A summer of backyard cooking gave me the perfect excuse to run two of Broil King’s flagship natural-gas grills through their paces: the Baron 590 Pro IR and the Regal 590 Pro IR. Both are built in North America and clearly aimed at grillers who take their steak night seriously. After weeks of burgers, ribs, and slow-smoked chicken, here’s the full breakdown of how they compare—and which one I’d buy again.
Key Difference at a Glance: Broil King Baron 590 vs Regal 590: Premium Gas Grill
While these grills share Broil King DNA—stainless construction, Flav-R-Wave vaporizing system, and natural-gas hookups—the Regal 590 turns things up a notch. It sports heavier 9 mm solid stainless rod grates, patented dual-tube burners with a 15-year warranty, and a powerful infrared side burner that hits a steak-searing 1,700 °F. The Baron 590 is slightly lighter, with standard stainless grates and a bit less BTU output, making it more budget-friendly while still serious about performance.
- FIVE STAINLESS STEEL Dual-Tube BURNERS
- AMPLE SPACE: 820 sq. in. total cooking space including stainless steel warming rack
- 5 stainless steel Dual-Tube burners deliver up to 55,000 BTUs of power, ideal for high temperatures to sear the...
- Stainless steel V-grids are reversible to offer versatility - the pointed side delivers perfect sear marks and the...
Quick Comparison Table: Broil King Baron 590 vs Regal 590: Premium Gas Grill
| Feature | Broil King Baron 590 Pro IR | Broil King Regal 590 Pro IR |
| Dimensions | 24″D x 63″W x 46.5″H | 25″D x 62.5″W x 49″H |
| Main Burners | 5 Dual-Tube | 5 Patented Dual-Tube (enhanced design) |
| Main Burner Output | 45,000 BTU | 55,000 BTU |
| Total Cooking Area | 820 sq. in. (570 primary) | 875 sq. in. (625 primary) |
| Grates | Standard stainless steel | 9 mm solid stainless rod |
| Infrared Side Burner | Yes | Yes (1,700 °F searing power) |
| Cabinet | Enclosed | Enclosed with improved heat retention |
| Warranty | Limited | 15-year on burners, extended overall |
| Fuel | Natural Gas (10 ft hose included) | Natural Gas (10 ft hose included) |
| Price Range | Lower | Higher |
| Check Best Price & Deals | Buy on Amazon | Buy on Amazon |
Detailed Comparative Review
Design & Build Quality
Both grills arrive in imposing, stainless-and-black outfits that look right at home on a serious patio. The Baron 590 is a touch more compact, but you still need a solid two-person lift for assembly. Its panels are sturdy, but side-by-side you feel the Regal’s extra heft—the lid alone has more mass, which helps with heat retention during long smokes.
The Regal also features thicker 9 mm stainless rod grates. During testing, these grates held heat longer and gave those photogenic steakhouse sear marks with less fuss. The Baron’s standard grates performed well but cooled slightly faster when I opened the lid repeatedly.
- FIVE STAINLESS STEEL Dual-Tube BURNERS
- AMPLE SPACE: 820 sq. in. total cooking space including stainless steel warming rack
- 5 stainless steel Dual-Tube burners deliver up to 55,000 BTUs of power, ideal for high temperatures to sear the...
- Stainless steel V-grids are reversible to offer versatility - the pointed side delivers perfect sear marks and the...
Ease of Use
Setup on both was straightforward: connect the included 10-foot natural-gas hose, season the grates, and you’re ready to grill. The control knobs are large and intuitive, lighting is consistent, and the Flav-R-Wave system does an excellent job vaporizing drippings for smoky flavor.
If you like to tinker with multi-zone cooking, the Regal’s dual-tube burner design makes it easier to create distinct hot and cool zones. I often ran two burners on high for searing while keeping the others at a gentle medium for vegetables.
- FIVE STAINLESS STEEL Dual-Tube BURNERS
- AMPLE SPACE: 820 sq. in. total cooking space including stainless steel warming rack
Cooking Performance
Here’s where the personality differences show.
- Baron 590: With 45,000 BTUs over five burners, it had no problem hitting 600 °F for pizzas and steaks. Chicken thighs grilled evenly, and slow racks of ribs stayed moist thanks to steady heat.
- Regal 590: The additional BTUs and heavy grates gave me faster preheat times and more consistent sears. The infrared side burner deserves special mention—it reached steakhouse temps so quickly that I could reverse-sear rib-eyes to perfection in minutes.
For weeknight burgers or weekend entertaining, both impressed. But for large gatherings or thick cuts that benefit from blistering heat, the Regal pulled ahead.
- 5 stainless steel Dual-Tube burners deliver up to 55,000 BTUs of power, ideal for high temperatures to sear the...
- Stainless steel V-grids are reversible to offer versatility - the pointed side delivers perfect sear marks and the...
Extra Features & Maintenance
Both models share the enclosed cabinet for propane tank or accessory storage (even though these versions are natural gas, I used the space for tools and wood chips). Cleaning is similar: a quick burn-off and brush gets most residue off the grates.
The Regal’s extended burner warranty (15 years) adds peace of mind for heavy users. If you grill three nights a week or more, that’s a meaningful advantage.
Broil King Baron 590 Pro IR Liquid Propane Grill
- FIVE STAINLESS STEEL Dual-Tube BURNERS
- AMPLE SPACE: 820 sq. in. total cooking space including stainless steel warming rack
Pros:
- Solid stainless construction with Flav-R-Wave system
- Generous 820 sq. in. cooking area
- Reliable 5-burner setup with infrared side burner
- Slightly more compact and more affordable
Cons:
- Standard stainless grates don’t retain heat as long as Regal’s 9 mm rods
- Lower BTU output means slightly slower preheat
Broil King Regal 590 Pro IR Natural Gas Grill
- 5 stainless steel Dual-Tube burners deliver up to 55,000 BTUs of power, ideal for high temperatures to sear the...
- Stainless steel V-grids are reversible to offer versatility - the pointed side delivers perfect sear marks and the...
Pros:
- 9 mm solid stainless rod grates for unmatched sear and heat retention
- Higher BTU burners and patented dual-tube design
- Infrared side burner hits 1,700 °F for steakhouse results
- Longer burner warranty and superior heat retention
Cons:
- Higher price and heavier build
- Takes up a bit more patio real estate
Conclusion & Recommendation:
After a full summer of use, here’s my takeaway: both grills are excellent, but they cater to different grillers.
- Choose the Broil King Baron 590 if you want top-tier performance at a slightly friendlier price and don’t need every possible upgrade. It’s more than enough grill for most families and still brings serious infrared searing power.
- Go with the Broil King Regal 590 if you’re an enthusiast who entertains often, craves perfect steakhouse sears, and appreciates premium touches like the thick 9 mm grates and longer warranty. Its extra BTUs and heavy construction make it a true backyard centerpiece.
For my own patio, I kept the Regal 590. The heavier grates and blistering infrared side burner simply make steak night unforgettable. But the Baron remains a fantastic value for anyone who wants Broil King quality without stretching the budget.
