There’s something about the aroma of melted cheese mingling with savory sausage that feels like coming home. It’s the kind of smell that draws everyone to the kitchen, noses first, wondering what’s for dinner. That’s the magic of Johnny Mac Casserole—a dish that takes the cozy familiarity of baked mac and cheese and turns it into a hearty, soul-satisfying feast.
This isn’t just another pasta bake. It’s a symphony of textures and flavors: tender noodles swathed in a velvety cheese sauce, savory crumbles of sausage, and a golden, crispy topping that crackles under your fork. Best of all? It’s as easy to make as it is delicious. Whether you’re feeding a hungry family on a weeknight or bringing a crowd-pleaser to a potluck, this casserole delivers comfort without the fuss.
Why This Recipe Works
- The Ultimate Comfort Food: Creamy, cheesy, and packed with savory goodness—this is the dish you crave after a long day.
- Flexible and Forgiving: Swap ingredients based on what’s in your fridge or pantry. No sausage? Use ground beef or turkey. Want veggies? Toss in some spinach or mushrooms.
- Meal Prep Hero: Assemble it ahead, stash it in the freezer, or bake it right away. Leftovers (if there are any) reheat like a dream.
- Kid-Approved Magic: Even the pickiest eaters won’t turn down cheesy pasta with a crispy topping.
The Story Behind the Sauce
The origins of Johnny Mac Casserole are a bit hazy, but its spirit is pure Americana. Think church potlucks in the Midwest, family reunions in the South, and Sunday suppers where seconds are mandatory. It’s the kind of dish that’s been passed down through generations, tweaked and perfected in home kitchens along the way.
Essential Ingredients & Tools
For the Pasta:
- 12 oz (340g) elbow macaroni – The classic choice, but any short pasta will do.
- 1 tbsp salt – For the pasta water. Don’t skip this—it’s your chance to season the noodles from the inside out.
For the Meat & Aromatics:
- 1 lb (450g) ground sausage – Mild Italian or breakfast sausage both work beautifully.
- 1 medium yellow onion, finely diced – The sweet backbone of the dish.
- 2-3 cloves garlic, minced – Because everything’s better with garlic.
For the Cheese Sauce (the Star of the Show):
- 4 tbsp (57g) unsalted butter – Richness starts here.
- 1/4 cup (30g) all-purpose flour – The foundation of your roux.
- 3 cups (710ml) whole milk – For creaminess that can’t be beat.
- 1 cup (240ml) chicken or vegetable broth – Adds depth to the sauce.
- 3 cups (340g) shredded sharp cheddar cheese – The sharper, the better.
- 4 oz (113g) cream cheese, cubed – The secret to ultra-smooth sauce.
- 1 tsp salt, 1/2 tsp black pepper, 1/2 tsp smoked paprika, 1/2 tsp dry mustard powder – The flavor dream team.
For the Topping (Because Crunch is Everything):
- 1 cup (50g) plain breadcrumbs or Panko – Panko gives extra crunch.
- 1/4 cup (25g) grated Parmesan cheese – Because more cheese is always the answer.
Tools You’ll Need
- Large pot (for pasta)
- Large skillet or Dutch oven (for browning and saucing)
- Whisk (your best friend for smooth sauce)
- 9×13-inch baking dish (the vessel for cheesy greatness)
- Measuring cups and spoons (precision matters)
Serves: 6-8 | Prep: 25 min | Cook: 35 min | Total: 60 min
How to Make Johnny Mac Casserole
- Preheat and Boil:
Crank your oven to 375°F (190°C)—this ensures even baking. Bring a big pot of salted water to a rolling boil (it should taste like the sea). Toss in the 12 oz (340g) elbow macaroni and cook it 1-2 minutes less than the package says. You want al dente—a slight bite—because it’ll keep cooking in the oven. Drain it, but don’t rinse! That starchy coating helps the sauce cling. - Brown the Sausage:
In a large skillet over medium-high heat, cook the 1 lb (450g) ground sausage, breaking it into small crumbles. Let it get a little crispy—those browned bits are flavor gold. Once done (about 5-7 minutes), scoop it out, leaving behind 1 tbsp of drippings for the onions and garlic. - Sauté the Aromatics:
Toss the 1 medium yellow onion, finely diced into the skillet and cook over medium heat until soft and translucent (about 5 minutes). Add the 2-3 cloves garlic, minced and cook for just 1 minute—garlic burns fast, and nobody wants that. - Make the Roux:
Push the onions to the edges, melt the 4 tbsp (57g) unsalted butter in the center, and whisk in the 1/4 cup (30g) all-purpose flour. Cook for 1-2 minutes until it’s pale gold. This cooks out the raw flour taste and sets the stage for a silky sauce. - Build the Sauce:
Slowly whisk in the 3 cups (710ml) whole milk and 1 cup (240ml) chicken or vegetable broth, pouring in a steady stream to avoid lumps. Crank the heat to medium-high and let it simmer, stirring constantly, until it thickens enough to coat the back of a spoon (about 3-5 minutes). - Cheese Time:
Reduce the heat to low (this is crucial). Whisk in the 4 oz (113g) cream cheese, cubed until melted, then gradually add the 3 cups (340g) shredded sharp cheddar cheese, stirring until smooth. Off-heat stirring is key—high heat turns cheese grainy. - Bring It All Together:
Stir in the 1 tsp salt, 1/2 tsp black pepper, 1/2 tsp smoked paprika, 1/2 tsp dry mustard powder, cooked sausage, and pasta. Fold gently to coat every noodle. Taste and adjust seasoning—the sauce should be a tad saltier than perfect now (the pasta will balance it). - Bake to Perfection:
Transfer to a greased 9×13-inch dish, sprinkle with the 1 cup (50g) plain breadcrumbs or Panko and 1/4 cup (25g) grated Parmesan cheese, and bake uncovered for 30-35 minutes until bubbly and golden. Let it rest 5-10 minutes before serving—this helps the sauce set so you get clean slices.
Pro Technique
Sauce Science:
- Low and slow is the mantra for smooth cheese sauce. High heat makes cheese proteins seize up, leading to graininess.
- Shred your own cheese. Pre-shredded stuff has anti-caking agents that can mess with melting.
Topping Tricks:
- For extra crunch, toast the breadcrumbs in a dry skillet with a little butter before sprinkling.
- If the topping browns too fast, tent the dish with foil—it’ll protect the top while the inside finishes cooking.
Chef’s Wisdom
Lumpy Sauce?
Don’t panic. Take it off the heat and whisk like your life depends on it. An immersion blender can also save the day.
Bland Flavor?
Season as you go! Taste the sauce before adding the pasta. It should be slightly over-seasoned at this stage.
Storage & Freshness Guide
Fridge:
Cool completely, cover tightly, and store for 3-4 days. Reheat individual portions with a splash of milk to revive the creaminess.
Freezer:
Wrap the unbaked casserole tightly in foil and plastic (or use a freezer-safe dish). Freeze for up to 3 months. Thaw overnight in the fridge before baking as directed.
Reviving Leftovers:
Bake at 350°F (175°C) for 20-25 minutes. Add fresh breadcrumbs halfway through to bring back the crunch.
Nutrition Profile
Per serving:
- Calories: ~650
- Protein: ~30g
- Carbs: ~55g
- Fat: ~35g
- Fiber: ~3g
Perfect Pairings
Complementary Dishes
- Crisp Green Salad: A tangy vinaigrette cuts through the casserole’s richness. Toss with radicchio or arugula for peppery contrast.
- Garlic Bread: Ideal for mopping up every cheesy bite. Brush with garlic-infused olive oil before toasting.
Drinks
- Chilled Lager: The carbonation and mild bitterness cleanse the palate between bites.
- Sparkling Apple Cider: Its sweetness balances the savory notes, especially for kids.
Something Sweet
- Berry Cobbler: The tartness of berries contrasts the casserole’s decadence. Serve warm with Vanilla Ice Cream.
- Dark Chocolate Truffles: A small, rich bite ends the meal on a luxurious note.
FAQs
Can I make this gluten-free?
Absolutely! Use GF pasta and swap the flour for cornstarch or a GF blend.
Why is my cheese sauce grainy?
Likely from overheating. Add cheese off the heat and shred your own.
How do I prevent a burnt topping?
Tent with foil if it’s browning too fast, and bake on the center rack.
Johnny Mac Casserole: A Warm Hug in Every Bite
Make Johnny Mac Casserole—a cheesy, sausage-loaded pasta bake that's pure comfort food. Perfect for weeknights or potlucks! Get the easy recipe now.
Ingredients
For the Pasta
-
12 oz elbow macaroni (340g)
-
1 tbsp salt
For the Meat & Aromatics
-
1 lb ground sausage (450g)
-
1 medium yellow onion (finely diced)
-
2-3 cloves garlic (minced)
For the Cheese Sauce
-
4 tbsp unsalted butter (57g)
-
1/4 cup all-purpose flour (30g)
-
3 cups whole milk (710ml)
-
1 cup chicken or vegetable broth (240ml)
-
3 cups shredded sharp cheddar cheese (340g)
-
4 oz cream cheese (113g, cubed)
-
1 tsp salt
-
1/2 tsp black pepper
-
1/2 tsp smoked paprika
-
1/2 tsp dry mustard powder
For the Topping
-
1 cup plain breadcrumbs or Panko (50g)
-
1/4 cup grated Parmesan cheese (25g)
Instructions
-
Preheat oven to 375°F (190°C). Cook 12 oz (340g) elbow macaroni in salted water 1-2 minutes less than package instructions. Drain but do not rinse.01
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Brown 1 lb (450g) ground sausage in a skillet over medium-high heat, then remove, leaving 1 tbsp drippings.02
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Sauté 1 medium yellow onion, finely diced in drippings until soft, then add 2-3 cloves garlic, minced for 1 minute.03
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Push onions aside, melt 4 tbsp (57g) unsalted butter, whisk in 1/4 cup (30g) all-purpose flour, and cook for 1-2 minutes.04
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Gradually whisk in 3 cups (710ml) whole milk and 1 cup (240ml) chicken or vegetable broth, simmer until thickened.05
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Reduce heat to low, whisk in 4 oz (113g) cream cheese, cubed, then 3 cups (340g) shredded sharp cheddar cheese until smooth.06
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Stir in 1 tsp salt, 1/2 tsp black pepper, 1/2 tsp smoked paprika, 1/2 tsp dry mustard powder, cooked sausage, and pasta. Transfer to a greased 9x13-inch dish.07
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Top with 1 cup (50g) plain breadcrumbs or Panko and 1/4 cup (25g) grated Parmesan cheese. Bake uncovered for 30-35 minutes.08
