Name: Chili Mac Casserole
Prep time: 20 min
Cook time: 50 min
Total time: 1 h 10 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 you can adjust later; 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 depending on how spicy you like it

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Chili Mac Casserole is the ultimate comfort food that perfectly blends hearty chili with creamy macaroni and cheese. Imagine a warm, bubbling dish loaded with tender pasta, savory ground meat, and vibrant beans, all topped off with a gooey layer of melted cheddar cheese. This cozy casserole is not just a meal; it’s an experience that brings friends and family together at the dinner table. Easy to whip up, it’s perfect for busy evenings or casual get-togethers, proving that feeding a crowd doesn’t have to be complicated or costly.

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I first discovered this delightful dish during a potluck with friends several years ago. Everyone raved about it, and I was intrigued by its rich flavors and the appealing presentation that made it a favorite among both kids and adults. After some experimentation, I’ve perfected my own version, which strikes the perfect balance between spice and comfort. Trust me, once you try this Chili Mac Casserole, it will become a staple in your home, and you’ll likely get requests from family to make it again and again.

Table of Contents

Why You’ll Love This Recipe
Ingredients You’ll Need
How to Make Chili Mac Casserole
Storing & Reheating
Chef’s Helpful Tips
Recipe FAQs
Chili Mac Casserole

Why You’ll Love This Recipe

Simple & Quick: With just 20 minutes of prep and 50 minutes of cooking, it’s an easy weeknight win.
Irresistible Flavor: The combination of chili spices and rich, cheesy goodness creates a flavor explosion.
Eye-Catching Appeal: The vibrant colors and bubbling cheese make it as pleasing to the eyes as it is to the palate.
Flexible Serving: Perfect for dinners, potlucks, or even game-day snacks. It fits any occasion!
Diet-Friendly Options: You can easily substitute ground turkey or chicken for a lighter meal or adjust the spice levels to suit your taste.

Ingredients You’ll Need

2 pounds lean ground beef or chicken or turkey: Use your favorite meat for a satisfying protein boost. Ground turkey is a leaner option.
1 medium onion, diced or minced: Adds sweetness and depth; a yellow onion works best for this dish.
4 cloves garlic, minced: Fresh garlic enhances the overall taste. Feel free to use garlic powder for a quicker alternative.
28-ounce can crushed tomatoes: This provides the base for the chili flavor; diced tomatoes are a good substitute if you prefer chunks.
6-ounce can tomato paste: Concentrates the tomato flavor and thickens the chili.
4-ounce can diced green chilis: Adds a mild heat and vibrant flavor. If you want it spicier, consider fresh jalapeños.
15.5-ounce can kidney beans, drained: Beans add fiber and substance; black beans can be a fun alternative.
1 teaspoon Better Than Bouillon beef: A great way to enhance the flavor; you can omit or substitute with vegetable bouillon for a meatless version.
¼ – ½ cup water: Helps to rinse out the tomato can while adding moisture to the dish.
2 cups elbow macaroni, uncooked: The classic pasta choice. You can use gluten-free pasta if needed.
2-4 cups shredded cheddar cheese: I love the mix of colby-jack and sharp cheddar for depth of flavor; feel free to experiment with your favorite kinds.
2 tablespoons chili powder: Essential for that classic chili flavor; reduce the amount if spice isn’t your thing.
2 teaspoons ground cumin: This earthy spice adds warmth; it complements the chili powder beautifully.
1 teaspoon smoked paprika: A little smokiness elevates the dish; regular paprika can be used if necessary.
1 teaspoon dried oregano: Adds a hint of herbal flavor; Italian seasoning can work in a pinch.
1 teaspoon kosher salt: Enhances all the flavors; you can adjust it later to your taste.
½ teaspoon black pepper: Freshly cracked pepper is preferable for the best flavor.
½ teaspoon garlic powder: A quick alternative to fresh garlic; omit if using fresh garlic only.
½ teaspoon onion powder: Similar to garlic powder, it adds extra depth.
¼ – ½ teaspoon crushed red pepper flakes (optional): Use according to your spice preference.
⅕ teaspoon cayenne pepper (optional): Great for those who enjoy a kick!

How to Make Chili Mac Casserole

Cook the pasta: Bring a large pot of salted water to a boil. Add the elbow macaroni and cook until al dente according to package directions. Drain and set aside. It’s important not to overcook the pasta, as it will continue cooking in the oven.
Preheat the oven: Set your oven to 375ºF (190° C). Lightly spray a 9×13-inch baking dish with cooking spray to prevent sticking.
Brown the meat & onions: In a large skillet or pot over medium heat, cook the ground beef or turkey with the diced onions until browned and crumbly. The aroma will be mouthwatering. Add garlic in the last few minutes of cooking for a fragrant finish. Drain excess fat if needed.
Add the homemade chili seasoning: Sprinkle all the spices — chili powder, cumin, smoked paprika, oregano, salt, black pepper, garlic powder, onion powder, red pepper flakes, and cayenne pepper — over the meat mixture. Stir well and cook for about a minute to bloom those spices, releasing their incredible flavors.
Build the chili base: Stir in the crushed tomatoes, tomato paste, diced green chilis, Better Than Bouillon, and drained kidney beans. It’s a vibrant mix! Bring everything to a simmer and let it cook for 10–15 minutes, allowing the flavors to meld beautifully. You might want to add a little water swirled around in your tomato can; this gives you a nice consistency.
Combine the chili and pasta: Carefully fold in the cooked macaroni and 1-2 cups of the shredded cheddar cheese. The creamy texture mixed with the chili sauce should coat the pasta nicely. If you’re a cheese lover, definitely go for the higher amount!
Bake: Once combined, transfer the mixture into your greased casserole dish. Top it with the remaining 1-2 cups of cheese. For an extra touch, spray some foil with oil and cover the dish tightly. Bake in your preheated oven for 20–25 minutes, then remove the foil and bake for another 5–10 minutes until the cheese is bubbly and golden.
Serve: Let it rest for about 5–10 minutes before serving. This allows the casserole to thicken slightly, making for the perfect portion each time.

Storing & Reheating

To store your Chili Mac Casserole, allow it to cool completely. Cover it tightly with plastic wrap or transfer it to an airtight container. It will last in the refrigerator for up to 4 days. If you want to freeze it, portion it out in freezer-safe containers, ensuring you label them. It’s best consumed within 3 months for optimal freshness. When you’re ready to enjoy, simply reheat in the oven at 350°F (175°C) for about 20 minutes, or until warmed through. The texture might change slightly, but a splash of water or broth can refresh it.

Chef’s Helpful Tips

Avoid overcooking the pasta to prevent a mushy casserole. Aim for al dente.
For consistent seasoning, taste your chili base before adding the macaroni and cheese; adjust if needed.
For extra flavor depth, consider browning the meat with a little Worcestershire sauce.
If you prefer a spicier dish, add jalapeños or experiment with different peppers.
This casserole is an excellent make-ahead option; you can prep it the night before and bake it fresh the next day.

Chili Mac Casserole is not just a meal; it’s a warm hug on a plate—hearty, comfort-filled, and sure to become a favorite in your rotation. It’s perfect for casual family dinners or gatherings with friends. Feel free to play with the ingredients to make it your own, whether that’s swapping meats or adjusting the spice level. I invite you to enjoy every delicious bite!

Recipe FAQs

Can I make this dish ahead of time?

Yes! You can prepare the entire casserole the night before and store it covered in the refrigerator. Just pop it in the oven when you’re ready to bake it. You may need to adjust the baking time since it will be cold.

Can I freeze Chili Mac Casserole?

Absolutely! Cool the casserole completely, and then wrap it tightly in plastic wrap followed by foil, or use a freezer-safe container. It’s best if consumed within 3 months; just thaw overnight in the refrigerator before baking.

What can I substitute for the meat?

Ground turkey, ground chicken, or even a combination of tofu and beans can make a delicious vegetarian version. You can also try lentils for added fiber!

How do I know when it’s done baking?

You’ll know it’s done when the cheese is melted and the casserole is bubbly around the edges. If you’re unsure, a quick check with a thermometer should read 165°F (74°C) in the center. Enjoy your cooking adventure!

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