Costco Deli Mac and Cheese
"That giant $12.99 tray of baked mac from the Costco deli — except homemade, cheesier, and with a breadcrumb topping that actually crunches."
Costco Copycat — This is a homemade version of the Costco Deli & Prepared Foods item. See it in store →
The Game Plan
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Preheat oven to 375°F. Lightly grease a 9x13 baking dish with butter or cooking spray.
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Bring a large pot of well-salted water to a rolling boil. Cook pasta one minute short of the package directions — it's going in the oven next, so you want it slightly underdone. Drain and set aside.
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In the same pot over medium heat, melt 4 tablespoons of butter. Whisk in the flour and cook for about 1 minute, stirring constantly, until it smells toasty and turns a shade darker. This is your roux — it's what keeps the sauce from being a watery disaster.
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Slowly pour in the milk and heavy cream, whisking nonstop to avoid lumps. Bring to a gentle simmer and cook for 3-4 minutes until the sauce thickens enough to coat the back of a spoon.
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Remove from heat. Stir in the sharp cheddar, Gruyère, and Monterey Jack a handful at a time, stirring between additions until each batch is fully melted. Off-heat melting is the key to a smooth sauce — direct heat makes cheese seize up and get grainy.
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Stir in the Dijon mustard, garlic powder, smoked paprika, and cayenne if using. Season generously with salt and pepper. Taste it — the sauce should be aggressively flavorful since the pasta will mellow everything out.
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Fold the cooked pasta into the cheese sauce until every nook is coated. Pour the whole thing into your prepared baking dish and spread it out evenly.
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In a small bowl, toss panko breadcrumbs with the 2 tablespoons of melted butter until evenly coated. Scatter over the top of the mac in an even layer.
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Bake for 20-25 minutes until the top is golden brown and the edges are bubbling. If the crumbs aren't browning fast enough, flip the broiler on high for 60-90 seconds — but stand there and watch it. Broilers don't forgive.
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Let it rest for 5 minutes before serving. This is the hardest part. The resting lets the sauce set up so it's creamy instead of running off the spoon like soup.
