This Chili Mac Casserole is the ultimate cozy, family-friendly dinner made with pantry staples and real spices, no packets required. It’s a hearty, cheesy, protein-packed meal that comes together with just 20 minutes of prep and is on the table in under an hour.
Freezer-friendly, this tried-and-true recipe is perfect for busy weeknights, meal prep, or sharing with friends. If you’re looking for a comforting casserole that delivers big flavor with minimal effort, this one’s a keeper!
This chili mac casserole is one of those back-pocket dinners you’ll find yourself making again and again. It’s hearty, cheesy, and packed with bold chili flavor, all baked together into one cozy, satisfying casserole the whole family loves!
This has become one of my husband’s and my favorite comfort meals. It’s easy to put together, freezes beautifully for another night, and is loaded with protein thanks to lean ground beef and beans. I’m also a big believer in using real, not packaged, spices whenever possible, which is why this recipe includes a simple homemade chili seasoning that gives you full control over the flavor and heat!
Made with pantry staples and ready in under an hour, this chili mac is perfect for busy weeknights, easy meal prep, and enjoying leftovers throughout the week. If you love classic comfort food like this one, you’ll also love my Cheesy Hashbrown Casserole or Baked Rigatoni Casserole recipes!
Why You’ll Love This Recipe
- Perfect for meal prep. This casserole stores and freezes beautifully, making it ideal for planning ahead or stocking your freezer.
- A picky-eater-approved dinner! Cheesy pasta, savory beef, and mild customizable spice make this a hit with kids and adults alike.
- Minimal prep, maximum payoff. Just 20 minutes of hands-on time, then the oven does the rest.
- Mostly pantry ingredients. Everything here is easy to find and budget-friendly.
- Flexible and forgiving! Adjust the spice level, swap proteins, or change up the cheese to suit your family.
If you’re really short on time, you can swap the homemade chili seasoning for a packet of chili seasoning mix. Just wait to add salt and pepper until the end so you don’t over-season!
Ingredients
- Lean Ground Beef: Adds hearty flavor and protein! Ground chicken or turkey work great too.
- Onion: Builds a savory base for the chili.
- Garlic: Adds depth and aromatic flavor.
- Crushed Tomatoes: Forms the backbone of the chili sauce!
- Tomato Paste: Thickens the sauce and intensifies tomato flavor.
- Diced Green Chilis: Adds mild heat and subtle tang.
- Kidney Beans: Classic chili texture and extra protein! Feel free to use black beans or pinto beans.
- Better Than Bouillon: A small amount of beef bouillon adds big, savory flavor.
- Water: Helps loosen the sauce a bit!
- Elbow Macaroni: The classic noodle for chili mac. Use gluten-free pasta or low-carb high protein pasta to customize it even more!
- Shredded Cheese: Colby-Jack and sharp cheddar melt beautifully and add richness. You can also use any Mexican cheese blend.
Homemade Chili Seasoning:
- Chili Powder: The main chili flavor, while it isn’t too spicy, adjust for heat if you are sensitive to spice.
- Ground Cumin: Adds warmth and earthiness.
- Smoked Paprika: Brings subtle smokiness!
- Dried Oregano: Balances the spice blend.
- Kosher Salt & Black Pepper: Enhances all the flavors.
- Garlic & Onion Powder: Boosts savory notes.
- Red Pepper Flakes & Cayenne: Optional heat, added to taste. You can also serve it with a dash of hot sauce if you prefer!
Get the full recipe in the recipe card below.
How to Make Chili Mac Casserole
Step 1 – Cook the Pasta
Bring a pot of salted water to a boil and cook the elbow macaroni until just al dente. Drain and set aside.
Preheat oven to 375°F (190°C) and lightly grease a 9×13-inch baking dish.
Step 2 – Brown the Beef
In a large skillet or pot, cook the ground beef and onion over medium heat until browned. Add garlic during the last few minutes. Drain excess fat if needed.
Sprinkle the homemade chili seasoning over the meat mixture and cook for 1 minute, stirring constantly.
Step 3 – Build the Chili
Stir in crushed tomatoes, tomato paste, diced green chilis, Better Than Bouillon, kidney beans, and water. Simmer 10–15 minutes until thickened and flavorful.
Fold in the cooked macaroni and 1–2 cups of shredded cheese.
Step 4 – Bake & Serve
Transfer to the prepared pan, top with remaining cheese, cover with foil, and bake 20–25 minutes. Uncover and bake 5–10 minutes more until bubbly.
Let rest 5–10 minutes before serving so it thickens slightly.
Expert Tips
- Homemade seasoning gives you control. I love mixing my own chili spices instead of using a packet because it lets me control the flavor and heat. That said, a store-bought chili seasoning works in a pinch; just hold off on adding salt and pepper until the end and then season to taste.
- Bouillon is optional, but highly recommended. You can skip the Better Than Bouillon if you prefer, but it adds a deep, savory boost that really makes the chili shine. It’s my not-so-secret flavor enhancer.
- Adjust the heat to your comfort level. I’m pretty spice-sensitive, so I usually add just a small shake of cayenne and a few pinches of red pepper flakes. Start light and add more as needed. You can always increase the heat, but you can’t take it away.
- Simmering builds better flavor. While you don’t technically have to simmer the chili, letting it cook for a bit allows the spices and tomatoes to meld together for a richer, more developed flavor.
- Use the cheese you love most. Any melting cheese works here, but I especially love a blend of Colby-Jack and sharp cheddar. For the smoothest melt, hand-grating cheese from a block works better than pre-shredded, though this is your chili mac, so do what works for you!
- Perfect for sharing or gifting. This casserole is a wonderful meal to bring to new parents, someone recovering from surgery, or a friend who could use a comforting dinner. Just dial back the spices if needed!
- Freeze half for later. Since this recipe makes a generous amount, I often divide it between two smaller baking dishes and freeze one for an easy future meal.
Variations
- Gluten-Free: This recipe is easily adapted to be gluten-free; simply replace the macaroni with your favorite gluten-free macaroni.
- Low-Carb Mac and Cheese: Omit or replace the macaroni with a low-carb, high-protein version. I love this Pete’s brand, it’s a little pricier, but delish!
- Dairy-Free: Use plant-based cheese in place of the regular cheese!
- Meat: Swap out the ground beef for ground chicken or ground turkey.
- Tomato Sauce: You could swap two cans of Rotel for the crushed tomatoes and the green chilies!
Storage
- Refrigerator: Store leftovers in an airtight container for 5–7 days.
- Reheat: Add a splash of water, cover, and reheat at 350°F until warmed through.
Freezing Before Baking
Assemble the casserole, add cheese, cool completely, then wrap tightly and freeze. Bake from frozen at 350°F for 60–75 minutes, uncovering the last 10 minutes.
Freezing After Baking
Cool completely, wrap tightly or portion into containers, and freeze. Reheat covered at 350°F or microwave individual portions.
FAQs
Can I use another type of noodle for chili mac casserole?
Yes, you can swap the elbow macaroni for any short pasta like shells, rotini, or cavatappi. Just be sure to cook the pasta until al dente so it doesn’t become too soft after baking.
Absolutely, this casserole is great for making ahead! You can assemble it completely, refrigerate or freeze it, and bake it when you’re ready to serve. Just add a little extra time in baking while covered.
Mushy noodles are usually caused by overcooking the pasta before baking. Cook the pasta just to al dente or even a minute under, so it holds its texture in the oven.
Traditional chili mac is typically cooked and served entirely on the stovetop. Chili mac casserole is baked with cheese, creating a thicker, heartier dish that can be sliced and served.
More Easy Casserole Recipes
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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
Homemade Chili Seasoning
- 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
Instructions
- Cook the pasta: Bring a pot of salted water to a boil and cook the elbow macaroni until al dente according to package directions. Drain and set aside.2 cups elbow macaroni
- Preheat oven to 375ºF (190° C). Lightly spray a 9×13-inch baking dish with cooking spray.
- Brown the meat & onions: In a large skillet or pot, cook the ground beef and onions over medium heat until browned and crumbled. Add garlic in the last few minutes. Drain excess fat if needed.2 pounds lean ground beef, 1 medium onion, 4 cloves garlic
- Add the homemade chili seasoning: Sprinkle all the spices over the meat mixture. Stir and cook for 1 minute to bloom the spices.2 tablespoons chili powder, 2 teaspoons ground cumin, 1 teaspoon smoked paprika, 1 teaspoon dried oregano, 1 teaspoon kosher salt, ½ teaspoon black pepper, ½ teaspoon garlic powder, ½ teaspoon onion powder, ¼ – ½ teaspoon crushed red pepper flakes, ⅕ teaspoon cayenne pepper
- Build the chili base: Stir in the crushed tomatoes, tomato paste, diced green chilis, Better than Bouillon, and drained kidney beans. Bring to a simmer and cook for 10–15 minutes to let flavors meld.* Adding a little water swirled around in your tomato can until chili is thick, but not dry. Taste and adjust seasonings.28 ounce can crushed tomatoes, 6 ounce can tomato paste, 4 ounce can diced green chilis, 15.5 ounce can kidney beans, 1 teaspoon Better than Bouillon Beef, ¼ – ½ cup water
- Combine the chili and pasta: Fold in the cooked macaroni and 1-2 cups (I like it cheesy) of the shredded cheddar cheese.2-4 cups shredded cheddar cheese
- Bake: Transfer the mixture to a greased casserole dish. Top with the remaining 1-2 cups of cheese (I like it extra cheesy). Spray some foil with oil and cover tightly, bake at 375°F (190° C) for 20–25 minutes, remove foil and bake 5-10 minutes until cheese is melted and it's hot and bubbly.
- Serve: Let it rest for 5–10 minutes before serving so it thickens slightly.
Notes
- I love making my own spice mixes, so instead of a package I built my own chili seasoning mix, but you can replace those spices with a package of chili seasoning mix (except salt and pepper, taste and add those at the end)
- You can skip the Boullion if you prefer, but it adds a great pop of flavor to the chili; it’s my secret ingredient.
- I’m a spice wimp, so I usually add a shake or two of cayenne pepper and a few shakes of the red pepper flakes, adjust the heat to your taste.
- You don’t “have to” simmer the chili, but I like the flavors better when I do.
- Use any kind of cheese you like. I love a mixture of Colby-Jack and sharp cheddar cheese. As a note, cheeses melt better when you hand-grate them off the block, vs. preshredded cheese, but this is your chili mac!
- This is a great meal to take to new parents (dial down the spices) or for someone after surgery or just because!
- We are empty nesters, and this recipe makes a lot. I typically split it into two 9×9 (or 7×11) baking dishes and freeze one for another meal.
- Gluten-Free: This recipe is easily adapted to be gluten-free; simply replace the macaroni with your favorite gluten-free macaroni.
- Low-Carb Mac and Cheese: Omit or replace the macaroni with a low-carb, high-protein version. I love this Pete’s brand, it’s a little pricier, but delish!
- Dairy-Free: Use plant-based cheese in place of the regular cheese!
- Swap out the ground beef for ground chicken or turkey.
- You could swap two cans of Rotel for the crushed tomatoes and the green chilies.
Nutrition
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