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The authors are working on the development of a mechanical-physical processing plant to prepare non-selectively collected residual municipal solid waste (RMSW) in the Zalaegerszeg region of Hungary. A key element of this processing plant is the newly developed KLME separator (the name KLME is the Hungarian abbreviation of 'combined magnetic, electric and air flow'). This separator is a combination of three widely applied separators, namely a magnetic separator, an eddy current separator and two types of air flow separators designed without the ordinarily necessary cross connecting belt conveyors and feeders. Extensive RMSW and WEEE (waste electrical and electronic equipment) sampling and analyses were carried out in three municipalities to obtain model materials before designing the technology. After fundamental research and laboratory-scale testing, a pilot-scale KLME separator prototype (1.5 ton/h) was made. It has one input stream and five output streams targeted towards five types of products: two-dimensional materials (foils), three-dimensional light materials, magnetic materials, electrically conductive materials and heavy inert materials. Systematic pilot scale testing was carried out and 18 discrete technological setups were tested. The technology as well as the machine were continuously improved and modified based on on-site observations. The best yields and the experience gained are being utilised for the design of an industrial size machine.