If you’re in the market for a high-performance 5-burner Broil King gas grill, the choice often comes down to the Baron 590 and the Regal S590 Pro. Both are premium backyard chefs’ favorites, but they serve slightly different needs. In this in-depth comparison, we’ll explore their features, build, performance, and value — so you can decide which one makes the most sense for your grilling style.
Main Difference
Baron 590 vs Regal 590
The main difference between the Baron 590 and the Regal S590 Pro centers on power output, build quality, and cooking-grid materials. The Regal S590 Pro offers a stronger 55,000 BTU main burner output and more robust 9 mm stainless rod cooking grids, giving it better heat retention and searing capacity. The Baron 590, on the other hand, trades a bit of raw BTU and grid thickness for a more budget-friendly option, while still delivering solid performance with its cast-iron or 8 mm stainless grids. These differences make the Regal more suited for those who prioritize high-heat searing and premium feel, while the Baron is ideal for those who want a well-balanced, durable grill without going all-in on specs.
Comparison Table
| Feature | Baron 590 (Pro / IR) | Regal S590 Pro |
|---|---|---|
| Main Burner Output | 45,000 BTU (Pro) | 55,000 BTU |
| Cooking Space (total / primary) | 820 sq in total, 570 sq in primary | 875 sq in total, 625 sq in primary |
| Cooking Grids | 8 mm stainless (Pro) | 9 mm solid stainless rod |
| Burner System | 5 Dual-Tube burners | 5 Dual-Tube burners |
| Side Burner | 10,000 BTU (Pro) | 10,000 BTU commercial grade |
| Rotisserie Burner | 15,000 BTU stainless steel + kit | 15,000 BTU rear rotisserie + kit |
| Heat System | Flav-R-Wave stainless | Flav-R-Wave stainless |
| Ignition | Sure-Lite electronic | Sure-Lite dual-electrode electronic |
| Design & Build Materials | Black porcelain-enameled hood, Therma-Cast™ aluminum cook box | Stainless steel cook box & lid, aluminum end caps |
| Dimensions (W × H × D) | 63″ × 46.5″ × 24″ | 62.5″ × 49.2″ × 24.8″ |
| Weight | 190 lb (LP) / 194 lb (NG) | 217 lb (LP) / 214 lb (NG) |
| Warranty | Limited lifetime on cook box, 15 years on burners & remaining parts | Limited lifetime on cook box, 10 years (or more) on burners, parts warranty varies |
- FIVE STAINLESS STEEL Dual-Tube BURNERS
- AMPLE SPACE: 820 sq. in. total cooking space including stainless steel warming rack
- PROPANE (LP): Designed for use with 20lb tank - not included
- 45,000 BTU main burner output
- PRIMARY COOKING SPACE: 570 sq.
- 5 stainless steel Dual-Tube burners deliver up to 55,000 BTUs of power, ideal for high...
- Stainless steel V-grids are reversible to offer versatility - the pointed side delivers...
- LIQUID PROPANE (LP): Designed for use with 20lb tank - not included
- 10,000 BTU side burner perfect for side dishes or searing, and a 15,000 BTU rear burner...
- Proudly made in North America - with domestic and globally sourced components
Performance & Heat Control
The **Baron 590 Pro** offers 45,000 BTU across its five Dual-Tube burners, which may not match the raw power of the Regal, but it’s plenty for most backyard grilling. Its linear-flow valves paired with 180° Sensi-Touch control knobs allow for very precise heat adjustment — whether you’re searing steaks or slow-cooking ribs.
In contrast, the **Regal S590 Pro**’s 55,000 BTU output gives it a clear edge for high-heat applications. The heavier 9 mm stainless rod grates absorb and radiate heat more effectively, helping the grill retain temperature even when you open the lid or add food. This makes the Regal especially well-suited for reverse searing or intense grilling sessions.
Grill Surface & Cooking Capacity
Both grills provide generous cooking real estate, but the Regal slightly outpaces the Baron: 875 sq in total (625 sq in primary) vs. the Baron’s 820 sq in total (570 sq in primary). That extra space on the Regal is useful when you’re entertaining larger groups or using the warming rack heavily.
The Baron’s warming rack and main grids use 8 mm stainless steel (or in some models, cast iron), which gives good durability and heat distribution. The Regal goes a step further with 9 mm solid stainless grid rods, offering superior heat retention and sear marks for steak lovers.
Build Quality, Materials & Durability
The **Baron 590** is built with a *Therma-Cast™ aluminum* cook box and a black porcelain-enameled hood capped with cast aluminum. This combination offers a balance of lightweight design and reasonable heat retention. The drop-down side shelves are stainless steel, and the grill rides on heavy locking casters, giving it mobility and stability.
On the **Regal S590 Pro**, you’re looking at a more premium construction: a stainless steel cook box, stainless lid, and cast aluminum end caps. The lexicon of materials used in the Regal makes it more robust, especially for long-term usage and exposure to the elements.
Flavor & Heat Distribution System
Both models use Broil King’s *Flav-R-Wave™* system. This stainless steel vaporizes drippings, protecting burners and infusing food with smoky flavor. The design helps ensure even heat distribution and reduces flare-ups by channeling grease away efficiently.
Thanks to the Dual-Tube burners in both grills, flame coverage is consistent. However, because of its lower BTU, the Baron may take a little longer to reach maximum temps compared to the Regal.
Ignition & Ease of Use
Both grills feature a **Sure-Lite electronic ignition system**, which provides reliable and quick starts. The Baron uses a standard single-electrode version, while the Regal typically employs a dual-electrode setup for even more dependable ignition.
Control knobs on both are illuminated, making night-time grilling much easier.
Rotisserie & Side Burner
Each model brings a 15,000 BTU stainless steel rear rotisserie burner, complete with a premium rotisserie kit, to roast whole poultry, roast, or anything you like to spin.
For side cooking, both grills include a 10,000 BTU burner. On the Baron 590 Pro, this is a professional inset side burner. On some variants, like the Baron S 590 Pro IR, the side burner is infrared. {index=39} The Regal’s side burner is also powerful and commercial-grade.
Mobility & Dimensions
– **Baron 590 Pro**: 63″ wide (42.5″ with shelves down), 46.5″ tall, 24″ deep.
– **Regal S590 Pro**: 62.5″ wide, 49.2″ tall, 24.8″ deep.
Weight-wise, the Baron is lighter (190 lb LP / 194 lb NG) compared to the Regal (217 lb LP / 214 lb NG). That makes the Baron a bit easier to move, though both are sizable grills.
Warranty & Longevity
– **Baron 590 Pro**: Limited lifetime warranty on the cook box, 15 years on the Dual-Tube burner system, and 15 years on parts and paint.
– **Regal S590 Pro**: Lifetime warranty on the cook box, plus a generous warranty on burners (reports vary, but many sources note long-term coverage).
This generous warranty on both models underlines Broil King’s confidence in their products, though real-world durability may depend on how well you maintain the grill (cleaning, covering, etc.).
User Feedback & Considerations
– Some grillers have noted that the **Regal’s heavier grates** help with searing and heat retention, making it ideal for steak and serious grilling sessions.
– Baron owners have praised its performance-to-price ratio, though a few have reported rust issues on cast-iron grids when not properly seasoned or maintained.
– From Reddit discussions:
> “Regal = 55k burner output … Baron = 50k burners … build quality is supposedly equal.”
> Some users of Baron report rust developing over time, while others appreciate the warranty support.
These community insights suggest that both ovens are well-regarded, but maintenance matters a lot — especially for cast-iron grids (Baron) or stainless components (Regal).
Which Grill Should You Choose?
Here are some guiding questions to help you decide:
1. **Do you prioritize searing and high-heat cooking?**
If yes, the **Regal S590 Pro** with its 55,000 BTU output and 9 mm stainless rod grates is likely the better choice.
2. **Is weight or mobility a concern?**
The **Baron 590 Pro** is lighter and a little more compact, making it easier to reposition.
3. **How much do grill aesthetics and materials matter?**
The Regal’s stainless steel build offers a more premium, rust-resistant finish. The Baron, with its cast-iron grids and enameled hood, delivers classic durability but may demand a bit more care.
4. **What’s your budget?**
Generally, the Baron is more budget-friendly than the Regal, but pricing can vary based on retailer, model (LP vs NG, IR vs non-IR), and available discounts.
5. **Usage Frequency and Maintenance:**
If you’re planning to grill often and want long-term performance, investing in a higher-spec model like the Regal may pay off. But if you’re a more occasional griller, the Baron offers excellent value and capability.
—
Conclusion
The **Broil King Baron 590** and **Regal S590 Pro** are both excellent 5-burner gas grills that serve serious backyard chefs. Your choice really comes down to whether you want the extra power and premium build of the Regal, or the more balanced, cost-effective performance of the Baron.
– Go for the **Regal S590 Pro** if you want **maximum heat**, **heavy-duty stainless grates**, and a more premium finish.
– Choose the **Baron 590** if you prefer **strong performance**, a **lighter grill**, and are okay with cast-iron or 8 mm stainless grids.
No matter which you pick, regular cleaning, proper cover usage, and thoughtful maintenance will help you enjoy years of great grilling. Happy BBQing! 🍔🔥
