Especially in the field of paper and print post-processing on an industrial scale, continuous cutting operations generate paper dust. Despite preventive measures like dedusting units, a high paper web velocity induces the release of particulate dust. As a result, the particles settle and accumulate on machine components and in the surrounding area. Resuspended particles around a potential ignition source represent a fire hazard. The prevention of such fire incidents requires frequent servicing and maintenance. However, the shutdown time on industrial scale applications remains cost-intensive. In this research, a cutting plotter executes reproducible knife edge cutting sequences to identify significant parameters affecting the paper dust formation on a macro and micro scale. For this purpose, an extraction system collects the exposed particles along the cutting line. The applied methods include gravimetric determination of the dust mass and dynamic image analysis to characterise particle size and shape. Final results indicate a significant influence of the blade wear condition.