Broil King Regal Review: S490, S590, Pro IR & Built-In Grill Models Compared
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Time to read 14 min
The Broil King Regal series is the sweet spot in the Broil King lineup — more features and build quality than the Baron, less footprint and cost than the Imperial, and a track record that makes it one of the most recommended freestanding gas grills in its price range. Every Regal ships with patented Dual-Tube™ burners, 9mm stainless steel cooking grids, Flav-R-Wave™ cooking system, and illuminated control knobs as standard. Pro and Pro IR models add a rear rotisserie burner and rotisserie kit at no extra cost. As an authorized Broil King dealer, we've sold and serviced the Regal line across hundreds of Long Island builds — this guide covers every current model, what each one offers, and how they compare side by side.
Quick Answer
Broil King's Regal gas grills are top of the Broil King freestanding lineup — packed with useful extras at a reasonable price. The S420 Pro is the 4-burner entry point at 44,000 BTU. The S490 Pro IR steps up to 50,000 BTU with a dedicated infrared side burner reaching 1,700°F. The S590 Pro IR is the most popular model: 5 burners, 55,000 BTU, 875 sq in total. The S690 Pro IR is the flagship: 6 burners, 60,000 BTU, two independent ovens, 1,030 sq in total. For outdoor kitchen builds, the Regal S420 and S520 built-in heads drop cleanly into any island cutout. All models are made in Huntington, Indiana.
Broil King Regal Series — Full Overview
Freestanding Regal Models
Built-In Regal Models — For Outdoor Kitchen Islands
Broil King Regal Models Compared: Full Specs
Every Regal Pro and Pro IR ships with a rear rotisserie burner, rotisserie kit, and Flav-R-Wave™ cooking system as standard. The differences come down to burner count, cooking area, and whether you need a dedicated infrared side burner. Here's how every current model stacks up.
Freestanding Models — S420, S490, S590 & S690
Built-In Models — S420 & S520 for Outdoor Kitchen Islands
Honest Assessment
The S590 Pro IR is the right call for most buyers — 625 sq in handles 20+ burgers at once, the 55,000 BTU output delivers strong preheat performance, the infrared side burner hits 1,700°F for dedicated searing, and the rotisserie kit is already in the box. That's a complete grilling system with no add-ons required. The S690 Pro IR makes sense when you're cooking for large groups regularly or need two independent temperature zones simultaneously. The S420 Pro is the entry point for buyers who don't need a rotisserie or IR side burner. The built-in models are purpose-built for island installation — if you're building a permanent outdoor kitchen, the S520 is the built-in equivalent of the S590 and the stronger choice of the two.
One note on the S690 warranty: Broil King offers a 15-year warranty on the Dual-Tube™ burners and Flav-R-Wave™ system on the S690 — compared to 10 years on the S420, S490, and S590. That extended coverage reflects the flagship position of the 6-burner model in the lineup.
Broil King Regal Features: What You're Actually Getting
Every Regal ships with a system of features that work together — here's what each one does and why it matters.
Patented Dual-Tube™ Burners
Tube-in-tube side-ported design fires two rows of flame per burner — double the ignition points of a conventional burner, eliminating cold spots and delivering even heat across the entire surface.
The horizontal flame ports also make the Regal highly wind resistant. Crosswind that drops a standard burner's output barely affects the Regal — a real advantage on exposed patios and coastal properties.
Flav-R-Wave™ System & 9mm SS Cooking Grids
Flav-R-Wave™
V-shaped stainless flame tamers above each burner spread heat evenly and vaporize drippings on contact — no flare-ups, consistent temperature across the grate, and authentic barbecue flavor infused back into the food.
9mm SS Cooking Grids
Heavier than standard wire grates — 9mm solid stainless holds temperature when cold protein hits the surface and produces deep sear marks. Rust-proof, dishwasher-safe, no seasoning required.
Sure-Lite™ Ignition & Illuminated Controls
Sure-Lite™ Ignition
One dedicated igniter per burner — push the knob and that burner lights every time. No cross-lighting, no multiple attempts. One of the most consistently praised features across verified Regal customer reviews.
Illuminated Knobs
Blue LED backlit Linear-Flow control knobs — readable after dark, precise from 225°F low-and-slow to 600°F searing with no dead zones in the temperature range.
Rotisserie Kit & Infrared Side Sear Burner
15,000 BTU Rear Rotisserie — Included
Spit rod, motor, and forks in the box on all Pro and Pro IR models. Rear-mounted burner radiates heat directly at the rotating protein — no drip flare-ups, self-basting results on chicken, turkey, lamb, and large roasts.
10,000 BTU IR Side Burner — 1,700°F
Pro IR models only. Infrared energy hits the food surface directly — 60 to 90 seconds per side produces a steakhouse crust. Sear on the IR burner, finish on the main surface. Worth the upgrade if you cook steaks regularly.
Authorized Dealer Note
As an authorized Broil King dealer on Long Island, we register every Regal warranty at point of sale and carry replacement parts for the full lineup. Buying from a big box store or warehouse club means no post-sale parts support — buying from us means we're still here when something needs replacing five years from now.
Who Makes the Broil King Regal — Brand Background
Broil King appears in a different category than most gas grill brands — it's not a big box house brand, not a direct-to-consumer startup, and not a rebranded import. It's a North American manufacturer with decades of continuity in the premium gas grill market.
50+ Years
Manufacturing gas grills in North America
Lifetime
Cookbox warranty on every Regal
Huntington, IN
Where every Broil King gas grill is built
Baron → Regal → Imperial
Regal is the mid-tier — above Baron, below Imperial
Broil King is a brand of Onward Manufacturing Company, based in Ontario, Canada, with its gas grill production facility in Huntington, Indiana. Every Regal gas grill — freestanding and built-in — is assembled at that facility using domestic and globally sourced components. The Huntington plant has been producing Broil King gas grills for decades, which is why the product line has the kind of parts continuity that lets a 2010 Regal owner still source replacement burners in 2025.
In the Broil King lineup, the Regal sits between the Baron and the Imperial. The Baron is the entry-level series — fewer features, thinner construction, lower price. The Imperial is the flagship — reversible cast stainless cooking grids, interior oven lights, larger cookbox, higher price. The Regal is the sweet spot: nearly all of the Imperial's core cooking system at a meaningfully lower price point, with 9mm SS grids, the full Dual-Tube™ and Flav-R-Wave™ system, illuminated controls, and rotisserie kit included.
The Regal is sold at Home Depot and warehouse clubs alongside the authorized dealer network. The product is the same — the difference is what happens after the sale. Authorized dealers register your warranty, stock replacement parts, and have a direct relationship with Broil King's North American customer service team. Big box retailers do not. For a grill with a lifetime cookbox warranty, that post-sale relationship matters. You can read our full Broil King grill reviews to see how the full lineup compares.
Also in the Regal Family — Regal Pellet Grills
Broil King also makes the Regal Pellet 400 and Regal Pellet 500 Pro — wood pellet grills that share the Regal name but are a separate product category from the gas lineup covered in this review. The Regal Pellet 500 Pro is the flagship pellet model: 500 sq in cooking area, dual-wall insulated cookbox for cold-weather performance, and a digital controller with meat probe. The Regal Pellet 400 is the entry-level version at a lower price point.
If you're deciding between gas and pellet, the core tradeoff is convenience vs flavor profile. Gas grills like the Regal S590 heat up in 10–15 minutes, offer precise temperature control across multiple zones, and include a dedicated IR side burner for searing. Pellet grills produce a light wood-smoke flavor that gas cannot replicate, excel at low-and-slow cooks, but require more startup time and pellet management. They are not direct replacements for each other — they serve different cooking styles.
The Regal Pellet series is worth a dedicated review of its own — we'll cover it in full in an upcoming post. If pellet is what you're after, contact us and we can walk you through the Regal Pellet lineup directly.
Shop Broil King Pellet GrillsWho Should Buy the Broil King Regal — And Who Shouldn't
The Regal has one of the strongest long-term ownership records in the freestanding gas grill category. Here's what verified purchase owners consistently report — and an honest look at where the Regal has limits.
What Owners Say — Recurring Themes from Customer Reviews
Gets hot fast
Owners consistently report rapid preheat — most reaching 500°F+ in under 15 minutes. The Dual-Tube™ burner output is a direct driver of this.
Works well in cold weather
Multiple verified purchase owners report grilling year-round in cold climates without performance issues — the wind-resistant burner design and heavy cookbox contribute to this.
Lasts 10–15+ years
Owners who bought Regals in the early 2000s still grill on them. When they replace, most buy another Regal. That retention rate is unusual in the gas grill category.
Great customer service
Broil King's North American customer service team is frequently called out by name in reviews — owners report fast parts shipments and responsive phone support when issues arise.
Amazing BBQ results
The Flav-R-Wave system's drip vaporization produces flavor that owners describe as noticeably better than competing grills — particularly on burgers, chicken, and anything with higher fat content.
No flare-ups
The Flav-R-Wave system is consistently credited by owners for eliminating the flare-up problem that causes burning on conventional grills — especially helpful for higher-fat proteins.
Buy It If
You want a freestanding gas grill that lasts a decade or more
You cook for 4–8 people regularly and need 500–625 sq in primary surface
You want rotisserie capability included without paying extra
You grill year-round including cold or windy conditions
You want a dedicated searing station — choose the Pro IR models
You're building an outdoor kitchen island — the S420 and S520 built-in heads are purpose-built for this
Don't Buy It If
You want reversible cast SS cooking grids — that's the Imperial, not the Regal
You primarily want wood-smoke flavor — look at the Regal Pellet series instead
You only grill a few times a year and don't need a premium build — the Baron is the lower-cost entry point
You need interior oven lights and a dual-drawer side shelf — Imperial-only features
You want smart Wi-Fi control without the full iQue upgrade cost — the base Regal Pro doesn't include it
Worth Knowing
The S690's 15-year burner warranty is a meaningful upgrade. Every other Regal gets 10 years on the Dual-Tube™ burners. The S690 gets 15. If you're keeping this grill for the long haul, that extended coverage on the most-used component matters.
The iQue upgrade is app-optional. Broil King's iQue Wi-Fi and Bluetooth system works without the app — the grill operates normally without it. The app adds remote monitoring but isn't required to grill.
Built-in models don't include rotisserie. The S420 and S520 built-in heads do not come with a rear rotisserie burner or kit — these are freestanding-model features only. Plan accordingly if rotisserie is important to your outdoor kitchen build.
Propane and natural gas versions are available on every model. All Regal freestanding models are available in LP and NG configurations. Confirm your gas connection before ordering — conversion between fuel types is not supported without a conversion kit.
Still Deciding?
Regal vs Imperial: If you want the best Broil King freestanding grill and budget isn't the primary concern, the Broil King Imperial review covers what the upgrade actually gets you — reversible cast SS grids, interior oven lights, and a larger cookbox. For most buyers the Regal S590 Pro IR is the better value.
Regal vs Napoleon: Napoleon's Prestige series is the most common alternative at this price point. Our Broil King vs Napoleon comparison breaks down the differences in build quality, warranty, and cooking system side by side.
Not sure which Regal model? Call us at 888-678-3530 or use the contact form. As an authorized dealer we can walk you through every configuration — freestanding, built-in, Pro, Pro IR, and iQue — and help you match the right model to your cooking style and outdoor kitchen setup.
Final Verdict: Which Broil King Regal Is Right for You?
The Regal series is one of the most consistently recommended freestanding gas grills in the $800–$1,800 range — and for good reason. The cooking system is proven, the build quality holds up over decades, and the included features make every Pro and Pro IR model a complete setup out of the box. Here's our verdict on each model and who it's best for.