BBQ Chicken Roll Recipe: Smoky Grill-Filled Bites

These smoky, flavor-packed rolls bring the essence of the grill to every bite. I developed this recipe to capture that classic BBQ experience in a hand-held format.

The secret lies in the balance of tender chicken, bold seasoning, and just the right amount of char. It’s a foolproof method for delivering restaurant-quality results at home.

Ingredients for Bbq Chicken Roll

Tender chicken, bold seasoning, and flaky pastry create these smoky, hand-held delights with ease.

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The chicken quality is paramount here. Boneless, skinless breasts from a reputable butcher or Whole Foods ensure tenderness. Pounding to an even thickness prevents dry spots during cooking. For the barbecue sauce, Stubb’s Original or Sweet Baby Ray’s deliver consistent smoky-sweet balance. Puff pastry from Pepperidge Farm is reliable, but any all-butter version works beautifully.

Short on time? Rotisserie chicken shreds work well (use 3 cups). No smoked paprika? Regular paprika plus a pinch of cayenne mimics the depth. Fresh garlic and onion can replace the powders at a 1:1 ratio, finely minced. For extra char, brush rolls with melted butter before baking. The pastry can be store-brand—just check it’s all-butter for best flakiness.

Assembled rolls keep 1 day refrigerated (cover tightly). Baked rolls are best served warm but reheat well at 350°F for 10 minutes. Freeze unbaked rolls for up to 3 months—bake straight from frozen, adding 5 extra minutes. Garnishes like sesame seeds toast faster if added mid-bake.

Step-by-Step Instructions for BBQ Chicken Rolls

Precision in technique ensures these flaky, smoky bites come out perfectly every time.

Step 1: Season and Cook the Chicken

Pound the 1.5 lb Chicken Breast to an even ¼-inch thickness between plastic wrap. This guarantees even cooking and prevents dry spots. Season both sides with 1 tsp Smoked Paprika, 1 tsp Garlic Powder, 1 tsp Onion Powder, 0.5 tsp Salt, and 0.5 tsp Black Pepper.

Heat a skillet over medium-high heat and cook the chicken for 4-5 minutes per side until fully cooked through and the internal temperature reaches 165°F. Let it rest for 5 minutes, then slice into thin strips.

Step 2: Prepare the Pastry and Filling

Lightly dust your work surface with 1 cup All-Purpose Flour to prevent sticking. Unfold the 2 sheets Puff Pastry Sheets and roll each slightly to smooth seams. Divide each sheet into 4 equal rectangles.

Spread a thin layer of 1 cup Barbecue Sauce over each rectangle, leaving a ½-inch border. Distribute the sliced chicken evenly across the pastry, pressing gently to adhere. This ensures every bite has a balanced ratio of filling to pastry.

Step 3: Seal and Bake the Rolls

Whisk the 1 whole Large Egg with 1 tbsp Olive Oil to create an egg wash. Brush the edges of each pastry rectangle with the wash, then tightly roll each into a log. Press the seams to seal, and brush the entire surface with more egg wash for a golden finish.

Place the rolls seam-side down on a parchment-lined baking sheet. Bake at 400°F for 18-20 minutes until the pastry is deep golden brown and puffed. Rotate the pan halfway through for even browning.

Step 4: Garnish and Serve

Remove the rolls from the oven and let them cool for 5 minutes. Slice each log into 2-inch pieces for individual portions. Drizzle with any remaining barbecue sauce for extra flavor and moisture.

Garnish with 0.25 cup Green Onions and 1 tbsp Sesame Seeds just before serving. These toppings add freshness and a subtle crunch that complements the smoky, savory filling perfectly.

Storing and Reheating Leftovers

Refrigerator Storage

Let your rolls cool completely, then store in an airtight container with parchment between layers. They’ll keep at 40°F or below for up to 3 days. The pastry softens slightly but regains crispness when reheated. ❄️

Freezer Storage

For longer storage, freeze unbaked rolls on a tray first, then transfer to a freezer bag. They’ll maintain quality for 3 months. Bake straight from frozen, adding 5 extra minutes to the cooking time.

Oven Reheating

Preheat to 350°F and warm rolls for 8-10 minutes until crisp. This method preserves the pastry’s flakiness better than microwave. I always check for 165°F internal temperature before serving. 🔥

Microwave Option

Place a single roll on a paper towel and microwave at 50% power for 30-45 seconds. The pastry won’t be as crisp but the filling stays moist. Cover with a damp towel to prevent drying.

Make-Ahead Tip

Assemble rolls up to 1 day ahead and refrigerate uncovered. This dries the surface slightly for better browning. Brush with egg wash just before baking for that golden finish.