Air frying has become an increasingly popular way to make healthier versions of traditionally fried foods. The air fryer uses hot air and a fan to circulate the heat and crisps up foods with little to no oil. Making a Costco chicken bake in the air fryer results in a crispy, golden exterior and a tender, juicy interior all while using just a fraction of the oil that deep frying requires.
What is a Costco Chicken Bake?
A Costco chicken bake is a handheld pastry stuffed with breaded chicken, bacon, cheese, and Caesar dressing. It was first introduced in the Costco food courts in 1999 and has become one of their most popular menu items. Here are some key features of a classic Costco chicken bake:
- A flaky, golden brown puff pastry crust
- Chunks of breaded and seasoned chicken breast
- Crispy pieces of bacon
- Ooey, gooey mozzarella cheese
- Tangy Caesar dressing
A standard chicken bake from Costco is roughly 8 inches long and contains 780 calories and 44 grams of fat. While tasty, these nutritional stats make it hard to justify eating them too often. Making a DIY version at home allows you to control the ingredients and serves as a healthier, lighter alternative.
Benefits of Air Frying
Here are some of the biggest benefits of using an air fryer to make chicken bakes at home:
- Uses Less Oil – Air fryers require just a teaspoon or two of oil to crisp up foods. Much healthier than deep frying in quarts of oil.
- Quick Cooking – Food cooks fast thanks to the circulating hot air. Chicken bakes take only 15-20 minutes.
- Crispy Texture – The outside gets perfectly crispy without needing to be dunked in fat.
- Tender Interior – The inside cooks gently so it stays nice and moist.
- Versatile – Make chicken bakes as well as fries, wings, vegetables and more.
Ingredients
To make chicken bakes in the air fryer, you will need:
| Ingredient | Amount |
|---|---|
| Puff pastry sheets, thawed | 2 sheets |
| Chicken breast, cubed | 1 pound |
| Bacon slices | 3-4 slices |
| Shredded mozzarella | 1/2 cup |
| Caesar salad dressing | 3 tbsp |
| Egg wash (1 egg beaten with 1 tbsp water) | For brushing |
| Oil or cooking spray | 1-2 tsp |
For seasoning the chicken, you’ll also need:
- 1/2 tsp salt
- 1/2 tsp pepper
- 1/2 tsp garlic powder
- 1/2 tsp onion powder
- 1/2 cup panko breadcrumbs
Step 1 – Prepare the Chicken
Start by prepping the chicken breast for the filling. Here’s how:
- Cut the chicken breast into 1 inch cubes.
- Place the chicken in a bowl. Season with the salt, pepper, garlic powder, onion powder and a few tbsp oil. Toss to coat evenly.
- Add the panko breadcrumbs to the same bowl. Toss again until the chicken is evenly coated in the breadcrumbs.
- Set aside while you prepare the other ingredients.
Step 2 – Cook the Bacon
The next step is to cook the bacon until nice and crispy. This can be done either on the stovetop or in the microwave.
To cook bacon on the stovetop:
- Place bacon strips in a cold skillet. Set heat to medium.
- Cook until evenly browned and crispy, about 5-6 minutes per side.
- Transfer cooked bacon to a paper towel lined plate to drain.
- Once cool enough, crumble the bacon into pieces.
To cook bacon in the microwave:
- Line a microwave safe plate with paper towels.
- Arrange bacon strips on the plate in a single layer, without overlapping.
- Microwave on high for 2-3 minutes. Check and rearrange strips as needed.
- Microwave in 30 second intervals until crispy as desired, for 1-2 minutes more.
- Transfer bacon to another paper towel lined plate to drain.
- Once cool enough, crumble the bacon into pieces.
Step 3 – Assemble the Bakes
Once the chicken and bacon are ready, it’s time to assemble the handheld chicken bakes.
- Take one puff pastry sheet and cut it lengthwise down the center to make two long strips.
- Brush the edges with egg wash.
- Load one half of each strip with the chicken, bacon, cheese and caesar dressing, leaving a 1/2 inch border.
- Fold the empty half over the filling and press the edges with a fork to seal.
- Use a knife to carefully cut each long strip into 3 or 4 smaller bakes.
- Place the assembled chicken bakes seam side down on an air fryer safe baking pan. Brush the tops with egg wash.
Repeat with the second puff pastry sheet to make a total of 6-8 chicken bakes.
Step 4 – Air Fry the Chicken Bakes
The last step is to air fry the assembled chicken bakes until golden brown and crispy.
- Preheat air fryer to 380°F.
- Lightly spray or brush the chicken bakes with oil.
- Place baking pan in air fryer basket. Work in batches if needed.
- Air fry for 14-18 minutes, flipping halfway, until puffed and golden brown.
- Check that inside filling is hot and chicken is cooked through.
- Let cool for 5 minutes before serving.
Tips for the Best Results
Follow these tips for perfectly air fried chicken bakes every time:
- Use frozen puff pastry that has thawed overnight in the fridge for best results.
- Brush with egg wash for a glossy, golden crust.
- Don’t overfill the pastries so the sides can seal tightly.
- Flip halfway during cooking for even browning.
- Adjust cooking time as needed based on air fryer size/power.
- Insert a meat thermometer to confirm chicken is cooked to 165°F.
- Let cool briefly before eating to avoid burnt mouth!
Customize It!
The beauty of making chicken bakes at home is that you can customize them in so many ways. Get creative with the fillings using these ideas:
- Buffalo Chicken – Toss chicken in hot sauce and use crumbled blue cheese.
- BBQ Chicken – Swap caesar for BBQ sauce and cheddar for the cheese.
- Taco – Season chicken with taco seasoning. Use shredded lettuce, cheese, salsa and sour cream.
- Italian – Use spinach and mozzarella with Italian dressing.
- Mediterranean – Add artichokes, roasted red peppers, feta and Greek dressing.
- Breakfast – Use scrambled eggs, ham, hash browns and cheddar cheese.
Storage Instructions
Properly stored, leftover chicken bakes will keep well for several days.
- Let chicken bakes cool completely before refrigerating.
- Place in a sealed container or zip top bag.
- Refrigerate for up to 4 days.
- Reheat in the air fryer or oven until hot, crispy and delicious.
- Can also freeze baked chicken bakes for up to 3 months.
Nutrition Information
Here is the nutrition information for a homemade air fried chicken bake made with the original filling recipe:
| Nutrition Facts | Per Serving |
|---|---|
| Calories | 345 |
| Fat | 16g |
| Carbs | 28g |
| Protein | 19g |
| Fiber | 1g |
| Sodium | 513mg |
Compare that to the 780 calories and 44g fat in a classic Costco chicken bake! Making it yourself results in less than half the calories and fat.
The Verdict
Air frying allows you to recreate the crispy, savory goodness of a Costco chicken bake right at home for a fraction of the calories. Ditch the deep fryer and break out the air fryer instead for the easiest, healthiest homemade chicken bakes ever.
With the option of using any fillings you like, you can customize these according to your tastes. Make a big batch for quick lunches and dinners all week long. Even just one or two fit easily into a healthy diet and satisfies that chicken bake craving in a better-for-you way.
So next time you get that itch for a Costco chicken bake, give this easy air fryer recipe a try!