Quick Recipe Version (TL;DR)
Quick Ingredients
- 12 oz (340 g) penne or ziti
- 1 lb (454 g) Italian sausage (sweet or hot), casings removed
- 4 oz (113 g) sliced pepperoni (plus 1–2 oz extra for the top)
- 1 medium yellow onion, diced
- 3 cloves garlic, minced
- 24 oz (680 g) marinara sauce
- 2 tsp Italian seasoning
- 1/2 tsp kosher salt, plus more for pasta water
- 1/4 tsp black pepper
- 1/4 tsp crushed red pepper flakes (optional)
- 4 cups (16 oz / 454 g) shredded low-moisture mozzarella, divided
- 1/2 cup (2 oz / 56 g) finely grated Parmesan
- 2 Tbsp chopped fresh basil or parsley (optional, for serving)
Do This
- 1) Heat oven to 375°F (190°C). Grease a 9×13-inch baking dish.
- 2) Boil pasta in salted water until 1 minute shy of al dente; drain.
- 3) Brown sausage with onion; add garlic, marinara, Italian seasoning, pepperoni, and spices.
- 4) Toss pasta with sauce; spread in dish. Add half the mozzarella in the middle.
- 5) Top with remaining mozzarella and Parmesan; finish with a pepperoni “pizza topping” layer.
- 6) Bake 25 minutes, then bake 10 minutes more until bubbly and browned.
- 7) Rest 10 minutes. Slice and serve like deep-dish.
Why You’ll Love This Recipe
- Deep-dish vibes, casserole ease: you get a browned, stretchy “pizza topping” layer without fussing with dough.
- Family-friendly and familiar: classic pepperoni, sausage, marinara, and mozzarella flavors.
- Great for feeding a crowd: one 9×13 pan serves 8 generous portions.
- Make-ahead friendly: assemble earlier, bake when you’re ready.
Grocery List
- Produce: 1 medium yellow onion, 3 cloves garlic, fresh basil or parsley (optional)
- Dairy: 16 oz (454 g) low-moisture mozzarella (block or pre-shredded), 2 oz (56 g) Parmesan
- Meat: 1 lb (454 g) Italian sausage, 4–6 oz (113–170 g) sliced pepperoni
- Pantry: 12 oz (340 g) penne or ziti, 24 oz (680 g) marinara sauce, Italian seasoning, kosher salt, black pepper, crushed red pepper flakes (optional)
Full Ingredients
Pasta Base
- 12 oz (340 g) penne or ziti
- Salt for pasta water (use 1 Tbsp kosher salt for a large pot of water)
Meat & Marinara
- 1 lb (454 g) Italian sausage (sweet or hot), casings removed
- 1 medium yellow onion, diced (about 1 1/2 cups)
- 3 cloves garlic, minced
- 24 oz (680 g) marinara sauce
- 2 tsp Italian seasoning
- 1/2 tsp kosher salt (adjust to taste; marinara varies)
- 1/4 tsp freshly ground black pepper
- 1/4 tsp crushed red pepper flakes (optional)
- 4 oz (113 g) sliced pepperoni, quartered (for mixing into the casserole)
Cheese + “Pizza Topping” Layer
- 4 cups (16 oz / 454 g) shredded low-moisture mozzarella, divided (2 cups for the middle, 2 cups for the top)
- 1/2 cup (2 oz / 56 g) finely grated Parmesan
- 1–2 oz (28–56 g) sliced pepperoni (for the top)
To Finish (Optional)
- 2 Tbsp chopped fresh basil or parsley
Step-by-Step Instructions
Step 1: Prep the pan and heat the oven
Arrange a rack in the center of the oven and preheat to 375°F (190°C). Lightly grease a 9×13-inch baking dish.
Tip: If your baking dish is deeper than average, place it on a sheet pan to catch any bubbling sauce just in case.
Step 2: Boil the pasta just under al dente
Bring a large pot of water to a boil. Add 1 Tbsp kosher salt, then add 12 oz penne or ziti.
Cook the pasta 1 minute less than the package directions for al dente (it will finish cooking in the oven). Drain well.
Step 3: Brown the sausage and soften the onion
While the pasta cooks, heat a large skillet over medium-high heat. Add the Italian sausage and cook for 6–8 minutes, breaking it up with a spoon, until browned and cooked through.
Add the diced onion and cook for 3–4 minutes until softened. If the pan looks dry, add a small splash of water to loosen browned bits (or a teaspoon of oil if needed), but usually the sausage provides enough fat.
Step 4: Build the pizza-style sauce
Add the minced garlic and cook for 30 seconds, just until fragrant.
Stir in the marinara, Italian seasoning, kosher salt, black pepper, and crushed red pepper flakes (if using). Add the quartered pepperoni and simmer for 2 minutes to bring everything together.
Step 5: Combine pasta, sauce, and the “hidden cheese” layer
In a large bowl (or right in the pasta pot), toss the drained pasta with the sauce until evenly coated.
Spoon half the pasta mixture into the prepared baking dish and spread into an even layer. Sprinkle 2 cups (half) of the mozzarella evenly over the top.
Add the remaining pasta mixture and gently spread it out, keeping the cheese layer tucked inside.
Step 6: Add the browned, stretchy “pizza topping” layer
Sprinkle the remaining 2 cups mozzarella evenly over the casserole. Add the Parmesan for extra savory flavor and browning.
Arrange 1–2 oz pepperoni slices on top like a pizza. This top layer is what gives you that deep-dish effect: browned edges, stretchy cheese, and crisped pepperoni cups.
Step 7: Bake until bubbly and deeply browned
Bake uncovered at 375°F (190°C) for 25 minutes, then continue baking for 10 minutes until the edges are bubbling and the top is browned in spots.
If you want a more pizza-shop finish, switch the oven to broil (high) and broil for 1–2 minutes to deepen the browning. Stay close; it can go from perfect to overdone quickly.
Step 8: Rest, slice, and serve
Let the casserole rest for 10 minutes before slicing. This helps it set so you can lift out portions that look like thick, cheesy deep-dish slices.
Sprinkle with fresh basil or parsley (optional) and serve hot.
Pro Tips
- Undercook the pasta slightly: stopping 1 minute short keeps it from turning soft after baking.
- Use low-moisture mozzarella: it melts stretchy and browns better than fresh mozzarella (which can make the top watery).
- Two-layer cheese is key: the hidden middle layer gives you gooey pulls inside, while the top layer browns like pizza.
- Go easy on added salt: sausage, pepperoni, and marinara are already salty; taste the sauce before adding more.
- For cleaner slices: rest the casserole the full 10 minutes, then cut with a sharp knife wiped clean between cuts.
Variations
- Biscuit-dough “pizza casserole” (no pasta): Replace the pasta with 1 can (16.3 oz / 462 g) refrigerated biscuit dough. Cut biscuits into quarters. In the greased 9×13, toss biscuit pieces with half the sauce, spread out, top with half the mozzarella, add remaining sauce, then top with remaining mozzarella, Parmesan, and pepperoni. Bake at 375°F (190°C) for 30–35 minutes until biscuits are cooked through (internal temp 195–200°F / 90–93°C) and the top is browned.
- Supreme style: Add 1 cup diced bell pepper and 8 oz sliced mushrooms when you add the onion (cook until softened). Add 1/2 cup sliced black olives with the marinara.
- Extra saucy, extra cheesy: Add an additional 1/2 cup marinara and an extra 1 cup mozzarella (increase bake time by 5 minutes if needed to brown).
Storage & Make-Ahead
Refrigerate: Cool completely, cover tightly, and refrigerate for up to 4 days.
Reheat: For best texture, reheat in a 350°F (175°C) oven, covered with foil, for 20–25 minutes (remove foil for the last 5 minutes to re-crisp the top). Microwave works for quick portions, 1–2 minutes, but the top won’t stay as crisp.
Make-ahead: Assemble the casserole up to 24 hours ahead, cover, and refrigerate. Bake as directed, adding 5–10 minutes to account for the cold dish.
Freeze: Wrap well and freeze for up to 2 months. Thaw overnight in the fridge, then bake at 375°F (190°C) until hot throughout (typically 35–45 minutes, depending on thickness and starting temperature).
Nutrition (per serving)
Approximate, based on 8 servings: 610 calories, 32 g protein, 48 g carbohydrates, 32 g fat, 3 g fiber, 1,250 mg sodium.
