Sausage Macaroni Bake (For A Crowd)

Prep: 20 min Cook: 30 min Serves: 48 Cuisine: American

A hearty, crowd-pleasing baked pasta dish featuring sausage, vegetables, and a creamy sauce, topped with crispy chips for added texture and flavor, perfect for gatherings.

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Ingredients

  • 4 lb. elbow macaroni
  • 8 lb. bulk pork sausage
  • 2 lb. butter or margarine
  • 2 1/2 lb. carrots
  • 1 1/4 lb. celery
  • 4 c. all-purpose flour
  • 1 c. instant minced onion
  • 1/3 c. dry mustard
  • 2 Tbsp. salt
  • 1 1/2 gal. milk
  • 1/2 lb. potato chips

Instructions

  1. Cook macaroni according to package directions; drain. Meanwhile, brown sausage in a skillet; drain well and set aside.
  2. Melt butter or margarine in a large pan.
  3. Add carrots and celery; cook about 10 minutes, or until almost tender, but not brown.
  4. In a small bowl, blend together flour, minced onion, dry mustard, and salt.
  5. Stir the flour mixture into the vegetable mixture to form a smooth paste.
  6. Gradually add milk, cooking and stirring constantly until thickened.
  7. Mix the sauce with cooked macaroni and browned sausage until well blended.
  8. Portion the mixture into two lightly buttered 20 x 12 x 2-inch pans.
  9. Sprinkle the tops with crushed potato chips.
  10. Bake at 350°F for 30 minutes or until hot and bubbly.

Tips & Substitutions

For extra flavor, consider adding some shredded cheese to the sauce before mixing it with the macaroni and sausage. You can substitute the pork sausage with turkey sausage for a lighter option. If you want a bit of crunch, try using crushed pretzels instead of potato chips on top. To save time, you can use pre-shredded carrots and pre-chopped celery.

Serving Suggestions

This hearty dish is perfect for potlucks or family gatherings. Serve it alongside a fresh garden salad or garlic bread for a complete meal. For a delicious pairing, try it with a side of Poppy Seed Finger Sandwiches for a nice contrast. It also works well with a light dessert like fruit salad to balance the richness.

Storage & Reheating

Store any leftovers in an airtight container in the refrigerator for up to 3 days. To reheat, place in a baking dish and cover with foil. Bake at 350°F for about 20-25 minutes, or until heated through. You can also microwave individual portions until warm, stirring occasionally.

Nutrition & Diet Analysis (per serving)

Each serving of Sausage Macaroni Bake (For A Crowd) contains roughly 763 calories, with 11g protein, 54g carbohydrates, and 56g fat. It is an excellent source of vitamin A (51% of the Daily Value) and protein (21% of the Daily Value), and a good source of iron and dietary fiber. Note that it is relatively high in sodium, at 711mg per serving (31% of the Daily Value).

763 kcal 38% DV
Protein Fat Carbs

Macronutrients

Protein 10.6g 21% DV
Total Fat 56.5g 72% DV
Carbs 54.1g 20% DV
Fiber 5g 18% DV
Sugar 17g 34% DV

Electrolytes

Sodium 710.6mg 31% DV
Potassium 645.8mg 14% DV
Cholesterol 146.5mg 49% DV

Vitamins & Minerals

Vitamin A 459.4mcg 51% DV
Vitamin C 8.4mg 9% DV
Vitamin D 0.7mcg 3% DV
Calcium 141.7mg 11% DV
Iron 3.5mg 19% DV
Contains Milk Wheat/Gluten

Estimated from ingredients & per-serving nutrition — verify against package labels for allergies or strict diets.

* % Daily Values based on a 2,000 calorie diet (FDA 2020).

Frequently Asked Questions

Can I prepare this dish ahead of time?

Yes, you can prepare this Sausage Macaroni Bake ahead of time. Simply assemble the dish, cover it, and refrigerate for up to 24 hours before baking. When ready to serve, add an extra 10-15 minutes to the baking time to ensure it heats through completely.

What can I use instead of elbow macaroni?

If you don't have elbow macaroni, you can substitute it with other pasta shapes like penne, shells, or fusilli. Each type will give a different texture, but the dish will remain delicious. Just be sure to adjust the cooking time according to the pasta shape you choose.

Can I freeze the Sausage Macaroni Bake?

Absolutely! This dish freezes well. Just prepare it as directed, let it cool completely, then wrap tightly with plastic wrap and aluminum foil before freezing. It can be stored for up to 3 months. To reheat, thaw overnight in the refrigerator and bake as directed.

Nutrition is estimated from USDA FoodData Central ingredient data and may vary with brand, portion and preparation — see our methodology. This information is for general educational purposes only and is not medical or dietary advice (disclaimer).

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