Chili Mac Casserole

Chili Mac Casserole, an Easy Comfort Food Dinner, combines two favorites, chili and macaroni and cheese. Instead of serving chili on its own, you combine it with cooked pasta, tomato sauce, cheese, and seasonings, then bake it into a hearty casserole! It’s a simple family-friendly main dish that’s especially handy when you have leftover chili in the fridge.

I’ve been making this chili mac for years, and it’s one of those recipes that’s easy to change depending on what you have on hand. Use homemade chili or your favorite canned chili, swap in a different pasta shape, or change up the cheese. It’s an easy weeknight dinner that makes great leftovers, too.

This recipe has been on the blog since 2020, but it was time for an update. You may have even seen it in my cookbook, Cupboard Cooking. And, I’ve added it to my Vegetarian Comfort Food Series.

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Please let me know if you have any questions about this recipe. I read all the comments myself and I try to help as soon as I can. I have readers from all levels of comfort and experience in the kitchen on my site, and I’ve tried to answer some of your questions already in the post. But if I’ve missed anything, please feel free to leave a comment and ask.

Why You’ll Love This Chili Mac

• Easy comfort food dinner: Simple ingredients come together for a cozy baked dinner.
• Great for leftover chili: Use about 2 cups of homemade chili instead of canned chili.
• Flexible recipe with several substitutions: Elbow macaroni is classic, but other small pasta shapes work too.
• Family-friendly: Pasta, chili, tomato sauce, and melted cheese make a satisfying combination.
  Uses simple pantry ingredients
• Budget-friendly: This recipe uses mostly pantry and refrigerator staples. Check out my Chickpea Soup Recipe for another great budget-friendly dinner
• Make-ahead and leftover friendly

What is chili mac?

Chili mac combines chili and macaroni into one hearty comfort food dish. This version is mixed with tomato sauce, cheddar cheese, Italian seasoning, and crispy fried onions, then baked until hot and bubbly.

It’s also a great way to use leftover chili. You can use homemade vegetarian chili, beef chili, bean chili, or your favorite canned chili.

For another great weeknight meal, check out my Pierogi Casserole.

Let’s take a quick look at the ingredients and their substitutions:

Pasta: Small elbow macaroni is my favorite because it’s classic chili mac and the small pasta makes it easy to get a little of everything in each bite. Penne, small shells, or rigatoni can also work.

Chili: Use about 2 cups of homemade chili or one 15-ounce can of your favorite chili. Vegetarian chili, beef chili, chili with beans, or chili without beans can all work.

Tomato sauce: When I first started making this recipe it called for a can of condensed tomato soup. It’s great with that, maybe a bit salty for my taste now. Since I stopped using canned soups due to the sodium, I’ve swapped the soup for canned tomato sauce. In the past, I’ve also used crushed tomatoes and jarred spaghetti sauce in a pinch. I will say that the jarred spaghetti sauce is my least favorite way to make it. Heck, you could even try a can of diced tomatoes, leave the juice in, for a chunky chili mac.

Fried onions: The canned fried onions are so good. But, yes, I have left them out on occasion. I do think it’s better with them; I mean, they’re so tasty! I just have to make sure I don’t snack on the whole can while I wait for the casserole to bake. And, no, they aren’t the healthiest ingredient ever, but everything in moderation, including moderation.

Cheese: Cheddar is my go-to here, but you can substitute another good melting cheese such as pepper Jack, Monterey Jack, mozzarella, or Gouda. I’ve also left out the cheese when I’m watching my cheese intake. Um, of course, it’s better with the cheese. Just saying. But it is possible to leave it out if you need to.

Italian seasoning: A little Italian seasoning adds extra flavor. You can also use a mixture of dried basil and oregano. Feel free to up the herbs as well, or use fresh herbs from the garden.

How to make

Here’s the breakdown of how to make the casserole. The full recipe with ingredients and instructions is in the recipe card below.

Cook the macaroni according to the package directions until al dente. The macaroni will continue cooking in the oven, so avoid overcooking it on the stovetop. Drain the pasta well. Excess water can make the casserole watery.

Mix the chili mac. Add the cooked macaroni, chili, tomato sauce, cheddar cheese, seasoning, and half of the crispy fried onions to a casserole dish. Don’t add all the fried onions at once. Adding half to the casserole gives you flavor throughout, while saving half for the end gives you that crispy topping.
 
Watch the salt. Chili, tomato products, cheese, and canned fried onions can all contain salt. Taste your chili mac before adding any additional salt.

Cover the casserole dish and bake until hot throughout.

Remove the casserole from the oven, take the lid off, and sprinkle the remaining fried onions over the top. Return the casserole to the oven and bake uncovered for about 5 minutes, or until the onions are golden and crisp.

Let the casserole cool for a few minutes before serving. Add extra shredded cheddar or your favorite chili toppings if desired.

Changes to the recipe

This chili mac is a flexible recipe, so feel free to make substitutions based on what you have in your pantry. We discussed those ingredients above.

• Vegetarian Chili Mac: use Crock Pot Vegetarian Chili
• Beef Chili Mac: use leftover beef chili.
• Spicy Chili Mac: use spicy chili and pepper Jack cheese.
• Extra Cheesy Chili Mac: add more cheddar or a combination of cheddar and Monterey Jack.
• Chili Mac with Different Pasta: use shells, penne, or rigatoni.
• Leftover Chili Mac: turn yesterday’s chili into a completely different dinner.

Can I use leftover chili?

Yes, leftover chili is a dream! This is one of my favorite ways to make chili mac.

Use about 2 cups of leftover homemade chili in place of the canned chili. This works with vegetarian chili, beef chili, bean chili, or chili without beans.

If your leftover chili is especially thick, you may want to add a little extra tomato sauce or even some broth to help everything mix together.

What Kind of Pasta Can I Use?

Small elbow macaroni is my first choice because it gives the dish that classic chili mac texture. However, you don’t have to make a special trip to the grocery store if you don’t have it. Small shells, penne, rigatoni, or another short pasta can work. Cook the pasta just until al dente so it doesn’t become too soft after baking.

Serving suggestions

Serve Chili Mac Casserole with a simple green salad, Oven baked mac and cheese, broccoli rice casserole, roasted vegetables, corn on the cob, garlic bread, or cornbread.

Top it with extra shredded cheddar, chopped green onions, sour cream, sliced jalapeños, or some hot sauce.

For a game day meal, serve it alongside your favorite appetizers and snacks.

Storage & Make-Ahead

You can assemble the casserole ahead of time, cover it, and refrigerate it until you’re ready to bake. If the casserole is very cold from the refrigerator, it may need a little additional baking time. Bake until heated through.

Store leftover Chili Mac Casserole in an airtight container in the refrigerator for up to 4 days.

Reheat individual portions in the microwave until hot, or reheat a larger portion covered in the oven at 350° F until heated through.

The fried onion topping will soften after refrigeration. For a crispier topping, add a few fresh fried onions before reheating or after reheating.

Can I Freeze Chili Mac?

Yes, chili mac can be frozen. For the best texture, freeze it in an airtight freezer-safe container and use within about 2–3 months.

Thaw overnight in the refrigerator and reheat until hot throughout. Keep in mind that the pasta may be softer after freezing and thawing.

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