An economic and efficient system for measuring drop sizes was developed. Pattern recognition technique was used with conventional oil-bath sampling and photographic method. The system was designed to measure and count relatively large number of drops in a very short time, and also to filter out abnormal images such as drops in contact or overlap as well as odd-shaped foreign materials. In this measuring system, most important error originates from the process of converting the original image to the binary image. If the photograph contains a large number of spray drops, the relative size of the pixel to the drops is not infinitesimally small; thus the proper choice of threshold level to convert the original image to the binary image becomes very important. In present case, most of the images lay in one of the two separate bands of brightness level and the arithmetic mean of the most popular brightness levels from each band was chosen as the threshold level. Present image processing system reduces the subjective error by the observers in counting and measuring drops and turns out to be substantially effective. The processing time can be further reduced by improving the hardware system concerned with the digital image coding.