Dust generation in solids handling involving free fall of bulk materials and impacts on a stockpile can cause many problems in industry and be a great danger for operators health. This paper describes an experimental set up to characterize the dust plume formed in free fall of powders from a hopper and investigates the influence of various outlet geometries on the dust plume. For this purpose an image analysis technique was developed to quantify the characteristics of the dust plume. (C) 2011 Elsevier B.V. All rights reserved.