Name: Coney Chili Mac Casserole
Prep time: 10 min
Cook time: 30 min
Total time: 40 min
Cuisine: American
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

A hearty, comforting blend of pasta, seasoned beef, and melted cheese that brings together the flavors of classic Coney chili and mac and cheese in one delicious casserole.

Why You’ll Love This Recipe

This Coney Chili Mac Casserole is the ultimate comfort food mash-up. It combines the zesty flavors of a Coney-style chili with the creamy satisfaction of macaroni and cheese. Perfect for busy weeknights, this crowd-pleaser comes together quickly and can be easily customized with your favorite toppings. It’s economical, filling, and guaranteed to satisfy even the pickiest eaters in your household. The combination of tangy tomato sauce, savory beef, and melted cheese creates a dish that’s both nostalgic and exciting – comfort food with a twist!

Ingredients

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

Ground beef provides the hearty protein base for this casserole, giving it that classic chili flavor and satisfying texture. For a leaner option, you could substitute ground turkey or even plant-based meat alternatives.
Elbow macaroni creates the perfect vehicle for capturing all the delicious sauce. Their hollow shape holds the chili mixture beautifully, ensuring flavor in every bite. Any short pasta shape would work in a pinch.
Tomato sauce forms the foundation of the chili flavor, providing rich acidity and smooth texture to bind everything together. It creates that classic Coney sauce consistency without being too chunky.
Beef broth adds depth and savory richness, thinning the sauce to the perfect consistency while enhancing the meaty flavor throughout the dish. Vegetable broth can be substituted if needed.
Mustard brings a tangy sharpness that cuts through the richness and adds that authentic Coney dog flavor profile. The acidity helps balance the overall dish.
Chili powder infuses the casserole with warm, earthy spice notes and that distinctive chili character. Adjust the amount based on your heat preference or the brand you’re using.
Cheddar cheese creates that irresistible gooey, melted layer that makes casseroles so comforting. The sharp flavor complements the chili seasoning perfectly, and it browns beautifully on top.
Optional toppings allow everyone to customize their serving. The crunch of fresh onions or tortilla chips, the heat of jalapeños, or the cooling creaminess of sour cream or Greek yogurt takes this dish to the next level.

Directions

Preheat oven to 350°F and grease a 9×13-inch baking dish.
Cook ground beef in a skillet over medium heat, breaking it up until no pink remains (6–8 minutes). Drain fat.
Stir in tomato sauce, beef broth, mustard, and chili powder. Simmer gently on low for 5–10 minutes.
Turn off heat and fold in cooked macaroni and half of the cheese until creamy.
Spread mixture in the baking dish and sprinkle remaining cheese on top.
Bake 20–25 minutes until bubbly and cheese is golden.
Let rest 5 minutes before serving. Add optional toppings as desired.

Servings and Timing

This Coney Chili Mac Casserole serves 6 people generously. It takes approximately 10 minutes to prep, 30 minutes to cook, for a total time of 40 minutes from start to finish. Each serving contains approximately 480 calories, making it a substantial but reasonable main dish. If you’re serving a larger crowd, the recipe doubles easily – just use a larger baking dish or two standard ones.

Variations

Spicy Southwest Style: Add a can of diced green chilies, substitute pepper jack for the cheddar cheese, and top with sliced avocado and cilantro.
Vegetarian Version: Replace the ground beef with a plant-based meat alternative or 2 cups of cooked lentils, and use vegetable broth instead of beef broth.
Deluxe Coney Style: Add 1/2 cup of diced bell peppers and onions when cooking the beef, and top with sliced hot dogs before adding the final cheese layer.
Cheesy Supreme: Use a combination of cheeses like cheddar, monterey jack, and mozzarella for a more complex flavor and extra gooey texture.
Baked Potato Twist: Mix in 1 cup of sour cream with the pasta and top with sliced green onions after baking.

Storage/Reheating

Refrigerator Storage: Allow the casserole to cool completely before covering tightly with aluminum foil or transferring to airtight containers. It will keep in the refrigerator for 3-4 days.
Freezer Storage: This casserole freezes beautifully for up to 3 months. For best results, assemble the casserole but don’t bake it. Cover tightly with plastic wrap and then aluminum foil. Alternatively, freeze individual portions in freezer-safe containers for quick lunches.
Reheating From Refrigerated: For best results, reheat individual portions in the microwave for 1-2 minutes or until heated through. To reheat the entire casserole, cover with foil and bake at 350°F for about 20 minutes or until warmed through.
Reheating From Frozen: Thaw overnight in the refrigerator if possible. If reheating from frozen, cover with foil and bake at 350°F for about 45 minutes, then uncover and bake for an additional 10-15 minutes until heated through and bubbly.

FAQs

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

Yes! You can assemble the entire casserole up to 24 hours in advance, cover it tightly, and refrigerate. When ready to serve, bake as directed, adding about 5-10 minutes to the cooking time since it will be cold from the refrigerator.

How do I know when the casserole is done baking?

The casserole is ready when the edges are bubbly and the cheese on top is melted and golden. If you insert a knife into the center, it should come out hot to the touch.

Can I use a different type of pasta?

Absolutely! While elbow macaroni is traditional, any short pasta shape works well. Try rotini, shells, penne, or even farfalle. Just cook until al dente before adding to the casserole.

My family doesn’t like spicy food. Can I reduce the chili powder?

Yes, you can adjust the chili powder to suit your family’s taste preferences. For a milder version, start with just 1 teaspoon and add more if desired. You could also substitute mild paprika for part of the chili powder.

What can I serve with this casserole?

This hearty casserole works well with simple sides like a green salad, steamed vegetables, or garlic bread. For a lighter meal, just serve smaller portions of the casserole with a larger salad.

Can I use ground turkey instead of beef?

Yes, ground turkey is a great substitute for a leaner option. Because turkey has less fat, you might want to add a tablespoon of olive oil when cooking it to prevent dryness.

Is there a way to make this recipe gluten-free?

Definitely! Simply substitute your favorite gluten-free pasta and ensure your broth and other packaged ingredients are certified gluten-free. The texture might be slightly different, but the flavor will be just as delicious.

How can I make this casserole more vegetable-rich?

You can easily add vegetables like diced bell peppers, onions, corn, or even finely chopped spinach. Add firmer vegetables like peppers when cooking the beef, and fold in quick-cooking or pre-cooked vegetables along with the pasta.

Can I use pre-shredded cheese, or should I shred my own?

While pre-shredded cheese is convenient, freshly shredded cheese melts more smoothly because it doesn’t contain the anti-caking agents found in packaged shredded cheese. If using pre-shredded, look for varieties without cellulose additives for the best melting quality.

Why does the recipe call for draining the fat from the ground beef?

Draining the fat prevents the casserole from becoming greasy and helps achieve the right consistency for the sauce. If using lean ground beef (93% or leaner), you may not need to drain much fat at all.

Conclusion

This Coney Chili Mac Casserole brings together the best of two comfort food classics – zesty chili and creamy mac and cheese – in one satisfying dish. Whether you’re feeding a hungry family on a weeknight or looking for a crowd-pleasing potluck contribution, this versatile recipe delivers big flavor with minimal effort. The combination of tangy tomato sauce, seasoned beef, and gooey cheese creates a meal that’s both familiar and exciting. Plus, with endless topping options and easy variations, you can customize it to please even the pickiest eaters. From prep to table in just 40 minutes, this hearty casserole is sure to become a regular in your dinner rotation – comfort food at its finest.