The development of sustainable processes is always a very complex task, in which a multitude of different aspects must be considered. The ideal process is resource-conserving, low-waste, effective, socially accepted as well as in compliance with legal regulations, and – especially – economical. To get as close as possible to this goal, the development work must follow a certain scheme. In the following chapter, the basic stages of process development are therefore traced using an example, the MagnetoRec process. This is a new recycling process that has been developed in recent years to recover rare earths from permanent magnets. In order for this process to survive under the difficult conditions of the rare earth market, a new unconventional method was introduced in the MagnetoRec process: solid chlorination. Behind this term is a dry digestion method that does without mineral acids and does not produce acidic wastewater. Compared to the state of the art, processes that rely on this new method use fewer chemicals, generate lower costs, and produce less waste. The downside of unconventional methods, however, is the significantly higher financial and technical risk, which makes implementation into industrial production more difficult. By knowing about the “paradox of process development” and consistently counteracting it, the MagnetoRec process can clearly demonstrate how unnecessary work on the way to a more sustainable process can be avoided and risks effectively reduced.