Toner shape has been found to influence performance characteristics such as developer flow, transfer, and cleaning. Chemically prepared toner (CPT) manufacturing methods provide control of particle shape, which allows one to optimize the toner performance. Shape analysis using automated digital imaging systems can be used both off-line and on-line to characterize toner shape. Most image analysis methods orient particles to display the two largest dimensions. By combining image analysis with other counting techniques that measure particle volume, such as the Coulter counter method, the minor axis information can be derived and the semi-minor and minor aspect ratios calculated. The inherent errors in edge detection for image analysis must be taken into account.