BACKGROUND This research aimed to determine the porosity and particle size distribution in canned Vienna‐type sausages using digital image analysis (DIA) on photographs captured with a digital camera and applying a Monte Carlo simulation. The methodology determined morphometric parameters (area and Feret diameter) by DIA of transverse and longitudinal sections of canned sausages. Those images were previously contrast enhanced, color threshold adjusted, and binarized. Subsequently, the estimation of the pore volume was carried out from the inverse Gaussian distributions of Feret diameter and area, as well as the porosity, using Monte Carlo simulation. RESULTS The pores had an average Feret diameter of 0.335 mm and an average area of 0.085 mm2. The highest estimated bivariate kernel density was presented for the smallest pores (around 0.02 mm2 in area and 0.25 mm in diameter). Simulation average values of pore volume, assumed as a cylinder, and porosity were 1.455 mm3 and 0.737 respectively. The average porosity value was consistent with the value experimentally estimated by the indirect method, in concordance with the definition of porosity, which was 0.715, presenting a mean relative percentage error of 3.08% concerning the estimated experimental value as well. CONCLUSION This research presents interesting perspectives for the quantitative analysis of the microstructure of food and biological materials through a novel, low‐cost, reliable, and fast proposal. Moreover, this is the first study to report the porosity determination in canned sausages by DIA. © 2022 Society of Chemical Industry.