RECIPE: Zucchini Roll Sandwich that Actually Holds Together

I haven't finished testing this, but I'm putting it out there as a 'non-recipe' to inspire others to be creative with the zucchini in the farm store these days. 

There are so many YouTube and Instagram videos on making a zucchini roll sandwich, and I have tried several of them, but they always fall apart!  I developed this recipe, which is more complicated than the videos, but it actually holds together.  I make it with yellow zucchini (also called yellow summer squash) because I like the flavor better, but green zucchini will work, too. 

The recipe is written for the small 10" x 11" tray that fits in our toasted oven.  I used that to insure the recipe would work.  Not only did it work beautifully, it's the right size for two people.  I will update the recipe the next time I make it in a half-sheet pan.

TRICKS: the tricks that make this work are (1) sweat the zucchini to release moisture, (2) shingle at least 30%, (3) brush with beaten egg white to 'glue' the slices together, (4) prebake the zucchini before adding the cheese and finally, (5) let the roll cool slightly before trying to roll it.

Zucchini Roll Sandwich that Holds Together

Serves 2-4

INGREDIENTS:

• Zucchini Base

• 3 medium yellow zucchini
• Himalayan pink salt, for drawing out moisture
• 1 egg white, lightly beaten
• 1 Tbsp butter
• 2 Tbsp sliced fresh garlic
• Freshly ground black pepper

• Cheese Layer

• 2 cups grated Oaxaca cheese (8 ounces)
  
• ½ cup finely grated Parmesan
• ¼ tsp Mexican oregano
• 1 cup sliced green onions (white, light green, and dark green parts)

• Toppings

• Warm cooked chorizo, well drained (taco-seasoned ground beef would also work)
• Shredded lettuce
• Avocado slices or guacamole
• Ripe tomato, chopped
• Red onion, thinly sliced or minced
• Reserved green onion tops, thinly sliced
• Sour cream (optional)
• Lime wedges

INSTRUCTIONS:

1. Using a mandoline or Benrinner, slice the zucchini lengthwise into 1/16-inch slabs. Arrange on a dish towel, sprinkle lightly with salt, and let stand about 30 minutes to release moisture. Begin blotting after about 20 minutes.  I used paper towels so I could see how much moisture was released, and I continued blotting every 5 minutes until there was little moisture left.

   

   Sweat zucchini on dish towel, then soak up moisture with paper towels.
   

   
   
2. Do not over-dry the zucchini or it will take longer to cook and it won't adhere - you just want to remove some of the internal water, not all of it.  
3. PREHEAT OVEN TO 375F.
4. Melt the butter and gently sweat the garlic over medium-low heat until fragrant and softened. Do not allow it to brown.  Set aside.
   
5. Line a 10 × 11-inch baking tray with 3 layers of parchment paper.  This will insure you have a sturdy underlayer with which to flip the roll, if you choose to do that.
   
6. Arrange the zucchini in overlapping shingles, completely covering the pan.  Overlap each layer at least 1/3.  There should be 2/3 showing, 1/3 covered with the next layer.  Overlap the sides about 1/8 inch.  
7. Brush evenly and generously with the beaten egg white and allow 5 min or so for the egg white to seep between the layers.

   

   Shingle zucchini, then brush with beaten egg white.
   

   
   
8. Scatter the sweated garlic over the zucchini and season lightly with freshly ground black pepper.
   
9. Bake at 375°F for 8–12 minutes, or until the egg white is set and the zucchini is tender.  It's important the zucchini is cooked through or it won't create a cohesive sheet or adhere to the cheese.
10. Combine the Oaxaca, Parmesan, Mexican oregano, and sliced green onions. Spread evenly over the zucchini.
11. Bake an additional 3–4 minutes, until the cheese has melted.  If the cheese cooks for too long, the fat will separate and it will become a greasy mess.
12. Switch to broil for about 2 minutes, watching carefully, until the cheese develops light golden-brown spots.
13. While the cheese browns, reheat the cooked chorizo in a skillet, allowing excess fat to render. Drain well.
14. Remove from the oven and let the flatbread rest 5 minutes.
15. Cut into four squares. The flatbread should lift cleanly from the parchment.  We could have rolled this, but choose to use it at "bread" instead.
    
16. Top each serving with shredded lettuce, warm chorizo, avocado, tomato, red onion, green onion tops, and sour cream. Serve with lime wedges.

    

    Zucchini-cheese covered with chorizo, lettuce, avocado
    

    
    

NOTE: If you want to roll this:  Cover a cutting board with a sheet of parchment.  After letting the roll cool for 5 minutes, flip the zucchini-cheese sheet onto a cutting board.  Spread the filling onto it, then roll it LENGTHWISE using the parchment to lift it.  It will be easier to roll with the zucchini inside the roll and the cheese will hold the slices together. 

OTHER FILLING OPTIONS:

Burger

• Ground beef
• Cheddar instead of oaxaca
  
• Lettuce chiffonade
• Thinly sliced tomatoes
  
• Thinly sliced dill pickles
  
• Sport peppers
  
• Mayonnaise
• Mustard

Mediterranean

• Grilled chicken
• Cherry tomatoes
• Kalamata olives
• Fresh basil
• Feta instead of oaxaca
  
• Lemon zest
• Tzatziki on the side

Greek

• Lamb
• Feta instead of oaxaca
  
• Cucumber
• Red onion
• Dill
• Mint
• Tzatziki

Moroccan

• Lamb 
• Roasted red peppers
  
• Harissa
• Dates
• Mandarin oranges
  
• Red onion
• Mint

Breakfast

• Crisp bacon or breakfast sausage
• Scrambled eggs
• Chives
• Cheddar instead of oaxaca
  
• Hot sauce