Hydraulic separators are commonly used for particle size classification and gravity concentration of minerals and coal. Unfortunately, the efficiency of these processes can be quite low due to poor equipment design and variations in feed consistency. To help alleviate these problems, an industry-driven R&D program has been undertaken to develop a new generation of hydraulic separators that are more efficient and less costly to operate and maintain. These units, which are commercially called the CrossFlow separator and HydroFloat separator, have the potential to improve performance (separation efficiency and throughput) and reduce operating costs (power consumption, water and reagent usage). In Phase I of this project, laboratory and pilot-scale test units were evaluated at various industrial sites in both the coal and mineral industries. Based on promising results obtained from Phase I, full-scale prototypes were purchased and installed by a major U.S. phosphate producer and a large eastern U.S. coal company. The test data obtained from these sites demonstrate that significant performance improvements can be realized through the application of these high-efficiency separators.