Cheesy Smoked Italian Pasta Shells: A Flavorful Twist on a Classic Dish

This Cheesy Smoked Italian Pasta Shells recipe combines the best of comfort food with a touch of smoky flair. By utilizing the Traeger grill, these stuffed pasta shells are infused with a deliciously subtle wood-fired flavor that elevates the classic baked pasta dish. Packed with cheesy goodness from ricotta, mozzarella, and Italian sausage, all nestled in marinara sauce and topped with a golden, bubbly cheese layer, this dish offers the ultimate indulgence for any occasion.

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Why This Recipe Is a Must-Try

• Smoky, Cheesy Goodness: The Traeger grill enhances the flavors with a perfect balance of smokiness, taking this dish to the next level.
• Ideal for Gatherings: This dish is perfect for family dinners, parties, or special occasions, and can be made ahead of time for convenience.
• Rich, Flavorful Italian Taste: The savory combination of Italian sausage, ricotta, and marinara sauce will leave everyone craving more.
• Versatile and Customizable: You can tailor the recipe by experimenting with different cheeses, meats, and sauces to suit your tastes.
• Baked to Perfection: The Traeger gives the dish a beautiful golden-brown cheese topping that’s simply irresistible.

Ingredients

(Tip: You’ll find the full list of ingredients and measurements in the recipe card below.)

For the Filling:

• 1 box jumbo pasta shells
• 1 lb Italian sausage (mild or spicy)
• 1 cup ricotta cheese
• 1 cup mozzarella cheese, shredded
• ½ cup Parmesan cheese, grated
• 1 egg
• 1 teaspoon garlic powder
• 1 teaspoon Italian seasoning
• ½ teaspoon salt
• ½ teaspoon black pepper

For the Sauce:

• 2 cups marinara sauce (store-bought or homemade)
• 1 teaspoon red pepper flakes (optional for extra heat)
• 1 teaspoon smoked paprika (adds extra smoky depth)

Toppings:

• 1 cup mozzarella cheese, shredded
• ½ cup Parmesan cheese, grated
• Fresh basil, for garnish

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Directions

Step 1: Preheat the Traeger

Begin by preheating your Traeger to 325°F. Let it warm up for about 15 minutes. Use hickory, oak, or cherry wood pellets to infuse a rich, smoky flavor into your dish.

Step 2: Cook the Pasta

Cook the jumbo pasta shells in salted water until they are al dente. Once cooked, drain the pasta and set it aside to cool. Make sure the shells are not overcooked, as they will continue to cook when they’re baked in the sauce.

Step 3: Prepare the Filling

• Brown the Sausage: In a skillet over medium heat, cook the Italian sausage until it’s browned. Once cooked, drain any excess fat and set it aside.
• Mix the Cheeses: In a large mixing bowl, combine the ricotta cheese, shredded mozzarella, grated Parmesan, egg, garlic powder, Italian seasoning, salt, and black pepper. Stir the ingredients together until they are well incorporated.
• Add the Sausage: Stir in the browned sausage to the cheese mixture, ensuring that it’s evenly distributed.

Step 4: Assemble the Dish

• Stuff the Shells: Carefully spoon the cheese and sausage mixture into each cooked pasta shell.
• Prepare the Baking Dish: Spread half of the marinara sauce evenly in a cast-iron skillet or aluminum baking dish.
• Arrange the Stuffed Shells: Place the stuffed pasta shells in the dish, ensuring they are arranged in a single layer. Pour the remaining marinara sauce over the shells.

Step 5: Smoke the Cheesy Shells

• Place on the Traeger: Set the assembled dish on the Traeger grill. Close the lid and smoke the shells for about 30–40 minutes until the sauce is bubbling.
• Add the Cheese Topping: After 30–40 minutes, sprinkle the remaining shredded mozzarella and Parmesan cheese on top of the shells. Close the lid and let it cook for an additional 10–15 minutes, until the cheese is melted and golden brown.

Step 6: Serve and Enjoy

• Rest the Dish: Once the shells are fully cooked, remove the dish from the Traeger and let it rest for about 5 minutes.
• Garnish: Sprinkle fresh basil on top for a burst of color and a hint of freshness.
• Serve: Serve the cheesy smoked Italian shells hot and enjoy the rich flavors!

Servings and Timing

• Servings: 6–8
• Prep Time: 20 minutes
• Cook Time: 50–55 minutes
• Total Time: 1 hour 15 minutes

Recipe Variations

• Spicy Version: Use hot Italian sausage for a kick, and add extra red pepper flakes for additional heat.
• Meatless Option: Replace the sausage with sautéed mushrooms and spinach for a vegetarian-friendly version.
• Alfredo Shells: For a creamy twist, swap the marinara sauce with Alfredo sauce and add shredded chicken.
• Four-Cheese Shells: Mix ricotta, mozzarella, provolone, and Parmesan cheeses for a cheesy explosion.
• Keto-Friendly: Substitute the pasta shells with zucchini slices or eggplant to make a low-carb version.

Storage and Reheating

• Storage: Keep any leftovers in an airtight container in the refrigerator for up to 4 days.
• Reheating: Warm the dish in the oven at 300°F for about 15 minutes, or reheat in the microwave using short bursts.
• Freezing: You can freeze the unbaked shells in a dish covered with plastic wrap and foil for up to 3 months. When ready to bake, cook from frozen at 350°F for 50 minutes.

Frequently Asked Questions

What’s the best wood for smoking stuffed shells?

Hickory, cherry, and oak are excellent choices for smoking stuffed shells. These woods provide a balanced smokiness that complements the cheesy filling without overpowering the flavors.

Can I make this ahead of time?

Yes! You can assemble the shells ahead of time and refrigerate them for up to 24 hours before smoking. This makes it a great option for meal prep or when hosting a gathering.

Can I use ground beef instead of Italian sausage?

Yes! Ground beef or turkey can replace the sausage. Be sure to adjust the seasoning to maintain the savory flavor.

How do I prevent the shells from drying out?

To retain moisture, loosely cover the dish with foil for the first 30 minutes of smoking. This will help keep the shells tender.

Can I cook this in a regular oven?

Absolutely! If you don’t have a Traeger, you can bake the dish at 375°F for 35–40 minutes. Finish by broiling the top for a few minutes to get a crispy, golden finish.

How can I make this extra creamy?

For a richer, creamier texture, mix in some heavy cream or an extra scoop of ricotta cheese before stuffing the shells.

Do I need a cast-iron skillet?

While a cast-iron skillet helps retain heat and enhances the smoky flavor, it’s not necessary. A regular baking dish or aluminum pan will work just fine.

Can I add vegetables to the dish?

Definitely! You can add sautéed mushrooms, spinach, or zucchini to the filling for added nutrition and flavor.

What should I serve with this dish?

Pair these cheesy smoked shells with garlic bread, a Caesar salad, or roasted vegetables for a complete and satisfying meal.

Can I double the recipe?

Yes! To make a larger batch, use a bigger baking dish and increase the cooking time by about 10 minutes.

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Conclusion

Cheesy Smoked Italian Pasta Shells are a rich, flavorful dish that’s perfect for any occasion. The combination of creamy ricotta, savory sausage, and marinara sauce is enhanced with the smoky depth from the Traeger grill. This dish is guaranteed to become a family favorite, whether you’re preparing it for a casual dinner or a special event. Fire up your Traeger, and treat yourself to this mouthwatering twist on classic stuffed shells!