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Chili Macaroni Casserole

This is a delicious layered dish of chili and macaroni and cheese, topped with tortilla chips and cheese for a nice crunch. Serve with a dollop of sour cream. My family loves it!
Print Recipe
Prep Time 15 minutes
Cook Time 55 minutes
Total Time 1 hour 10 minutes
Course lunch/dinner
Cuisine American
Servings 12 people
Calories 7551.1 kcal

Equipment

  • 1 Large Pot For cooking macaroni
  • 1 Colander For draining pasta
  • 1 Large Skillet For preparing chili
  • 1 Saucepan For making cheese sauce
  • 1 10x15-inch Baking Dish For assembling and baking the casserole

Ingredients
  

Main

  • 1 16 ounce package elbow macaroni
  • 2 pounds lean ground beef
  • ½ cup chopped onion
  • 2 8 ounce cans tomato sauce
  • 1 14.5 ounce can diced tomatoes
  • 1 14 ounce can whole kernel corn, drained
  • 1 15 ounce can kidney beans, rinsed and drained
  • 1 1.25 ounce package taco seasoning mix
  • 1 1.25 ounce package chili seasoning mix
  • 1 10.75 ounce can condensed cheddar cheese soup
  • 1 10.75 ounce can milk
  • 1 cup shredded Cheddar cheese
  • ½ cup sour cream Optional
  • 1 ½ teaspoons garlic powder
  • ½ teaspoon salt
  • ½ teaspoon black pepper
  • 1 cup shredded Cheddar cheese
  • 1 cup crushed tortilla chips
  • ½ cup sour cream Optional

Instructions
 

  • Preheat oven to 350 degrees F (175 degrees C).
  • Fill a large pot with lightly salted water and bring to a rolling boil over high heat. Once the water is boiling, stir in the macaroni, and return to a boil. Cook the pasta uncovered, stirring occasionally, until the pasta has cooked through, but is still firm to the bite, about 8 minutes. Drain well in a colander set in the sink.
  • In a large skillet over medium heat, cook and stir the ground beef with onion until the meat is browned, about 10 minutes. Break the meat up into crumbles as it cooks; drain excess grease. Mix in the tomato sauce, diced tomatoes, corn, kidney beans, taco seasoning, and chili seasoning; bring to a boil, reduce heat to a simmer, and cook, stirring occasionally, for about 20 minutes.
  • Whisk the Cheddar cheese soup and milk in a saucepan until smooth, and bring to a simmer over medium-low heat. Whisk in 1 cup of shredded Cheddar cheese, 1/2 cup of sour cream, and garlic powder; season to taste with salt and black pepper.
  • Arrange the cooked macaroni into the bottom of a 10x15-inch baking dish, and mix with the soup mixture. Pour the ground beef chili over the macaroni, and sprinkle with 1 more cup shredded Cheddar cheese and crushed tortilla chips.
  • Bake in the preheated oven until the casserole is hot and bubbling and the cheese topping has melted, 20 to 30 minutes. Serve topped with dollops of sour cream.

Notes

To elevate this chili mac, consider browning your ground beef until deeply caramelized, building a richer umami base. For the chili, incorporating a touch of smoked paprika or a dash of chipotle in adobo will add depth and a subtle smoky heat. When making the cheese sauce, ensure it's smooth and lump-free; a sharp cheddar can replace or supplement some of the mild cheddar for a more pronounced cheese flavor. Be mindful not to overcook the macaroni, as it will continue to cook in the oven. For a superior crust, you can toast the tortilla chips briefly before crushing and adding them, or even mix them with a small amount of melted butter.