Name: Chili Mac Casserole Recipe
Prep time: 15 min
Cook time: 35 min
Total time: 50 min
Cuisine: American
Ingredients: 2 pounds lean ground beef (or chicken or turkey); 1 medium onion (diced or minced); 4 cloves garlic (minced); 28 ounce can crushed tomatoes; 6 ounce can tomato paste; 4 ounce can diced green chilis; 15.5 ounce can kidney beans (drained); 1 teaspoon Better than Bouillon Beef; ¼ - ½ cup water (rinse the tomato container with it); 2 cups elbow macaroni (uncooked); 2-4 cups shredded cheddar cheese (I like Colby-Jack and Sharp Cheddar); 2 tablespoons chili powder (reduce by half if you don’t like it spicy); 2 teaspoons ground cumin; 1 teaspoon smoked paprika; 1 teaspoon dried oregano; 1 teaspoon kosher salt (adjust as needed); ½ teaspoon black pepper; ½ teaspoon garlic powder; ½ teaspoon onion powder; ¼ - ½ teaspoon crushed red pepper flakes (optional); ⅕ teaspoon cayenne pepper (optional, adjust to spice preference)

Jump to Recipe· 4.1 from 11 reviews

If you’re craving a comforting meal that hits all the right notes—hearty, cheesy, and packed with bold flavors—this Chili Mac Casserole Recipe is your new best friend. It’s the perfect dish to cozy up to on any night, combining tender elbow macaroni with a robust, homemade chili that’s bursting with spices, juicy ground beef, and melty cheddar cheese. This recipe is a crowd-pleaser that easily feeds a hungry group and fills your kitchen with mouthwatering aromas you’ll want to savor before the first bite.

Ingredients You'll Need

Inside a white pan, cooked ground meat forms the bottom layer, light brown and crumbly, spread evenly around the base. On one side, there is a heap of shiny red kidney beans with a dark brown spoonful of thick sauce on top near the center. Next to the beans, bright green chopped pickles add a chunky texture. Covering another part of the pan is a layer of smooth, thick red tomato sauce, which looks rich and slightly glossy. A gray spoon rests inside the pan, partially over the meat and sauce. The pan is set on a white marbled surface with a red and white checkered cloth partly visible on the right side. photo taken with an iphone --ar 4:5 --v 7

Every ingredient in this Chili Mac Casserole Recipe plays a crucial role, from the aromatic spices that build depth to the creamy cheddar that adds luscious texture. They’re simple pantry staples that come together to create something truly special and comforting.

2 pounds lean ground beef: The hearty protein base that makes this casserole so satisfying; you can swap in chicken or turkey if you prefer.

1 medium onion (diced): Adds natural sweetness and a savory backbone when cooked down with the meat.
4 cloves garlic (minced): Infuses the dish with its signature aromatic charm.
28 ounce can crushed tomatoes: Provides rich, tangy flavor and contributes to the sauce’s luscious texture.

6 ounce can tomato paste: Intensifies the tomato flavor and thickens the chili base beautifully.
4 ounce can diced green chilis: Brings a subtle heat and slight smoky element to the dish.
15.5 ounce can kidney beans (drained): Adds creaminess and a welcomed bite that complements the meat and pasta.

1 teaspoon Better than Bouillon Beef: Boosts the savory, umami depth in the chili base.
¼ - ½ cup water: Used to rinse out the tomato can and loosen the sauce to the perfect consistency.
2 cups elbow macaroni (uncooked): Tender little pasta tubes that soak up all the delicious chili juices.

2-4 cups shredded cheddar cheese: A gooey, melty crown on top—Colby-Jack and sharp cheddar are great choices for balance and boldness.
2 tablespoons chili powder: The cornerstone spice that delivers warmth and robust chili flavor; adjust to your heat preference.
2 teaspoons ground cumin: Adds earthy notes that deepen the flavor profile wonderfully.

1 teaspoon smoked paprika: Introduces a subtle smoky backdrop that elevates the chili experience.
1 teaspoon dried oregano: Provides herbal freshness that brightens the sauce.
1 teaspoon kosher salt: Season to taste and enhance all the other flavors in the dish.

½ teaspoon black pepper: Adds just enough kick and complexity.
½ teaspoon garlic powder: Reinforces the fresh garlic's essence for more pronounced flavor.
½ teaspoon onion powder: Complements diced onions for a well-rounded savoriness.

¼ - ½ teaspoon crushed red pepper flakes (optional): For those who like a little extra heat.
⅕ teaspoon cayenne pepper (optional): Adds a sharp, spicy edge, but use sparingly to keep it balanced.

How to Make Chili Mac Casserole Recipe

Step 1: Cook the Pasta

Start off by bringing a large pot of salted water to a rolling boil. Cook your elbow macaroni until it’s perfectly al dente, meaning just tender but still with a little bounce. This texture is key because the pasta will continue to cook in the oven, so you don’t want it mushy. Once done, drain it well and set it aside to await its flavorful chili partner.

Step 2: Brown the Meat and Onions

Heat a large skillet or pot over medium heat and add your ground beef along with the diced onions. Cook, stirring occasionally, until the meat is nicely browned and crumbled, and the onions are softened and translucent. Toss in the minced garlic during the last few minutes to avoid burning and to release its aroma. If any fat pools up, drain it to keep your casserole from becoming greasy.

Step 3: Add the Homemade Chili Seasoning

Sprinkle all your carefully blended spices over the meat mixture: chili powder, cumin, smoked paprika, oregano, salt, pepper, garlic powder, onion powder, and the optional red pepper flakes and cayenne. This step is where magic happens—cooking the spices briefly unlocks their full flavor potential, making your chili base irresistibly fragrant and layered.

Step 4: Build the Chili Base

Next, stir in your crushed tomatoes, tomato paste, diced green chilis, Better than Bouillon beef paste, and drained kidney beans. Pour in that reserved water from rinsing out your tomato can—it helps loosen the sauce without watering down the flavor. Bring everything to a gentle simmer and let it cook for 10 to 15 minutes so the flavors meld beautifully. Taste and adjust your seasonings as needed here; this is your chance to get the balance just right.

Step 5: Combine Pasta and Cheese

Now it’s time to fold your cooked macaroni into that fragrant chili base along with one to two cups of shredded cheddar cheese. The cheese melts into the warm chili, adding creaminess that coats every bite. You’re building layers of texture and flavor that will make this Chili Mac Casserole Recipe truly unforgettable.

Step 6: Bake to Perfection

Transfer your cheesy chili mac mixture into a lightly greased 9x13-inch casserole dish. Pile the remaining shredded cheese on top for a beautifully bubbly, golden crust. Cover the dish tightly with a foil sheet sprayed lightly with cooking spray to prevent sticking. Pop it into a 375°F (190°C) oven and bake for 20 to 25 minutes. Remove the foil and bake for an additional 5 to 10 minutes until the cheese on top is melted and gorgeous. Your kitchen will smell like a dream.

Step 7: Rest Before Serving

Once out of the oven, let the casserole rest for 5 to 10 minutes before digging in. This brief pause allows the chili mac to thicken up slightly, making it easier to serve and ensuring every spoonful is luscious and satisfying.

How to Serve Chili Mac Casserole Recipe

A large white pan filled with a mixed dish of elbow macaroni and chunky red sauce with ground meat and kidney beans. The macaroni is yellow and soft, scattered evenly throughout the thick red sauce that has a slightly shiny, wet texture. The meat is finely chopped and well blended with the sauce and beans. A gray spoon is partially submerged in the mixture on the right side of the pan. The pan sits on a white marbled surface with a red and white checkered cloth nearby. Photo taken with an iphone --ar 4:5 --v 7

Garnishes

Enhance your Chili Mac Casserole Recipe by adding fresh garnishes that bring brightness and contrast to the rich casserole. Try a sprinkle of chopped fresh cilantro or green onions for a pop of color and freshness. A dollop of sour cream or a drizzle of cool avocado crema adds creaminess and tames any extra heat. If you love crunch, crushed tortilla chips or a light dusting of smoked paprika finished on top can add a fantastic texture layer.

Side Dishes

This casserole stands tall on its own, but pairing it with simple sides can turn it into a well-rounded feast. A crisp green salad with a tangy vinaigrette cuts through the richness. Roasted or steamed veggies like broccoli, green beans, or corn bring balance and nutrition. For a fun Tex-Mex twist, warm up some corn tortillas or serve alongside classic cornbread to scoop up every last bite.

Creative Ways to Present

If you want to impress guests or mix things up at family dinners, try serving your Chili Mac Casserole Recipe in individual ramekins for a cute, personalized touch. Or, top each portion with extra shredded cheese and broil for a minute or two to get a bubbly, golden crust. For a party, turn this casserole into a chili mac dip by baking it in a shallow dish and offering chips and veggies alongside for scooping. It’s always a hit!

Make Ahead and Storage

Storing Leftovers

This Chili Mac Casserole Recipe keeps beautifully in the refrigerator for up to 4 days. Store leftovers in an airtight container to maintain freshness and prevent drying out. When you’re ready to enjoy it again, the flavors remain as comforting as the first day—perfect for quick lunches or easy dinners.

Freezing

You can freeze this casserole in portions or as a whole dish before baking or after baking once it has fully cooled. Wrap tightly with plastic wrap and foil or store in a freezer-safe container for up to 3 months. Thaw overnight in the refrigerator before reheating to preserve texture and flavor integrity.

Reheating

Reheat leftovers in the oven at 350°F (175°C) until warmed through to keep the cheese melty and the casserole deliciously moist. Alternatively, microwave individual portions covered with a damp paper towel to keep the pasta from drying out. Stir halfway through heating to ensure an even warm-up and that incredible chili flavor shines in every bite.

FAQs

Can I use ground chicken or turkey instead of beef?

Absolutely! Ground chicken or turkey are excellent substitutes and make the casserole leaner while still staying flavorful. Just follow the same cooking steps for browning and seasoning.

Is it possible to make this recipe vegetarian?

Yes! Swap the ground meat for a plant-based ground meat substitute or extra beans and veggies like bell peppers and mushrooms. Adjust the Better than Bouillon accordingly to keep that deep umami flavor.

How spicy is this Chili Mac Casserole Recipe?

The heat level is adjustable depending on your taste. The recipe’s default mixes several spices and optional cayenne or crushed red pepper flakes, but you can reduce those for a milder version or amp them up for serious kick.

Can I prepare the casserole ahead of time and bake it later?

Definitely! You can prepare the entire casserole assembly up to the baking step, cover tightly, and refrigerate for up to 24 hours before baking. Just add a few extra minutes to the cooking time if it’s cold straight from the fridge.

What’s the best cheese combination for this dish?

Using a mix of Colby-Jack and sharp cheddar provides a smooth melt and sharp tang that balances the chili nicely. Feel free to experiment with classic cheddar, Monterey Jack, or even pepper jack for a little extra spice.

Final Thoughts

This Chili Mac Casserole Recipe is truly a winner when you want a no-fuss, comforting meal full of rich, cheesy, and spicy goodness. Whether you’re feeding your family or looking for a hearty dish to bring to a potluck, it’s sure to become a favorite that you’ll want to make again and again. Give it a try—you won’t regret the warm, satisfying flavors and the smiles it brings to the table.

Chili Mac Casserole Recipe

Ingredients You'll Need