Polymer nanocomposites can provide improved mechanical, barrier, flame retardancy, and other properties at low filler loading, but these properties depend on the dispersion of the nanoparticles. In this work, the impact of feeding configuration on dispersion, mechanical properties, and airborne particle concentration was examined in a model nanocomposite system. Dynamic mechanical analysis and differential scanning calorimetry were performed to determine glass transition temperature of the nanocomposite. Transmission electron microscopy was used to assess dispersion of the nanoparticles in the polymer matrix whereas mechanical properties were measured using ISO standards. A fast mobility particle analyzer was used to measure airborne particle levels at from the hopper and the feed ports. These levels were correlated to the particle size and material loss. An indirect relationship was established among material loss, measured dispersion levels, and mechanical properties. POLYM. ENG. SCI., 50:154-164, 2010. (C) 2009 Society of Plastics Engineers