Name: Coney Chili Mac Casserole
Prep time: 15 min
Cook time: 35 min
Total time: 50 min
Cuisine: American
Ingredients: 1 pound ground beef; 1 onion, chopped; 1 packet chili seasoning; 1 can (15 ounces) tomato sauce; 1 can (15 ounces) kidney beans, drained and rinsed; 1 cup elbow macaroni; 2 cups shredded cheddar cheese; 1 cup shredded mozzarella cheese; Salt and pepper to taste; 1/2 teaspoon garlic powder; 1/2 teaspoon onion powder; 1 tablespoon olive oil; 1/2 cup water

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A hearty, cheesy casserole that combines the best of chili and mac and cheese into one delicious dish that will warm your soul and satisfy even the hungriest appetites.

Why You'll Love This Recipe

This Coney Chili Mac Casserole is the ultimate comfort food fusion, bringing together two beloved classics - chili and macaroni and cheese. The rich, savory beef chili mingles with tender pasta and melts into a blanket of gooey cheese for a meal that's both satisfying and simple to prepare. It's perfect for busy weeknights when you need a hearty dinner that the whole family will enjoy. This one-dish wonder also makes excellent leftovers, tasting even better the next day as the flavors continue to develop. Whether you're feeding a crowd or meal prepping for the week ahead, this casserole delivers comfort in every bite.

Ingredients

(Tip: You'll find the full list of ingredients and measurements in the recipe card below.)

Ground beef provides the hearty foundation for this casserole, adding protein and rich flavor. You can substitute ground turkey or plant-based alternatives if preferred.

Onion adds aromatic sweetness that develops depth as it cooks with the beef. It creates an essential flavor base for the chili component.

Chili seasoning packet offers convenience and consistent flavor with its blend of cumin, chili powder, garlic, and other spices. If you prefer to use your own spice blend, combine 1 tablespoon chili powder, 1 teaspoon each of cumin and oregano, and ½ teaspoon of paprika.

Tomato sauce provides the tangy, rich base for the chili. Its smooth consistency helps bind the casserole together while adding classic chili flavor.

Kidney beans contribute protein, fiber, and that quintessential chili texture. You can substitute black beans or pinto beans based on preference or what you have on hand.

Elbow macaroni brings the "mac" to this chili mac, offering a comforting pasta element that soaks up the savory sauce. Any small pasta shape like shells or rotini works well too.

Cheddar cheese delivers sharp, tangy flavor and creates that irresistible golden top when melted. Medium or sharp varieties work best for maximum flavor.

Mozzarella cheese adds a creamy, stretchy element that creates those Instagram-worthy cheese pulls when serving. Its mild flavor complements the sharper cheddar perfectly.

Garlic powder and onion powder enhance the overall savoriness without adding additional texture, infusing the dish with aromatic notes throughout.

Olive oil helps sauté the onions and brown the beef, adding a subtle richness to the base of the casserole.

Water helps thin the chili to the perfect consistency, allowing the flavors to meld while keeping the sauce from becoming too thick during baking.

Directions

Preheat the oven to 350°F (175°C).
In a large skillet, heat the olive oil over medium heat. Add the chopped onion and cook for 2-3 minutes, or until softened.
Add the ground beef to the skillet and cook until browned. Drain any excess fat.
Stir in the chili seasoning, garlic powder, onion powder, tomato sauce, kidney beans, and water. Let the mixture simmer for 10 minutes, stirring occasionally.
Meanwhile, cook the elbow macaroni according to the package instructions. Drain and set aside.
In a large casserole dish, combine the cooked macaroni and chili mixture. Stir to combine evenly.
Top the casserole with shredded cheddar and mozzarella cheese.
Cover the dish with aluminum foil and bake for 20 minutes. Remove the foil and bake for an additional 10 minutes, or until the cheese is melted and bubbly.
Let the casserole cool for a few minutes before serving.

Servings and Timing

This Coney Chili Mac Casserole serves 6 people generously, making it perfect for family dinners or gatherings. The recipe requires approximately 15 minutes of prep time and 35 minutes of cooking time, totaling about 50 minutes from start to finish. Each serving contains approximately 480 calories, providing a satisfying and complete meal. For smaller households, you can easily halve the recipe or freeze portions for future meals.

Variations

Spicy Chili Mac: Add 1-2 diced jalapeños to the onions or mix in ¼ teaspoon of cayenne pepper with the chili seasoning for a heat kick.

Taco Chili Mac: Replace the chili seasoning with taco seasoning and top with crushed tortilla chips and sliced black olives before serving.

Vegetarian Chili Mac: Omit the ground beef and double the beans, or substitute with a plant-based ground meat alternative and vegetable broth.

Tex-Mex Chili Mac: Add a can of corn and diced bell peppers to the chili mixture, and top with a dollop of sour cream and sliced avocado before serving.

Buffalo Chicken Chili Mac: Substitute ground chicken for beef, add ¼ cup of buffalo sauce to the mixture, and use blue cheese instead of mozzarella.

Loaded Chili Mac: Top the finished casserole with diced green onions, chopped fresh tomatoes, and a dollop of sour cream for a loaded effect.

Storage/Reheating

Refrigerator Storage: Store leftover Coney Chili Mac Casserole in an airtight container in the refrigerator for up to 4 days. The flavors often develop and improve overnight, making this an excellent make-ahead meal.

Freezer Storage: This casserole freezes beautifully. Portion cooled leftovers into freezer-safe containers or wrap tightly in aluminum foil and freeze for up to 3 months. Label with the date for easy reference.

Reheating Single Portions: For individual servings, microwave on high for 2-3 minutes, stirring halfway through until heated thoroughly. Add a splash of water or broth if it seems dry.

Reheating Full Casserole: To reheat the entire casserole from refrigerated, cover with foil and bake at 350°F for 20-25 minutes until heated through. For frozen casserole, bake covered at 350°F for 45-50 minutes, then uncover for the last 10 minutes.

Freshening Up: Add a sprinkle of fresh cheese on top before reheating to revitalize the cheesy layer. A dash of hot sauce or fresh herbs after reheating can also brighten the flavors.

FAQs

Can I make this Coney Chili Mac Casserole ahead of time?

Yes, you can prepare this casserole up to 24 hours in advance. Assemble the casserole as directed, but don't bake it. Cover tightly and refrigerate. When ready to serve, add about 10 minutes to the covered baking time since you're starting with a cold dish.

What if I don't have a chili seasoning packet?

No problem! Make your own by combining 1 tablespoon chili powder, 1 teaspoon cumin, 1 teaspoon oregano, ½ teaspoon paprika, ¼ teaspoon garlic powder, ¼ teaspoon onion powder, and a pinch of cayenne pepper (optional).

Can I use a different type of pasta?

Absolutely! While elbow macaroni is traditional, any short pasta like shells, rotini, or penne works well. Just be sure to cook it al dente, as it will continue to cook slightly in the oven.

Is there a way to make this casserole healthier?

Yes, you can use lean ground turkey or chicken instead of beef, whole wheat pasta instead of regular, and reduce the cheese by half. You could also add more vegetables like bell peppers, zucchini, or spinach to increase the nutritional value.

My casserole seems too dry. What should I do?

If your casserole appears dry before baking, add ¼ to ½ cup of beef broth or water. If it's after baking, serve with a side of warm tomato sauce or a dollop of sour cream to add moisture.

Can I make this in a slow cooker?

Yes, but with modifications. Brown the meat and onions first, then transfer to a slow cooker with the remaining ingredients except pasta and cheese. Cook on low for 4-5 hours, then stir in cooked pasta and top with cheese. Cover and cook until cheese melts, about 15-20 minutes more.

What sides go well with Coney Chili Mac Casserole?

A simple green salad, steamed vegetables, garlic bread, or cornbread complement this hearty casserole perfectly. For a lighter meal, serve smaller portions with a larger side salad.

My family doesn't like kidney beans. What can I substitute?

You can easily substitute black beans, pinto beans, or even white beans. If beans aren't popular at all, you can omit them entirely and add an extra ¼ pound of ground beef.

Can I add vegetables to this recipe?

Definitely! Diced bell peppers, corn, carrots, or zucchini make great additions. Add them when you're cooking the onions to ensure they soften properly.

How can I tell when the casserole is done baking?

The casserole is done when the cheese on top is completely melted and starting to brown slightly at the edges, and the mixture is bubbling around the sides of the dish. Let it rest for 5-10 minutes before serving to allow it to set up properly.

Conclusion

Coney Chili Mac Casserole is comfort food perfection, combining two beloved classics into one irresistible dish. The hearty blend of seasoned ground beef, beans, and pasta topped with a blanket of melted cheese creates a meal that satisfies on every level. Whether you're feeding a hungry family on a weeknight or looking for a crowd-pleasing dish for a potluck, this recipe delivers both convenience and flavor. The simple preparation and adaptable nature of this casserole make it a reliable addition to your recipe collection, while its comforting, nostalgic appeal ensures clean plates all around. Next time you're craving something warm, filling, and utterly delicious, this Coney Chili Mac Casserole is sure to hit the spot.