Costco’s food court is legendary. From the iconic hot dog combo to the pizza slices that could double as personal pizzas, it’s a post-shopping ritual for many. But recently, a new menu item has stirred up a controversy of epic proportions: the new roast beef sandwich. Some hail it as a culinary masterpiece, others decry it as an overpriced disappointment. Whatever your stance, it’s sparked a conversation – and a whole lot of DIY recipe attempts. Let’s dive into the controversy, explore the sandwich itself, and then, most importantly, arm you with the recipes to recreate (or improve upon!) the Costco food court roast beef sandwich experience at home.
**The Costco Food Court Roast Beef Sandwich: A Divisive Delight?**
The new sandwich replaced the popular (and affordable) turkey provolone sandwich, immediately drawing criticism. The initial reaction was largely centered on the price point. At around $9.99, it’s significantly more expensive than other food court offerings, like the aforementioned hot dog combo which remains a staple for under $2. The price hike raised eyebrows, with some questioning if the ingredients and quality justified the cost.
Then came the taste test. Reviews are mixed, to say the least. Proponents praise the generous portion of roast beef, the creamy sauce, and the overall satisfying nature of the sandwich. Detractors complain about the dryness of the beef, the blandness of the cheese, and the disproportionate ratio of bread to filling. Some even claim the sandwich is simply not worth the price, regardless of taste.
This controversy highlights a core element of Costco’s food court appeal: affordability and consistency. People expect a certain level of value, and the new sandwich seemingly challenges that expectation. However, the strong opinions on both sides demonstrate a clear interest in the sandwich’s potential. That is where the DIY recipes comes into play.
**Dissecting the Sandwich: What Are We Working With?**
Before we jump into the recipes, let’s break down the components of the Costco roast beef sandwich. This will help us understand what we need to replicate and, more importantly, where we can improve.
* **The Roast Beef:** This is the star of the show. Costco uses (or claims to use) a high-quality roast beef, but the preparation and slicing are key to the overall texture and flavor. Many reviewers complain about dryness, suggesting the beef may be overcooked or sliced too thinly.
* **The Bread:** The sandwich features a toasted roll, often described as a ciabatta or similar style. The bread needs to be sturdy enough to hold the generous filling without falling apart, but also soft enough to be enjoyable to eat. The toasting adds texture and prevents the bread from becoming soggy.
* **The Sauce:** This is where the mystery lies. The sauce is described as creamy, tangy, and slightly horseradish-y. It’s the element that ties all the flavors together and adds moisture to the sandwich. Most suspect it is a horseradish aioli or creamy horseradish sauce.
* **The Cheese:** It seems to be a mild provolone cheese, although some speculate that a different cheese might be used. The cheese’s role is primarily to add a subtle flavor and a touch of creaminess.
* **Toppings (Sometimes):** Some locations were reported to have included lettuce, tomato, or onion, but this seems to vary, which could explain the inconsistency in opinions. These toppings add freshness and crunch, balancing the richness of the beef and sauce.
**DIY Costco Roast Beef Sandwich Recipes: Level Up Your Lunch Game**
Now, let’s get to the good stuff! Here are a few DIY recipes that you can use to recreate the Costco roast beef sandwich experience at home. We’ll provide options for different skill levels and ingredient preferences.
**Recipe 1: The “Close Enough” Costco Roast Beef Sandwich**
This recipe focuses on simplicity and accessibility. It uses readily available ingredients and requires minimal cooking skills. It is for the everyday foodie who just wants a good roast beef sandwich inspired by Costco’s attempt.
* **Ingredients:**
* 1 lb Cooked Roast Beef (deli style, sliced medium-thick)
* 2 Ciabatta Rolls (or similar sturdy rolls)
* 4 slices Provolone Cheese
* 1/4 cup Mayonnaise
* 1 tbsp Prepared Horseradish
* 1/2 tsp Dijon Mustard
* Lettuce (optional)
* Tomato slices (optional)
* **Instructions:**
1. **Prepare the Horseradish Aioli:** In a small bowl, combine the mayonnaise, horseradish, and Dijon mustard. Mix well until smooth and creamy. Adjust the amount of horseradish to your taste preference.
2. **Toast the Rolls:** Slice the ciabatta rolls in half horizontally. Toast them in a toaster oven or under a broiler until lightly golden brown.
3. **Assemble the Sandwiches:** Spread a generous layer of the horseradish aioli on both halves of each toasted roll.
4. Layer two slices of provolone cheese on the bottom half of each roll.
5. Arrange half of the roast beef on top of the cheese on each roll. Fold over thicker slices.
6. If desired, add lettuce and tomato slices.
7. Top with the other half of the roll.
8. Cut the sandwiches in half and serve immediately.
* **Tips and Variations:**
* For a richer flavor, use a high-quality mayonnaise, like Duke’s or Hellmann’s.
* If you don’t have Dijon mustard, you can substitute it with a pinch of dry mustard powder.
* Add a pinch of garlic powder or onion powder to the horseradish aioli for extra flavor.
* For a spicier kick, add a few drops of your favorite hot sauce to the aioli.
* Warm the roast beef slightly in a skillet or microwave for a more tender texture.
**Recipe 2: The “Gourmet” Costco Roast Beef Sandwich**
This recipe takes a more sophisticated approach, focusing on using higher-quality ingredients and more refined techniques. This recipe is for those that want to elevate the Costco sandwich to something worthy of a restaurant.
* **Ingredients:**
* 1 lb Rare Roast Beef (preferably eye of round or sirloin tip, cooked in-house and sliced thinly against the grain)
* 2 Artisan Rolls (sourdough or brioche)
* 4 slices Smoked Provolone Cheese
* 1/4 cup Homemade Aioli (see instructions below)
* 1 tbsp Prepared Horseradish
* 1 clove Garlic, minced
* 1 tbsp Lemon Juice
* 1 tbsp Olive Oil
* Arugula (optional)
* Caramelized Onions (optional)
* **Instructions:**
1. **Prepare the Homemade Aioli:** In a small bowl, whisk together 1/4 cup of high-quality mayonnaise, 1 minced clove of garlic, 1 tbsp of lemon juice, 1 tbsp of olive oil, and salt and pepper to taste. For the horseradish aioli, add 1 tbsp of prepared horseradish.
2. **Caramelize the Onions (Optional):** Thinly slice one large onion. Heat 1 tbsp of olive oil in a skillet over medium heat. Add the sliced onions and cook, stirring occasionally, until they are golden brown and caramelized (about 20-30 minutes). Be patient and don’t rush the process.
3. **Toast the Rolls:** Slice the artisan rolls in half horizontally. Toast them in a toaster oven or under a broiler until lightly golden brown.
4. **Assemble the Sandwiches:** Spread a generous layer of the homemade horseradish aioli on both halves of each toasted roll.
5. Layer two slices of smoked provolone cheese on the bottom half of each roll.
6. Arrange half of the roast beef on top of the cheese on each roll. Spread the slices out so that they cover the entire surface.
7. If desired, add arugula and caramelized onions.
8. Top with the other half of the roll.
9. Cut the sandwiches in half and serve immediately.
* **Tips and Variations:**
* For the best flavor, use roast beef that is cooked in-house and sliced thinly against the grain. This will ensure that the beef is tender and flavorful.
* Experiment with different types of artisan rolls to find your favorite. Sourdough adds a tangy flavor, while brioche provides a richer, more buttery taste.
* Consider adding other toppings, such as roasted red peppers, grilled mushrooms, or pickled onions.
* For a more intense horseradish flavor, use freshly grated horseradish instead of prepared horseradish.
* If you don’t have time to make homemade aioli, you can use a high-quality store-bought aioli instead.
**Recipe 3: The “From Scratch” Costco Roast Beef Sandwich**
This recipe is for the ambitious home cook who wants to control every aspect of the sandwich, from the roast beef to the bread. Prepare for a day in the kitchen. It is worth it though.
* **Ingredients:**
* **For the Roast Beef:**
* 3-4 lb Eye of Round Roast
* 2 tbsp Olive Oil
* 1 tsp Salt
* 1/2 tsp Black Pepper
* 1/2 tsp Garlic Powder
* 1/2 tsp Onion Powder
* 1/4 tsp Dried Thyme
* 1/4 tsp Dried Rosemary
* **For the Ciabatta Rolls:**
* 3 1/2 cups Bread Flour
* 1 3/4 cups Warm Water
* 1 tsp Instant Yeast
* 1 tbsp Olive Oil
* 1 1/2 tsp Salt
* **For the Horseradish Aioli:**
* 1/2 cup Mayonnaise (Homemade preferred, recipe follows)
* 2 tbsp Prepared Horseradish
* 1 clove Garlic, minced
* 1 tbsp Lemon Juice
* Salt and Pepper to taste
* **For the Homemade Mayonnaise (Optional):**
* 1 Large Egg Yolk
* 1 tbsp Lemon Juice or White Wine Vinegar
* 1/2 tsp Dijon Mustard
* 1 cup Neutral Oil (like canola or grapeseed)
* Salt and Pepper to taste
* **For the Sandwich Assembly:**
* 4 slices Provolone Cheese
* Lettuce (optional)
* Tomato Slices (optional)
* **Instructions:**
1. **Prepare the Roast Beef:**
* Preheat oven to 325°F (160°C). Pat the eye of round roast dry with paper towels. In a small bowl, combine salt, pepper, garlic powder, onion powder, thyme, and rosemary.
* Rub the roast with olive oil, then generously season with the spice mixture.
* Place the roast on a roasting rack in a baking pan. Roast for approximately 20-25 minutes per pound for medium-rare, or until a meat thermometer inserted into the thickest part registers 130-135°F (54-57°C).
* Remove from oven and let rest for at least 15-20 minutes before slicing thinly against the grain. Resting is crucial for retaining moisture.
2. **Prepare the Ciabatta Rolls:**
* In a large bowl, combine warm water, yeast, and a pinch of sugar. Let stand for 5 minutes until foamy.
* Add olive oil and salt to the yeast mixture. Gradually add the bread flour, mixing until a shaggy dough forms.
* Turn the dough out onto a lightly floured surface and knead for 8-10 minutes, until smooth and elastic. Alternatively, use a stand mixer with a dough hook.
* Place the dough in a lightly oiled bowl, turning to coat. Cover with plastic wrap and let rise in a warm place for 1-1.5 hours, or until doubled in size.
* Punch down the dough and divide it into 2 equal pieces. Shape each piece into a long, oval-shaped roll.
* Place the rolls on a baking sheet lined with parchment paper. Cover with a clean kitchen towel and let rise for another 30-45 minutes.
* Preheat oven to 450°F (232°C) and have a tray of water at the bottom for steam. Bake for 20-25 minutes, or until golden brown and the internal temperature reaches 200-210°F (93-99°C).
* Let cool completely on a wire rack before slicing.
3. **Prepare the Homemade Mayonnaise (Optional):**
* In a food processor or with an immersion blender, combine the egg yolk, lemon juice (or vinegar), and Dijon mustard. Process until well combined.
* Slowly drizzle in the neutral oil, processing continuously, until the mayonnaise emulsifies and thickens. Be patient and add the oil in a slow, steady stream.
* Season with salt and pepper to taste.
4. **Prepare the Horseradish Aioli:**
* In a small bowl, combine the mayonnaise (homemade or store-bought), prepared horseradish, minced garlic, and lemon juice. Mix well and season with salt and pepper to taste.
5. **Assemble the Sandwiches:**
* Slice the ciabatta rolls in half horizontally. Toast them lightly in a toaster oven or under a broiler.
* Spread a generous layer of the horseradish aioli on both halves of each toasted roll.
* Layer two slices of provolone cheese on the bottom half of each roll.
* Arrange half of the sliced roast beef on top of the cheese on each roll.
* If desired, add lettuce and tomato slices.
* Top with the other half of the roll.
* Cut the sandwiches in half and serve immediately.
* **Tips and Variations:**
* For the roast beef, use a meat thermometer to ensure it is cooked to your desired level of doneness. The internal temperature will continue to rise slightly after removing it from the oven.
* If you don’t have time to make homemade mayonnaise, you can use a high-quality store-bought mayonnaise instead. However, homemade mayonnaise will elevate the flavor of the sandwich.
* Experiment with different types of cheese, such as Swiss, Gruyere, or Havarti. Just be sure to choose a cheese that complements the flavor of the roast beef.
* Add other toppings, such as caramelized onions, roasted red peppers, or pickled vegetables.
* For a spicier kick, add a pinch of red pepper flakes to the horseradish aioli.
**Recipe 4: The “Vegan” Costco Inspired Sandwich**
For those that enjoy the sandwich idea but do not partake in meat products. This recipe is designed to cater to vegan requirements.
* **Ingredients:**
* 1 package (8-10 oz) Plant-Based Roast Beef Slices (available at most grocery stores; brands like Lightlife or Tofurky)
* 2 Ciabatta Rolls (check label to ensure they are vegan)
* 4 slices Vegan Provolone Cheese (Violife or Daiya are popular brands)
* 1/4 cup Vegan Mayonnaise (choose your favorite brand)
* 2 tbsp Prepared Horseradish (check label to ensure it’s vegan; some contain honey)
* 1 tsp Dijon Mustard (check label to ensure it’s vegan; some contain honey)
* Lettuce (optional)
* Tomato slices (optional)
* Red Onion slices (optional)
* **Instructions:**
1. **Prepare the Horseradish Aioli:** In a small bowl, combine the vegan mayonnaise, horseradish, and Dijon mustard. Mix well until smooth and creamy. Adjust the amount of horseradish to your taste preference. Taste and add a pinch of salt and pepper if needed.
2. **Toast the Rolls:** Slice the ciabatta rolls in half horizontally. Toast them in a toaster oven or under a broiler until lightly golden brown.
3. **Warm the Plant-Based Roast Beef (Optional):** While not strictly necessary, warming the plant-based roast beef slices can enhance their flavor and texture. You can do this by briefly pan-frying them in a little olive oil or microwaving them for a few seconds.
4. **Assemble the Sandwiches:** Spread a generous layer of the vegan horseradish aioli on both halves of each toasted roll.
5. Layer two slices of vegan provolone cheese on the bottom half of each roll.
6. Arrange half of the plant-based roast beef slices on top of the cheese on each roll. Spread the slices out so that they cover the entire surface.
7. If desired, add lettuce, tomato slices, and red onion slices.
8. Top with the other half of the roll.
9. Cut the sandwiches in half and serve immediately.
* **Tips and Variations:**
* **Brand Matters:** The taste and texture of plant-based roast beef and vegan cheese can vary significantly between brands. Experiment to find your favorites.
* **Add Some Heat:** A sprinkle of red pepper flakes to the aioli, or a dash of hot sauce to the plant-based roast beef, can add a nice kick.
* **Marinated Vegetables:** For extra flavor, consider marinating sliced bell peppers or zucchini in a balsamic vinaigrette and adding them to the sandwich.
* **Elevate the Sauce:** Infuse the vegan mayonnaise with herbs like dill or chives for a more complex flavor.
* **Make it a Melt:** After assembling the sandwich, you can grill it in a panini press or on a skillet until the vegan cheese is melted and gooey.
**The Verdict: Is the Costco Roast Beef Sandwich Worth Recreating?**
Whether you love it or hate it, the Costco roast beef sandwich has undoubtedly made its mark. The controversy surrounding its price and taste has only fueled the desire to recreate it at home. By experimenting with different ingredients and techniques, you can create a sandwich that not only rivals the Costco version but surpasses it in terms of flavor, quality, and customization.
Ultimately, the “best” roast beef sandwich is the one that you enjoy the most. So, get in the kitchen, experiment with these recipes, and find your perfect combination. Who knows, you might even create a sandwich that becomes a legend in your own household.
**Beyond the Sandwich: Other Costco Food Court Favorites to Recreate at Home**
While we’ve focused on the roast beef sandwich, the Costco food court offers a plethora of other beloved items that are ripe for DIY recreation. Here are a few ideas to get you started:
* **Costco Pizza:** There are countless copycat recipes online for Costco’s pizza, focusing on the dough recipe and the specific blend of cheeses used. Experiment with different flour types and cheese combinations to find your perfect pizza.
* **Costco Hot Dog:** While the price is hard to beat, you can certainly elevate the hot dog experience at home with high-quality beef hot dogs, gourmet buns, and a variety of toppings.
* **Costco Chicken Bake:** These cheesy, chicken-filled pockets are surprisingly easy to make at home. Use pre-made pizza dough or puff pastry for a shortcut, and experiment with different cheese and sauce combinations.
* **Costco Churros:** While they changed up the churro recipe, you can find great recipes online to recreate them. Be sure to coat them in plenty of cinnamon sugar for an authentic experience.
**Conclusion: The Costco Food Court – An Inspiration for Home Cooks**
Even if the new roast beef sandwich didn’t immediately win you over, the conversation and the creativity it has inspired is a testament to the power of food and the desire to create satisfying meals at home. The Costco food court, with all its quirks and controversies, serves as a fantastic inspiration for home cooks looking to recreate their favorite comfort foods. So, grab your ingredients, fire up the oven, and start experimenting! You might just discover your new favorite recipe.