What We don't like

  • Takes time to achieve high levels of heat

  • Tricky assembly

Cooking Surface644 square inches (444 square inches of the central grilling space + 200 square inches on the side stove)
PriceIt does offer a lot, but we can’t help but think that the price tag could be a bit lower
Durability7 out of 10

With so many products assembled in China or Asia, it’s nice to see that an item is made in North America. That is the case with Broil King Baron 440. It’s one of the best grilling units available in the Baron series produced by the mentioned manufacturer. I have no doubt that this is a premium BBQ unit, but does it have enough to justify its price tag? That’s what we will try to find out in this review. If you are eager to learn more about this model, you will find all the relevant info in this article.


I like to start by giving you a quick overview of the product’s dimensions and essential features. Here are the details about the Broil King Baron 440 review.

  • Dimensions: 39.8 x 25.6 x 39.8 inches
  • Weight: 154 pounds
  • Heat output: 40,000 BTUs
  • Fuel: Gas (propane or natural gas)

We will now move on to the features and here’s what we will discuss in that section:

  • Dual-Tube burners
  • Sensi-Touch control knobs
  • Flav-R-Wave system
  • A side burner for sauces, soups, and side dishes
  • Foldable shelves

Those are just the crucial features of this product. If you want to find out about all the extras that come with it, follow to the next section.


Regardless of what barbecue review website you visit, we will all agree on one thing. A grilling unit cannot be considered to be of high quality if it doesn’t come with extraordinary burners.  Broil King is one of the manufacturers that first realized that. It is why their Baron series comes with dual-tube burners they patented.

First of all, there are four heaters in this product. Each of them is capable of delivering 10,000BTUs of heat per hour, which brings the total heat output of the unit to 40,000 BTUs. The burners are all made of stainless steel of the best quality. However, all that was not a reason to patent them, but it was the fact that they came up with a new form for the heaters. They named this feature Dual-Tube which is pretty self-explanatory.

The design could be called tube-in-tube. The main characteristic is that the burners deliver two rows of flame thanks to this. That secures that the distribution of heat across the cooking surface is as equal as it can get. It’s an entirely different approach than the other companies offer and it works. That is supported by the fact that the manufacturer provides a 10-year warranty on this component.

Sensi-Touch Control Knobs

We are used that the gas grills manufactured today have knobs that provide total control over the heat. Broil King Baron 440 takes things one step further with its Sensi-Touch Control Knobs feature. Most of the other BBQ units offer you to choose between preset temperatures. But with this model, you can control the heat entirely thanks to the fact that the knob can be turned up to 180 degrees.

In theory, that means that you can adjust the desired temperature down to a particular degree. In practice, it works a bit differently. You can take a look at the thermometer mounted on the cover to see the current level of heat in the cook box. While it is mostly accurate, the truth is that there will be a difference of up to 10 degrees compared to the real temperature level in the firebox. Regardless of this small issue, the Sensi-Touch control knobs provide infinite command over the grilling unit. In a day or two, you will learn how to correctly adjust the knobs and avoid any potential burns or over-grilling the food.

Reversible Cooking Grids

Broil King Baron 440 is far from a usual grill. We just love when the manufacturer puts in the effort to surprise us, and that’s what happened with the cooking grids. We took them out of the packaging and realized that they are reversible! It was a pleasant surprise, and we couldn’t wait to test both of the sides to see how they perform.

We were feeling like having a steak which is why we turned them to the side that is recommended for searing. Needless to say, the unit did a phenomenal job. The cast iron grid impressively secures heat while making sure to lock in the flavor and juices. The searing marks looked just like we used a charcoal grill and we loved the taste of the food.

The next day we had a bit more time, and we reversed the grids to the side intended for barbecuing food. We were delighted with the results once again. The grill managed to capture all the juices and provide delicious food. We do have to be honest and say that it was not all thanks to the grids. A portion of the contribution goes to the next feature we will describe.

Flav-R-Wave Cooking System

You can see every step of the way that the manufacturer thought about everything. Aside from making sure that they design a product that will be different than the competition, they also put great effort into marketing. Flav-R-Wave system is the name of the name of the feature that intrigued us. It turned out that this is how Broil King named stainless steel bars located below the grates. Any dripping that falls through the grates goes directly onto these bars. Thanks to the fact that they are heated, the drippings vaporize instantly, and the juices return back to the food. That is how the Baron series manages to be so successful in delivering tasty food.

Aside from participating in securing the high quality of the food, there is another thing that the Flav-R-Wave bars do. They protect the stainless steel burners from the drippings. The grease won’t fall onto the burners, which makes the cleaning process swift. It also extends the life of the heaters, securing that they will work flawlessly for an extended period.

Cook a Complete Meal for up to 8 People

Let’s talk facts first. The total cooking surface of this product is 644 square inches. However, the central grilling area takes up ‘only’ 444 square inches. The rest of it is reserved for the side burner located on the left side of the unit. If you lift the cover, you will open up 200 square inches of extra cooking space. These are powered by a separate burner that can provide up to 10,000 BTUs per hour.

The side burner is just the addition you need to round up your meal. We know that meat is the core of the meal you are preparing, but the truth is that other ingredients play a significant factor, too. With regular grills, you often end up running to the kitchen to make sauces, soups or side dishes. But with this extra stove that Broil King Baron 440 comes with, you can make a complete meal in your backyard. Want to simmer some vegetables to use as a side dish? You can do it! Maybe you need a sauce that will alter the taste of your burger and give it the extra touch of deliciousness? It’s possible with this feature!

I am aware that the last section sounds like a commercial for this product, but it’s an excellent way to make you see the effectiveness and versatility of the side burner. As for the primary cooking surface, 444 square inches can fit about 15-20 burgers at the same time, depending on the size. To be honest, that is not a lot. When you see the total cooking area, you think that you can cook for up to 10 people. Unfortunately, that number is reduced because a portion of the space falls off on the side burner. That being said, you can use the Baron unit to grill for up to eight people. The good news is that you will be able to prepare a complete meal for them – both the meat and the side dishes – without having to go to the kitchen or improvise.

Foldable Shelves

The side burner doubles as a side shelf that you can use as a workspace. The only thing that you need to do is to close the cover. And if that doesn’t seem like enough to you, there is another side shelf located on the right with as much space available. That’s more than enough room to accommodate all your utensils and other grilling tools you might need.

But that’s not where the convenience ends. If you feel like you don’t need these shelves, why would you have to look at them? The good news is that you don’t need to do such a thing. They are foldable, and you can fold them away in seconds. That is not only convenient to get close to your unit when you are not using the side burner. It is also an excellent space saver when storing the unit. The Baron takes up less room when the tables are folded and can be stored away in every corner of the yard to remain unnoticeable when you are not using it.

Other Features

This unit has some additional features that we failed to mention so far. For starters, we haven’t said a thing about the mobility of the product, and it’s admirable. It has four rollers on the bottom of the cart. The level Q casters make the unit sturdy even when you put it on a surface that is not even. The wheels also make it a piece of cake to drag the unit from one place to another. Although, we should pinpoint that you shouldn’t pull it too far since it’s kinda heavy.

The cart itself has a cabinet with two doors and ample storage room. I still failed to meet a griller who doesn’t think that this feature is fantastic. The considerable space you have at your disposal is diminished by the propane tank you need to put in there, but there is still a lot of room to store away your stuff.

Why You Should Choose Broil King Baron 440

We didn’t say a lot about the materials used in designing this grill so far because we were saving the words for this paragraph. Broil King has the reputation of being one of the few companies that can parry Weber when it comes to durability of the BBQs, and this unit is a proof of that. Wherever you look, you will find that the quality of construction is fantastic.

Most components are made of stainless steel to ensure that they are resistant to rust. The burners have an impressive 10-year warranty, which proves that the manufacturer is aware that they made a high-quality product. Other components have a two-year warranty, but we have no doubt that the lifespan of this model is much longer than that. In fact, if you take proper care of it, there is no reason why the other parts can’t last as much as the burners or maybe more.

We would like to turn particular attention to the cook box. It is made of a combination of stainless steel and cast aluminum. That means it not only has excellent durability, but it does an impressive job when it comes to retaining heat and securing its equal distribution. It’ s also nice to see that the thermometer on the cover is reasonably accurate and shows the temperature within ten degrees of the real situation.


If you want to take things one step further, a bunch of accessories is available for Broil King Baron 440. I always like to mention the rotisserie kit. If you ask me, I will ensure to include it in any premium BBQ unit by default. The fact is that it comes in the regular packaging in other models of the Baron series, but you will have to purchase it separately for this unit. The good news is that it is a high-quality rotisserie kit. It is powered by a stainless steel burner that can deliver up to 15,000 BTUs per hour.

As for other extras, Broil King has everything you can wish for. If you are a fan of skewer racks, you can purchase one. Griddles, smoker boxes, and planks are also an option. I particularly liked the pizza baking accessory as it delivered some tasty dinner food to my table. While you are choosing for extras, I suggest that you invest in a grill cover to prolong the lifespan of your BBQ unit.

Choose the Model for You

You already know that this is just one model of the series. If you think that this Baron is not suitable for you, perhaps one of the others will be. The edition offers something for everybody. The basic version – Baron 320 – is a regular-sized BBQ system perfect for families and small parties. It doesn’t have a side stove, and it is powered by three burners.

The enhanced version comes in the form of Broil King Baron 440. It has four primary burners plus the additional one, as well as a larger cooking surface than the previously mentioned unit. However, if that amount of grilling area is not enough for you, you can choose the largest model available in the series. Baron 590 has more than 800 square inches and is powered by five burners. It also comes with a rotisserie kit included. While that is an excellent extra, there is no need to splash the cash on such a massive model if you are not serving large parties often.


Let’s start from the beginning. While you are assembling the Broil King Baron 440, you will notice that the material used are durable and heavy. The manufacturer carefully chose the materials for the components. They made the right choice when it comes to the cast-iron cooking grids and the cast aluminum cook box. That secures several things – durability of the product and impressive heat retention.

And while we are on the topic of retaining heat, let’s mention that distributing it matters just as much. The Dual-Tube burners patented by this company do a phenomenal job in this area. Many of the grills manage to decrease the chance of burning your food with their burners, but with the heaters that Baron 440 uses, there is no chance of any flare-up happening.

All things that we mentioned so far are beautiful, but they are not worth anything if the quality of food is not adequate. But this unit can cook any food that comes to your mind and delivers equally fantastic results. That is achieved thanks to the cooking grids that are reversible depending on your needs. And for the dose of extra juiciness, you can turn to the Flav-R-Wave system that vaporizes any dripping instantly and enables the meat to secure its juices.

Aside from the meat, you can also prepare side dishes, sauces, or soups thanks to the side stove that comes with the product. That means that you can make an entire meal here. And thanks to the ample cooking surface, you can do so for up to eight people. If you are wondering where you will take the cousins that are coming for the weekend to lunch, you won’t make a mistake if you take them to your backyard and surprise them with some finely-grilled steaks.

Finally, let’s mention that you don’t have to be an expert to use this BBQ. After all, it is a gas grill, which means that your job comes down to turning the knobs and setting the desired temperature. The product also supports both propane and natural gas, although you will need a conversion kit if you are planning on using the latter option.


There is no doubt that the Baron can deliver results, but we had our doubts when it comes to how quickly it can provide them. After the testing, it turned out that we were right. The power of the burners is a bit limiting and that’s why the product took over ten minutes to heat to the desired grilling temperature (500F). Fortunately, that doesn’t affect the quality of the food. You will still get tasty and perfectly-grilled burgers. It will just take a bit longer to get the machine running.

You should keep in mind that the assembly of this model can get tricky. The manual is not that straightforward. It will show you all the parts that you need to have, but the confusion can appear when you realize that a portion of them has already been assembled together. A bunch of screws also doesn’t help the process, which is why you should consider getting help from a professional. If you have never set up a BBQ unit before, that will be an excellent way to save a lot of time and nerves.

Our Final Verdict

The only reason why we decided against giving the Broil King 440 Baron a higher score is its price. It does offer everything you can expect from an outdoor kitchen plus some bells and whistles. However, that still doesn’t seem enough for this cost. Keep in mind that this doesn’t mean we are questioning this product’s excellent performance. If you are looking for a reliable BBQ unit that can consistently deliver results for years and price is not your primary concern, then this model can be just what you need.


Leave a reply