How to Make Delicious Italian Sausage Sandwiches

Italian sausage sandwiches are a flavorful and satisfying meal that can be made quickly and easily. With just a few simple ingredients like Italian sausage, bell peppers, onions, tomato sauce and crusty bread rolls, you can have an incredible sandwich in under 30 minutes.

In this article, I’ll walk you through the entire process of making incredible Italian sausage sandwiches step-by-step I’ll share my tips and tricks for the best sausage, vegetables and rolls so your sandwiches come out perfectly every time Whether you are cooking for a family dinner or entertaining a crowd, these Italian sausage sandwiches are sure to be a hit!

Ingredients You’ll Need

Here are the ingredients you’ll need to make a batch of classic Italian sausage sandwiches:

• Italian Sausage – Sweet or hot bulk Italian sausage works great. Look for good quality sausage with lots of seasoning.

• Rolls – Crusty hoagie rolls, sub rolls or ciabatta rolls work best. Look for rolls that can stand up to the juicy sausage filling.

• Bell Peppers – A mix of red yellow and orange bell peppers provides a sweet crunch.

• Onions – Yellow or red onions both work well. They add lots of flavor.

• Tomato Sauce – Use your favorite ready-made marinara sauce or my homemade sauce recipe.

• Olive Oil – For sautéing the veggies.

• Seasonings – Italian seasoning, garlic powder, salt and pepper.

• Cheese – Mozzarella and provolone cheese to melt on top.

Preparing the Vegetables

The first step in making Italian sausage sandwiches is to prepare the bell peppers and onions. Here are some tips:

• Wash and dry the peppers – Be sure to wash the peppers well and pat them completely dry with paper towels. Any excess water will hinder browning.

• Remove cores and seeds – Use a sharp paring knife to cut around the stem and remove it along with the seeds and membranes. This prevents the peppers from becoming watery during cooking.

• Cut into strips – Slice the bell pepper halves into 1/2-inch wide strips. This shape and size works perfectly in the sandwiches.

• Peel, trim and slice onions – Remove the ends, peel off the papery skins and slice the onions into 1/2-inch wide strips as well.

• Sauté the veggies – In a large skillet, heat 1-2 Tbsp olive oil over medium-high heat. Add the onions first then the peppers. Cook for 5-7 minutes until starting to soften. Season with a pinch each salt and pepper.

Cooking the Italian Sausage

With the veggies sautéing, you can start on the sausage. Here’s how to perfectly cook Italian sausage for sandwiches:

• Use bulk sausage – Bulk sausage works better than links for this recipe. It cooks more evenly and integrates into the sandwiches easier.

• Cook completely – In the same skillet after removing the veggies, cook the sausage over medium heat, breaking it up with a wooden spoon as it cooks, until no pink remains.

• Drain excess grease – Once cooked, use a slotted spoon to transfer the sausage to a paper towel lined plate to drain excess grease.

• Season – While the sausage is cooking, season it with Italian seasoning, garlic powder, salt and pepper.

Bringing It All Together

Now it’s time to assemble the sandwiches. Follow these steps for the very best results:

• Add tomato sauce to the sausage – Return the cooked sausage to the skillet and add 1-2 cups of tomato sauce. Stir to coat evenly and heat through.

• Toast the rolls – Split rolls open and place on a baking sheet under the broiler for 2-3 minutes until lightly toasted. Watch closely so they don’t burn.

• Add cheese layer – Sprinkle 1-2 Tbsp shredded mozzarella and provolone cheese over the bottom half of each toasted roll.

• Pile on sausage mixture – Use a slotted spoon to scoop the sausage mixture over the cheese, letting excess sauce run off.

• Top with veggies – Add a generous layer of the sautéed peppers and onions.

• Finish with more cheese – Top with another sprinkle of shredded cheese.

• Melt the cheese – Place the filled rolls on the baking sheet and bake at 400F for 5-7 minutes until the cheese melts.

• Dig in! – Your Italian sausage sandwiches are ready to serve hot and delicious!

Tips for the Best Sausage Sandwiches

With a few simple tips, you’re guaranteed amazing Italian sausage sandwiches every time:

• Use crusty, sturdy rolls that can stand up to the juicy sausage filling without getting soggy. Hoagies and ciabatta work wonderfully.

• Cook the peppers and onions well so they are softened with lightly browned edges. Undercooked veggies will be crunchy and taste raw.

• Drain the sausage well after cooking to remove excess grease for cleaner, more flavorful sandwiches.

• Add plenty of seasoning – Don’t be afraid to generously season the sausage, veggies and tomato sauce.

• Pile on two layers of cheese – Cheese on the bottom soaks up sausage juices while cheese on top provides amazing melted stretch.

• Use quality ingredients – Great sausage and sauce make a huge difference in the final sandwiches.

• Customize to your taste! – Make it your own with hot sausage, extra sauce, roasted garlic, pepperoncini, etc.

Variations You’ll Love

One of the best things about Italian sausage sandwiches is how versatile they are. You can customize them to your liking with different additions. Here are some amazing variations to try:

• Pizza style – Add sliced pepperoni, fontina cheese, pickled pepper rings, and red pepper flakes.

• Chicken sausage – Substitute chicken Italian sausage and roasted red peppers.

• Spicy sausage – Use spicy Italian sausage and pepper jack cheese for extra heat.

• Loaded subs – Add banana peppers, sliced olives, lettuce, tomato, oil and vinegar.

• Cheesesteak style – Use provolone cheese and add sautéed green bell peppers and mushrooms.

• Baked ziti filling – Make baked ziti and use it as your sausage sandwich filling.

• Meatball subs – Swap cooked Italian meatballs for the sausage.

Serving Suggestions

Italian sausage sandwiches pair well with so many sides, giving you lots of options:

• Pasta salad – Try rotini pasta salad, tortellini salad or pesto pasta salad.

• Potato salad – Creamy potato salad or tangy German style pairs nicely.

• Chips – Can’t go wrong with classic potato chips or another favorite.

• Fries – French fries, waffle fries or sweet potato fries are perfect.

• Veggies – Grilled zucchini, roasted squash, or a simple salad.

• Soup – Pair with a brothy soup like minestrone, tortellini or Italian wedding.

Storing Leftovers

Since these Italian sausage sandwiches are so tasty, you’ll want to enjoy the leftovers too. Here are some storage tips:

• Let cool completely before storing leftovers. Transfer to airtight containers.

• Sausage mixture – Store leftover sausage, veggies and sauce together in one container in the fridge.

• Sandwiches – Individually wrap extra assembled sandwiches in foil and refrigerate.

• Rolls – Store leftover rolls in a separate bag. Refresh in oven before using.

• Fridge life – Leftover sandwiches and sausage mixture will keep for 3-4 days in the fridge.

• Reheating – Reheat sandwiches wrapped in foil at 350F for 15 minutes. Or reheat sausage mixture in a skillet.

Make Ahead Tips

Short on time? You can prep parts of this recipe in advance:

• Cook sausage 1-2 days ahead – Let cool completely then refrigerate in an airtight container.

• Sauté peppers and onions up to 3 days in advance. Store in the fridge until ready to assemble sandwiches.

• Prep rolls – Split rolls in half and store in a zip top bag for up to 3 days. Refresh in oven before using.

• Assemble sandwiches without cheese up to 8 hours in advance. Add cheese and bake just before serving.

• Freeze uncooked sausage for up to 3 months. Thaw overnight in fridge before using.

Frequently Asked Questions

What’s the best type of sausage to use? Sweet or hot Italian sausage works great. Check the seasonings as some are more flavorful than others.

Do I need to use tomato sauce? You don’t have to