The Sellafield Waste Vitrification Plant (WVP) immobilises highly active liquid waste (HAL) arising from the reprocessing of spent nuclear fuel in the UK. In order to optimise WVP operations a full scale working replica of a WVP processing line, the Vitrification Test Rig (VTR), was constructed to processes non-active HAL simulants. Recently the VTR has been used to determine an operational envelope for the vitrification of HAL from Magnox reprocessing at a waste oxide incorporation rate in glass of up to 35wt% (compared to a “standard” incorporation rate of 25wt%). This paper discusses the differences in operating conditions necessary to achieve acceptable waste throughput at the increased incorporation rate. The chemical durability of the resulting vitrified product is also discussed, along with the formation of secondary phases, and a comparison is drawn between 35wt% incorporation glasses and products made at the standard 25wt% incorporation.