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A dish filled with baked Squash, Kale and Sausage Stuffed Shells is being served out, with one plate containing gooey cheese covered shells to the side.

Squash, Kale and Sausage Stuffed Shells

A cozy autumn meal doesn't get any better than these gooey, cheesy stuffed jumbo shells. A combination of roasted and pureed squash, kale and Italian sausage is enhanced with a sage scented bechamel sauce and plenty of fresh grated mozzarella. Here is the full amount to feed eight, but easily divide in half for a family of four.
Course Main Course
Cuisine North American
Keyword sage bechamel sauce, squash, kale, sausage, stuffed shells
Prep Time 1 hour
Cook Time 30 minutes
Servings 8

Ingredients

Filling

  • 4 cups cubed butternut squash, about one medium squash, or 2 smaller ones, see Notes
  • 2 tbsp olive oil, divided, more as needed
  • 1/2 tsp each salt and pepper, or a bit more as desired
  • 2 medium Italian sausages, hot or mild, approximately 293 grams or 10 oz
  • 1 small onion, finely diced
  • 2 garlic cloves, minced
  • 2 cups lacinato kale, chopped small
  • 475 g (16 oz) tub Smooth Ricotta cheese, If your tub of ricotta is a bit smaller or a bit larger, don't worry, use what you can find.
  • 45 g 1/2 cup parmesan cheese
  • 1 tsp nutmeg
  • 1/2 tsp kosher salt, more if needed
  • 1/2 tsp black pepper
  • 1 egg

Sage Bechamel Sauce

  • 57 g 1/4 cup butter, cubed
  • 33 g 1/4 cup flour, can use a cup for cup gluten free blend
  • 1 litre 4 cups milk, whole milk, or even half and half if you want the sauce to be richer.
  • 1/4 tsp nutmeg
  • salt and pepper to taste
  • 2 tbsp finely chopped fresh sage leaves
  • 1 package jumbo shells, (12 oz or 340 grams) There should be roughly 30 or so shells in one package
  • 170 g (1 1/2 cups) freshly grated mozzarella cheese, or more if desired!
  • 15 or so medium fresh sage leaves, left whole
  • 1/2 tsp olive oil

Instructions

Roast the Squash

  1. Preheat the oven to 400F. Line a baking sheet(s) with parchment paper. In a bowl, toss the cubed squash with 1 tbsp olive oil, salt and pepper to coat evenly. If you need more oil, go ahead and drizzle just a bit more, to cover the cubes evenly.
  2. Spread out the cubes evenly on the prepared sheet(s) Roast in the centre of the oven till the squash is tender and just starting to crisp up on the edges. A fork should easily slide into the cubes. This should take around 30 minutes, depending on your oven.
  3. Place the squash into a bowl and use a potato masher to create a smoothish puree. You can also use a blender if so desired. You may just need to add a splash of water to help the squash move in the blender. Set aside to cool. You will need 2 cups of pureed squash for this recipe. Any remaining squash can be stored in the fridge or even the freezer.

Filling

  1. Remove the sausage filling from the casings. Heat a skillet over medium high heat and add the sausage meat. Cook till crispy, breaking up the meat into small crumble. Once cooked through, transfer to a large bowl.

  2. Add 1 tbsp olive oil if there is no fat remaining in the skillet. Saute the onion till starting to soften, about 8 minutes. Add in the garlic and cook another 2 minutes. Add the kale and saute till softened. If more oil is needed, add another 1/2 tbsp or so. Set aside to cool down a bit.

  3. In the large bowl with the crumbled cooked sauasge meat, add 2 cups of pureed squash, the ricotta cheese, the sauteed onion, garlic and kale, the parmesan cheese, nutmeg, salt and pepper. Whisk an egg and add to the mixture. Stir to evenly blend. Set aside while you prepare the pasta shells and Sage Bechamel Sauce.

  4. Prepare the shells per the package directions in a large pot of salted water. Drain well.

Sage Bechamel Sauce

  1. Preheat the oven to 400F
  2. In a large skillet set over medium high heat, add the cubed butter. Once it has melted and is starting to bubble, add the flour gently. Whisk till the flour and butter combine. Continue whisking for another two minutes, to cook out any rawness from the flour.
  3. Slowly add in the milk, about 1/3 cup at a time, whisking continuously. Keep doing so, till all the milk has been incorporated. Once the milk is bubbling and starting to thicken, take the pan off the heat and stir in the nutmeg, salt and pepper, and chopped sage leaves. Taste and reseason as desired.
  4. Prepare a large baking dish ( 9x13 inch or so) by coating it with a thin layer of oil or non stick spray.
  5. Spread a thin layer of the Sage Bechamel Sauce across the bottom of the baking dish.

  6. Using a tablespoon, fill each cooked shell with a good amount of th Squash filling. Place the stuffed shells onto the sauce covered baking dish. Continue till you have filled all the shells. There should be enough filling for 32 or so shells.

  7. Drizzle the remaining Sage Bechamel Sauce over the stuffed shells. Scatter the grated mozzarella cheese evenly over the shells.
  8. Place the fresh sage leaves in a small bowl and drizzle with a little olive oil. Use your fingers to brush the oil evenly over the leaves. Place the leaves evenly over the cheese.
  9. Bake the stuffed shells till the sauce is bubbling and the cheese is turning golden brown, This should take about 20-25 minutes.
  10. Let the shells rest for a few minutes to help the filling set which will make it easier to serve them intact.

Recipe Notes

Use any squash you like. You can also used canned pumpkin. In the end you will want about 2 cups of pureed squash. You can prepare the squash in advance. I am including my method for roasting and pureeing Honeynut Squash here.
The filling is enough for 30-32 jumbo shells. This should easily feed 6-8 depending on whether you are serving this as a main or side.
Feel free to omit the sausage if you want to serve this as a vegetarian dish.
Leftovers will keep in a sealed container in the fridge for a few days. Reheat in the oven or toaster oven at 375F till warmed through and the cheese is melty again.
You can prepare the dish, covering the shells with the sauce and then freeze n(omiting the grated cheese and sage leaves). Bake from frozen, adding 10-15 minutes extra time to ensure the filling is heated through. Add the cheese and sage leaves halfway through the baking process.
For best results, thaw the dish in the fridge overnight before baking as you normally would. While the oven warms up, grate the cheese and prepare the sage leaves. Add to the thawed dish and bake as per the recipe.