Grilled Mozzarella BBQ Chicken Sandwiches

A Sizzling Summer Favorite Packed with Flavor

There’s nothing quite like a grilled chicken sandwich—especially one that’s smothered in smoky BBQ sauce and crowned with melted mozzarella cheese. The Grilled Mozzarella BBQ Chicken Sandwich takes a classic comfort food and turns it into an unforgettable experience. Whether you're hosting a backyard cookout or just craving a hearty dinner with bold flavors, this sandwich is sure to satisfy.

In this comprehensive guide, we’ll walk you through how to make the ultimate BBQ chicken sandwich, complete with ingredient tips, cooking methods, delicious variations, and expert serving ideas. Prepare to unlock your new favorite grilled recipe!

Introduction
Why Grilled Chicken Sandwiches Are a Must-Try
The Star Ingredients Explained
Step-by-Step Instructions
Tips for Juicy, Flavor-Packed Chicken
How to Grill Perfectly Every Time
Melting the Mozzarella the Right Way
Choosing the Right Buns
Toppings and Add-Ons to Elevate Your Sandwich
Side Dishes That Pair Perfectly
Sauce Suggestions Beyond BBQ
Variations You’ll Want to Try
Storage and Reheating Instructions
Nutrition Information
Final Thoughts and Serving Inspiration

1. Introduction

Grilling brings out the best in chicken. The smokiness, the char marks, the way it locks in the juices—all of it adds to the incredible experience of a grilled meal. But when you combine grilled chicken with barbecue sauce and the gooey richness of mozzarella cheese, something magical happens. This sandwich is equal parts smoky, savory, and sweet with just the right amount of indulgence.

2. Why Grilled Chicken Sandwiches Are a Must-Try

Grilled chicken sandwiches strike the perfect balance between healthy and hearty. They’re lighter than a beef burger but still incredibly satisfying. Here’s why they deserve a regular place on your menu:

Lean protein: Chicken breast is high in protein and low in fat.
Versatility: Easily customizable to your flavor preferences.
Kid-friendly: BBQ and cheese are always a winning combo.
Quick to prepare: Great for weeknight dinners or last-minute lunches.
Cookout crowd-pleaser: Perfect for summer barbecues or family gatherings.

3. The Star Ingredients Explained

Chicken Breasts

Use boneless, skinless chicken breasts and pound them to an even thickness. This ensures they cook evenly and stay juicy on the grill.

Barbecue Sauce

Go with a BBQ sauce you love—sweet, smoky, spicy, or tangy. You can even make your own with ketchup, brown sugar, vinegar, and spices.

Mozzarella Cheese

Fresh mozzarella melts beautifully and offers a mild creaminess that balances the smoky BBQ.

Sandwich Buns

Brioche or potato buns add a rich, buttery taste, but any sturdy bun will work.

Optional Toppings

Caramelized onions
Coleslaw
Pickles
Sliced tomatoes
Avocado

4. Step-by-Step Instructions

Ingredients:

4 boneless, skinless chicken breasts
1 tablespoon olive oil
Salt and pepper to taste
1 teaspoon garlic powder
1 teaspoon smoked paprika
½ cup BBQ sauce (plus more for serving)
8 slices mozzarella cheese
4 sandwich buns
Butter for toasting buns
Optional toppings: caramelized onions, pickles, coleslaw, lettuce

Instructions:

Step 1: Prep the Chicken

Pound each chicken breast to ¾-inch thickness. Season both sides with salt, pepper, garlic powder, and smoked paprika. Drizzle with olive oil and rub in the seasoning.

Step 2: Preheat the Grill

Heat your grill or grill pan over medium-high heat. Clean and oil the grates for the best sear.

Step 3: Grill the Chicken

Place the chicken on the grill and cook for 5–6 minutes per side or until internal temperature reaches 165°F (74°C). During the last 2 minutes, brush with BBQ sauce and flip once more to caramelize.

Step 4: Add the Cheese

Top each piece of chicken with 2 slices of mozzarella. Cover the grill (or tent with foil) and let the cheese melt for 1–2 minutes.

Step 5: Toast the Buns

Butter the insides of the buns and place them cut-side down on the grill for about 1 minute, or until golden and crisp.

Step 6: Assemble

Layer chicken onto the toasted buns. Add toppings of your choice, an extra drizzle of BBQ sauce, and top with the bun lid.

5. Tips for Juicy, Flavor-Packed Chicken

Marinate if you have time: A simple marinade of olive oil, lemon juice, and herbs boosts flavor.
Let it rest: After grilling, allow the chicken to rest for 5 minutes to retain its juices.
Use a thermometer: Always check for doneness at 165°F (74°C) internally.

6. How to Grill Perfectly Every Time

Preheat your grill and oil the grates.
Don’t overcrowd the grill pan or flames.
Use tongs—never pierce the chicken with a fork to flip.
Close the lid during cheese melting for even heat distribution.

7. Melting the Mozzarella the Right Way

Use fresh mozzarella for best meltability. If you're using shredded mozzarella, place a piece of foil over the chicken after topping with cheese to trap the heat and encourage melting.

8. Choosing the Right Buns

The bun can make or break your sandwich. Here are a few options:

Brioche Buns: Buttery, sweet, and soft.
Pretzel Buns: Chewy with a slightly salty crust.
Ciabatta Rolls: Crunchy and rustic—great for heavier toppings.
Kaiser Rolls: Classic, sturdy, and lightly crusty.

9. Toppings and Add-Ons to Elevate Your Sandwich

Great toppings can take your sandwich to gourmet status:

Caramelized Onions: Adds a savory-sweet touch.
Crunchy Slaw: Balances richness with freshness and texture.
Pickles: Cuts through BBQ sweetness with tang.
Bacon: Because bacon makes everything better.
Avocado: Creamy and nutritious.

10. Side Dishes That Pair Perfectly

Complete the meal with any of these complementary sides:

Sweet Potato Fries
Grilled Corn on the Cob
Potato Salad or Macaroni Salad
Baked Beans
Garden Salad with Ranch or Balsamic

11. Sauce Suggestions Beyond BBQ

If you want to switch things up, try these tasty alternatives:

Chipotle Mayo: Spicy and smoky.
Garlic Aioli: Creamy and garlicky.
Honey Mustard: Sweet, tangy contrast.
Buffalo Sauce: For a spicy twist.
Pesto: Adds an herby Italian flair.

12. Variations You’ll Want to Try

Spicy Mozzarella BBQ Chicken

Add jalapeños, pepper jack cheese, and spicy BBQ sauce.

Hawaiian Style

Top with grilled pineapple and teriyaki BBQ sauce.

BBQ Chicken Caprese

Add fresh basil and a drizzle of balsamic glaze.

Breakfast BBQ Sandwich

Top with a fried egg and serve on an English muffin.

Vegetarian Version

Grill marinated portobello mushrooms instead of chicken.

13. Storage and Reheating Instructions

To Store:

Keep grilled chicken in an airtight container in the fridge for up to 3 days.
Store buns and toppings separately.

To Reheat:

Warm chicken in a skillet or microwave.
Toast buns again before assembling.

Freezer Tips:

Freeze cooked, sauced chicken (without toppings) for up to 2 months.
Wrap tightly and thaw overnight before reheating.

14. Nutrition Information (Per Sandwich, Estimate)

Nutrient	Amount
Calories	530–580 kcal
Protein	38g
Carbs	40g
Fat	22g
Sugar	12g
Fiber	2g
Sodium	800mg

Nutritional content may vary depending on sauces, cheese, and toppings used.

15. Final Thoughts and Serving Inspiration

The Grilled Mozzarella BBQ Chicken Sandwich is more than a sandwich—it’s a complete flavor experience. From the juicy, smoky chicken to the gooey melted mozzarella and sweet-savory BBQ sauce, it checks every box for comfort food bliss. Whether you enjoy it with fries on the patio or serve it up at your next cookout, it’s a guaranteed hit.