This study investigates multi-stage dry magnetic separation beneficiation pathways centred on the DryFlow Magnetics system to improve the sustainability and efficiency of iron ore processing and beneficiation. The research focuses on reducing energy and water consumption, limiting over grinding, and achieving high-grade iron recovery through progressive dry comminution and magnetic separation. To this end, this study aims to identify optimal combinations of comminution technologies and DryFlow magnetic separation configurations that minimise energy use while maximising recovery and product quality. Ore samples from South Australian magnetite deposits are processed through sequential stages of size reduction using various dry comminution technologies including GRolls® crusher, vertical roller milling (VRM), and ball/rod milling, followed by successive stages of dry magnetic separation using the DryFlow dry magnetic separator. Each stage is analysed to determine how particle size distribution across coarse, intermediate, and fine fractions influences iron oxide recovery, grade, and overall process efficiency. Results presented in this paper provide a comparative assessment between conventional dry and wet comminution technologies and magnetic separation processes and the emerging DryFlow enabled dry beneficiation route, respectively demonstrating how a fully dry flow sheet can materially reduce energy intensity, eliminate water dependency, and enhance the economic and environmental performance of future iron ore operations. The findings suggest that integration of DryFlow’s proprietary magnetic separation technology enables accurate, water-free concentration of magnetite and hematite ores at each step, establishing a new benchmark for low-emission mineral processing.