Phosphorus (P) is an essential resource for food production and chemical industry. Phosphorus use has to become more sustainable and should include phosphorus recycling from secondary sources. About 20% of P ends up in sewage sludge, making this a substantial secondary P source. There is currently a technological gap to recover P from sludge locally at wastewater treatment plants (WWTP) that remove P by dosing iron. Vivianite (Fe₃(PO₄)₂•8(H₂O)) is the main iron phosphate mineral that forms during anaerobic digestion of sewage sludge, provided that enough iron is present. Vivianite is paramagnetic and can be recovered using a magnetic separator. In this study, we have scaled up vivianite separation from lab-scale to bench- and pilot-scale. Bench-scale tests showed good separation of vivianite from digested sewage sludge and that a pulsation force is crucial for obtaining a concentrate with a high P grade. A pilot-scale magnetic separator (capacity 1.0 m³/h) was used to recover vivianite from digested sewage sludge at a WWTP. Recirculating and reprocessing sludge allows over 80% vivianite recovery within three passes. A concentrated P-product was produced with a vivianite content of up to 800 mg/g and a P content of 98 mg/g. P recovery is limited by the amount of P bound in vivianite and can be increased by increased iron dosing. With sufficient iron dosing, the vivianite content can be increased, and subsequently more P can be recovered. This would allow compliance with existing German legislation, which requires a P recovery larger than 50%.