This project developed an industrial prototype 3D imaging and analysis system for measuring the size distribution of iron ore green pellets. The system is installed and operational at a pellet production plant capturing and analysising 3D surface data of piled pellets on the conveyor belt. It provides fast, frequent, non-contact, consistent measurement of the pellet sieve size distribution and opens the door to autonomous closed loop control of the pellet balling disk or drum in the future. Segmentation methods based on morphological image processing are applied to the 3D surface data to identify individual pellets. Determination of entirely visible pellets (non-overlapped) is made using a two feature classification strategy, the advantage being that this system eliminates the bias the results from sizing overlapped particles based on their limited visible profile. The system achieves what a number of commercial 2D fragmentation measurement systems could not satisfactorily achieve for the pellet producer, that is, accurate sizing of the green pellets.