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SECTION C
This document covers cakes, brownies, muffin tops and filled cakes in a flexible pouch for
use by the Department of Defense as a component of operational rations.
C-1 ITEM DESCRIPTION
PCR-C-007F, CAKES, BROWNIES, MUFFIN TOPS AND FILLED CAKES,
PACKAGED IN A FLEXIBLE POUCH, SHELF STABLE
Types and flavors.
Type I –

Pound cakes

Flavor 1 –
Flavor 6 –
Flavor 7 –
Flavor 10 –
Flavor 11 –
Flavor 12 –
Type II –

Brownies

Flavor 1 –
Flavor 2 –
Type III –

Fudge with chocolate drops
Dark chocolate fudge with chocolate drops

Muffin tops

Flavor 1 –
Flavor 2 –
Type IV –

Vanilla
Lemon poppy seed
Spice
Carrot
Marble
Applesauce

Chocolate banana nut
Maple

Filled pound cakes

Flavor 1 –

Chocolate with chocolate filling

Styles.
Style 1 –

Regular
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Style 2 –

Trans fat free

Packages.
Package A –
Package B –
Package C –
Package J –

Meal, Cold Weather (MCW)
Food Packet, Long Range Patrol (LRP)
Meal, Ready-to-Eat™ (MRE™)
First Strike Ration® (FSR™)

C-2 PERFORMANCE REQUIREMENTS
A. Product standard. A sample shall be subjected to first article (FA) or product
demonstration model (PDM) inspection as applicable, in accordance with the tests and
inspections of Section E of this Performance-based Contract Requirements (PCR) document.
The approved sample shall serve as the product standard. Should the contractor at any time
plan to or actually produce the product using different raw material or process methodologies
from the approved product standard, which result in a product noncomparable to the product
standard, the contractor shall submit a replacement FA or PDM for approval. In any event, all
product produced must meet all requirements of this document including product standard
comparability.
B. Shelf life. The packaged product shall meet the minimum shelf life requirement of 36
months at 80ºF.
C. Appearance.
(1) General. The finished product shall be intact. The product shall show no signs of
excessive heating (materially darkened or scorched). The product surface may have slightly
browned edges. The product shall have a uniform cell (crumb) structure and shall show no
evidence of compression streaks. The finished product shall be free from foreign materials.
(2) Type I.
a. Flavor 1. The vanilla pound cake shall have a light tan surface and a pale, offwhite crumb.
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b. Flavor 6. The lemon poppy seed pound cake shall have a light golden surface
and a yellow crumb with poppy seeds distributed throughout.
c. Flavor 7. The spice pound cake shall have a medium beige surface and a light
beige crumb and may have flecks of spices.
d. Flavor 10. The carrot pound cake shall have a medium brown to golden brown
surface and a medium golden brown crumb with small pieces of orange carrot distributed
throughout.
e. Flavor 11. The marble pound cake shall have a light golden brown to dark brown
swirled surface and crumb.
f. Flavor 12. The applesauce pound cake shall have a golden brown surface and a
light to medium beige crumb with dark tan apple pieces distributed throughout.
(3) Type II.
a. Flavor 1. The fudge brownie with chocolate drops shall have a medium to dark
brown surface and crumb and shall have chocolate drops distributed throughout.
b. Flavor 2. The dark chocolate fudge brownie with chocolate drops shall have a
dark brown surface and crumb and shall have chocolate drops distributed throughout.
(4) Type III.
a. Flavor 1. The chocolate banana nut muffin top shall be round and shall have a
dark brown surface and crumb containing off-white to pale yellow banana flavored drops and
walnut pieces distributed throughout.
b. Flavor 2. The maple muffin top shall be round and shall have a light to medium
golden brown surface and a pale yellow crumb. Muffin top may have pale yellow maple
flecks on the surface. The crumb may contain air structure pockets.

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(5) Type IV, flavor 1. The chocolate filled pound cake with chocolate filling shall
have a dark brown surface and crumb. The chocolate filling shall be a dark brown color. The
pound cake shall not have any filling leaking through the cake portion of the product.
D. Odor and flavor. The packaged food shall be free from foreign odors and flavors.
(1) Type I.
a. Flavor 1. The vanilla pound cake shall have a sweet vanilla odor and flavor.
b. Flavor 6. The lemon poppy seed pound cake shall have a sweet, mild lemon and
poppy seed odor and flavor.
c. Flavor 7. The spice pound cake shall have a sweet spice odor and flavor.
d. Flavor 10. The carrot pound cake shall have a sweet, caramelized spiced odor
and flavor with cinnamon, nutmeg, and cloves.
e. Flavor 11. The marble pound cake shall have a semi-sweet chocolate and sweet
vanilla odor and flavor.
f. Flavor 12. The applesauce pound cake shall have a sweet cooked apple and
brown spice odor and flavor.
(2) Type II.
a. Flavor 1. The fudge brownie with chocolate drops shall have a sweet chocolate
odor and flavor.
b. Flavor 2. The dark chocolate fudge brownie with chocolate drops shall have a
sweet dark chocolate odor and a sweet, slightly bitter dark chocolate flavor.
(3) Type III.
a. Flavor 1. The chocolate banana nut muffin top shall have a sweet, mild cocoa
with banana and walnut odor and flavor.
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b. Flavor 2. The maple muffin top shall have a sweet, maple odor and flavor.
(4) Type IV, flavor 1. The chocolate pound cake shall have a sweet, mild chocolate
odor and flavor. The chocolate filling shall have a sweet, mild chocolate odor and flavor.
E. Texture.
(1) Type I.
a. Flavors 1, 7, and 11. The vanilla, spice, and marble pound cakes shall have a
dense, firm, tender, moist, fine grain crumb texture.
b. Flavor 6. The lemon poppy seed pound cake shall have a dense, firm, tender,
moist, fine grain crumb texture with slightly crunchy poppy seeds.
c. Flavor 10. The carrot pound cake shall have a dense, firm, tender, moist, fine
grain crumb texture with pieces of soft carrot.
d. Flavor 12. The applesauce pound cake shall have a dense, firm, tender, moist,
fine grain crumb texture with pieces of soft apple.
(2) Type II, flavors 1 and 2. The fudge brownie with chocolate drops and dark
chocolate fudge brownie with chocolate drops shall have a very dense, firm, moist texture
with chocolate drops.
(3) Type III.
a. Flavor 1. The chocolate banana nut muffin top shall have a tender, moist, fine
grain crumb texture with slightly firm banana drops and firm walnuts.
b. Flavor 2. The maple muffin top shall have a tender, moist, fine grain crumb
texture. Maple flecks may be slightly crunchy.

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(4) Type IV, flavor 1. The chocolate pound cake with chocolate filling shall have a
dense, firm, tender, moist, fine grain crumb texture with a thick, smooth pudding-like filling.
The filling shall not be excessively thin or runny.
F. Percent filling. For type IV, the percent filling by weight shall be not less than 20.0
percent.
G. Dimensions. Types I and IV pound cakes and type II brownies shall be not greater than
4-3/4 inches long and 3-1/4 inches in width. Type III muffin tops shall be not greater than 41/4 inches in diameter.
H. Net weight.
(1) Type I. The average net weight of type I pound cakes shall be not less than 2.5
ounces (71 grams). The net weight of an individual pouch shall be not less than 2.3 ounces
(65 grams).
(2) Type II. The average net weight of type II brownies shall be not less than 3.0
ounces (85 grams). The net weight of an individual pouch shall be not less than 2.6 ounces
(74 grams).
(3) Type III. The average net weight of type III muffin tops shall be not less than 2.2
ounces (62 grams). The net weight of an individual pouch shall be not less than 2.0 ounces
(57 grams).
(4) Type IV. The average net weight of type IV filled pound cakes shall be not less
than 3.0 ounces (85 grams). The net weight of an individual pouch shall be not less than 2.6
ounces (74 grams).
I. Palatability and overall appearance. The finished product shall be equal to or better than
the approved product standard in palatability and overall appearance.
J. Analytical requirements.
(1) Fat.

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a. For types I, II, and III, the fat content shall be not less than 18.0 percent.
b. For type IV, the fat content shall be not less than 12.0 percent.
c. For style 2, the trans fat content shall be not greater than 0 grams per serving.

(2) Moisture.
a. The moisture content for type I pound cakes shall be not less than 13.0 percent.
b. The moisture content for type II brownies shall be not less than 15.0 percent.
c. The moisture content for type III, flavor 1 chocolate banana nut muffin tops shall
be not less than 10.0 percent. The moisture content for type III, flavor 2 maple muffin tops
shall be not less than 13.0 percent.
d. The moisture content for type IV filled pound cake shall be not less than 20.0
percent.
(3) Water activity. The water activity (aw) shall be not greater than 0.85.
(4) Oxygen. The oxygen content of the filled and sealed pouch shall not exceed 0.30
percent.
SECTION D
D-1 PACKAGING
A. Packaging. One unit of product and one oxygen scavenger shall be packaged in a
preformed or form-fill-seal barrier pouch as described below.
(1) Preformed pouches.
a. Pouch material. The preformed pouch shall be fabricated from 0.002 inch thick
ionomer or polyethylene film laminated or extrusion coated to 0.00035 inch thick aluminum
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foil which is then laminated to 0.0005 inch thick polyester. Tolerances for thickness of
plastic films shall be plus or minus 20 percent and tolerance for the foil layer shall be plus or
minus 10 percent. The material shall show no evidence of delamination, degradation, or
foreign odor when heat sealed or fabricated into pouches. The material shall be suitably
formulated for food packaging and shall not impart an odor or flavor to the product. The
complete exterior surface of the pouch shall be uniformly colored and shall conform to
number 20219, 30219, 30227, 30279, 30313, 30324, or 30450 of FED-STD-595, Colors
Used in Government Procurement.
b. Pouch construction. The pouch shall be a flat style preformed pouch having
maximum inside dimensions of 5-1/2 inches wide by 6-3/4 inches long. The pouch shall be
made by heat sealing three edges with 3/8 inch (-1/8 inch, +3/16 inch) wide seals. The side
and bottom seals shall have an average seal strength of not less than 6 pounds per inch of
width and no individual specimen shall have a seal strength of less than 5 pounds per inch of
width. Alternatively, the filled and sealed pouch shall exhibit no rupture or seal separation
greater than 1/16 inch or seal separation that reduces the effective closure seal width to less
than 1/16 inch when tested for internal pressure resistance. A tear nick, notch or serrations
shall be provided to facilitate opening of the filled and sealed pouch. A 1/8 inch wide lip may
be incorporated at the open end of the pouch.
c. Pouch filling and sealing. One unit of product and one oxygen scavenger shall be
inserted into the pouch. The filled pouch shall be sealed. The closure seal shall be free of
foldover wrinkles or entrapped matter that reduces the effective closure seal width to less
than 1/16 inch. Seals shall be free of impression or design on the seal surface that would
conceal or impair visual detection of seal defects. The average seal strength shall be not less
than 6 pounds per inch of width and no individual specimen shall have a seal strength of less
than 5 pounds per inch of width. Alternatively, the filled and sealed pouch shall exhibit no
rupture or seal separation greater than 1/16 inch or seal separation that reduces the effective
closure seal width to less than 1/16 inch when tested for internal pressure resistance.
(2) Horizontal form-fill-seal pouches.
a. Pouch material. The horizontal form-fill-seal pouch shall consist of a formed
tray-shaped body with a flat sheet, heat sealable cover or a tray-shaped body with a trayshaped heat sealable cover. The tray-shaped body and the tray-shaped cover shall be
fabricated from a 3-ply flexible laminate barrier material consisting of, from outside to
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inside, 0.0009 inch thick oriented polypropylene bonded to 0.0007 inch thick aluminum foil
with 10 pounds per ream pigmented polyethylene or adhesive and bonding the opposite side
of the aluminum foil to 0.003 inch thick ionomer or a blend of not less than 50 percent linear
low density polyethylene and polyethylene. The linear low density polyethylene portion of
the blend shall be the copolymer of ethylene and octene-1 having a melt index range of 0.8 to
1.2 g/10 minutes in accordance with ASTM D1238, Standard Test Method for Melt Flow
Rates of Thermoplastics by Extrusion Plastometer and a density range of 0.918 to 0.922 g/cc
in accordance with ASTM D1505, Standard Test Method for Density of Plastics by DensityGradient Technique. Alternatively, 0.0005 inch thick polyester may be used in place of the
oriented polypropylene as the outer ply of the laminate. The flat sheet cover shall be made of
the same 3-ply laminate as specified for the tray-shaped body except the aluminum foil
thickness may be 0.00035 inch. Tolerances for thickness of plastic films shall be plus or
minus 20 percent and tolerance for the foil layer shall be plus or minus 10 percent. The color
requirements of the exterior (oriented polypropylene or polyester side) of the laminate shall
be as specified in D-1,A(1)a. The material shall show no evidence of delamination,
degradation, or foreign odor when heat sealed or fabricated into pouches. The material shall
be suitably formulated for food packaging and shall not impart any odor or flavor to the
product.
b. Pouch construction. The tray-shaped body and the tray-shaped cover shall be
formed by drawing the flexible laminate material into an appropriately shaped cavity. The
flat cover shall be in the form of a flat sheet of the barrier material taken from roll stock. One
unit of product and one oxygen scavenger shall be placed into the tray-shaped body of the
pouch. Pouch closure shall be effected by heat sealing together the cover and body along the
entire pouch perimeter. The closure seal width shall be a minimum of 1/8 inch. The closure
seal shall have an average seal strength of not less than 6 pounds per inch of width and no
individual specimen shall have a seal strength of less than 5 pounds per inch of width.
Alternatively, the filled and sealed pouch shall exhibit no rupture or seal separation greater
than 1/16 inch or seal separation that reduces the effective closure seal width to less than 1/16
inch when tested for internal pressure resistance. The maximum outside dimensions of the
sealed pouch shall be 6 inches wide by 6 inches long. A tear nick, notch or serrations shall be
provided to facilitate opening of the filled and sealed pouch. The sealed pouch shall not show
any evidence of material degradation, aluminum stress cracking, delamination or foreign
odor. Heat seals shall be free of entrapped matter that reduces the effective closure seal width
to less than 1/16 inch. Seals shall be free of impression or design on the seal surface that
would conceal or impair visual detection of seal defects.
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(3) Oxygen scavenger. The oxygen scavenger shall be constructed of materials that
are safe for direct and indirect food contact, and shall be suitable for use with edible
products. The oxygen scavenger shall be in compliance with all applicable FDA regulations.
D-2 LABELING
A. Pouches. Each pouch shall be correctly and legibly labeled. Printing ink shall be
permanent black ink or other dark contrasting color which is free of carcinogenic elements.
The label shall contain the following information:
(1)
(2)
(3)
(4)
(5)
(6)

Name and flavor of product (letters not less than 1/8 inch high)
Ingredients
Date 1/
Net weight
Name and address of packer
“Nutrition Facts” label in accordance with the Nutrition Labeling and Education
Act (NLEA) and all applicable FDA regulations

1/ Each pouch shall have the date of pack noted by using a four digit code beginning with the
final digit of the current year followed by the three digit Julian day code. For example, 14
February 2014 would be coded as 4045. The Julian day code shall represent the day the
product was packaged into the pouch.
D-3 PACKING
A. Packing. Not more than 40 pounds of product shall be packed in a fiberboard shipping
box constructed in accordance with style RSC-L of ASTM D5118/D5118M, Standard
Practice for Fabrication of Fiberboard Shipping Boxes. The fiberboard shall conform to type
CF, class D, variety SW, burst grade 200 or ECT grade 32 of ASTM D4727/D4727M,
Standard Specification for Corrugated and Solid Fiberboard Sheet Stock (Container Grade)
and Cut Shapes. Each box shall be closed in accordance with ASTM D1974/D1974M,
Standard Practice for Methods of Closing, Sealing, and Reinforcing Fiberboard Boxes.
D-5 MARKING
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A. Shipping containers. Shipping containers shall be marked in accordance with DLA
Troop Support Form 3556, Marking Instructions for Boxes, Sacks, and Unit Loads of
Perishable and Semiperishable Subsistence.
SECTION E INSPECTION AND ACCEPTANCE
The following quality assurance criteria, utilizing ANSI/ASQ Z1.4, Sampling Procedures and
Tables for Inspection by Attributes, are required. Unless otherwise specified, single sampling
plans indicated in ANSI/ASQ Z1.4 will be utilized. When required, the manufacturer shall
provide the Certificate(s) of Conformance to the appropriate inspection activity.
Certificate(s) or Conformance not provided shall be cause for rejection of the lot.
A. Definitions.
(1) Critical defect. A critical defect is a defect that judgment and experience indicate
would result in hazardous or unsafe conditions for individuals using, maintaining, or
depending on the item; or a defect that judgment and experience indicate is likely to prevent
the performance of the major end item, i.e., the consumption of the ration.
(2) Major defect. A major defect is a defect, other than critical, that is likely to result
in failure, or to reduce materially the usability of the unit of product for its intended purpose.
(3) Minor defect. A minor defect is a defect that is not likely to reduce materially the
usability of the unit of product for its intended purpose, or is a departure from established
standards having little bearing on the effective use or operation of the unit.
B. Classification of inspections. The inspection requirements specified herein are classified
as follows:
(1) Product standard inspection. The first article or product demonstration model shall
be inspected in accordance with the provisions of this document and evaluated for
appearance, odor, flavor and texture. Any failure to conform to the performance requirements
or any appearance or palatability failure shall be cause for rejection of the lot.
(2) Periodic review evaluation. The approved first article or product demonstration
model shall be used as the product standard for periodic review evaluations. All food
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components that are inspected by the USDA shall be subject to periodic review sampling and
evaluation. The USDA shall select sample units during production of contracts and submit
them to the following address for evaluation:
US Army Research, Development and Engineering Command
Natick Soldier Research, Development and Engineering Center
RDNS-CFF
15 Kansas Street
Natick, MA 01760-5056
One lot shall be randomly selected during each calendar month of production or as otherwise
specified in the contract. Three (3) sample units shall be randomly selected from that one
production lot. The three (3) sample units shall be shipped to Natick within five (5) working
days from the end of the production month from which they are randomly selected and upon
completion of all USDA inspection requirements. The sample units will be evaluated for
overall quality against the current first article or product demonstration model.
(3) Conformance inspection. Conformance inspection shall include the
examinations/tests and methods of inspection cited in this section.
E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT)
A. Product examination. The finished product shall be examined for compliance with the
performance requirements specified in Section C of this Performance-based Contract
Requirements document utilizing the double sampling plans indicated in ANSI/ASQ Z1.4.
The lot size shall be expressed in pouches. The sample unit shall be the contents of one
pouch. The inspection level shall be S-3 and the acceptable quality level (AQL), expressed in
terms of defects per hundred units, shall be 1.5 for major defects and 4.0 for minor defects.
Defects and defect classifications are listed in table I.
TABLE I. Product defects 1/ 2/ 3/
Category
Major

Defect
Minor
General

101

Product not type or not flavor or not style as specified.
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102

Evidence of excessive heating (materially darkened or scorched).

103

Pouch does not contain one intact oxygen scavenger. 4/

Category
Major

201

Product not intact.

202

Product does not have a uniform cell (crumb) structure.

203

Evidence of compression streaks.

204

Product not dimensions as specified.

TABLE I. Product defects 1/ 2/ 3/ - Continued
Defect
Minor
205

Net weight of any individual type I pound cake less than 2.3 ounces (65
grams). 5/

206

Net weight of any individual type II brownie less than 2.6 ounces (74
grams). 6/

207

Net weight of any individual type III muffin top less than 2.0 ounces
(57 grams). 7/

208

Net weight of any individual type IV filled pound cake less than 2.6
ounces (74 grams). 8/
Type I – Pound cakes
Flavor 1 – Vanilla
Pound cake not a sweet vanilla odor or flavor.

104
209

Pound cake does not have a light tan surface or does not have a pale,
off-white crumb.
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210

Pound cake texture not dense or not firm or not tender or not moist or
not fine grain crumb.
Flavor 6 – Lemon poppy seed
Pound cake not a sweet, mild lemon and poppy seed odor or flavor.

105
211

Pound cake does not have a light golden surface or does not have a
yellow crumb with poppy seeds distributed throughout.

212

Pound cake texture not dense or not firm or not tender or not moist or
not fine grain crumb or not with slightly crunchy poppy seeds.

TABLE I. Product defects 1/ 2/ 3/ - Continued
Category
Major

Defect
Minor
Flavor 7 – Spice
Pound cake not a sweet spice odor or flavor.

106
213

Pound cake does not have a medium beige surface or does not have a
light beige crumb.

214

Pound cake texture not dense or not firm or not tender or not moist or
not fine grain crumb.
Flavor 10 – Carrot
Pound cake not a sweet, caramelized spiced odor or flavor with
cinnamon, nutmeg, and cloves.

107

215

Pound cake does not have a medium brown to golden brown surface or
does not have a medium golden brown crumb with small pieces of
orange carrot distributed throughout.

216

Pound cake texture not dense or not firm or not tender or not moist or
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not fine grain crumb or not with pieces of soft carrot.
Flavor 11 – Marble
Pound cake not a semi-sweet chocolate and sweet vanilla odor or
flavor.

108

217

Pound cake does not have a light golden brown to dark brown swirled
surface and crumb.

218

Pound cake texture not dense or not firm or not tender or not moist or
not fine grain crumb.
Flavor 12 – Applesauce
Pound cake not a sweet cooked apple and brown spice odor or flavor.

109

Category
Major

TABLE I. Product defects 1/ 2/ 3/ - Continued
Defect
Minor
219

220

Pound cake does not have a golden brown surface or does not have a
light to medium beige crumb with dark tan apple pieces distributed
throughout.
Pound cake texture not dense or not firm or not tender or not moist or
not fine grain crumb or not with pieces of soft apple.
Type II – Brownies
Flavor 1 – Fudge with chocolate drops
Brownie not a sweet chocolate odor or flavor.

110
221

Brownie does not have a medium to dark brown surface and crumb
with chocolate drops distributed throughout.

222

Brownie texture not very dense or not firm or not moist or not with
chocolate drops.
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Flavor 2 – Dark chocolate fudge with chocolate drops
Brownie not a sweet dark chocolate odor or not a sweet, slightly bitter,
dark chocolate flavor.

111

223

Brownie does not have a dark brown surface and crumb with chocolate
drops distributed throughout.

224

Brownie texture not very dense or not firm or not moist or not with
chocolate drops.
Type III – Muffin tops
Flavor 1 – Chocolate banana nut
Muffin top not a sweet, mild cocoa with banana and walnut odor or
flavor.

112

Category
Major

TABLE I. Product defects 1/ 2/ 3/ - Continued
Defect
Minor
225

226

113
227
228

Muffin top not round or does not have a dark brown surface and crumb
containing off-white to pale yellow banana flavored drops and walnut
pieces distributed throughout.
Muffin top texture not tender or not moist or not fine grain crumb or
not with slightly firm banana drops or not with firm walnuts.
Flavor 2 – Maple
Muffin top not a sweet, maple odor or flavor.
Muffin top not round or does not have a light to medium golden brown
surface or does not have a pale yellow crumb.
Muffin top texture not tender or not moist or not fine grain crumb.
Type IV – Filled pound cakes 9/
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114

Flavor 1 – Chocolate with chocolate filling
Filled pound cake not a sweet, mild chocolate odor or flavor.

115

Chocolate filling not a sweet, mild chocolate odor or flavor.
229

Filled pound cake does not have a dark brown surface and crumb.

230

Chocolate filling not a dark brown color.

231

Cake portion of the product not free of filling leakage.

232

Filled pound cake texture not dense or not firm or not tender or not
moist or not fine grain crumb.

233

Filled pound cake does not have a thick, smooth, pudding-like filling,
or filling is excessively thin or runny.

1/ Presence of any foreign materials such as, but not limited to dirt, insect parts, hair, glass,
wood, or metal, or any foreign odors or flavors such as, but not limited to burnt, scorched,
rancid, sour, stale, musty or moldy shall be cause for rejection of the lot.
2/ Finished product not equal to or better than the approved product standard in palatability
and overall appearance shall be cause for rejection of the lot.
3/ For style 2, the trans fat content shall be verified by the NLEA “Nutrition Facts” label.
Product not conforming to the trans fat content as specified in Section C of this document
shall be cause for rejection of the lot.
4/ Construction of the oxygen scavenger and compliance with FDA regulations will be
verified by Certificate of Conformance (CoC).
5/ Type I, sample average net weight less than 2.5 ounces (71 grams) shall be cause for
rejection of the lot.
6/ Type II, sample average net weight less than 3.0 ounces (85 grams) shall be cause for
rejection of the lot.

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7/ Type III, sample average net weight less than 2.2 ounces (62 grams) shall be cause for
rejection of the lot.
8/ Type IV, sample average net weight less than 3.0 ounces (85 grams) shall be cause for
rejection of the lot.
9/ For type IV, the percent filling shall be verified by CoC.
B. Methods of inspection.
(1) Shelf life. The contractor shall provide a Certificate of Conformance that the
product has a 36 month shelf life when stored at 80°F. Government verification may include
storage for 6 months at 100°F or 36 months at 80oF. Upon completion of either storage
period, the product will be subjected to a sensory evaluation panel for appearance and
palatability and must receive an overall score of 5 or higher based on a 9 point quality scale
to be considered acceptable.
(2) Net weight. The net weight shall be determined by weighing each sample unit on
a suitable scale tared with a representative empty pouch and an oxygen scavenger. Results
shall be reported to the nearest 0.1 ounce or to the nearest 1 gram.
(3) Analytical. The sample to be analyzed shall be a composite of eight filled and
sealed pouches which have been selected at random from the lot. The composite sample shall
be prepared and analyzed in accordance with the following methods of the Official Methods
of Analysis (OMA) of AOAC International or approved methods of the American
Association of Cereal Chemists (AACC):
Test
Fat
Moisture

Method Number
922.06, 991.36, 2008.06 or AACC 30-10
925.45A or 2008.06

Test results shall be reported to the nearest 0.1 percent. Government verification will be
conducted through actual testing by a Government laboratory. Any result not conforming to
the analytical requirement shall be cause for rejection of the lot.

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(4) Water activity (aw) testing. Eight filled and sealed pouches shall be randomly
selected from one production lot and tested for aw in accordance with the latest edition of the
Official Methods of Analysis (OMA) of AOAC International, method 978.18, using an
electric hygrometer system self temperature controlled (at 25°C) or an equivalent instrument.
Water activity shall be determined not less than 4 days but not more than 14 days after
baking to allow moisture equilibration in the product. The sample unit shall be a specimen
from the center of the product. Test results shall be reported to the nearest 0.01 aw.
Government verification will be conducted through actual testing by a Government
laboratory. Any nonconforming aw result shall be cause for rejection of the lot.
(5) Oxygen content testing. Eight filled and sealed pouches shall be randomly
selected from one production lot and individually tested for oxygen content. Testing shall be
accomplished after the filled and sealed pouches have been allowed to equilibrate at room
temperature for not less than 48 hours from the time of sealing. Test results shall be reported
to the nearest 0.01 percent. Government verification will be conducted through actual testing
by a Government laboratory. Any individual result not conforming to the oxygen content
requirement shall be classified as a major defect and shall be cause for rejection of the lot.
E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING
MATERIALS)
A. Packaging.
(1) Pouch material certification. The pouch material shall be tested for these
characteristics. A Certificate of Conformance (CoC) may be accepted as evidence that the
characteristics conform to the specified requirements.
Characteristic
Thickness of films for
laminated material

Requirement paragraph
D-1,A(1)a and D-1,A(2)a

Test procedure
ASTM D2103 1/

Aluminum foil thickness

D-1,A(1)a and D-1,A(2)a

ASTM B479 2/

Laminated material
identification and construction

D-1,A(1)a and D-1,A(2)a

Laboratory evaluation

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Color of laminated material

D-1,A(1)a and D-1,A(2)a

FED-STD-595 3/

1/ Standard Specification for Polyethylene Film and Sheeting
2/ Standard Specification for Annealed Aluminum and Aluminum-Alloy Foil for Flexible
Barrier, Food Contact, and Other Applications
3/ Colors Used in Government Procurement
(2) Unfilled preformed pouch certification. A CoC may be accepted as evidence that
unfilled pouches conform to the requirements specified in D-1,A(1)a and b. When deemed
necessary by the USDA, testing of the unfilled preformed pouches for seal strength shall be
as specified in E-6,B(1)a.
(3) Filled and sealed pouch examination. The filled and sealed pouches shall be
examined for the defects listed in table II. The lot size shall be expressed in pouches. The
sample unit shall be one pouch. The inspection level shall be I and the AQL, expressed in
terms of defects per hundred units, shall be 0.65 for major defects and 2.5 for minor defects.

Category
Major
101

TABLE II. Filled and sealed pouch defects 1/
Defect
Minor
Tear or hole or open seal.

102

Seal width less than 1/16 inch. 2/

103

Presence of delamination. 3/

104

Unclean pouch. 4/

Category
Major
105
106

TABLE II. Filled and sealed pouch defects 1/ - Continued
Defect
Minor
Pouch has foreign odor.
Any impression or design on the heat seal surfaces which conceals or
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impairs visual detection of seal defects. 5/
107

Not packaged as specified.

108

Presence of stress cracks in the aluminum foil. 6/ 7/
201

Label missing or incorrect or illegible.

202

Tear nick or notch or serrations missing or does not facilitate opening.

203

Seal width less than 1/8 inch but greater than or equal to 1/16 inch. 2/

204

Presence of delamination. 3/

1/ Any evidence of rodent or insect infestation shall be cause for rejection of the lot.
2/ The effective closure seal is defined as any uncontaminated, fusion bonded, continuous
path, minimum 1/16 inch wide, from side seal to side seal that produces a hermetically sealed
pouch.
3/ Delamination defect classification:
Major - Delamination of the outer ply in the pouch seal area that can be propagated to
expose aluminum foil at the food product edge of the pouch after manual flexing of the
delaminated area. To flex, the delaminated area shall be held between the thumb and
forefinger of each hand with both thumbs and forefingers touching each other. The
delaminated area shall then be rapidly flexed 10 times by rotating both hands in alternating
clockwise- counterclockwise directions. Care shall be exercised when flexing delaminated
areas near the tear notches to avoid tearing the pouch material. After flexing, the separated
outer ply shall be grasped between thumb and forefinger and gently lifted toward the food
product edge of the seal or if the separated area is too small to be held between thumb and
forefinger, a number two stylus shall be inserted into the delaminated area and a gentle lifting
force applied against the outer ply. If separation of the outer ply can be made to extend to the
product edge of the seal with no discernible resistance to the gentle lifting, the delamination
shall be classified as a major defect. Additionally, spot delamination of the outer ply in the
body of the pouch that is able to be propagated beyond its initial borders is also a major
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defect. To determine if the laminated area is a defect, use the following procedure: Mark the
outside edges of the delaminated area using a bold permanent marking pen. Open the pouch
and remove the contents. Cut the pouch transversely not closer than 1/4 inch (+1/16 inch)
from the delaminated area. The pouch shall be flexed in the area in question using the
procedure described above. Any propagation of the delaminated area, as evidenced by the
delaminated area exceeding the limits of the outlined borders, shall be classified as a major
defect.
Minor - Minor delamination of the outer ply in the pouch seal area is acceptable and
shall not be classified as a minor defect unless it extends to within 1/16 inch of the food
product edge of the seal. All other minor outer ply delamination in the pouch seal area or
isolated spots of delamination in the body of the pouch that do not propagate when flexed as
described above shall be classified as minor defects.
4/ Outer packaging shall be free from foreign matter which is unwholesome, has the potential
to cause pouch damage (for example, glass, metal filings) or generally detracts from the clean
appearance of the pouch. The following examples shall not be classified as defects for
unclean:
a. Foreign matter which presents no health hazard or potential pouch damage and
which can be readily removed by gently shaking the package or by gently brushing the pouch
with a clean dry cloth.
b. Dried product which affects less than 1/8 of the total surface area of one pouch face
(localized and aggregate).
5/ If doubt exists as to whether or not the sealing equipment leaves an impression or design
on the closure seal surface that could conceal or impair visual detection of seal defects,
samples shall be furnished to the contracting officer for a determination as to acceptability.
6/ Applicable to form-fill-seal pouches only.
7/ The initial examination shall be a visual examination of the closed package. Any suspected
visual evidence of stress cracks in the aluminum foil (streaks, breaks, or other disruptions in
the laminated film) shall be verified by the following physical examination. To examine for
stress cracks, the inside surface of both tray-shaped bodies shall be placed over a light source
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and the outside surface observed for the passage of light. Observation of light through the
pouch material in the form of a curved or straight line greater than 2 mm in length shall be
evidence of the presence of stress cracks. Observation of light through the pouch material in
the form of a curved or straight line 2 mm in length or smaller or of a single pinpoint shall be
considered a pinhole. Observation of ten or more pinholes per pouch shall be evidence of
material degradation.
B. Methods of Inspection.
(1) Seal testing. The pouch seals shall be tested for seal strength as required in a, b, or
c, as applicable.
a. Unfilled preformed pouch seal testing. The seals of the unfilled preformed pouch
shall be tested for seal strength in accordance with ASTM F88/F88M, Standard Test Method
for Seal Strength of Flexible Barrier Materials. The lot size shall be expressed in pouches.
The sample unit shall be one pouch. The sample size shall be the number of pouches
indicated by inspection level S-1. Three adjacent specimens shall be cut from each of the
three sealed sides of each pouch in the sample. The average seal strength of any side shall be
calculated by averaging the three specimens cut from that side. Any average seal strength of
less than 6 pounds per inch of width or any test specimen with a seal strength of less than 5
pounds per inch of width shall be classified as a major defect and shall be cause for rejection
of the lot.
b. Pouch closure seal testing. The closure seals of the pouches shall be tested for
seal strength in accordance with ASTM F88/F88M. The lot size shall be expressed in
pouches. The sample unit shall be one pouch. The sample size shall be the number of
pouches indicated by inspection level S-1. For the closure seal on preformed pouches, three
adjacent specimens shall be cut from the closure seal of each pouch in the sample. For formfill-seal pouches, three adjacent specimens shall be cut from each side and each end of each
pouch in the sample. The average seal strength of any side, end or closure shall be calculated
by averaging the three specimens cut from that side, end or closure. Any average seal
strength of less than 6 pounds per inch of width or any test specimen with a seal strength of
less than 5 pounds per inch of width shall be classified as a major defect and shall be cause
for rejection of the lot.

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c. Internal pressure test. The internal pressure resistance shall be determined by
pressurizing the pouches while they are restrained between two rigid plates. The lot size shall
be expressed in pouches. The sample unit shall be one pouch. The sample size shall be the
number of pouches indicated by inspection level S-1. If a three seal tester (one that
pressurizes the pouch through an open end) is used, the closure seal shall be cut off for
testing the side and bottom seals of the pouch. For testing the closure seal, the bottom seal
shall be cut off. The pouches shall be emptied prior to testing. If a four-seal tester (designed
to pressurize filled pouches by use of a hypodermic needle through the pouch wall) is used,
all four seals can be tested simultaneously. The distance between rigid restraining plates on
the four-seal tester shall be equal to the thickness of the product +1/16 inch. Pressure shall be
applied at the approximate uniform rate of 1 pound per square inch gage (psig) per second
until 14 psig pressure is reached. The 14 psig pressure shall be held constant for 30 seconds
and then released. The pouches shall then be examined for separation or yield of the heat
seals. Any rupture of the pouch or evidence of seal separation greater than 1/16 inch in the
pouch manufacturer’s seal shall be considered a test failure. Any seal separation that reduces
the effective closure seal width to less than 1/16 inch (see table II, footnote 2/) shall be
considered a test failure and shall be classified as a major defect and shall be cause for
rejection of the lot.

C. Packing.
(1) Shipping container and marking examination. The filled and sealed shipping
containers shall be examined for the defects listed in table III. The lot size shall be expressed
in shipping containers. The sample unit shall be one shipping container fully packed. The
inspection level shall be S-3 and the AQL, expressed in terms of defects per hundred units,
shall be 4.0 for major defects and 10.0 for total defects.

Category
Major
101
102

TABLE III. Shipping container and marking defects
Defect
Minor
Marking missing or incorrect or illegible.
Inadequate workmanship. 1/
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201

More than 40 pounds of product.

1/ Inadequate workmanship is defined as, but not limited to, incomplete closure of container
flaps, loose strapping, inadequate stapling, improper taping, or bulged or distorted container.

SECTION J REFERENCE DOCUMENTS
Unless otherwise specified, the applicable version of these documents is that which is active
on the date of the solicitation or contract.
DLA Troop Support Form
Form 3556

Marking Instructions for Boxes, Sacks, and Unit Loads of
Perishable and Semiperishable Subsistence

FEDERAL STANDARD
FED-STD-595

Colors Used in Government Procurement
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NON-GOVERNMENTAL STANDARDS
AMERICAN SOCIETY FOR QUALITY (ASQ) www.asq.org
ANSI/ASQ Z1.4

Sampling Procedures and Tables for Inspection by
Attributes

ASTM INTERNATIONAL www.astm.org
B479

Standard Specification for Annealed Aluminum and
Aluminum-Alloy Foil for Flexible Barrier, Food
Contact, and Other Applications

D1238

Standard Test Method for Melt Flow Rates of
Thermoplastics by Extrusion Plastometer

D1505

Standard Test Method for Density of Plastics by the
Density-Gradient Technique

D1974/D1974M

Standard Practice for Methods of Closing, Sealing,
and Reinforcing Fiberboard Boxes

D2103

Standard Specification for Polyethylene Film and
Sheeting

D4727/D4727M

Standard Specification for Corrugated and Solid
Fiberboard Sheet Stock (Container Grade) and Cut
Shapes

D5118/D5118M

Standard Practice for Fabrication of Fiberboard
Shipping Boxes

F88/F88M

Standard Test Method for Seal Strength of Flexible
Barrier Materials
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AOAC INTERNATIONAL www.aoac.org
Official Methods of Analysis (OMA) of AOAC International
AMERICAN ASSOCIATION OF CEREAL CHEMISTS (AACC)
Approved Methods of the American Association of Cereal Chemists
(Application for copies should be addressed to: American Association of Cereal Chemists,
3340 Pilot Knob Road, St. Paul, MN 55121.)

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For DLA Troop Support Website Posting
RDNS-SEC-EM

4 February 2016

TO: DLA Troop Support - Subsistence DSCP-FTRE
SUBJECT: ES16-022 (DSCP-SS-16-00433); Document change; USDA Proposal to add an
additional Official Method of Analysis (OMA) of the Association of Official Analytical
Chemists (AOAC) International Fat Test Method 2008.06 to four bakery documents
1. Natick received an Engineering Support Case (ES Case) from DLA - Troop Support
stating the USDA Laboratory has made a proposal to add an additional method for fat testing
to four bakery product specifications, resulting in a potential savings of thousands of dollars
per year. The additional test method they proposed is Official Method of Analysis (OMA) of
the Association of Official Analytical Chemists (AOAC) International Fat Test Method
2008.06.
2. USDA states that validation testing has already been performed for the brownie with
comparable results. As other products are included, validation testing could be performed to
establish reliability as compared to AOAC Fat Test Method 922.06. Using the AOAC OMA
Fat Test Method 2008.06 will result in an estimated cost savings of $77.00 per exam with a
yearly projected savings of $11,627 based upon last year's figures.
3. USDA is requesting that AOAC OMA Fat Test Method 2008.06 be added to PCR-C-007F
Cakes, Brownies, Muffin Tops and Filled Cakes, Packaged in a Flexible Pouch, Shelf Stable
and PCR-C-075 Cornbread, Packaged in a Flexible Pouch, Shelf Stable; for use in Meal,
Ready-to-Eat (MRE); PCR-C-024D Cakes and Brownies, Packaged in a Polymeric Tray,
Shelf Stable and PCR-C-071 Cornbread, Packaged in a Polymeric Tray, Shelf Stable; for use
in Unitized Group Ration Heat and Serve (UGR – H&S).
4. Natick Research Chemists reviewed this request and concur with USDA’s proposal to add
AOAC OMA Fat Test Method 2008.06 as an additional fat test method to the four subject
documents.
5. Natick submits the following changes to subject documents for all current, pending, and
future procurements until these documents are formally amended or revised:
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a. In PCR-C-007F, Cakes, Brownies, Muffin Tops and Filled Cakes, Packaged in a
Flexible Pouch, Shelf Stable, on Page 18, Paragraph B. (3), under column for Fat
Test Method Number, insert “2008.06”.
b. In PCR-C-075, Cornbread, Packaged in a Flexible Pouch, Shelf Stable, on Page 9,
Paragraph B. (3), under column for Fat Test Method Number, insert “2008.06”.
c. In PCR-C-024D, Cakes and Brownies, Packaged in a Polymeric Tray, Shelf
Stable, on Page 28, Paragraph B. (3), under column for Fat Test Method Number,
insert “2008.06”.
d. In PCR-C-071, Cornbread, Packaged in a Polymeric Tray, Shelf Stable, on Page
8, Paragraph B. (3), under column for Fat Test Method Number, insert “2008.06”.
6. Attached is Change 01, PCR-C-007F, Cakes, Brownies, Muffin Tops and Filled Cakes,
Packaged in a Flexible Pouch, Shelf Stable document dated 4 February 2016, with change
highlighted.
7. Attached is Change 02, PCR-C-075, Cornbread, Packaged in a Flexible Pouch, Shelf
Stable document dated 4 February 2016, with change highlighted.
8. Attached is Change 01, PCR-C-024D, Cakes and Brownies, Packaged in a Polymeric
Tray, Shelf Stable document dated 4 February 2016, with change highlighted.
9. Attached is Change 01, PCR-C-071, Cornbread, Packaged in a Polymeric Tray, Shelf
Stable document dated 4 February 2016, with change highlighted.

29