Quick Verdict: Choose the Regal S590 Pro if you want maximum searing power, heavier 9mm stainless rod grids, and the option for 2025 iQue™ smart-grilling technology. Choose the Baron 590 Pro if you want a lighter, more budget-friendly grill with solid 45,000 BTU performance and durable cast-aluminum cookbox.
- 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
Main Difference: Power, Build, and Grids
The Regal S590 Pro offers stronger 55,000 BTU main burner output and heavier 9 mm stainless rod grids, giving it better heat retention and searing capacity. The Baron 590 trades some raw BTU and grid thickness for a more budget-friendly option with solid 45,000 BTU performance. The Regal excels for steakhouse-quality searing, while the Baron is ideal for balanced, durable backyard grilling.
Side-by-Side Comparison
| Feature | Baron 590 (Pro / IR) | Regal S590 Pro | Winner |
|---|---|---|---|
| Main Burner BTUs | 45,000 | 55,000 | Regal |
| Cooking Space (Total / Primary) | 820 sq in / 570 sq in | 875 sq in / 625 sq in | Regal |
| Cooking Grids | 8 mm stainless (Pro) | 9 mm solid stainless rods (reversible) | Regal |
| Burner System | 5 Dual-Tube burners | 5 Dual-Tube burners | Tie |
| Side Burner | 10,000 BTU (Pro) | 10,000 BTU commercial grade | Tie |
| Rotisserie Burner | 15,000 BTU stainless steel + kit | 15,000 BTU rear rotisserie + kit | Tie |
| Heat System | Flav-R-Wave™ stainless | Flav-R-Wave™ stainless | Tie |
| Ignition & Smart Features | Sure-Lite electronic ignition | Sure-Lite dual-electrode, optional 2025 iQue™ smart-grilling | Regal |
| Cookbox Material | Cast Aluminum | 304 Stainless Steel + Aluminum End Caps | Regal |
| Dimensions (W × H × D) | 63″ × 46.5″ × 24″ | 62.5″ × 49.2″ × 24.8″ | Regal |
| Weight | 190 lb (LP) / 194 lb (NG) | 217 lb (LP) / 214 lb (NG) | Regal |
| Warranty | Limited lifetime on cook box, 15 years on burners & parts | Limited lifetime on cook box, 10+ years on burners & parts | Tie |
- 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
Baron 590 Pro: 45,000 BTU across 5 Dual-Tube burners, linear-flow valves, and 180° Sensi-Touch control knobs allow precise heat adjustments for searing or slow-cooking. Moderate BTU density per sq. in.
Regal S590 Pro: 55,000 BTU output with heavier 9 mm stainless rod grids. Higher BTU density per square inch delivers more intense heat, critical for steakhouse-quality crusts and reverse searing. Excellent heat retention even when opening the lid or adding food.
Grill Surface & Cooking Capacity
Regal slightly outpaces Baron with 875 sq in total (625 sq in primary) vs. Baron’s 820 sq in total (570 sq in primary). Reversible grids: Regal’s 9 mm rods are heavy; pointed side for searing, grooved side for delicate foods. Baron’s 8 mm grids work well for general grilling.
Build Quality, Materials & Durability
Baron 590: Cast Aluminum cookbox, black porcelain-enameled hood, stainless drop-down shelves, heavy locking casters. Lightweight, rust-proof, but less heat-retentive under extreme cycles.
Regal S590 Pro: 304 Stainless Steel cookbox + Aluminum End Caps, stainless lid, cast aluminum end caps. Robust construction, better longevity, and coastal durability. Heavier and more premium feel.
Flavor & Heat Distribution
Both use Flav-R-Wave™ stainless system. Dual-Tube burners ensure consistent flame coverage. Regal’s higher BTU density enhances searing performance.
Ignition & Smart Features
Baron 590: Sure-Lite single-electrode electronic ignition. Regal S590 Pro: Sure-Lite dual-electrode, optional iQue™ smart-grilling variant with digital temperature control (2025 update).
Rotisserie & Side Burner
Both have 15,000 BTU rear rotisserie burners with kits. Side burners: 10,000 BTU, Baron Pro features standard or infrared depending on variant; Regal is commercial-grade.
Warranty & Longevity
Baron: Limited lifetime on cook box, 15 years on burners and parts. Regal: Limited lifetime on cook box, 10+ years on burners and parts. Proper cleaning, covering, and maintenance extend lifespan.
User Feedback & Considerations
- Regal’s heavier 9 mm grids improve searing and heat retention.
- Baron praised for performance-to-price ratio, but cast-iron grids may develop rust if not seasoned.
- Both grills have reversible grids: Regal’s heavier rods offer pointed side for searing, grooved side for basting.
Which Grill Should You Choose?
- Searing & High-Heat Priority: Regal S590 Pro with 55,000 BTU and heavier grids.
- Mobility Concern: Baron 590 is lighter and easier to reposition.
- Premium Materials & Rust Resistance: Regal’s stainless build is superior; Baron cast aluminum is lighter.
- Budget: Baron 590 is more affordable; Regal offers higher-spec performance.
- Usage Frequency: Frequent grillers benefit from Regal; occasional grillers may prefer Baron.
Conclusion
The Broil King Baron 590 and Regal S590 Pro are both excellent 5-burner grills. Choose Regal for maximum searing, BTU density, and premium build. Choose Baron for strong performance, lighter weight, and value. Proper maintenance ensures years of backyard grilling enjoyment. Happy BBQing! 🍔🔥
- 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
