Easy Layered Zucchini and Orzo Bake with Whipped Tofu and Feta

This site contains affiliate links, view the disclaimer page for more information.

This Zucchini and Orzo bake is one of my favorite easy weeknight dinners. It’s cozy, flavorful, and feels fancy without being complicated. I make it when I want comfort food but still want to load up on veggies. And the best part? The whipped tofu and feta mixture adds a creamy, cheesy layer without being heavy. It’s kind of like ricotta in lasagna, but lighter and tangier and it holds the layers all together.

When I first made this recipe it started as a Zucchini Lasagna, I’ll be honest, it was a watery mess. I layered all this beautiful zucchini, poured on tomato sauce, and thought it would come out of the oven like a lasagna. Instead, I got a soggy puddle with zucchini slices swimming around in it. I remember trying to salvage it by scooping out water from the sides with a spoon. Not exactly dinner-party worthy. But here’s the thing, I loved the flavors, and I knew this dish had potential. So, I went back to the kitchen, tried again, and figured out the perfect fix: adding orzo to soak up the extra water and create a firm, delicious bottom layer.

If you’re looking for a veggie-forward dinner that’s satisfying, customizable, and looks beautiful on the table, you’re going to love this Zucchini and Orzo bake.

A hand holding a spoon is spreading tomato sauce over layered zucchini slices in a baking dish, with additional sliced zucchini nearby.

Why You’ll Love This Zucchini and Orzo Bake

Let me break it down for you, because this isn’t just another casserole.

It’s easy. The hardest part is slicing the zucchini, and if you have a vegetable peeler or mandoline, it’s done in minutes. I use this mandoline and it makes prep a breeze.
It’s hearty but healthy. Between the zucchini, tomato sauce, and orzo, you get a filling dinner that won’t weigh you down.
It’s flexible. Want it vegan? Leave out the feta. Gluten-free? Swap in chickpea orzo.
It’s one-pan magic. Seriously, everything bakes together in one casserole dish.
It’s a crowd-pleaser. Even people who don’t love tofu won’t guess it’s in there.

I’ve made this Zucchini and Orzo bake for my family, and I’ve also made it for friends who came over on a weeknight. Every single time, someone asks me for the recipe.

A slice of Zucchini and Orzo bake served on a white plate beside the casserole dish on a table with a striped tablecloth and a brick wall in the background.

The Ingredients for Zucchini and Orzo Bake

Here’s what you’ll need. Nothing fancy, just good, solid ingredients that come together in a delicious way.

24 oz jar of tomato sauce – You can go homemade, but honestly, a good jarred sauce works great. I like one that’s herby and not too sweet.
½ cup orzo – Regular orzo works perfectly, but if you’re gluten-free, try chickpea orzo or rice.
4 tbsp olive oil – Divided between the whipped mixture, the baking dish, and maybe a drizzle on top.
4 zucchinis – Medium size works best. Too big, and the seeds make the slices watery.
1 block of firm tofu (14 oz) – Drain it well. This is the creamy base of the whipped mixture.
1 block feta – Adds tang and richness. Omit for vegan, or swap in a plant-based feta.
Italian spices – Think oregano, basil, thyme, or use a premade Italian seasoning mix.
Salt & pepper – To taste. Don’t skip it.
Optional toppings – Shredded mozzarella, parmesan, or a dollop of pesto.

A wooden surface with a casserole dish filled with orzo and olive oil, a bowl of tomato sauce with a spoon, a plate of zucchini ribbons, and a food processor containing whipped tofu mixture.

Step-by-Step Instructions

I’m going to walk you through exactly how I make my Zucchini and Orzo bake. I’ve tested this method enough times to know it works.

Step 1: Prep the zucchini

Wash your zucchini, trim off the ends, and slice it lengthwise into ribbons. I like using a vegetable peeler because it gives me nice, thin, flexible slices. A mandoline works too, just be careful with your fingers. You want long strips, almost like zucchini lasagna sheets.

A baking dish with layers of thinly sliced zucchini, ready to be assembled into a Zucchini and Orzo bake, next to a plate of additional zucchini slices.

Step 2: Make the whipped tofu-feta mixture

In a food processor , add the block of tofu, the block of feta, 2 tablespoons of olive oil, Italian spices, salt, and pepper. Blend until smooth and creamy. Taste it, it should be tangy, salty, and spreadable. If it’s too thick, add a splash of olive oil.

When I first tried this mixture, I was shocked by how good it was. The tofu mellows out the feta, and together they make something that tastes indulgent without being heavy.

Check out my favorite food processor from Cuisinart

A split-screen image showing a food processor; on the left, chunks of tofu, feta, herbs, and olive oil before blending; on the right, a smooth, blended mixture of the ingredients.

Step 3: Assemble the base layer

Take your 9×13 casserole dish (heres the one I use) and coat it with olive oil. Then spread about ½ cup of tomato sauce on the bottom. Sprinkle ½ cup of uncooked orzo evenly over the sauce. This step is the game-changer. The orzo will cook in the oven, soaking up any liquid that seeps out of the zucchini. It creates a tender, flavorful base that keeps the whole dish from being soggy.

A casserole dish with a layer of olive oil at the bottom, followed by a layer of tomato sauce, and topped with orzo, arranged side by side.

Step 4: Start layering

Now the fun part, layering. Here’s how I do it:

Lay down a layer of zucchini slices.
Spread some of the whipped tofu-feta mixture on top.
Add another layer of zucchini.
Spoon on some tomato sauce.
Keep layering: zucchini → tofu-feta → zucchini → tomato sauce.
End with zucchini and a final layer of tomato sauce on top.

It’s not an exact science. Sometimes I run out of one thing before the other, but it always turns out delicious.

A person using a spoon to spread tomato sauce over layers of zucchini in a baking dish, with sliced zucchini arranged on a plate in the background.

A hand spreading whipped tofu and feta mixture over layers of zucchini and tomato sauce in a casserole dish.

Step 5: Bake

Preheat your oven to 350°F. Cover the casserole dish tightly with foil and bake for 60-70 minutes. Yes, it takes a while, but that’s how the orzo cooks and the zucchini softens into layers.

If you want to take it up a notch, uncover the dish at the end, sprinkle on some mozzarella, and let it bake for another 5-10 minutes until bubbly. A spoonful of pesto on top doesn’t hurt either.

A casserole dish filled with layered zucchini and orzo, topped with tomato sauce, sitting on a wooden table.

A baked Zucchini and Orzo dish in a blue casserole dish, topped with a rich tomato sauce and golden-brown crust.

Step 6: Rest and serve

Here’s a tip I learned the hard way: let your Zucchini and Orzo bake rest for at least 10 minutes after it comes out of the oven. If you cut it too soon, the layers slide apart. But if you give it time, it sets up beautifully, and you can slice it into neat squares.

A baked zucchini and orzo dish with layers of zucchini, tomato sauce, and a creamy mixture, partially sliced and served in a blue casserole dish.

Tips & Tricks for the Perfect Zucchini and Orzo Bake

Use medium zucchini, not oversized ones. Smaller zucchini have less water and firmer flesh.
Don’t skip salting the whipped mixture, it balances the flavors.
If you want extra protein, stir cooked lentils or chickpeas into the tomato sauce before layering.
Store leftovers in an airtight container. They reheat best in the oven, but the microwave works in a pinch.

Variations and Substitutions

One of the reasons I keep coming back to this Zucchini and Orzo bake is how versatile it is.

Vegan version: Just skip the feta. The whipped tofu on its own is creamy and satisfying. Add nutritional yeast if you want a cheesy flavor.
Gluten-free: Swap orzo for chickpea orzo, rice, or quinoa. The key is having something to absorb moisture.
Extra veggies: Add sautéed mushrooms, spinach, or eggplant slices in between the layers.
Cheesy upgrade: Top with shredded mozzarella or parmesan for a gooey finish.

Why the Whipped Tofu-Feta Is a Game-Changer

Let’s talk about this mixture for a second. It’s creamy like ricotta, tangy like Greek yogurt, and spreadable like hummus. The tofu gives it protein and smoothness, while the feta brings bold flavor. Together, they create the perfect “cheese” layer.

I’ve even used it outside this recipe, spread on pita, dolloped on roasted veggies, or stirred into pasta. It’s that good.

A person spreading a creamy mixture made from tofu and feta on layers of zucchini and tomato sauce in a casserole dish.

When I Served This Bake to Friends

One night, I had friends coming over last-minute. I hadn’t gone grocery shopping in days, but I had zucchini, a jar of tomato sauce, and a block of tofu in the fridge. I remembered this recipe and threw it together in about 20 minutes.

While it baked, I set the table, opened a bottle of wine, and tossed together a quick salad. When I pulled the Zucchini and Orzo bake out of the oven, it smelled like an Italian restaurant. My friends had no idea it was mostly vegetables and tofu. A few of them even asked me for the recipe because it tasted so good.

That’s when I knew this was going to be a regular dinner in my house. It’s easy enough for a weeknight, but impressive enough for guests.

Serving Suggestions

I like serving this Zucchini and Orzo bake with:

Pair with a green salad tossed in lemon vinaigrette.
Serve with garlic bread or crusty sourdough.
Add a glass of red wine (Chianti or Pinot Noir pairs beautifully).
For a summer dinner, serve alongside grilled veggies or corn.
For a winter meal, pair with roasted chicken or salmon.

If I’m cooking for my family, I’ll sometimes add roasted chicken or grilled salmon on the side. But honestly, it doesn’t need it. This dish is filling enough on its own especially with the protein rich tofu layers.

Can You Meal Prep or Freeze It?

Yes! This Zucchini and Orzo bake is meal-prep gold.

Meal prep: Assemble the dish earlier in the day, refrigerate, then bake before dinner.
Leftovers: Store in the fridge for up to 4 days.
Freezing: Freeze individual slices wrapped in foil, then reheat in the oven. It won’t be quite as firm, but it’s still delicious.

Why This Zucchini and Orzo Bake Works

Here’s the secret: balance. The zucchini keeps it light, the orzo gives it structure, the tomato sauce adds acidity, and the whipped tofu-feta mixture makes it creamy. It’s like lasagna’s lighter, fresher cousin.

And while it takes time in the oven, the hands-on work is minimal. You can prep it in 20 minutes, pop it in the oven, and go do something else while it bakes. By the time it’s done, your kitchen smells amazing, and dinner is ready.

A baked Zucchini and Orzo dish in a casserole dish, showing layered zucchini and tomato sauce with a few portions removed.

This Zucchini and Orzo bake is one of those recipes I’m proud of because it came out of trial and error. I messed it up, learned from it, and now it’s a dish I look forward to making.

If you’re tired of the same pasta and veggie dinners, give this a try. It’s comforting, healthy, and customizable. And if you do make it, let me know, I’d love to hear if your family enjoys it as much as mine does.

Recipe: Layered Zucchini and Orzo Bake

A slice of baked Zucchini and Orzo dish served on a white plate, with the casserole dish in the background.

Ingredients

24 oz jar tomato sauce
½ cup orzo
4 tbsp olive oil
4 zucchinis, sliced into ribbons
1 block tofu (14 oz), drained
1 block feta
Italian spices, salt, and pepper
Optional: mozzarella, parmesan, pesto

Instructions

Preheat oven to 350°F.
Slice zucchini into thin layers or ribbons.
In food processor, blend tofu, feta, olive oil, spices, salt, and pepper until smooth.
Oil a 9×13 casserole dish. Spread ½ cup tomato sauce on bottom, then sprinkle ½ cup orzo.
Layer zucchini, whipped mixture, zucchini, tomato sauce, repeating until finished. End with sauce.
Cover with foil and bake 60-70 minutes.
Optional: uncover, add cheese or pesto, and bake 5-10 minutes more.
Rest 10 minutes before serving.

With Love,

Bri & Cat

You can also make this recipe with other vegetables too! Check out my Sweet Potato Lasagna Version!

Other Recipes You Will Love:

Orzo Pasta Salad with Tofu, Roasted Veggies, and Pesto

One Pan Baked Raviolis with Pesto and Pine Nuts

The Ultimate One-Pot Baked Penne with Sun Dried Tomatoes and Feta

Affiliate Disclaimer:
As an Amazon Associate I earn from qualifying purchases. This comes at no additional cost to you. We only recommend products that we believe will add value to our readers.