A large part of pharmaceutical manufacturing involves the use of particulate materials. It is well known that both particle size and shape affect the physical characteristics of tablets. An image processing and analysis algorithm based on the invariant image moment technique was developed in this work to determine the particle shape by comparing features (moments) extracted from templates to those extracted from each of the objects in the image. First it determines the particle shape (rectangle, circle, etc.) and then calculates its specific dimensions (diameter, aspect ratio). The statistical validation of the vision system obtained a repeatability of 0.0012 in and 0.5% relative standard deviation and accuracy within 0.1 to 0.9% of the average value considered as true value. Also the pattern recognition technique indicated high precision and accuracy for images containing particles with some level of contact between them. The shape recognition of microcrystalline cellulose (MCC) indicated that particles of equant and acicular shape as defined by USP are predominant. The results suggest that image processing and analysis would be a suitable tool for pharmaceutical process analytical technologies (PAT) and process optimization. (c) 2006 Elsevier B.V. All rights reserved.