I can fix the actual image quality and blending somewhat easy but the problem I am having is the size.
If anyone has any idea please help.
The steps I am doing are as follows.

I scan the chip
I then crop the chip 1.60x1.60
I open it in my image editor and create a circular crop just outside the chip
then I click save and give it a name.

I do the exact same thing each time and each chip is turning out a different size. I am not concerned about the file size as the colors and others will play a part in that. Even when you look at the thumbnails the chips all appear differently even though they were scanned and cropped the same way.