Advances in rare-earth magnetic material properties, magnetic roll and drum designs, and optimization of machine designs have enhanced the technical performance and economic viability of high-intensity magnetic separation in the last few years. Greater machine unit capacities and improved manufacturing techniques have reduced the total cost to nearly half of the level only six years ago (1990). New industrial uses are made possible, such as berate ore tailings retreatment, pigment cleaning, preconcentration of coarse size iron ores and magnesite, gold concentrate cleaning, high-purity quartz and heavy minerals concentrates processing. Comparative tests with new magnetic materials and magnetic roll configurations are reported. Large diameter drum separators are discussed.