San Giorgio Mac and Cheese Recipe: Ultra Creamy Shells With a Crispy Top

There’s a reason San Giorgio shells are mac and cheese royalty—their perfect shape holds creamy cheese sauce like no other. I’ve refined this recipe to deliver that ideal balance of smooth, velvety pasta coating with just the right amount of resistance in each bite.

The secret lies in the sauce construction: a proper roux base ensures the cheese integrates seamlessly without separating. Layering the shells with sauce before baking creates pockets of creamy goodness, while the final bake develops that promised crispy golden top.

What emerges from the oven is comfort food perfection—tender shells enrobed in rich cheese sauce, capped with a buttery breadcrumb crust that shatters with each spoonful. The texture contrast between the crispy topping and creamy interior makes this dish unforgettable.

This method guarantees restaurant-quality results every time, with no curdled sauce or soggy noodles. The process is straightforward but precise, delivering on both key promises without compromise.

Ingredients for San Giorgio Mac and Cheese

Premium cheeses and San Giorgio shells create that signature creamy interior with crispy breadcrumb topping everyone loves.

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The cheeses are non-negotiable for optimal melt and flavor. Cabot or Tillamook sharp cheddar delivers the right tang, while Gruyère from Whole Foods adds nutty complexity. Avoid pre-shredded—it contains anti-caking agents that disrupt sauce smoothness. The shells must be San Giorgio jumbo; their ruffled edges hold sauce perfectly. For the vegetarian Worcestershire, Annie’s or Edward & Sons are reliable brands.

Short on Gruyère? Fontina or Monterey Jack at equal amounts work well. No jumbo shells? Cavatappi or elbow macaroni are acceptable substitutes (adjust cook time). The milk can be 2% if needed, but whole yields the creamiest sauce. For extra depth, add a pinch of nutmeg to the cheese mixture. The Dijon mustard is key—don’t substitute yellow mustard.

Assemble and bake immediately for best texture contrast. Leftovers keep 4-5 days refrigerated, though the topping softens. Reheat covered with foil at 350°F for 15 minutes. Freezes well for 3 months—thaw overnight before reheating.

Step-by-Step Instructions for San Giorgio Mac and Cheese

Achieve ultra creamy shells with a perfectly crisp topping using this refined technique.

Step 1: Cook and Prepare the Shells

Cook the 12 oz San Giorgio Jumbo Shells al dente according to package instructions, then drain immediately. The shells should be firm to the bite, as they will continue cooking in the oven. Rinse briefly with cool water to stop the cooking process and prevent sticking.

While the shells cook, preheat your oven to 375°F and grease a 9×13-inch baking dish with a portion of the 0.5 cup Unsalted Butter. This prevents the final dish from sticking during baking and ensures easy serving.

Step 2: Create the Velouté Base

In a large saucepan over medium heat, melt the remaining Unsalted Butter. Add the 0.33 cup All-Purpose Flour and whisk constantly for 2-3 minutes until the mixture turns a light golden color and emits a nutty aroma. This roux is the foundation for your cheese sauce.

Gradually pour in the 3 cups Whole Milk while whisking continuously to prevent lumps. Cook, stirring frequently, until the mixture thickens enough to coat the back of a spoon, about 5-7 minutes. The sauce should be smooth and velvety.

Step 3: Build the Cheese Sauce

Reduce heat to low and stir in the 1 tbsp Dijon Mustard, 1 tsp Worcestershire Sauce, 0.5 tsp Garlic Powder, 0.5 tsp Onion Powder, 1.5 tsp Kosher Salt, and 0.25 tsp Ground White Pepper. These seasonings enhance the depth of flavor without overpowering the cheese.

Add the 3 cups Sharp Cheddar Cheese, 1.5 cups Gruyère Cheese, and 0.5 cup Parmesan Cheese, stirring after each addition until fully melted and smooth. The sauce should be rich, creamy, and free of any graininess.

Step 4: Assemble and Top the Dish

Combine the cooked shells with the cheese sauce in a large bowl, ensuring every shell is thoroughly coated. Transfer the mixture to the prepared baking dish, spreading it evenly. The shells should be mostly submerged in the sauce to prevent drying out.

In a small bowl, mix the 1 cup Panko Breadcrumbs with a bit of melted Unsalted Butter if needed for moisture. Sprinkle this evenly over the top of the shells, pressing down lightly to help it adhere. This topping will bake into a golden, crispy layer.

Step 5: Bake to Perfection

Bake in the preheated oven for 20-25 minutes or until the top is golden brown and the edges are bubbling. The breadcrumbs should be crisp and deeply colored, while the sauce underneath remains creamy.

Remove from the oven and let rest for 5 minutes before garnishing with the 0.25 cup Fresh Parsley, finely chopped. This allows the dish to set slightly, making it easier to serve while maintaining its creamy texture.

Essential Equipment for This Recipe

Quality Saucepan

A heavy-bottomed 3-quart saucepan prevents hot spots that can scorch your roux. I swear by my All-Clad Stainless—it distributes heat evenly and lasts forever. Avoid nonstick for cheese sauces as they can’t handle high heat needed for proper roux development.

Whisk Selection

Use a balloon whisk for your roux and sauce—its shape fits perfectly in saucepan corners. The OXO Good Grips 11-inch is my go-to. A flat whisk works too, but requires more elbow grease to prevent lumps in your velouté base. 💪

Baking Dish

A 9×13-inch glass or ceramic dish gives the perfect surface area for crispy topping while allowing sauce to bubble up. I use Pyrex because it’s durable and lets me monitor browning. Metal pans work but may require adjusted baking times.

Cheese Grater

Freshly grated cheese melts better than pre-shredded. A box grater with multiple sides handles cheddar, Gruyère, and Parmesan efficiently. For speed, the Cuisinox 4-sided is worth the investment. Always grate just before using to prevent drying out.

Fine Mesh Strainer

If your sauce develops any lumps, a fine mesh strainer saves the day. I keep a 5-inch strainer handy for quick fixes. Press the sauce through with a spatula for silky smooth results—this is my secret for restaurant-quality texture.

Long-Handled Spoon

A wooden spoon with a long handle lets you stir the sauce and fold in shells without burning your hands. The 12-inch OXO spoon reaches deep into pots. Wood won’t scratch your cookware or react with acidic ingredients like metal might.

Frequently Asked Questions