There is something incredibly comforting and downright delicious about a hearty baked pasta, and this Coney Chili Mac Casserole Recipe delivers just that in spades. It combines tender elbow macaroni with a flavorful chili made from ground beef, tomatoes, and beans, all topped with gooey melted cheddar cheese. Every bite is a beautiful harmony of smoky, savory, and slightly tangy flavors wrapped in a warm, creamy embrace. Whether you’re feeding a family or just need a satisfying meal that feels like a big, cozy hug, this recipe is sure to become a favorite in your kitchen.

Ingredients You’ll Need
This Coney Chili Mac Casserole Recipe calls for ingredients that are simple but pack a ton of flavor and texture. Each component plays a crucial role, from the rich ground beef to the creamy sour cream that adds a luscious finish.
- Ground beef, 1 pound: The hearty protein base that brings richness and depth to the chili mixture.
- Onion, chopped: Adds sweetness and aromatic depth, creating a savory foundation for the dish.
- Chili beans, 1 (15 oz) can, undrained: Provides both texture and that classic chili element with beans soaking up all the flavors.
- Tomato sauce, 1 (15 oz) can: Brings tanginess and moisture; it melds the chili ingredients beautifully.
- Diced green chilies, 1 (4 oz) can: Adds a nice mild heat and a little green freshness that enhances the chili.
- Chili seasoning mix, 1 packet (1 oz): The spice blend that gives the chili its signature kick and warmth.
- Elbow macaroni, 2 cups cooked and drained: The tender pasta that soaks up all those chili flavors while adding satisfying chewiness.
- Shredded cheddar cheese, 1 1/2 cups: Melts beautifully for a gooey, golden crust and a punch of sharp, creamy flavor.
- Sour cream, 1/2 cup: Adds creaminess and slight tang, balancing the spice and acidity perfectly.
- Olive oil, 1 tablespoon: Used for sautéing the onions to bring out their natural sweetness.
- Salt and pepper to taste: Essential seasonings to bring everything into harmony.
How to Make Coney Chili Mac Casserole Recipe
Step 1: Prepare to Bake
Start by preheating your oven to 375 degrees Fahrenheit (190 degrees Celsius). Get your 9×13-inch baking dish ready by greasing it well; this ensures your casserole won’t stick and will have a nice, easy clean-up later.
Step 2: Sauté Onions
Heat the olive oil in a large skillet over medium heat. Add your chopped onions and cook them until they’re soft and fragrant, about three minutes. This step builds a fragrant foundation that flavors the entire dish.
Step 3: Brown the Beef
Next, toss your ground beef in with those lovely sautéed onions. Cook until the beef is nicely browned, breaking it up as it cooks to create that perfect crumbly texture. Drain any excess fat to keep the casserole from getting greasy.
Step 4: Simmer the Chili Mixture
Stir in your chili seasoning, chili beans (with their juicy liquid), tomato sauce, and diced green chilies. Bring this flavorful medley to a gentle simmer and let it bubble away for about 10 minutes. Stir occasionally to marry all those fantastic flavors, adding salt and pepper to taste along the way.
Step 5: Combine Pasta and Mixture
In a large bowl, mix your cooked elbow macaroni with the hot chili mixture, sour cream for that creamy texture, and one cup of shredded cheddar cheese. Stir everything together gently but thoroughly so every bite is perfectly coated.
Step 6: Assemble the Casserole
Pour the combined mixture into your greased baking dish. Sprinkle the remaining half cup of shredded cheddar cheese evenly over the top. This cheese layer will bake into a bubbly, golden crust that’s irresistible.
Step 7: Bake Until Bubbly
Place the casserole in your preheated oven and bake for 20 minutes. You want that cheese to melt fully and sparkle with a little golden color. Once out of the oven, let it rest for about five minutes to settle and make it easier to serve.
How to Serve Coney Chili Mac Casserole Recipe

Garnishes
To elevate your Coney Chili Mac Casserole Recipe, sprinkle some chopped fresh parsley or green onions on top for a fresh burst of color and a mild oniony zing. If you like a bit of heat, a few jalapeño slices or a dash of hot sauce can brighten up the flavors beautifully.
Side Dishes
This casserole shines as a complete meal but pairs wonderfully with crisp, refreshing sides. A simple green salad with a tangy vinaigrette or some steamed broccoli adds a fresh crunch that balances the richness perfectly. Cornbread or warm dinner rolls are classic companions to mop up every last delicious bite.
Creative Ways to Present
For casual gatherings, scoop the casserole into individual ramekins and serve with a sprinkle of cheese and some fresh herbs on top for a charming presentation. You could also turn leftovers into hearty stuffed peppers or top tortilla chips for a fun chili mac nachos twist that’ll wow the crowd.
Make Ahead and Storage
Storing Leftovers
Once cooled, transfer any leftover Coney Chili Mac Casserole Recipe to an airtight container and refrigerate. It will keep well for up to three days, letting you enjoy the comfort of this dish again without any hassle.
Freezing
This casserole freezes beautifully! Portion it out into freezer-safe containers or wrap tightly with foil and plastic wrap. Freeze for up to two months. When you’re ready to enjoy, thaw it overnight in the refrigerator before reheating.
Reheating
To reheat, pop your portion in the oven at 350 degrees Fahrenheit until warmed through and the cheese is bubbling again. Alternatively, a microwave works well for a quick warm-up, but the casserole may not stay quite as crispy on top.
FAQs
Can I make this Coney Chili Mac Casserole Recipe vegetarian?
Absolutely! Swap the ground beef for plant-based crumbles or cooked lentils, and make sure you use vegetarian chili seasoning. The beans and chilies provide plenty of hearty texture and flavor to keep it satisfying.
What kind of cheese works best for this casserole?
Cheddar is the classic choice for its sharp flavor and melting qualities, but feel free to experiment with Monterey Jack or a blend of Mexican cheeses for a different twist.
Can I use a different type of pasta?
Yes! While elbow macaroni is traditional, small pasta shapes like shells, rotini, or penne work just as well. Just make sure to cook and drain them before mixing.
Is this recipe spicy?
The Coney Chili Mac Casserole Recipe is mildly spiced thanks to the chili seasoning and green chilies, making it approachable for most palates. You can always add extra chili powder or hot sauce if you love heat.
How can I make this recipe gluten-free?
Simply substitute regular elbow macaroni with a gluten-free pasta variety. Make sure your chili seasoning mix doesn’t contain gluten ingredients, and you’re all set!
Final Thoughts
I cannot recommend this Coney Chili Mac Casserole Recipe enough for anyone craving a satisfying, cozy meal that’s surprisingly easy to pull off. It’s the perfect dinner to warm up your weeknight routine or impress hungry friends with minimal fuss. Give it a try and see how quickly it becomes a staple in your home kitchen—you’ll wonder how you ever lived without it!
