One chilly Friday evening after work, I was invited to a casual potluck with a few coworkers and their families. The room buzzed with laughter and the tempting smell of home-cooked meals. Among the dishes, a casserole stood out — rich, hearty, and perfectly cheesy. It was the kind of dish that brings everyone together around the table.
My coworker shared that it was her go-to recipe whenever she needed comfort food that could feed a crowd without much fuss. Inspired, I decided to create my own version, blending the deep flavors of chili with creamy mac and cheese, giving it a Midwest diner vibe but made from scratch in my kitchen.
The moment I sliced into the bubbly casserole, the aroma of chili powder, mustard, and melting cheddar filled the room. The mix of textures — tender pasta, savory beef, and gooey cheese — instantly reminded me of family dinners growing up, where food was a way of showing care. It wasn’t fancy, but it was satisfying. Since then, this dish has become a regular for game nights, lazy weekends, and even simple weeknight dinners, always bringing a warm, comforting feeling to the table.
This casserole balances rich, meaty flavors with the creamy comfort of mac, making it a crowd-pleaser that feels like a warm hug in every bite.
Short Description
Coney Chili Mac Casserole is a hearty baked dish combining seasoned ground beef, elbow macaroni, tomato-based chili sauce, and melted cheddar cheese. It’s a perfect blend of spicy, tangy, and cheesy flavors, ideal for family dinners or casual gatherings.
Key Ingredients
- 1 lb ground beef
- 2 cups cooked elbow macaroni
- 1 cup tomato sauce
- ½ cup beef broth
- 1 tbsp mustard
- 1 tbsp chili powder
- 1 cup shredded cheddar cheese, divided
- Optional Toppings: diced onions, jalapeños, sour cream or Greek yogurt, crushed tortilla chips
Tools Needed
- Large skillet
- 9×13-inch baking dish
- Cooking spatula
- Measuring cups and spoons
- Strainer (for macaroni)
- Oven
Cooking Instructions
Step 1: Preheat the Oven
Set your oven to 350°F (175°C). Lightly grease a 9×13-inch baking dish using cooking spray or butter to prevent sticking.
Step 2: Brown the Ground Beef
Heat a large skillet over medium heat and add the ground beef. Break it up evenly with a spatula and cook for 6–8 minutes until fully browned. Make sure the beef has a rich, deep color without pink spots. Drain any excess fat carefully to keep the dish from becoming greasy.
Step 3: Make the Chili Sauce
Add tomato sauce, beef broth, mustard, and chili powder to the skillet with the beef. Stir well to combine all ingredients. Lower the heat and let the mixture simmer gently for 5–10 minutes. This step helps the flavors meld into a rich, spicy sauce.
Step 4: Combine with Macaroni and Cheese
Turn off the heat and fold in the cooked elbow macaroni and half of the shredded cheddar cheese. Mix gently until the cheese melts slightly and everything is evenly coated in the sauce.
Step 5: Transfer to Baking Dish
Pour the beef and macaroni mixture into the prepared baking dish. Spread it out evenly for consistent baking. Sprinkle the remaining shredded cheddar cheese on top for a golden, gooey finish.
Step 6: Bake
Bake in the preheated oven for 20–25 minutes, or until the casserole bubbles and the cheese on top turns golden brown and slightly crispy.
Step 7: Serve
Remove from oven and allow it to cool for 5 minutes. Add optional toppings like diced onions, jalapeños, sour cream, or crushed tortilla chips to add texture and bursts of flavor. Serve warm and enjoy!
Troubleshooting Tip:
If the casserole seems dry before baking, add a splash more beef broth. If the cheese on top browns too fast, cover loosely with foil.
Why You’ll Love This Recipe
– Comforting and filling with balanced, savory flavors
– Simple and quick to prepare on busy nights
– Versatile enough to feed a family or a crowd
– Customizable with toppings and spice levels
– Combines pantry staples with a twist on classic chili and mac
Mistakes to Avoid & Solutions
Overcooking the Beef: Browning the beef too long can dry it out. Cook until just browned, then drain immediately.
Dry Casserole: If the sauce is too thick, add extra beef broth a tablespoon at a time until it reaches a creamy consistency.
Undercooked Pasta: Use al dente macaroni. Overcooked pasta can turn mushy after baking.
Cheese Burns: Cover with foil if the cheese browns too quickly in the oven.
Uneven Spreading: Spread mixture evenly in the dish to ensure uniform baking.
Serving and Pairing Suggestions
– Serve it warm straight from the oven as a main course.
– Pair with a crisp green salad or roasted broccoli to balance the richness.
– Add cornbread or garlic toast for a heartier meal.
– For a party, cut into squares and serve with a topping bar—let guests add jalapeños, sour cream, or crushed chips.
Storage and Reheating Tips
Store leftovers in an airtight container in the fridge for up to 3 days.
Freeze portions for up to 2 months; thaw overnight in the fridge before reheating.
Reheat in the oven at 325°F until warmed through to keep the cheese melty and pasta tender.
Microwave reheating works but cover to retain moisture and prevent drying.
FAQs
1. Can I use ground turkey instead of beef?
Yes, ground turkey works well and lowers fat content. Cook it the same way but check for doneness carefully.
2. Can I make this casserole ahead of time?
Absolutely. Prepare it through Step 5, cover, and refrigerate. Bake just before serving.
3. Is it possible to use a different type of pasta?
Yes, small shapes like shells or rotini hold sauce well, but adjust cooking time if needed.
4. How spicy is this recipe?
Moderate heat from chili powder. Add more or less to taste, and jalapeños as a topping add extra kick.
5. Can I make this vegetarian?
Try substituting beef with cooked lentils or plant-based crumbles, and use vegetable broth instead of beef broth.
Tips & Tricks
Toast your chili powder in the skillet before adding liquids for a deeper flavor.
Use sharp cheddar for a bold cheese taste or a blend with Monterey Jack for creaminess.
Let the casserole rest after baking to set, making it easier to serve neat slices.
Recipe Variations
Spicy Coney Chili Mac: Add 1 diced chipotle pepper in adobo sauce to the chili mix for smoky heat. Top with pickled jalapeños.
Cheesy Bacon Mac: Stir in 4 slices of cooked, crumbled bacon with the beef mixture. Sprinkle extra bacon bits on top before baking.
Veggie Boost: Add 1 cup of sautéed bell peppers and onions with the beef. For extra texture, fold in a handful of fresh spinach before baking.
Slow Cooker Version: Combine all ingredients except cheese in a slow cooker. Cook on low for 4 hours, then stir in cheese and broil for a few minutes to melt the top.
Final Thoughts
This casserole always brings back warm memories of friendly gatherings and easy dinners filled with laughter. It’s one of those dishes that feels like home on a plate — satisfying, flavorful, and comforting. The blend of chili spices and gooey cheddar makes it a comforting classic with a little extra personality. It’s flexible enough to suit different tastes, yet simple enough to whip up without fuss.
Perfect for feeding hungry family members or surprising guests with something homemade but effortless. When the oven timer goes off and the aroma fills the kitchen, it’s clear that this Coney Chili Mac Casserole is a keeper, ready to be enjoyed again and again.
Coney Chili Mac Casserole
Ingredients
- 1 lb ground beef
- 2 cups cooked elbow macaroni
- 1 cup tomato sauce
- ½ cup beef broth
- 1 tbsp mustard
- 1 tbsp chili powder
- 1 cup shredded cheddar cheese divided
- Optional Toppings: diced onions jalapeños, sour cream or Greek yogurt, crushed tortilla chips
Instructions
- Set oven to 350°F (175°C). Grease a 9×13-inch baking dish with spray or butter.
- Cook ground beef in a skillet over medium heat for 6–8 minutes until browned. Drain excess fat.
- Add tomato sauce, beef broth, mustard, and chili powder to beef. Simmer on low for 5–10 minutes.
- Remove from heat. Stir in cooked macaroni and half the cheddar cheese until coated.
- Spread mixture evenly in the dish. Top with remaining cheddar cheese.
- Bake 20–25 minutes until bubbly and cheese is golden.
- Cool 5 minutes. Add optional toppings and serve warm.
