My family loves pasta, and this hearty casserole was born as a way to use leftovers while delivering big flavor. It combines the comfort of mac and cheese with creamy Alfredo-style béchamel and bright basil pesto for a satisfying, crowd-pleasing meal. The recipe yields a generous amount, so I often portion it into disposable casserole pans with cardboard lids for the freezer; if you prefer reusable dishes, wrap them tightly in foil and label before freezing.
Ingredients
2 lb rigid elbow pasta, penne, or ziti
2 packages smoked sausage (kielbasa), diced
4 cups diced ham (leftover ham works great)
3 cups frozen peas (or substitute vegetables, see notes)
1 large onion, finely diced
1 stick (8 tbsp) butter
12 oz pesto (homemade or store-bought)
1 cup all-purpose flour
4 cups milk
Salt and freshly ground black pepper, to taste
2 tsp granulated garlic
12 oz grated Parmesan cheese
24 oz grated mozzarella cheese
Bring a large pot of salted water to a boil and cook the pasta for about 3 minutes less than the package directions (the pasta will finish cooking in the oven). Drain and transfer to a large mixing bowl. Add the diced sausage, diced ham, and frozen peas; toss to combine evenly.
In a 4–6 quart saucepan over medium heat, melt the butter and add the diced onion. Sauté until the onion is soft, translucent, and just beginning to caramelize. Stir in the flour and cook about one minute to form a roux.
Gradually whisk in the milk, stirring constantly to avoid lumps. Keep stirring and simmer gently until the béchamel thickens, about 15–20 minutes. Scrape the bottom frequently so the flour doesn’t scorch. Remove from heat, season with salt, pepper, and granulated garlic, then stir in the grated Parmesan until melted and smooth.
Fold the pesto into the cheese sauce until evenly combined. Pour the sauce over the pasta, meats, and peas, and mix thoroughly so everything is coated.
Lightly spray casserole pans with nonstick spray and fill with the pasta mixture, smoothing the tops with the back of a spoon. Generously top each casserole with the grated mozzarella so you get a melty, golden finish when baked.
If you plan to freeze portions, label the lids with baking instructions — for example, “350°F: bake until cheese melts and bubbles” — and add the date and dish name. Freeze flat until solid. To bake from frozen, thaw overnight in the refrigerator and bake at 350°F for about 40 minutes, or until heated through and the cheese is bubbly. If baking from fresh, bake at 350°F until warmed and bubbly, about 35–40 minutes.
Vegetable and protein swaps work well: broccoli, cauliflower, carrots, parsnips, sun-dried tomatoes, or black olives are great alternatives to peas. You can also replace the ham and sausage with cooked chicken and bacon for a different flavor profile. Be creative and adjust seasonings to taste.
Serve this casserole with a crisp green salad and toasted garlic bread for a complete meal. Leftovers reheat beautifully and make a convenient, tasty lunch.