Early integration of sustainability decisions and mineralogical attributes into the design of minerals processing units offers potential for reducing environmental impacts at mining and processing sites. The objective of this study is to demonstrate how the integration of sustainability indicators and mineralogical attributes could be achieved in developing an integrated modelling framework of a magnetic separator. A magnetic separator unit model based on existing literature was developed to include process stream mineralogical data and to output sustainability indicators. The overall sustainability of processing three ore types (low, medium and high grade iron ore) was evaluated using the developed model. Novel measures for evaluating magnetic separation (Grade Recovery Deviation Index (GRDI)) and energy efficiency (Rotational Energy Transfer Efficiency (RETE)) that incorporate the use of ore characteristics were developed in this study. These measures were used to calculate the separation and energy efficiency sustainability indicator ratings. In total eleven magnetic separator sustainability indicators were identified. Each indicator was assigned a weighting value out of 10 based on its importance. Of the 11 sustainability indicators identified; safety, reliability, Carbon dioxide (CO2) emissions, water use, noise and job creation ratings did not vary with changing mineralogical attributes of the feed ore. GRDI, RETE, electricity cost, particle emissions and waste generation ratings were observed to be dependent on the ore characteristics and therefore their values varied with different feed ore grades. The Analytic Hierarchy Process (AHP) and Weighted Sum Method (WSM) methods were applied to the sustainability indicator ratings and weightings to evaluate an overall sustainability cardinal score of processing a particular ore feed. Results of this study demonstrate the dependence of overall process sustainability indicators on feed ore mineralogical attributes. The results also provide an indication of the effect of ore variability (typical within a single deposit) on sustainability indicators. (C) 2016 Elsevier Ltd. All rights reserved.