Smoky Cheesy Italian Shells: A Wood-Fired Comfort Dish

If you’re a fan of hearty, cheesy pasta dishes with a hint of smoky flavor, then this recipe for Smoky Cheesy Italian Shells is about to become your new favorite. Perfectly baked and infused with the rich aroma of wood-fired goodness, this dish is ideal for family dinners, holiday gatherings, or even meal prep. Whether you’re using a Traeger pellet grill or your trusty oven, this dish delivers layers of creamy, savory deliciousness that everyone will love.

Why You’ll Love This Recipe

1. Smoky and Cheesy Perfection – The subtle smokiness from the grill complements the gooey cheese and savory fillings beautifully.
2. Perfect for Any Occasion – Impress your guests at dinner parties or enjoy it as a cozy weeknight meal.
3. Customizable – Adjust the spice level, swap out proteins, or add veggies to make it uniquely yours.
4. Easy Prep – With straightforward instructions and minimal hands-on time, even beginner cooks can master this recipe.
5. Crowd-Pleasing Flavors – Combining ricotta, mozzarella, marinara, and fresh herbs, every bite is packed with classic Italian-inspired flavors.

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
• Lean ground protein (such as turkey or plant-based alternatives)
• 1 cup ricotta cheese
• 1 cup shredded mozzarella cheese
• ½ cup grated Parmesan cheese
• 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 heat)
• 1 teaspoon smoked paprika (for extra depth)

For Toppings:

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

Step-by-Step Instructions

Step 1: Preheat Your Grill or Oven

Set your Traeger pellet grill to 325°F and allow it to preheat for about 15 minutes. If using an oven, set it to 375°F. Choose wood pellets like hickory, cherry, or oak for a balanced smoky flavor. These woods provide just enough aroma without overpowering the dish.

Step 2: Cook the Pasta Shells

Bring a large pot of salted water to a boil. Add the jumbo pasta shells and cook until they’re slightly firmer than al dente—this helps them hold their shape during baking. Drain the shells and spread them out on a baking sheet lined with parchment paper to cool completely. Cooling prevents the shells from sticking together and makes them easier to handle when stuffing.

Step 3: Prepare the Filling

In a skillet over medium heat, brown your chosen protein until fully cooked through. Break it into small crumbles as it cooks for better incorporation into the filling. Once done, drain any excess fat and transfer the meat to a mixing bowl.

To the same bowl, add ricotta, mozzarella, Parmesan, egg, garlic powder, Italian seasoning, salt, and black pepper. Stir everything together until well combined. The ricotta adds creaminess, while the mozzarella ensures stretchy, melty bites throughout the dish.

Step 4: Assemble the Dish

Using a spoon, carefully stuff each cooled pasta shell with the cheese-and-protein mixture. Be gentle to avoid tearing the shells. Place the stuffed shells in a single layer inside a cast-iron skillet or aluminum baking pan. Spread half of the marinara sauce evenly across the bottom of the pan before arranging the shells. Pour the remaining sauce over the top, ensuring all the shells are generously coated.

Step 5: Smoke or Bake the Shells

Place the assembled dish onto the preheated grill or in the oven. If smoking, let the shells cook uncovered for 30–40 minutes, or until the sauce begins to bubble around the edges. For added cheesiness, sprinkle the remaining mozzarella and Parmesan on top during the last 10–15 minutes of cooking. This creates a golden, bubbly crust that’s irresistible.

If baking in the oven, cover the dish loosely with foil for the first 30 minutes to prevent the shells from drying out. Then, remove the foil, add the cheese topping, and bake for an additional 10–15 minutes until golden brown.

Step 6: Let It Rest and Serve

Once the dish is finished cooking, let it rest for 5 minutes before serving. This allows the flavors to meld and the sauce to thicken slightly. Garnish with fresh basil leaves for a pop of color and freshness. Serve hot alongside garlic bread, Caesar salad, or roasted vegetables for a complete meal.

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Serving Suggestions and Storage Tips

This recipe serves 6–8 people, making it perfect for feeding a crowd. Leftovers can be stored in an airtight container in the refrigerator for up to 4 days. To reheat, warm individual portions in the microwave in short bursts or place the entire dish in the oven at 300°F for about 15 minutes.

For longer storage, freeze unbaked stuffed shells in a freezer-safe dish wrapped tightly with plastic wrap and aluminum foil. They’ll keep for up to 3 months. When ready to bake, thaw overnight in the fridge and bake at 350°F for 50 minutes, or bake directly from frozen, increasing the time by about 10–15 minutes.

Variations to Try

1. Spicy Version: Add more red pepper flakes or use hot Italian seasoning for a fiery kick.
2. Meatless Option: Replace the protein with sautéed mushrooms, spinach, or zucchini for a vegetarian twist.
3. Alfredo Shells: Swap marinara for Alfredo sauce and mix in shredded chicken for a creamy alternative.
4. Four-Cheese Shells: Experiment with different cheeses like provolone, fontina, or gouda for a richer flavor profile.
5. Keto-Friendly: Use thinly sliced zucchini or eggplant instead of pasta shells for a low-carb option.

Frequently Asked Questions (FAQs)

What’s the best wood for smoking stuffed shells?

Hickory, cherry, and oak are excellent choices because they impart a mild yet distinct smoky flavor that enhances the dish without overwhelming it.

Can I make this ahead of time?

Absolutely! Assemble the stuffed shells up to 24 hours in advance and store them covered in the refrigerator. Simply pop them in the oven or smoker when ready to cook.

How do I prevent the shells from drying out?

Cover the dish loosely with foil for the first half of the cooking process to lock in moisture. Alternatively, adding a splash of heavy cream to the filling can boost creaminess.

Can I substitute marinara sauce?

Yes! Try swapping marinara for Alfredo, pesto, or even a white wine sauce for a unique twist.

What should I serve with this dish?

Pair these cheesy shells with garlic bread, a crisp green salad, or roasted broccoli for a well-rounded meal.

Can I double the recipe?

Definitely! Use a larger baking dish and increase the cooking time by approximately 10 minutes to ensure the center heats through.

Final Thoughts

Smoky Cheesy Italian Shells are the ultimate comfort food, combining tender pasta, creamy fillings, and a touch of wood-fired magic. Whether you’re hosting a dinner party or simply craving something indulgent, this dish has you covered. Fire up your grill or oven, gather your ingredients, and prepare to wow your taste buds—and maybe even your friends and family—with this unforgettable creation. Don’t forget to share your results with us; we’d love to see how your version turns out!

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