Costco Sausage Pasta Easy Copycat Recipe
This Costco sausage pasta recipe captures everything people love about the deli version: smoky sausage, a creamy tomato sauce, and rigatoni that holds onto every bit of it. It comes together in about 40 minutes, so it’s a real option on a Tuesday night.
Most of the work happens in one pan. That means less cleanup and a sauce that actually builds flavor as you go.
Why I Love This Recipe
The sauce does something nice here. The tomato and cream balance each other out, neither too sharp nor too rich, and the sausage fat seasons everything as it renders.
It reheats well, too. The rigatoni stays firm overnight because you pull it just before al dente, and the sauce tightens up into something even better the next day.
This is the version I keep coming back to when I need something filling that does not require much thinking.
Recipe Ingredients
- 1 lb (450g) rigatoni – The ridged shape catches sauce; penne works too
- 1 lb (450g) smoked beef or pork sausage, sliced into ½-inch rounds – Costco’s Kirkland smoked sausage is the direct match
- 1 tbsp olive oil – For browning the sausage
- 1 medium yellow onion, diced – Builds the savory base
- 4 garlic cloves, minced – Fresh only; jarred garlic goes flat in this sauce
- 1 tsp smoked paprika – Deepens the smoky note from the sausage
- ½ tsp red pepper flakes – Adds a gentle background heat; skip if cooking for kids
- 1 can (28 oz / 800g) crushed tomatoes – San Marzano variety gives a sweeter, less acidic result
- ½ cup (120ml) heavy cream – Rounds out the tomato’s sharpness
- ½ cup (120ml) pasta water, reserved – Loosens the sauce and helps it cling
- 1 tsp salt, plus more for pasta water – Kosher salt preferred
- ½ tsp black pepper – Freshly ground
- ½ cup (45g) grated Parmesan – For finishing; a Romano blend works here too
- 2 tbsp fresh flat-leaf parsley, chopped – Brightens the finished dish
Variations / Substitutions
- Chicken sausage – Works well and keeps the dish lighter; just watch the pan because it browns faster than pork or beef.
- Spicy Italian sausage (removed from casing) – Gives you a looser, crumbled texture in the sauce, closer to a Bolognese.
- Coconut cream instead of heavy cream – Keeps it dairy-free without adding a coconut flavor, though the sauce will be slightly thinner.
- Penne or ziti instead of rigatoni – Either shape holds the sauce well; avoid spaghetti since the chunky sausage doesn’t distribute evenly.
- Smoked gouda stirred in at the end – Melts into the sauce and adds a sharp, nutty note that works well with the smoked paprika.
- A squeeze of lemon instead of parsley – Cuts through the richness if the sauce tastes heavy to you.
If you like this, Costco Chicken Bake Copycat Recipe is worth trying next.
How To Make Sausage Pasta
Step 1: Sear the Sausage
Bring a large pot of heavily salted water to a boil over high heat, then set it aside while you start the sauce. In a wide, deep skillet or Dutch oven, heat the 1 tbsp olive oil over medium-high heat. Add the 1 lb sliced sausage in a single layer and cook for 3 to 4 minutes per side without moving them, until each round has a dark brown crust on both faces.
That crust matters. The browned bits that stick to the pan will dissolve into the sauce and give it a depth that you cannot get any other way. Once the sausage is browned, transfer it to a plate and leave the rendered fat in the pan.
Step 2: Soften the Onion and Garlic
Reduce the heat to medium. Add the diced onion to the same pan and cook for 5 to 6 minutes, stirring occasionally, until it turns soft and just translucent at the edges. Add the 4 minced garlic cloves, the 1 tsp smoked paprika, and the ½ tsp red pepper flakes. Stir everything together and cook for another 60 seconds.
The garlic should smell toasty and fragrant, not sharp and raw. If it starts to go brown before the minute is up, pull the pan off the heat briefly. Burnt garlic turns bitter fast and there is no fixing it once it happens.
Step 3: Simmer the Tomato Sauce
Pour in the 28 oz can of crushed tomatoes. Stir well to lift any browned bits from the bottom of the pan, then return the sausage (and any resting juices) to the pan. Season with the 1 tsp salt and ½ tsp black pepper. Bring to a gentle simmer over medium heat and cook uncovered for 12 to 15 minutes, until the sauce thickens slightly and deepens in color.
While the sauce simmers, drop the 1 lb rigatoni into your boiling water and cook for 2 minutes less than the package directions say. You want it just underdone because it will finish cooking in the sauce.
Step 4: Stir in the Cream and Pasta
Before you drain the rigatoni, scoop out ½ cup of the starchy pasta water and set it aside. Drain the pasta, then pour the ½ cup heavy cream into the simmering tomato sauce. Stir and let it cook together for 1 minute. Add the drained rigatoni straight into the pan and toss to coat, adding splashes of the reserved pasta water as needed to loosen the sauce until it clings without pooling at the bottom. This usually takes about 2 to 3 minutes over medium heat.
The pasta will absorb the sauce quickly at this stage. If it looks tight, add another splash of pasta water. The finished texture should be glossy and saucy, not soupy.
Step 5: Plate and Garnish
Spoon the pasta into warmed bowls. Shower each portion with the ½ cup grated Parmesan, dividing it evenly across the servings, then scatter the 2 tbsp chopped fresh parsley over the top. Serve immediately while the sauce is still loose and the cheese is just starting to melt into it.
Recipe Tips
- Slice the sausage on a slight angle to get more surface area per piece, which means more browning and more flavor in the sauce.
- Do not crowd the pan when searing – if your skillet is smaller than 12 inches, brown the sausage in 2 batches. Crowding steams the meat instead of searing it.
- Taste the sauce before adding salt at the end because smoked sausages vary a lot in their salt content; some brands are already quite salty and you may need little to none.
- Warm your serving bowls by filling them with hot tap water for a minute while the pasta finishes. Pasta in a cold bowl seizes up fast.
Cook times by pasta shape and pot size:
| Pasta Shape | Pot Size | Boil Time (al dente) |
|---|---|---|
| Rigatoni | 6 qt / 5.7L | 10 to 11 min |
| Penne | 6 qt / 5.7L | 9 to 10 min |
| Ziti | 6 qt / 5.7L | 10 to 11 min |
How To Store
- Refrigerate – Store leftovers in an airtight container for up to 4 days. The sauce thickens as it sits, which is not a bad thing.
- Reheating – Warm in a skillet over medium-low heat with a splash of water or chicken broth to loosen the sauce back up. Microwave works too at 2-minute intervals, stirring between each.
What To Serve With Sausage Pasta
A simple green salad with a sharp vinaigrette cuts through the richness of the cream sauce better than anything elaborate. Garlic bread is the obvious move, and it earns its place here because you will want something to drag through the sauce left in the bowl. If you want a vegetable on the plate, roasted broccoli holds up well next to the smoky sausage and does not go soggy by the time you sit down.
Frequently Asked Questions
Can I make this sauce ahead of time?
Yes. The tomato and sausage sauce keeps in the fridge for up to 3 days. Cook the pasta fresh when you’re ready to eat and combine them in the pan for 2 to 3 minutes.
Can I freeze this dish?
Freeze the sauce only, not the assembled pasta. Cooked rigatoni turns grainy after freezing. The sauce freezes well for up to 2 months in an airtight container.
What sausage does Costco actually use?
The Costco deli version uses their Kirkland Signature fully cooked smoked sausage. It’s a beef and pork blend, which is why this recipe calls for a smoked sausage rather than a fresh one.
Can I make this without cream?
Yes. Replace the heavy cream with ¼ cup of the pasta water plus 2 tbsp of cream cheese stirred in off the heat. The sauce will be thinner but still cohesive.
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Ingredients
Method
- Heat 1 tbsp olive oil in a large skillet over medium-high heat. Sear the 1 lb sliced sausage for 3 to 4 minutes per side until deeply browned, then transfer to a plate.
- Reduce heat to medium. Cook the diced onion in the same pan for 5 to 6 minutes until soft, then add the 4 minced garlic cloves, 1 tsp smoked paprika, and ½ tsp red pepper flakes and stir for 60 seconds.
- Pour in the 28 oz crushed tomatoes, return the sausage to the pan, season with 1 tsp salt and ½ tsp black pepper, and simmer uncovered for 12 to 15 minutes. Meanwhile, cook the 1 lb rigatoni in heavily salted boiling water for 2 minutes less than package directions.
- Reserve ½ cup pasta water, drain the rigatoni, stir the ½ cup heavy cream into the sauce, then add the pasta and toss over medium heat for 2 to 3 minutes, adding pasta water as needed until the sauce clings.
- Spoon into bowls, top with ½ cup Parmesan and 2 tbsp chopped parsley, and serve immediately.
