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Ultimate Pizza Casserole

This hearty pizza casserole combines rotini pasta, rich marinara, Italian sausage, pepperoni, and a triple-cheese blend, all baked to bubbly perfection. It's a guaranteed crowd-pleaser that delivers all the flavors of pizza in an easy-to-serve casserole format.
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Prep Time 15 minutes
Cook Time 35 minutes
Total Time 50 minutes
Servings: 8 servings
Course: Main Course
Cuisine: Italian-American
Calories: 520
Ingredients Equipment Method Notes

Ingredients
  

  • 1 lb rotini pasta or penne, cavatappi
  • 1 lb Italian sausage mild or hot, casings removed
  • 1 medium yellow onion diced
  • 3 cloves garlic minced
  • 1 24 oz jar marinara sauce or your favorite pizza sauce
  • 1 14.5 oz can diced tomatoes drained
  • 2 cups shredded mozzarella cheese divided
  • 1 cup shredded provolone cheese or fontina
  • 1/2 cup grated Parmesan cheese divided
  • 4 oz pepperoni slices divided, about 30 slices
  • 1 tsp dried oregano
  • 1/2 tsp dried basil or 2 tbsp fresh, chopped
  • 1/4 tsp red pepper flakes optional
  • to taste salt and black pepper

Equipment

  • 9x13 inch baking dish
  • Large pot for boiling pasta
  • Large skillet or Dutch oven
  • Colander
  • Mixing bowls
  • Wooden spoon or spatula

Method
 

  1. Preheat your oven to 375°F (190°C). Bring a large pot of generously salted water to a boil. Cook the pasta according to package directions for al dente, usually about 8-9 minutes. Drain well but do not rinse; you want the starch to help the sauce cling.
  2. While the pasta cooks, heat a large skillet or Dutch oven over medium-high heat. Add the Italian sausage, breaking it up with a spoon. Cook for 5-6 minutes until browned. Add the diced onion and cook for another 4-5 minutes until softened. Stir in the minced garlic and cook for just 30 seconds until fragrant—trust me, you don't want it to burn.
  3. Reduce the heat to low. To the skillet, add the marinara sauce, drained diced tomatoes, oregano, basil, red pepper flakes (if using), and half of the Parmesan cheese. Season with a pinch of salt and pepper. Let the sauce simmer gently for 5 minutes to allow the flavors to meld.
  4. In a large mixing bowl, combine the drained pasta and the meat sauce, stirring until every piece is well coated. Fold in 1 cup of the mozzarella cheese and all of the provolone cheese. This creates a wonderfully cheesy base layer.
  5. Transfer the pasta mixture to a greased 9x13 inch baking dish, spreading it evenly. Top with the remaining 1 cup of mozzarella, the rest of the Parmesan, and arrange the majority of the pepperoni slices in a single layer. For extra crispiness, add a few more pepperoni on top.
  6. Bake, uncovered, for 25-30 minutes, or until the cheese is fully melted, bubbly, and starting to turn golden in spots. If you like a browned top, broil for the final 1-2 minutes, watching closely. Let the casserole rest for 10 minutes before serving—this crucial step allows it to set for perfect slices.

Notes

Chef's Tips:
• For a crispier top, use whole-milk, low-moisture mozzarella. It browns better than pre-shredded blends with anti-caking agents.
• Avoid overmixing the pasta and sauce once the cheese is added, as it can become gummy.
• Serve with a simple green salad dressed with Italian vinaigrette to cut through the richness.
Food Safety:
• Ensure ground sausage reaches an internal temperature of 160°F (71°C) during browning.
• Refrigerate leftovers within 2 hours of cooking.