Italian Beef Sandwich with Roasted Garlic Aioli Recipe

Tender, savory beef piled high on a crisped roll and slathered with a rich, creamy aioli—there are few comforts more satisfying than an Italian Beef Sandwich with Roasted Garlic Aioli. It’s soul-warming, impossibly juicy, and loaded with bold Italian flavors that make every bite sing. Whether you’re looking to impress guests, treat your family, or simply enjoy a meal that feels like an irresistible hug, this sandwich checks all the boxes. The slow-cooked beef soaks up every nuance of spice and tang from pepperoncini, while the homemade roasted garlic aioli delivers a swoon-worthy finish. Once you try it, you’ll understand why this classic deserves a spot in your regular rotation!

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Ingredients You’ll Need

The Italian Beef Sandwich with Roasted Garlic Aioli is all about bold, wholesome flavors coming together simply and beautifully. Each ingredient brings something essential—be it melt-in-your-mouth texture, pops of heat, velvety richness, or irresistible aroma. Here’s what you’ll need, along with tips for maximum flavor:

• Chuck roast or top round beef (2 pounds): Pick a well-marbled cut for that signature, fall-apart tender shreds.
• Olive oil (1 tablespoon): Gives a golden, flavorful sear to the beef, locking in juices early.
• Salt (1 teaspoon): Essential for seasoning the beef from the start; don’t skimp!
• Black pepper (1/2 teaspoon): Adds mellow heat that balances the punchy spices perfectly.
• Dried oregano (1 teaspoon): Lends classic Italian herbiness to the simmering juices.
• Crushed red pepper flakes (1/2 teaspoon): For just the right kick—adjust to your preferred heat.
• Garlic (4 cloves, minced): Infuses the cooking liquid with deep, aromatic flavor.
• Beef broth (1 cup): Keeps the meat juicy and creates a delicious jus for basting.
• Jarred pepperoncini with juice (1/2 cup): Adds tang and gentle heat, plus a signature zing.
• Onion powder (1/2 teaspoon): Backs up the beef with sweet, subtle allium notes.
• Hoagie rolls or Italian sandwich rolls (4): The sturdy base that soaks up all the goodness without falling apart.
• Provolone or mozzarella cheese (1 cup, sliced): For melty, gooey grandeur that crowns the sandwich.
• Roasted red peppers (1/2 cup, optional): Adds sweetness, color, and a roasted edge—completely worth it!

• Head of garlic (1): Roasting transforms it into a mild, caramelized treat that’s the backbone of the aioli.
• Mayonnaise (1/2 cup): Brings creaminess and richness to the aioli without overpowering the roasted garlic.
• Lemon juice (1 teaspoon): Just a splash to brighten everything up.
• Salt and pepper to taste: Fine-tune your aioli for that perfect, balanced kick.

How to Make Italian Beef Sandwich with Roasted Garlic Aioli

Step 1: Roast the Garlic for Aioli

Start with the star ingredient for your aioli. Preheat your oven to 400°F (200°C). Slice the very top off the garlic head to expose the cloves, drizzle generously with olive oil, then wrap tightly in foil. Roast for 30 to 35 minutes, until the cloves turn soft, buttery, and golden. Let it cool just enough to handle, then squeeze out every last ounce of that luscious, caramelized garlic into a small bowl.

Step 2: Make the Roasted Garlic Aioli

In that bowl of roasted garlic, mash the cloves with a fork until paste-like. Stir in mayonnaise, lemon juice, salt, and pepper. Taste and adjust seasoning—it should be tangy, velvety, and deeply garlicky. Cover and chill until you’re ready to assemble your Italian Beef Sandwich with Roasted Garlic Aioli; letting it sit for a bit helps the flavors mingle.

Step 3: Season and Sear the Beef

Pat your beef roast dry and sprinkle all over with salt, black pepper, dried oregano, and crushed red pepper flakes. In a large skillet, heat olive oil until shimmering, then sear the meat on all sides until beautifully browned. This quick step locks in flavor, building the base for that incredible sandwich filling.

Step 4: Slow Cook the Beef

Transfer the seared beef to your slow cooker (or Dutch oven). Scatter minced garlic over the roast, then pour in beef broth, pepperoncini with their juice, and onion powder. Set your slow cooker to low and let it work its magic for 6 to 8 hours (or bake in the oven, covered, at 300°F (150°C) for 3 to 4 hours). You want the beef to practically fall apart at the sight of a fork, juicy and fragrant.

Step 5: Shred and Return the Beef

When the beef is tender, transfer it to a cutting board and shred into bite-sized pieces with two forks. Ladle some of that flavorful cooking liquid over the shredded beef to keep everything moist and delicious. Return the beef to the slow cooker to soak up even more of those savory juices until assembly time.

Step 6: Assemble and Broil the Sandwiches

Slice the hoagie rolls and toast them until golden—this helps them stand up to the juicy filling. Slather both sides generously with roasted garlic aioli. Pile the rolls high with that luscious Italian beef, top with provolone or mozzarella, and add roasted red peppers if desired. Slide under the broiler for 1 to 2 minutes, just until the cheese melts into gooey perfection. Serve hot, and get ready for sandwich bliss.

How to Serve Italian Beef Sandwich with Roasted Garlic Aioli

Garnishes

Don’t skip the finishing touches. Sprinkle a handful of crisp giardiniera over the top for crunch and a punchy Chicago-inspired flavor. Fresh chopped parsley adds a bright pop of color, while an extra spoonful of roasted garlic aioli on the side is always a welcome move for true garlic lovers.

Side Dishes

An Italian Beef Sandwich with Roasted Garlic Aioli pairs beautifully with a range of sides. Classic choices include a crisp mixed green salad, kettle chips, or tangy coleslaw, which all balance the hefty, savory richness of the sandwich. For a heartier meal, roasted potatoes or a simple pasta salad are perfect partners at the table.

Creative Ways to Present

Think outside the standard sandwich! Try slider buns for a party platter, or serve the shredded beef and aioli deconstructed for build-your-own fun. For a low-carb twist, pile the beef and cheese over roasted vegetables and drizzle with aioli for a “sandwich bowl.” However you serve it, the flavors of an Italian Beef Sandwich with Roasted Garlic Aioli always steal the show.

Make Ahead and Storage

Storing Leftovers

If you find yourself with leftover Italian Beef Sandwich with Roasted Garlic Aioli, lucky you—these flavors get even better the next day. Store extra beef (with its juices) and aioli separately in airtight containers in the refrigerator. The beef will happily keep for up to 4 days, while the aioli retains its flavor and texture for 2 to 3 days.

Freezing

The shredded Italian beef freezes beautifully. Once cooled, portion into freezer-safe bags or containers, making sure to include some jus to keep things moist. Freeze for up to 3 months. The roasted garlic aioli doesn’t freeze well, so plan to whip that up fresh for best results.

Reheating

To reheat the beef, place it with its juices in a saucepan over low heat until hot (adding a splash of beef broth or water if needed), or microwave in short intervals, stirring as you go. Toast your rolls and prepare fresh aioli for sandwiches that taste every bit as amazing as day one.

FAQs

Can I make the Italian Beef Sandwich with Roasted Garlic Aioli without a slow cooker?

Absolutely! The oven method works just as well. Use a Dutch oven, cover your seasoned and seared beef with all the ingredients, and bake at 300°F (150°C) for about 3 to 4 hours until fork-tender and easy to shred.

What other cuts of beef can I use?

If you can’t find chuck roast or top round, brisket or rump roast make excellent substitutes. Just look for a cut with enough marbling—this helps ensure juicy, tender beef that’s perfect for shredding.

Can I make the roasted garlic aioli in advance?

Yes! Making the aioli a day ahead is a great way to get even more flavor as the garlic and lemon mellow and blend. Just store it covered in the fridge until you’re ready to assemble your Italian Beef Sandwich with Roasted Garlic Aioli.

Are there any shortcuts for weeknight prep?

If you’re in a hurry, you can use pre-roasted garlic from the store, and prepare the beef a day or two in advance. Reheat gently and assemble your sandwiches fresh for a super-quick dinner that still delivers big, bold flavor.

What’s the best way to make this sandwich spicy?

For extra heat, double the red pepper flakes or add sliced hot peppers alongside the pepperoncini. You can also spread a little hot giardiniera on top when serving for a satisfying fiery crunch.

Final Thoughts

This Italian Beef Sandwich with Roasted Garlic Aioli is pure comfort—meaty, garlicky, and outrageously flavorful. Every element comes together for a sandwich that’s as impressive as it is deeply satisfying. Give it a try; I promise it’ll become a new favorite in your kitchen, and one you’ll want to share again and again!

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