Smoky Gouda Macaroni Casserole

If you’re craving a comforting, cheesy, and smoky pasta dish that hits all the right notes, then this Smoky Gouda Macaroni Casserole is your new go-to. It’s rich, creamy, and packed with flavor, combining the smooth smokiness of Gouda with the sharpness of cheddar, all baked to golden perfection with a crunchy breadcrumb topping. This casserole is the perfect meal to serve for family dinners, potlucks, or anytime you want a little indulgence that feels like a warm hug on a plate.

What Makes This Recipe Special

This recipe stands out because of the unique combination of smoked Gouda and cheddar cheeses that create a luscious, velvety sauce. The smokiness of the Gouda adds depth and a subtle complexity that’s hard to beat. The addition of cooked turkey bacon brings a meaty, savory layer that perfectly balances the creamy cheese sauce without overpowering it. Plus, the use of simple pantry staples and straightforward steps makes it accessible for any home cook, while still delivering impressive flavor.

Unlike ordinary mac and cheese, this casserole has a delightful crunchy breadcrumb crust that adds texture and a buttery finish. It’s a dish that’s both hearty and sophisticated, perfect for those who want a little twist on a classic favorite.

What We’re Using

• 2 cups elbow macaroni – The perfect pasta shape for holding onto the creamy cheese sauce.
• 2 tablespoons olive oil – For sautéing the aromatics and adding a touch of richness.
• 1 small onion, finely chopped – Adds sweetness and depth to the base.
• 2 cloves garlic, minced – For a subtle punch of flavor.
• 1 cup cooked turkey bacon, chopped – A smoky, savory protein that complements the cheese beautifully.
• 2 cups shredded smoked Gouda cheese – The star ingredient, bringing a creamy, smoky flavor.
• 1 cup shredded cheddar cheese – Adds sharpness and richness to the cheese sauce.
• 2 cups milk – The creamy base for the sauce; whole milk works best for richness.
• 1/4 cup all-purpose flour – Helps thicken the cheese sauce to a perfect consistency.
• 1 teaspoon mustard powder – Enhances the cheese flavor with a subtle tang.
• 1/2 teaspoon black pepper – For a gentle kick of spice.
• 1/2 teaspoon paprika – Adds warmth and color.
• 1/2 teaspoon salt – Balances and amplifies all the flavors.
• 1/2 cup breadcrumbs – Creates a crispy, golden topping.
• 2 tablespoons butter, melted – Mixed with breadcrumbs for a rich, toasty finish.

Equipment Breakdown

• Large pot – To boil the elbow macaroni until al dente.
• Large skillet or saucepan – For sautéing onions and garlic and making the cheese sauce.
• Whisk – To smoothly combine the flour and milk for the béchamel base.
• Mixing spoon – To stir all ingredients together evenly.
• Baking dish (9×9 inch or similar) – To bake the macaroni casserole to bubbly perfection.
• Measuring cups and spoons – For precise ingredient amounts.

Method: Smoky Gouda Macaroni Casserole

Step 1: Cook the Pasta

Bring a large pot of salted water to a boil. Add 2 cups of elbow macaroni and cook according to package instructions until just al dente (usually about 7-8 minutes). Drain the pasta and set aside.

Step 2: Sauté Onions, Garlic, and Turkey Bacon

In a large skillet, heat 2 tablespoons olive oil over medium heat. Add the finely chopped onion and cook until soft and translucent, about 4 minutes. Stir in the minced garlic and cook another 30 seconds until fragrant. Add 1 cup chopped cooked turkey bacon and cook for 2 minutes, allowing the flavors to meld.

Step 3: Make the Cheese Sauce

In the same skillet, sprinkle 1/4 cup all-purpose flour over the onion, garlic, and turkey bacon mixture. Stir continuously for about 1 minute to cook the flour taste out. Gradually whisk in 2 cups milk, making sure to whisk constantly to avoid lumps. Bring the mixture to a gentle simmer and cook until it thickens, about 5 minutes.

Step 4: Add Cheese and Seasonings

Reduce the heat to low. Stir in 2 cups shredded smoked Gouda and 1 cup shredded cheddar cheese until melted and smooth. Season the cheese sauce with 1 teaspoon mustard powder, 1/2 teaspoon black pepper, 1/2 teaspoon paprika, and 1/2 teaspoon salt. Taste and adjust seasoning if needed.

Step 5: Combine Pasta and Cheese Sauce

Add the cooked elbow macaroni to the cheese sauce and stir until all the pasta is coated evenly.

Step 6: Prepare Breadcrumb Topping

In a small bowl, combine 1/2 cup breadcrumbs with 2 tablespoons melted butter. Mix well to coat the crumbs evenly with butter.

Step 7: Assemble and Bake

Transfer the cheesy macaroni mixture into a greased 9×9 inch baking dish. Sprinkle the breadcrumb mixture evenly over the top. Bake in a preheated oven at 350°F (175°C) for 25-30 minutes, or until the topping is golden brown and the casserole is bubbly around the edges.

Step 8: Serve and Enjoy

Remove from the oven and let it rest for 5 minutes before serving. This helps everything set and makes it easier to scoop out. Dig into your smoky, cheesy goodness!

Ingredient Flex Options

• Swap the turkey bacon for diced smoked chicken or turkey sausage for a different protein twist.
• Use whole milk or a 2% milk alternative like oat or almond milk for a lighter version.
• Try substituting smoked Gouda with smoked mozzarella or a smoked cheddar for a varied smoky flavor.
• For a gluten-free option, replace all-purpose flour with a gluten-free flour blend and use gluten-free breadcrumbs.
• Add sautéed mushrooms or roasted red peppers for extra veggies and flavor layers.

Mistakes That Ruin Smoky Gouda Macaroni Casserole

• Overcooking the pasta until mushy – The pasta should be al dente to hold its shape after baking.
• Not whisking the flour and milk properly – This can lead to lumps in your cheese sauce.
• Using pre-shredded cheese that contains anti-caking agents – It may prevent smooth melting. Always shred your cheese fresh.
• Skipping the mustard powder – It may seem minor, but this ingredient really elevates the cheese flavor.
• Not browning the breadcrumb topping with butter – The butter is key to achieving that crunchy, golden crust.

Save for Later: Storage Tips

Once cooled, cover the casserole tightly with plastic wrap or transfer leftovers to an airtight container. Refrigerate for up to 4 days.

To reheat, warm individual portions in the microwave or reheat the entire dish in a 350°F oven until heated through and bubbly again. You may want to add a little extra shredded cheese on top before reheating to refresh the gooey texture.

This casserole also freezes well. Freeze in airtight containers for up to 2 months. Thaw overnight in the fridge before reheating.

Ask & Learn

Can I make this Smoky Gouda Macaroni Casserole ahead of time?

Absolutely! You can assemble the casserole up to a day in advance, cover it tightly, and refrigerate. When ready, bake it as directed, just add a few extra minutes to ensure it’s heated through.

What’s the best way to get a crispy breadcrumb topping?

Mix your breadcrumbs with melted butter before sprinkling on top. This helps them brown evenly and crisp up beautifully in the oven.

Can I use a different type of pasta?

Yes! While elbow macaroni is traditional and works best for holding cheese sauce, penne, shells, or cavatappi also work well in this casserole.

How do I make this dish extra creamy?

Use whole milk or even add a splash of heavy cream to the cheese sauce. Also, make sure not to overbake the casserole, as that can dry it out.

Try These Next

• Mac And Cheese Style Pasta Bake – Another creamy, cheesy pasta dish with a unique twist.
• Four Cheese Baked Ziti – A deliciously cheesy baked pasta loaded with four types of cheese.
• Loaded Baked Mac Cheese With Bacon – A hearty mac and cheese loaded with crispy bacon and rich cheese sauce.

Before You Go

Make sure you have all your ingredients prepped before starting to cook – it really helps the process go smoothly. Don’t be shy about tasting your cheese sauce before baking; adjust seasoning to your liking. This Smoky Gouda Macaroni Casserole is a fantastic way to upgrade your pasta night with layers of smoky, cheesy, and crispy textures that everyone will love. Get ready for some serious comfort food magic!

Whether you’re serving this casserole for a cozy family dinner or bringing it to a gathering, it’s sure to impress with its rich flavors and inviting aroma. So grab your baking dish and get ready to savor every bite of this irresistible cheesy delight.

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