Crispy Air Fryer Tofu Katsu Sando with Sprouted Breadcrumbs

A sprouted plant-based take on the iconic grab-and-go Japanese sandwich, our Crispy Air Fryer Tofu Katsu Sando with Sprouted Breadcrumbs is all about simple swaps that stay as true to the spirit of the original as possible but make it healthy, plant-based, and accessible to families on the hunt for fun, high-protein, high-fibre meals that fit their full lives.

Course Main Course, Lunch, Dinner, Sandwich

Cuisine Japanese, Plant-based

Diet Vegan, Vegetarian

Keyword Sandwiches

Servings sandwiches

Author Silver Hills Bakery

Ingredients

Ingredients for the Crispy Air Fryer Tofu Katsu Sando (Makes 2 or 3 sandwiches):

4 or 6 slices Silver Hills Bakery Soft Wheat sprouted bread (recommended)
¼ – ½ small green cabbage , finely shredded
3 – 6 Tbsp shortcut plant-based Japanese mayo (recipe below, or use store-bought KEWPIE Vegan Mayo)
4 – 6 Tbsp homemade vegan katsu sauce (recipe below, or use store-bought Bull-Dog Vegetable & Fruit Sauce (Tonkatsu Sauce))
3 – 4 Tbsp non-dairy buttery spread (or softened plant-based butter)
2 – 3 tsp grainy mustard (such as Maison Orphée Old-Fashioned Mustard)
4 air fryer katsu cutlets (2 per large sandwich or 1 1/3 per smaller sandwich)

Ingredients for the Crispy Air Fryer Tofu Katsu with Sprouted Breadcrumb Crust:

1 package (350g / 12.3 oz to 454g / 16 oz (1 lb)) firm or extra firm tofu , sliced horizontally into four 1-cm / ½ inch cutlets and poached in seasoned broth (recipe with optional aromatics below)
⅓ cup cornstarch (or flour)
1 Tbsp ground chia (or 2 tablespoons ground flaxseed)
1 cup non-dairy milk , unsweetened
2 ½ – 3 cups sprouted breadcrumbs , from our easy sprouted breadcrumb recipe
vegetable oil spray (such as olive or avocado)

Ingredients for the Seasoned Poaching Broth with Optional Aromatics:

4 cups water
1 Tbsp salt (omit or reduce if using soy sauce or tamari)
4 Tbsp soy sauce or tamari (or 2 vegan chicken bouillon cubes (or equivalent powder or paste)** (optional)
2 inches fresh ginger , sliced (optional)
3 – 4 cloves garlic , smashed or sliced (optional)
2 – 3 green onions , sliced into 2-inch pieces (or ½ yellow onion cut into 3 or 4 large slices) (optional)

Ingredients for the Easy Homemade Vegan Katsu Sauce:

½ cup ketchup
6 Tbsp apple cider vinegar
3 Tbsp soy sauce (or tamari)
2 Tbsp brown sugar
1 tsp cornstarch
2 tsp yellow mustard
¼ tsp onion powder
¼ tsp garlic powder
½ tsp ground ginger
¼ tsp allspice (optional)

Ingredients for the Shortcut Plant-based Japanese Mayo:

1 cup plant-based mayo
1 Tbsp sugar
2 Tbsp seasoned rice vinegar (or 2 Tbsp rice vinegar + 1 tsp sugar)
½ – 1 tsp kombu dashi powder (or white miso), or to taste
½ tsp Dijon mustard

Instructions

Instructions for the Crispy Air Fryer Tofu Katsu Sando:

Prepare crispy air fryer tofu katsu with sprouted breadcrumb crust, shortcut plant-based Japanese mayo (if making), and homemade vegan katsu sauce (if making). Shred cabbage as finely as possible (see tip).
Lightly butter the inside of each slice of Soft Wheat bread. Spread grainy mustard on one side of each sandwich, and 1 – 2 tablespoons plant-based Japanese mayo on the other.
For three sandwiches: slice one crispy air fryer tofu katsu cutlet into thirds and use 1 1/3 cutlets per sandwich; For two large sandwiches: use 2 crispy air fryer tofu katsu cutlets per sandwich.
Add a generous handful of finely shredded cabbage to one side of each sandwich, then drizzle about a tablespoon of vegan katsu sauce on the cabbage before placing crispy air fryer tofu katsu crust on top. Drizzle a second tablespoon of vegan katsu sauce on the tofu katsu. Close the sandwich and enjoy!

Instructions for the Crispy Air Fryer Tofu Katsu with Sprouted Breadcrumb Crust:

Prepare sprouted breadcrumbs: If you haven't made sprouted breadcrumbs yet, toast sprouted bread in the oven until golden brown (a little longer than our sprouted breadcrumb recipe calls for).
If you've already made sprouted breadcrumbs: heat a large frying pan over medium heat. Toast sprouted breadcrumbs in the hot, dry pan, stirring constantly until golden brown and fragrant. Remove from the pan and set aside to cool.
If air frying: Preheat your air fryer to 375°F. If baking: Preheat your oven to 400°F.
Prepare sprouted breadcrumb breading station: In one of three shallow bowls or pie plates, mix non-dairy milk and ground chia or ground flaxseed together to make your plant-based egg, and set aside to gel.
Prepare seasoned poaching water or poaching broth with optional aromatics:

For simple seasoned poaching water: Bring 4 cups water to a boil in a large frying pan or wide sauce pan, then add 1 tablespoon salt.

For poaching broth with optional aromatics: Add ginger, garlic, and green onions to a large frying pan or wide sauce pan with oil and sauté 2 minutes. Add 4 cups water and soy sauce, bring to a boil, reduce heat to simmer and allow to infuse for 5 minutes.
Poach the tofu katsu cutlets: Carefully lower tofu cutlets into the water so it doesn't fall apart (a large, slotted spoon or wire mesh spider helps). Bring the poaching water or broth back to a gentle boil, cover, then boil for 5 minutes. Carefully remove tofu cutlets and place on a plate with a paper towel. Pat dry and set aside until cool enough to handle for breading.

*You need enough water to submerge your tofu slices completely. Depending on the size and shape of your pot, if more water is needed, use 6 cups water + 1 1/2 tablespoons salt (or add more 2 tablespoons soy sauce) or 8 cups water + 2 tablespoons salt (or double the soy sauce).

** if using low or no sodium bouillon, add salt in the ratios provided in step 3—sodium is key to changing the texture of the tofu and infusing flavour through poaching)
Bread the tofu katsu cutlets: Set your plant-based egg bowl between two other shallow bowls or pie plates. Place cornstarch in the first bowl, and toasted sprouted breadcrumbs in the third bowl. Set a large plate or baking sheet nearby.

Working one at a time, dredge each tofu cutlet in cornstarch until evenly coated and gently tap off excess starch. Next, dip the tofu in plant-based egg until all surfaces are covered. Then gently press battered tofu into toasted sprouted breadcrumbs until evenly breaded on all sides. Set aside and repeat until all tofu is breaded.
Air fry or bake the breaded tofu katsu cutlets with sprouted breadcrumb crust:

To air fry the tofu katsu with sprouted breadcrumbs: Spray breaded tofu katsu cutlets with oil on both sides. Place in the basket of a preheated air fryer in a single layer. Air fry the first side 6 – 8 minutes, flip, then air fry the second side 4 – 5 minutes or until crispy and golden brown. Set aside and repeat until all sprouted breadcrumb tofu katsu cutlets have been air fried.

(Depending on your air fryer, each batch may take a little less time on the second side. Check after 3 minutes for each batch after the first).

To bake the tofu katsu with sprouted breadcrumbs: Place a wire cooling rack on a baking sheet, then arrange breaded tofu katsu cutlets on the rack. Bake for 10 – 12 minutes, flip, and return the second side to the oven for another 10 minutes, or until crispy and golden brown.

Instructions for the Easy Homemade Vegan Katsu Sauce:

In a small saucepan, whisk together all ingredients. Turn stove to medium heat. When sauce starts to warm, stir constantly until sugar has completely dissolved.
Allow to cool, then transfer to a jar or squeeze bottle. Refrigerate up to 2 weeks.

Instructions for the Shortcut Plant-based Japanese Mayo:

In a small bowl, whisk together sugar, seasoned rice vinegar, kombu dashi powder (or white miso), and Dijon mustard. Add plant-based mayo and mix until well combined. Transfer to a jar or squeeze bottle. Refrigerate up to 5 days.

Tips

- **Use a mandoline for the finest shredded cabbage** if you have one.

- **Packing these high-protein, high-fibre sandwiches to go?** Keep that air fryer tofu katsu crispy with a tip from our [How to Pack a Non-Soggy Sandwich](https://silverhillsbakery.ca/healthy-lunch-hack-how-to-pack-a-non-soggy-sandwich/) article—pack the parts and sauces separately until lunch time (or picnic time!), then put them together right before you eat. Or enjoy your sando commuter-style and let the flavours meld and soften on the way to school or work. They’re delicious either way!

- **Crave more zip?** Dress your shredded cabbage lightly with lemon juice or seasoned rice vinegar before packing your bento or topping your sando. Or pair with some pickled ginger to taste.

- **To toast or not to toast?** While the outside of traditional katsu sando is always kept soft, the inside is often toasted to complement the crispy, crunchy fillings. Use the bagel setting on your toaster to get a one-side toast that fits right in with this air fryer tofu katsu sandwich.

- **Can you make Crispy Air Fryer Tofu Katsu Sandwiches with other Silver Hills Bakery sprouted breads?** Katsu sando are traditionally served on Japanese shokupan milk bread—one of the softest, fluffiest, whitest white breads in the world! That’s why we recommend Soft Wheat for this recipe specifically, because it’s our softest, closest-to-white-bread sprouted loaf.

But if Soft Wheat isn’t your jam or your go-to grocer doesn’t carry it, of course you can use another Silver Hills Bakery sprouted bread—just choose the softest, smoothest loaf you like!

(As much as we love Squirrelly bread, The Big 16, and Full Seed Ahead for almost any other recipe, their hearty, fully sprouted character takes this dish in a direction less true to the spirit of the original.

Check out the [Flavour & Texture Spectrum](https://silverhillsbakery.ca/what-is-the-best-silver-hills-bread-for-you/#flavour-and-texture-spectrum) on our *What is the Best Silver Hills Bread for You* page to see our sprouted breads sorted from soft and tender to richly textured.)

To Freeze

Freeze made-ahead or leftover Crispy Air Fryer Tofu Katsu cutlets in an air-tight container for up to a month. That’s not just good for reducing food waste or making a future weeknight meal faster—freezing the tofu will give it a firmer, chewier texture than poaching alone and make your katsu cutlets even better!

To Reheat

To keep frozen or cold Air Fryer Tofu Katsu cutlets crispy, reheat on a baking sheet in the oven or toaster oven at 350°F for 8 – 10 minutes or until hot inside and crisp outside. Or reheat in an air fryer for 5+ minutes (time varies by make and model, check often so they don’t over-brown or burn). To avoid soggy tofu katsu cutlets, skip the microwave.