This easy Italian Beef is smoked on a pellet grill like a Traeger, but you can use any pellet grill, or even a regular grill or oven. Cook the roast to medium-rare, slice it thin, and serve it drenched in the au jus that cooks with the meat. You don’t have to travel to Chicago to enjoy an authentic-style Italian beef sandwich.
Italian Beef Sandwich
The first time I tried an Italian beef was after my husband raved about a double-dipped sandwich at Portillo’s. Since then I’ve made this version that captures the essentials: tender, thinly sliced beef, soaked in savory jus, served on a sturdy roll. The recent popularity of the show “The Bear” has brought renewed attention to this Chicago classic.
I didn’t make it to Portillo’s on my last Chicago trip, but I did taste an authentic Italian beef sandwich and it lived up to the hype. This recipe aims to recreate that experience at home.
What is an Italian Beef?
The Chicago-style Italian beef sandwich is known for juicy, flavorful sliced beef served on a roll and often soaked in its cooking juices. Common serving styles include:
- Dry: Excess juices are drained so the roll stays relatively dry.
- Wet: The beef is served with some of its cooking juices so the roll absorbs flavor.
- Dipped: The entire sandwich—bread and meat—is dunked into the au jus for a very moist, flavorful (and somewhat messy) experience.
Sandwiches are often topped with “sweet” peppers (sauteed bell peppers) or “hot” peppers such as giardiniera (a spicy pickled vegetable mix). Choose what you like.
Recipe Shopping List
If you need to shop, here are the essentials. For precise amounts, see the recipe card below.
- Chuck roast or other well-marbled roast suitable for slicing.
- Beef broth to form the cooking liquid; low-sodium if you want to control salt.
- Italian seasoning mix (or seasoned rub) to flavor the roast.
- Pepperoncini peppers (with juice) — the juice contributes tang and heat.
- Garlic powder and onion powder for depth.
- Hoagie rolls or Italian rolls sturdy enough to hold the meat.
- Provolone cheese (optional) for a melty finish.
How To Make This Recipe
There are many regional and shop-specific ways to prepare Italian beef. This version focuses on smoking for flavor, then braising to tenderize and collect a rich au jus for the sandwiches.
- Season the roast — Rub the chuck roast all over with Italian seasoning (or a mix of coarse black pepper, salt, garlic, oregano, basil, and red pepper flakes). Let it sit while you preheat your grill to a low smoke temperature (about 180–200°F) if smoking.
- Smoke the beef — Place the seasoned roast on the grill grates and smoke for about 1.5–2 hours to build flavor.
- Braise low and slow — Transfer the roast to a deep pan or Dutch oven. Pour in beef broth and add the jar of pepperoncini with their juice. Cover tightly and cook at about 275°F until the meat reaches medium-rare (125–130°F) and is fork-tender enough to shred or slice thinly, typically a few hours.
- Shred, slice, and soak — Remove the roast and either shred or thinly slice it. Let the sliced beef rest in the juices for 15–30 minutes so it absorbs more flavor.
- Assemble and serve — Lightly toast rolls if desired, pile on the shredded or sliced beef, add provolone if you like, and serve with extra au jus for dipping or dipping the whole sandwich (dipped style).
Recipe Tips
- Buy good beef: Quality and marbling matter for flavor and texture.
- Be patient: Low-and-slow cooking yields the best flavor and tenderness.
- Cook to temperature, not time: Aim for 125–130°F for medium-rare before slicing.
- Cool before slicing: Chilling or partially freezing the roast makes it much easier to slice very thinly if you don’t have a meat slicer.
FAQ
Is this like Al’s or Portillo’s?
This recipe is a faithful, home-friendly version inspired by classic Chicago Italian beef. It won’t be an exact clone of every shop’s version, but it delivers the essential flavors and is great to serve to family or guests.
What cut of meat should I use?
Choose a well-marbled roast that slices thinly—chuck roast, sirloin roast, or eye of round work well. You don’t need prime rib; the goal is tender, thin slices that can soak up the jus.
What seasonings work best?
Italian seasoning blends (garlic, basil, oregano) are a natural match. You can use a premade blend or a custom rub of black pepper, garlic, onion powder, oregano, basil, and red pepper flakes.
How long should I cook the roast?
Cook to internal temperature, not to a fixed time. Remove the roast when it reaches about 125–130°F for medium-rare. After cooking and chilling, slice thin to serve.
Make Ahead & Variations
This recipe works well for making ahead. Cook and chill the roast, then slice and store it in the jus. Reheat gently in the broth before serving. If you don’t have a pellet grill, you can follow a nearly identical process in the oven; you’ll miss the smoky note but still get a delicious sandwich.
Serving Suggestions
These sandwiches are hearty. Popular sides include:
- French fries — extra crispy on the side.
- Coleslaw — cool and crunchy to balance the rich meat.
- Grilled Brussels sprouts — caramelized and flavorful.
- Caesar pasta salad — a chilled salad with romaine and creamy dressing.
- Loaded mashed potatoes — smoky, creamy potatoes pair beautifully.
More Sandwich Recipes
- Blackstone Smashed Chicken Parmesan Sandwich
- Blackstone Steak Sandwich
- Homemade Hot Roast Beef Sandwich
- Chopped Italian Sandwich
- Traeger Grilled Steak Sandwich
- Traeger Reuben Sandwich
Grilled Italian Beef Sandwich — Recipe Card
Yield: 6 sandwiches
This homemade Chicago-style Italian beef is a repeat-worthy sandwich that’s smoky, savory, and full of jus.
Times
- Prep: 20 minutes
- Cook: ~3 hours (varies with size and method)
- Chill: ~3 hours (recommended for easier slicing)
- Total: ~6 hours 20 minutes
Ingredients
- 3–4 lb beef roast (chuck, eye of round, or similar)
- Rub: 1½ tbsp coarse black pepper, 1 tsp kosher salt, 1 tbsp granulated garlic, 2 tsp dry oregano, 2 tsp dry basil, 1 tsp crushed red pepper flakes
- Or: 3 tbsp Italian seasoning and 1 tsp multi-season salt blend
- Gravy: 8 cups beef broth
- Sandwiches: 8 Italian rolls, giardiniera (optional)
Instructions
- Preheat your pellet grill to 325°F. If using a gas or charcoal grill, set up for medium indirect heat. If using an oven, preheat to 325°F and use a covered roasting pan.
- Rub the roast with the rub ingredients or Italian seasoning. Place the roast on a rack inside a high-sided pan that can hold the broth.
- Pour beef broth into the pan. If smoking, place it on the grill; if in the oven, put the pan in the oven.
- If you have a probe, set it to 130°F for medium-rare. Cook until the roast reaches the target temperature. Times vary by roast size and cut.
- Remove the roast and chill until cold to make slicing easier. Reserve the gravy in the fridge and skim excess fat if desired.
- Slice the roast as thinly as possible with a sharp knife or meat slicer.
- Warm rolls and gently reheat the reserved gravy to just below a simmer. Dip slices of beef in the hot gravy for a minute, then pile on rolls. Top with giardiniera and provolone if desired, and serve with extra jus for dipping.
Recommended (optional) products
- Italian seasoning or crushed Italian herb blend
- Giardiniera (Chicago-style pickled vegetable mix)
- Au jus mix (optional for extra gravy flavor)
Nutrition (estimate per serving)
Calories: ~1145; Total Fat: ~69g; Saturated Fat: ~27g; Cholesterol: ~316mg; Sodium: ~3061mg; Carbohydrates: ~31g; Fiber: ~4g; Sugar: ~2g; Protein: ~94g. Nutrition data are estimates; consult a trusted source if you need precise values for medical reasons.