Aerosol size distributions from ferrous foundry cupola furnaces vary depending on semicontinuous process dynamics, time along the tap-to-tap cycle, dilution ratio, and the physical and chemical nature of the charge and fuel. All of these factors result in a highly time-dependent emission of particulate matter (PM) 2.5 pm or less in aerodynamic diameter (PM2.5)--even on a mass concentration basis. Control measures are frequently taken on the basis of low-reliability parameters such as emission factors and loosely established mass ratios of PM2.5 to PM 10 microm or less in aerodynamic diameter (PM1.0). The new environmental requirements could entail unexpected and undesired drawbacks and uncertainties in the meaning and effectiveness of process improvement measures. The development of process-integrated and flue-gas cleaning measures for reduction of particle emissions requires a better knowledge of generation mechanisms during melting. Available aerosol analyzers expand the range of control issues to be tackled and contribute to greatly reduce the uncertainty of engineering decisions on trace pollutant control. This approach combines real-time size distribution monitoring and cascade impactors as preseparators for chemical or morphological analysis. The results allow for establishing a design rationale and performance requirement for control devices. A number size distribution below 10 microm in aerodynamic equivalent diameter was chosen as the main indicator of charge influence and filter performance. Size distribution is trimodal, with a coarse mode more than 12 microm that contributes up to 30% of the total mass. A temporal series for these data leads to identification of the most relevant size ranges for a specific furnace (e.g., the most penetrating size range). In this cupola, this size range is between 0.32 and 0.77 microm of aerodynamic equivalent diameter and defines the pollution control strategy for metals concentrating within this size range. Scrap quality effect is best monitored at less than 0.2 microm in aerodynamic equivalent diameter and has been confirmed as strongly dependent on the physical state of the charge.