

While it heats, finely dice the onion into 1/4-inch pieces, mince the 4 garlic cloves, shred the mozzarella from a block (this melts much better than pre-shredded), and grate the parmesan.

Lightly beat the egg in a small bowl to help bind the cheese layer.

Having everything prepped before you start cooking ensures smooth timing and lets you focus on building flavor.

Step 2: Build the Sauce with Sausage and Aromatics

• 3 tbsp olive oil
• 1 lb italian sausage, crumbled
• 1 onion, finely diced
• 4 garlic cloves, minced
• 1/4 tsp pepper flakes
• 24 oz marinara sauce
• 1/2 tsp salt
• 1/2 tsp black pepper
• 1/2 tsp dried oregano

Heat 3 tablespoons of olive oil in a large pot over medium-high heat.

Add the crumbled italian sausage and cook for 6-8 minutes, breaking it into 1/2-inch pieces as it cooks, until it’s browned and no longer pink.

Add the diced onion, minced garlic, and red pepper flakes, then sauté for 3-5 minutes until the aromatics are fragrant and the onion is softened.

Stir in the marinara sauce, salt, black pepper, and dried oregano, then reduce heat to low and simmer for 10-15 minutes to let the flavors meld.

I like to let this sauce simmer a bit longer than the minimum time—it really deepens the flavor and brings everything together beautifully.

Step 3: Cook Pasta to the Right Texture

• 1 lb penne pasta

Bring a pot of salted water to a boil and cook the penne for 6-7 minutes, which is about 2 minutes less than al dente.

This undercooking is crucial—the pasta will finish cooking in the oven and absorb sauce without becoming mushy.

Drain the pasta well and set aside.

Step 4: Combine Cheese Filling

• 1 3/4 cups ricotta
• 1 egg, lightly beaten
• 2 oz parmesan, grated
• shredded mozzarella

In a bowl, mix together the ricotta, lightly beaten egg, grated parmesan, and 1 cup of the shredded mozzarella.

This creates a creamy, bound cheese layer that will set during baking and hold the casserole together.

Step 5: Assemble the Casserole

• cooked pasta from Step 3
• sausage sauce from Step 2
• cheese filling from Step 4
• remaining shredded mozzarella

In a 9×13 inch baking dish, combine the drained pasta from Step 3 with the sausage sauce from Step 2, mixing well to coat evenly.

Spread the pasta mixture in an even layer.

Dollop the cheese mixture from Step 4 over the top and gently spread it into an even layer.

Sprinkle the remaining shredded mozzarella (about 1 cup) over the top for a golden, melty finish.

Step 6: Bake and Rest

Bake the assembled casserole at 375°F for 30-40 minutes, until the cheese is bubbly, golden brown on top, and the sauce is bubbling around the edges.

Remove from the oven and let rest for 10 minutes—this resting time helps the casserole set so it cuts cleanly and won’t fall apart when you serve it.

Step 7: Finish and Serve

• 12 basil leaves, chiffonade cut

Top the rested casserole with the 12 basil leaves cut into a chiffonade (thin ribbons), which adds a fresh, aromatic finish that brightens the rich, savory dish.

Italian Sausage Baked Mostaccioli

Delicious Italian Sausage Baked Mostaccioli recipe with step-by-step instructions.

Print Recipe Pin Recipe

Prep Time 25 minutes mins

Cook Time 55 minutes mins

Total Time 1 hour hr 20 minutes mins

Servings 8 servings

Calories 3650 kcal

Ingredients

  

For the meat sauce::

• 3 tbsp olive oil
• 1 lb italian sausage (removed from casings and crumbled into 1/2-inch pieces)
• 1 onion (finely diced into 1/4-inch pieces)
• 4 garlic cloves
• 1/4 tsp pepper flakes
• 24 oz marinara sauce (I like Rao’s Homemade for the best flavor shortcut)
• 1/2 tsp salt
• 1/2 tsp black pepper
• 1/2 tsp dried oregano

For the pasta::

• 1 lb penne (cooked 2 minutes less than al dente to prevent sogginess)

For the cheese mixture::

• 1 3/4 cups ricotta
• 1 egg (lightly beaten to help bind the cheese layer)
• 2 oz parmesan
• 10 oz mozzarella (shredded from a block for better melting and stretch)

For the garnish::

• 12 basil leaves (chiffonade cut into thin ribbons)

Instructions

 

• Preheat your oven to 375°F. While it heats, finely dice the onion into 1/4-inch pieces, mince the 4 garlic cloves, shred the mozzarella from a block (this melts much better than pre-shredded), and grate the parmesan. Lightly beat the egg in a small bowl to help bind the cheese layer. Having everything prepped before you start cooking ensures smooth timing and lets you focus on building flavor.
• Heat 3 tablespoons of olive oil in a large pot over medium-high heat. Add the crumbled italian sausage and cook for 6-8 minutes, breaking it into 1/2-inch pieces as it cooks, until it's browned and no longer pink. Add the diced onion, minced garlic, and red pepper flakes, then sauté for 3-5 minutes until the aromatics are fragrant and the onion is softened. Stir in the marinara sauce, salt, black pepper, and dried oregano, then reduce heat to low and simmer for 10-15 minutes to let the flavors meld. I like to let this sauce simmer a bit longer than the minimum time—it really deepens the flavor and brings everything together beautifully.
• Bring a pot of salted water to a boil and cook the penne for 6-7 minutes, which is about 2 minutes less than al dente. This undercooking is crucial—the pasta will finish cooking in the oven and absorb sauce without becoming mushy. Drain the pasta well and set aside.
• In a bowl, mix together the ricotta, lightly beaten egg, grated parmesan, and 1 cup of the shredded mozzarella. This creates a creamy, bound cheese layer that will set during baking and hold the casserole together.
• In a 9x13 inch baking dish, combine the drained pasta from Step 3 with the sausage sauce from Step 2, mixing well to coat evenly. Spread the pasta mixture in an even layer. Dollop the cheese mixture from Step 4 over the top and gently spread it into an even layer. Sprinkle the remaining shredded mozzarella (about 1 cup) over the top for a golden, melty finish.
• Bake the assembled casserole at 375°F for 30-40 minutes, until the cheese is bubbly, golden brown on top, and the sauce is bubbling around the edges. Remove from the oven and let rest for 10 minutes—this resting time helps the casserole set so it cuts cleanly and won't fall apart when you serve it.
• Top the rested casserole with the 12 basil leaves cut into a chiffonade (thin ribbons), which adds a fresh, aromatic finish that brightens the rich, savory dish.