Soggy Sandwiches Must Be Stopped — Use These Chef Tips to Build the Perfect Portable Sandwich

Properly packing a sandwich is an art form. Here’s how to layer ingredients to prevent dreaded sogginess, according to a pro sandwich maker.

If you’ve had the unfortunate experience of biting into a wet, gummy sandwich, it probably didn’t come from a dedicated sandwich shop or deli. The pros have perfected the art of making a sandwich that can withstand the test of time, whether that’s a commute to work or a drive to a beach.

“Most types of sandwiches travel well,” says Trevor Kunk, a former fine dining chef who now works as the culinary director of Shy Bird in Boston, where he slings creations like a ranch fried chicken sandwich and smashed falafel wrap. Still, he says, any sandwich can be susceptible to sogginess without taking a few steps to keep it fresh. Read on for pro tips from Kunk for how to preserve your creation until mealtime, whether you’re packing school lunches or the perfect park snack.

Related: 40 Sandwiches to Sink Your Teeth Into

Start with sturdy bread

Using quality bread is your first step to sandwich success. Kunk likes a Pullman loaf, hearty marble rye, or a hoagie roll.

If you’re eating your sandwich immediately or within a shorter time frame, you can toast it, though this step isn’t necessary if you’re packing the sandwich to go, says Kunk. If you do toast your bread, Kunk suggests toasting only the exterior in a cast-iron pan or similar with a little oil or butter.

“What we find is that if you toast both sides, when you bite into your sandwich, a lot of the ingredients are going to slide out the side because it’s a hard barrier as opposed to a soft cushion,” he explains.

Related: The Best Sandwich in Every State

Use mayonnaise or another oil-based condiment

“Sauce is boss,” says Kunk — but not just any sauce. He suggests an oil-based condiment like mayonnaise, which has water-repelling molecules that can prevent moisture from soaking into the sandwich. As such, a light layer of mayo on the interior of each slice of bread can actually help to keep your sandwich dry.

“The oil component, depending on how long your sandwich travels or is wrapped for, will slowly absorb into the bread, but it absorbs in a way where it keeps it moist without causing it to become gummy or wet or fall apart,” Kunk explains.

Water-based condiments like ketchup or mustard can all cause sogginess, but if you’d like to use them, Kunk simply suggests combining the condiment with a little mayo. If you want to add Dijon mustard to your sandwich, for example, make a Dijonnaise by combining the mustard with just a little mayo for extra protection.

Or, if you want to make a vinaigrette for an Italian-style hero, “you can replicate it by using a mayonnaise base and just adding a healthy, healthy amount of oregano and pepper, then a little bit of vinegar,” Kunk advises. “It’s going to be very similar to a broken dressing.”

If you’re in the mayo-haters camp, there’s still hope. Spread the interior of your bread with a thin layer of olive oil or softened butter for a similar effect. In general, opt for thicker condiments to prevent excess moisture, such as coarse-ground mustard rather than regular yellow mustard, says Kunk.

Build your sandwich with cold, dry ingredients

There’s logic behind this tip — the condensation from warm ingredients can cause a soggy sandwich — but it also feels right. “If you’re going to eat a sandwich cold, why not just build [it] cold?” reasons Kunk. One of his favorite sandwiches is a split hoagie roll stuffed with cold chicken tenders.

You don’t need to be overly fussy about wiping down each ingredient, says Kunk, but if you’re washing anything such as lettuce or arugula make sure to thoroughly dry it in a salad spinner. Pat dry any ingredients that are wet like pickles to ensure the juice doesn’t seep into your sandwich.

Related: Club Sandwich

Pay attention to the order

After spreading a mayo-based condiment on the interior of the bottom bread slice, Kunk immediately tops it with shredded lettuce, which also works to create a barrier against moisture. He follows with the focus of the sandwich, such as cured meat or falafel, then cheese if he’s using it.

If using cold cuts, Kunk suggests slicing them thinly. “As you’re eating your sandwich, the meat will break down with each bite, and is able to mix in with either the condiments or the vegetables, whatever it might be on that sandwich,” he says. Add about four to five ounces of meat (that’s nine to 11 thin slices!), then one to two slices of cheese.

Kunk is a firm believer in putting the “fun stuff on top” — your pickled onions , your giardiniera, and what have you — to keep the palate excited. After that, complete your sandwich with the other slice of condiment-laden bread, or close the sandwich if you’re building it on a roll.

Skip the tomatoes — or take care to dry them

“I will not put a tomato on a sandwich unless it is pickled, fried, or roasted,” says Kunk, noting their high water content. But if you must use tomatoes, you can take a few steps to make sure they’re sandwich-ready.

“Pat them dry as best possible. And if you have some extra time, even 15 minutes, take those tomato slices and just lightly season them with salt before draining them or patting them dry. That’s definitely going to extend the life of the sandwich,” says Kunk.

As a foolproof step, you can always pack your tomatoes separately.

Pack your sandwich for success

You’ve built the perfect sandwich, so don’t ruin all your hard work by wrapping or storing it in plastic, which doesn’t absorb moisture well. Instead, take a note from sandwich shops around the world and wrap your sandwich in a double layer of parchment paper or butcher paper. First, wrap the whole sandwich in a layer of paper, slice it in half, then wrap the halves in the paper again. For additional insurance, place the wrapped sandwich in an airtight container before packing it, says Kunk. If you’re using a cooler for your sandwich, for instance, keeping it in a container within the cooler will protect it from moisture.

Follow these steps, and you’ll never suffer a soggy sandwich again.

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