Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI (continuation).

9.

10.

il.

12.

After the sample unit has been evaluated for style, or
if the sample unit is skipped for style evaluation,
cook a representative portion of the chopped broccoli
as outlined in File Code 130-A-38. You may wish to
select only "suspect" units for the cooking test. Also,
it isn't necessary to cook each sample unit unless a
problem develops, such as fibrous units or grit.

Evaluate the cooked broccoli for flavor and odor. Assign
the letter grade (A, B or SSTD) for flavor and odor in
the section for "prerequisites." It isn't necessary to
cook each sample unit unless a problem develops. Consider
any objectionable "off-flavor" ("hay-like," "straw-like,"
"smoke," "chemical," or "sour"), but edible sample unit,
as Substandard. Permit a slight "hay-like" or "straw-like
odor in grade B.

Evaluate the cooked broccoli for grit or silt. Assign
the letter grade (A, B or SSTD) for freedom from grit in
the section for "prerequisites." It isn't necessary to
cook each sample unit for the grit evaluation unless a
problem develops.

Evaluate the cooked broccoli for fiber. Be alert for
fiber located in the pieces (chops) that are made from
the base end of the stalk. Fiber is a "fooler." It's
usually more tender after cooking than would be expected.
It isn't necessary to cook each sample unit unless a
problem develops. However, cook enough of the "suspect"
units to set your sights.

If any detectable fiber is to be counted against the
sample unit, cook the entire sample unit. Follow this
procedure:

a. Separate all of the units with major fiber (nonwoody-
noticeable fiber but can be eaten without difficulty)
and place them on a suitable scale. Record the
composite weight. Count each 2.5 g increment of this
weight as 1 major defect;

See also the next page.

59


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
BROCCOLI PIECES (continuation).
10. Fiber (continuation).

Example 71:

Blemished (Seriously)
Fiber (Woody)
HEM (Class 1)

TOTAL SEVERE
Grade A
Grade B

Blemished (Materially)
Fiber (Nonwoody)
TOTAL MAJOR
Grade A 1.511.5 | 3
Grade B 113 3

AA rdw

CUSUM

DPoup ez

CUSUM -——-f——---—-—~ 4

Woody fiber = 62 g —---—~--—- —---—- --
5

Nonwoody fiber = 128 g--—— — -%

5

11. Compare the total number of defects that you've found
in the sample with the acceptance number for the
applicable AQL and sample size in the "Regulations"
(File Code 109-A-1, Tables XV-XIX).

12. Assign a grade to the sample based on the procedure
outlined in File Code 120-A-7 (Lot Single Sampling Plan).

123


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).

8. Weigh the detached fragments, if any, in the sample unit.
Don't include loose leaves or pieces of leaves in the
weight, these are minor defects. Ignore any chaff.

Don't be overly critical but count each 28g increment of
detached fragments as 1 major defect. Record on the defect
tally the number of detached fragment defects as

follows:

0 - 28 g=1 defect

29 - 56 g = 2 defects

57 - 84 g = 3 defects, etc.
Example 20:

Color (Reas. Good) In grade A
Detached Fragments
Blemished (Materially)
Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)
TOTAL MAJOR
Grade A
Grade B [1 6 4

ROU

cUSUM

se 4 ele

Detached fragments = 60 g --~-- - —-~~— —-
28

34




Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

BROCCOLI PIECES (continuation).

5.

Separate all of the blemished units into 3 categories:
a. Slightly; or
b. Materially; or

ce. Seriously.

Place each category, separately, on to a suitable scale.
Record the weight. Each 5 g increment of this weight
is 1 defect.

Blemished broccoli is the most common defect. Usually
blemishes are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration) ;

b. Yellow leaves;

c. Orange buds (3 or more orange buds in a single area
is the cut-off point between blemished and
nonblemished) ;

d. Olive-green leaf stem (petiole);

e. Record on the defect tally the number of blemished
defects (each 5 g increment is 1 defect) as follows:

i. Minor; or \

ii. Major; or “4—Use photoguides for spears, if available.

f

iii. Severe. y)

See also the next page.

119


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS

1.

Follow the procedure outlined in File Code 120-A-7 (Lot
Single Sampling Plan [Attributes]).

Use the same defect tally sheet for lot inspection as
you would use for on-line inspection. Ignore the section
of the tally devoted to CUSUM values.

Open each individual container that you have drawn for
the sample. Keep the product in its container. Ona
container-by-container basis, without sorting through
the product, tentatively evaluate the following
prerequisites:

a. Evaluate "brightness" and record the letter grade
(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard.

b. At the same time that brightness is evaluated, record
in the "prerequisites" section of the defect tally
the letter grade (A or SSTD) for similar varietal
characteristics.

c. Evaluate the broccoli for odor. Assign the letter
grade (A, B or SSTD) for odor in the section for
"prerequisites." Consider any objectionable
"off-odor" ("hay-like," "straw-like," "smoke,"
"chemical" or "sour") as Substandard. But the sample
must be edible in step 19. Permit a slight "hay-like"
or "straw-like" odor in Grade B.

d. Assign the letter grade (A, B or SSTD) for freedom
from grit in the section for "prerequisites."

e. If any container is "suspect" because of "brightness,"
"odor," or "grit," identify the container and its
product for further examination.

See also the next page.

68


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

14.

i5.

16.

Count the total number of pieces of harmless extraneru3
material (HEM) in the sample (not each container).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Record on the defect
tally the total number of pieces of HEM as follows:

a. Severe; or
b. Critical.

Establish by observation the predominant length of the
broccoli spears in the sample. Don't be overly

critical. If it is apparent the spears vary less

than 5 cm from the predominant length, accept them

as meeting length requirements. If some spears obviously
vary more than 5 cm from the predominant length, do the
following:

a. Determine size variation so that the least number
of defects are tallied against length; and

b. Record on the defect tally the number of length
defects in the total sample (not each container).

See also example 2, page 6; example 3, page 7; and
example 4, page 8.

Establish by observation the predominant diameter of the
broccoli spears in the sample. Don't be overly critical.
If it is apparent the spears vary less than 2 cm from
the predominant diameter, accept them as meeting
requirements. If some spears obviously vary more than

2 cm from the predominant diameter, do the following:

a. Determine diameter variation so that the least
number of defects are tallied against diameter; and

b. Record on the defect taily the number of diameter
defects in the sample (not each container).

See also example 5, page 10.

79


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

10. Weigh the loose leaves and pieces of leaves, if any, in
the sample unit. Count each 14 g increment of loose
leaf material as 1 minor defect. Record on the defect
tally the number of loose leaf defects as follows:

0-14 g =1 defect

15 - 28 g = 2 defects

29-428

3 defects, etc.

Example 9:

Size (Diameter)

Loose Leaves

Broken

Damaged

Blemished (Slightly)

| Trim (Reas. Well) In grade A
‘Trim (Poor) In grade B

RPOBAHR

TOTAL MINOR

/

Loose leaves = 50 g--------- 7 - _-
14

15




Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

9.

10.

il.

Count the number of broken spears. These should be the
same spears that were reassembled in step 5, if any.
Record on the defect tally the total number of broken
spears in the sample (not each container).

Count the number of spears with mechanical damage to the
head of the spear. Don't be overly critical. Don't
count broken spears (step 9) or trimmed spears (step 12)
as damaged, or vice versa. Record on the defect tally
the total number of damaged spears in the sample (not
each container).

Count the number of spears in the sample that are

blemished (not each container). Blemished broccoli

is the most common defect. Usually, blemishes are:

a. Discolored hollow or pithy stalks (Don't count
hollow or pithy stalks unless they're associated
with discoloration) ;

b. Yellow leaves;

c. Orange buds (6 or more orange buds in a single area
of the head is the cut-off point between blemished
and nonblemished);

d. Olive-green leaf stem (petiole); and

e. Record on the defect tally the total number of
blemished spears as follows:

i. Minor;
ii. Major; or ) @—Use photoguides, if available.

iii. Severe.

74


Frozen Broccoli
July 1980.

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).

4. While the short spears are arranged in a continuous row,
check for uniformity of size. Uniformity of size is
separate from the style defectives done in step 3,
previously. Don't be overly critical. If it is apparent
that short spears are reasonably similar in weight, accept
them as meeting requirements. If some short spears vary
greatly in weight from others, do the following:

a. Locate the point in the continuous row where the
short spears vary in weight more than 4 times (4X)
from the other units;

b. Determine size variation so that only the least
number of defects are tallied against size. This
may be only the small unit, only the large units,
or both the large units and the small units; and

ce. ‘Record the number of size defects on the defect
tally as minor defects.

See also the next page.

27


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CUT BROCCOLI (continuation).

8. Style (continuation).

Example 59:

s !
: Minor (Shorter than ¥.5 cm) i +,
p |cusuM | GSID 4 dt
E |Head Material L {
—_ Tt
Leaf Material i {

t
1 (
J i
Longer than 5 cm = 158 g-—~—~ —~ -~— ~~ _—¥7 H
5 t
‘
7]
Shorter than 1.5 cm = 302 g --——-- “

5

9. After the sample has been evaluated for style, cook
a representative portion of the cut broccoli as
outlined in File Code 130-A-38. You may wish to
select only "suspect" units (step 3) for the cooking
test. Also, it isn't necessary to cook the entire
sample.

10. Evaluate the cooked broccoli to verify the
tentative grade given for odor in step 3.

11. Evaluate the cooked broccoli by chewing representative

portions. This should verify the tentative grade
given for grit and silt in step 3.

103


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).
13. Trimming (continuation).

Example 23: (Designated grade B production).

Color (Reas. Good) In grade A
Detached Fragments
Blemished (Materially)
Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)
TOTAL MAJOR
Grade A
Grade B

RPOUPR

CUSUM

Size (More than 4X)
Loose Leaves

Broken

Damaged

Blemished (Slightly)

| Trim (Reas. Well) In grade A

Trim (Poor) In grade B

Development (Reas. Well) In A
TOTAL MINOR

TOTAL ALL CLASSES
Grade A

| Grade B

SAMPLE UNIT GRADE

RPOBHR

CUSUM

OP HOH

Don't tally defects that are counted only against grade A~

39


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
BROCCOLI PIECES (continuation).

7. Separate all of the pieces of harmless extraneous material
(HEM) into 2 categories as follows:

a. Severe (Class 1); or
b. Critical (Class 2).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Place each piece of
HEM, by class, end-to-end (use the longest dimension) in
a continuous row. Measure each class separately. Record
on the defect tally the number of HEM defects (each 2.5 cm
increment is 1 defect).

Example 39:

HEM (Class 2)

TOTAL CRITICAL
Grade A
Grade B

CUSUM
Blemished (Seriously)
Fiber (Woody)
HEM (Class 1)

TOTAL SEVERE
|Grade A
Grade B

BP <b [PRAHA

CUSUM

Class 1=3cem-_~_ ~~ =
2.5

64


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

19.

20.

21.

Evaluate the cooked broccoli for grit or silt. Assign
the letter grade (A, B or SSTD) for freedom from grit
in the section for "prerequisites."

Evaluate the cooked broccoli for fiber. Be alert for

fiber located at the base end of the spear. Any
detectable fiber should be classified as follows:

a. Major (nonwoody - noticeable fiber but can be
eaten without difficulty); or

b. Severe (woody).

Total the classes of defects on the defect tally and
compute the CUSUM values outlined in File Code 120-A-6.

24


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

BROCCOLI PIECES (continuation).

12.

13.

Total the classes of defects on the defect tally and
compute the CUSUM values as outlined in File Code
120-A-6.

The style of "pieces" is a catch all from "cut" and
"chopped" broccoli. It doesn't have a requirement for
head material; thus, the entire sample unit could be
stalk and leaf material. Any sample unit that fails
requirements for "cut" or "chopped" is to be classified
as "pieces." However, this is not true for "spears"
or "short spears."

67


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CUT BROCCOLI (continuation).

12. Evaluate the cooked broccoli for fiber. Be alert for
fiber located in the pieces (cuts) that are made from
the base end of the stalk. Fiber is a "fooler." It's
usually more tender after cooking than would be expected.
Cook enough of the "suspect" cuts to set your sights.

If any detectable fiber is to be counted against the
sample, cook all of the "suspect" units. Follow this
procedure:

a. Separate all of the cuts with major fiber (nonwoody-
noticeable fiber but can be eaten without difficulty)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 major defect;

b. Separate all of the cuts with severe fiber (woody)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 severe defect;

c. Record the number of major and severe fiber defects
on the defect tally.

Example 60:

s \Blemished (Seriously)
E |Fiber (Woody)

V |HEM (Class 1)
E
R
E

TOTAL SEVERE
Grade A
Grade B

[Blemished (Materially)

‘Fiber (Nonwoody) a

\

TOTAL MAJOR \
Grade A 1.5 [1.5 | 3 ' \
Grade B 113 3 t !
1

|

‘

‘CUSUM

~.

(cus |

Four sz

Woody fiber = 62g ~-—~~~—-~ ~~ ~~ __- a
5
Nonwoody fiber = 128 g—- ~ — _ _ _-”
5

104


Frozen Broccoli
July 1980

Example No. 72: (Failed grade A, adjusted for grade B)

|
!
|

Similar Varietal Characteristics
Brightness

Flavor/Odor

i Grit/silt

TOTAL CRITICAL z
Grade A 0.2 | 0.2|0.8
Grade B 0.5 | 0.5/1.5

“Om wh

13x50 = 6S0

CUSUM

HHO

Color (Poor)
Blemished (Seriously)
Fiber (Woody) !
HEM (Class 1) _. po
TOTAL SEVERE jo

Grade A
i CUSUM
| US Grade B

| Color (Reas. Good) In grade A oe
Size (Length) Lk
Detached Fragments

Blemished (Materially)
Trim (Poor) In grade A : z 5
Development (Poor) ' [e)
Fiber (Nonwoody) | __
| TOTAL MAJOR — 13h. #1
Grade A 1 4
Grade B 1 6
Size (Diameter) a
Loose Leaves 1

HAAS H

Hl
uk

AOoupP es

CUSUM

7

Broken

Damaged —_—t ——5
‘Blemished (Slightly) _ 2
L
: =

BOSH

Trim (Reas. Well) In grade A |
‘Trim (Poor) In grade B
Development (Reas. Well) In A | 35
~~ TOTAL MINOR

TOTAL ALL CLASSES
|Grade A
Grade B

SAMPLE UNIT GRADE
FINAL GRADE B

¥

“---Failed grade A

CUSUM

Hb HOH

125


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
CUT BROCCOLI

1. Select at random a 250 g sample unit from the processing
line (either before freezing or after freezing). You may
also use the following optional sample unit sizes:

a. 500 g (100 - 5 g increments - use the 100 plan §2852.38b); or
b. 1000 g (200 - 5 g increments - use the 200 plan §2852.38b).

You should remember that larger sample unit sizes require
more time to grade. Regardless of the sample unit size
that you chose, keep it constant for each basic grading
period. You may vary the sample unit size between style
compliance and quality compliance.

Example 26:

Sample Unit Size Use for Style Use for Quality
500 g 250 g 500 g
1000 g 250 g 1000 g
1000 g 500 g 1000 g

2. Arrange the sample unit of cut broccoli on a grading tray
to make each unit visible to you.

3. Evaluate "brightness" and record the letter grade (A, B or SSTD)
in the "prerequisites" section of the defect tally. The
overall brightness may be slightly dull in grade B. Count
"off-color" (yellowish or brownish discoloration) as
-Substandard.

4. At the same time that brightness is evaluated, record the
letter grade (A or SSTD) in the "prerequisites" section of
the defect tally for similar varietal characteristics.

5. Evaluate the cut broccoli for development (head and bud
cluster stages of maturity). Even though the USDA photo-
guides which show various stages of development, cover
only spears, you may use these photoguides as an
indication of the cut-off point between "reasonably well
developed" and "poorly developed."

See also the next page.

45


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SHORT SPEARS OR FLORETS (continuation).

8. Weigh the loose leaves and pieces of leaves, if any,
in the total sample (not each container). Count each
14 g increment of the composite weight (all of the
loose leaf material in the sample) as 1 minor defect.
Record on the defect tally the total number of loose
leaf defects as follows:

O-14¢g

1 defect
15 - 28 g = 2 defects
29 - 42 g = 3 defects, etc.

Example 52:

ize (More Than 4X)
oose Leaves

sroken

ama ged

lemished (Slightly)

‘rim (Reas. Well) In grade A
‘rim (Poor) In grade B
evelopment (Reas. Well) In A

DBOBH Ss

TOTAL MINOR 7
a
7
Loose leaves = 250 g—- — — — — — — -- +=
14

87


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).
4. Uniformity of length (continuation).

Example 4:

pe,
Acceptable 5 cm variation ~~

Sy

1
(largest) !
1
ant
maT Oe eee ee \
f |
/ < Z
— ae =
i
|
\
i (smallest)
|
|
_
4
n t
Sette Count 2 defects -~---—--- -—


Frozen Broccoli
July 1980

Page

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

Spears-—---—— ——— on == een 3
Short Spears or Florets-----—---- -- -= —n n-ne 25,
Cut Broccoli- —— —=-- -- — — 45
Chopped Broccoli-- —----53
Broccoli Piecesq-—------ =n nnn ne San Sanne Sa 61
SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
Spears: _ ee — 68
Short Spears or Florets- — —— 82
Cut Broccoli- — —-- --- eee -=--95,
Chopped Broccoli-—------------ -------------- —--------------106
Broccoli Pieces----------—---------- ---------------—--------116

SPECIAL LOT INSPECTION SITUATIONS

1. Inspection of Large Cartons (e.g., 2-1/2 1b)-------------124

2. Inspection of Small Cartons (e.g., 8 02)--—------------=- 124
3. How to Adjust a Defect Tally: — -----+ 124
HOW TO REEVALUATE A DEFECT TALLY: 126


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS oR FLORETS (continuation).

14. Development (continuation).

Example 25: (Designated grade B production).

[Color (Reas. Good) In grade A

Detached Fragments

Blemished (Materially)

| Trim (Poor) In grade A

Development (Poor)

Fiber _(Nonwoody) _
TOTAL MAJOR

Grade A

Grade B |
-Size (More than 4x)_

Loose Leaves

Broken

| Damaged

Blemished (Slightly)

| Trim _(R (Reas, Well) In grade A

| ‘im (Poor) I: n eead

DOUP

| CUSUM |

S
8

POBZHE

| CUSUM | -
{ s | Grade B

SAMPLE UNIT GRADE

T
0
T
A
L

Don't tally defects that are counted only against grade A —~

42


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

8. Weigh the loose leaves and pieces of leaves, if any,
in the total sample (not each container). Count each
14 g increment of the composite weight (all of the
loose leaf material in the sample) as 1 minor defect.
Record on the defect tally the total number of loose
leaf defects as follows:

0-14 g = 1 defect
15 - 28 g = 2 defects
29 - 42 g = 3 defects, etc.

Example 45:

JOX/3 = 650

Size (Diameter)

Loose Leaves

Broken

Damaged

Blemished (Slightly) _
[rim (Reas. Well) In grade
[rim (Poor) In grade B
Development (Reas. Well) In A
TOTAL MINOR

BOBHR

Loose leaves = 250 g- — ~-_ _—_ _~ _ _-_ __ -
14

73


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS

1.

2.

Follow the procedure outlined in File Code 120-A-7 (Lot
Single Sampling Plan [Attributes]).

Use the same defect tally sheet for lot inspection as
you would use for on-line inspection. Ignore the
section of the tally devoted to CUSUM values.

Open each individual container that you have drawn for
the sample. Keep the product in its container. Ona
container-by-container basis, without sorting through
the product, tentatively evaluate the following
prerequisites:

a. Evaluate "brightness" and record the letter grade
(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard.

b. At the same time that brightness is evaluated, record
in the "prerequisites" section of the defect tally
the letter grade (A or SSTD) for similar varietal
characteristics.

c. Evaluate the broccoli for odor. Assign the letter
grade (A, B or SSTD) for odor in the section for
"prerequisites." Consider any objectionable
“off-odor" ("hay-like," "straw-like," "smoke,"
"chemical" or "sour") as Substandard. But the sample
must be edible in step 18. Permit a slight "hay-like"
or "straw-like" odor in grade B.

d. Assign the letter grade (A, B or SSTD) for freedom
from grit in the section for "prerequisites."

e. If any container is "suspect" because of "brightness,"
"odor," or "grit," identify the container and its
product for further examination.

See also the next page.

82


GRADING MANUAL

FROZEN
BROCCOLI

"UNITED STATES DEPARTMENT OF AGRICULTURE

FOOD SAFETY AND QUALITY SERVICE
PRUIT AND VEGETABLE QUALITY DIVISION
PROCESSED PRODUCTS BRANCH


Frozen Broccoli
July-1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CHOPPED BROCCOLI (continuation).
3. Prerequisites, container-by-container (continuation).

The grade for a lot of chopped broccoli may not be higher
than the grade of any "prerequisite" grade for any
individual sample unit in the sample. If the sample
should fail the anticipated grade because of a
prerequisite factor, don't skip the other factors.
Continue grading the sample but don't spend a lot of
time with style or problem areas, such as blemishes

or fiber.

4. While the chopped broccoli is identified by individual
containers, determine compliance with head material
and leaf material. It isn't necessary to check each
individual carton but enough cartons should be checked
to satisfy yourself the requirement is met or failed.
In the cartons that are selected for the check, do
the following:

a. Separate the head material and weigh ("Bald" units
completely stripped of flower buds should not be
counted as head material);

b. Separate the leaf material and weigh;

ce. Allow the following:

Average: Head material not less than 25%.
Leaf material not more than 25%.
Individual sample cartons:

Head material not less than 15%.

Leaf material not more than 35%.

108




Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CHOPPED BROCCOLI (continuation).

5. Assemble (physically or mentally) into one sample all
_of the chopped broccoli from all of the cartons that
were drawn. Adjust the entire sample (either by randomly
removing units or adding units) to meet the closest
weight possible in the lot single sampling plan. If
any of the cartons are "suspect" in step 3, you may wish
to assemble the broccoli mentally into one sample. This
procedure would enable you to retain the identity of the
"suspect" cartons.

Example 62:
_—e |
6 13 21 29
Total Weight of Broccoli 1/
(grams)
|
6 90 195 315 435 |
2 |
3 |
g
13 195 423 683 943 i
I | |
x |
Cc
R 25 375 813 1313 1813
E
M
E
N 50 750 1625 2625 3625 i
T
s
100 i 1500 3250 5250 7250
1/ Sample size x 2.5 g increments = weight of chopped broccoli

equivalent to the number of sample units times the standard
sample unit size.

109


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

4. Uniformity of size (continuation).

Example 16:

Acceptable 4X variation -—,
y

seg Tertaston ;

t
t
(largest) t
i
v
ce ee oN ee ee HN
YO tn,
eerie
\
(smallest)
i ‘
4
\
Count only 1 defect

29


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SHORT SPEARS OR FLORETS (continuation).
12. Trim (continuation).

Example 53: (Failed grade A, check against grade B)

SOX 18 = 650 Maoh dota

Color (Reas. Good) In grade A
Detached Fragments

Blemished (Materially)

Trim (Poor) In grade A
Development (Poor)

Fiber (Nonwoody)

TOTAL MAJOR

Grade A
Grade B

Size (More Than 4X)
[Loose Leaves

Broken

\Damaged

Blemished (Slightly)

jIrim (Reas. Well) In grade A
‘Trim (Poor) In grade B

[Development (Reas. Well) In A
TOTAL MINOR
TOTAL ALL CLASSES

rade A
(CUSUM |

rade B

SAMPLE UNIT GRADE
FINAL GRADE

RBOU>

CUSUM

BPOoaner

MP HOH

Drop the defects that are counted only against grade A, before
checking for compliance with grade B= — —- - — — ---+--

90


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

4. Assembling the sample (continuation).

Example 49:
NUMBER OF CARTONS
6 13 21 29
(Number of Short Spears)
s
Pp 6 36 78 126 174
E
A
R 13 78 169 273 377
Ss
Pp 25 150 325 525 725
E
R
50 300 650 1050 1450
c
A
R 100 600 1300 2100 2900
T
ie}
N

5. Reassemble any broken short spear. Count each reassembled
short spear as a single unit.

6. Evaluate the color of the individual short spears. The
color classification of each short spear is one of the
following: .

a. Good color (grade A color) - not a defect in any grade;

b. Reasonably good color (grade B color) - a defect in
grade A only; or

c. Poor color (Substandard color) - a defect in grade A
and grade B.

See also the next page.

84


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).
8. Color of individual spears (continuation).

Example 6: (Designated grade A production).

Color (Poor)

Blemished (Seriously)

Fiber (Woody)

HEM (Class 1)

TOTAL SEVERE

AA oadhH

Grade A 0.5} 0.5/1.5
CUSUM

fo} [e)

i Grade B 1.5] 1.5] 3

Color (Reas. Good) In grade A

Size (Length)

Detached Fragments

Blemished (Materially)

Trim (Poor) In grade A
Development (Poor)

BRPOUP =

Fiber (Nonwoody)

TOTAL MAJOR

Grade A i 4

uo

CUSUM

Grade B i 6 14

TOTAL ALL CLASSES

CUSUM

HOH

Grade B 2 414

[ J i
Grade A 2 [12 | 5 1
7

SAMPLE UNIT GRADE

Drop the defects that are counted aly against grade

checking for compliance with grade B--------------

12

A,

before

~- ee Hee


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED

BROCCOLI (continuation).

5.

6.

Development (continuation).

The development classifications of chopped broccoli are
as follows:

a. Grade A - the broccoli may be only "reasonably
well developed" (grade B); or

b. Grade B - the broccoli may be only "poorly
developed" (SSTD) if the appearance is not
materially affected. Poorly developed means
the individual buds are in the flowering stage.

Record the letter grade (A, B or SSTD) for development
in the "prerequisites" section of the defect tally.

Separate all of the blemished units into 3 categories:

a. Slightly; or
b. Materially; or

c. Seriously.

Place each category on a suitable scale. Record the
weight. Each 2.5 g increment of this weight is 1 defect.

Blemished broccoli is the most common defect. Usually
blemishes are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration);

b. Yellow leaves;

c. Orange buds (3 or more orange buds in a single area
is the cut-off point between blemished and nonblemished) ;

d. Olive-green leaf stem (petiole);

See also the next page.

54


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

3. Prerequisites, container by container (continuation).

e.

Evaluate the cut broccoli for development (head and bud

cluster stages of maturity). Even though the USDA
photoguides which show various stages of development,
cover only spears, you may use these photoguides as
an indication of the cut-off point between "reasonably
well developed" and "poorly developed."

The development classifications of cut broccoli are
as follows:

a. Grade A - the broccoli may be only "reasonably
well developed" (grade B); or

b. Grade B - the broccoli may be only "poorly
developed" (SSTD) if the appearance is not
materially affected. Poorly developed means
the individual buds are in the flowering stage.

Assign the letter grade (A, B or SSTD) for development
in the "prerequisites" section of the defect tally.

If any container is "suspect" because of "brightness,"
"odor," "grit" or "development," identify the container
and its product for further examination.

Example 55: (Prerequisites on a container-by-container basis)

Similar Varietal Char.

Brightness

Flavor and Odor
Grit and Silt

Development

Carton No. 1 Carton No. 2 Carton No. 3, etc.

A A A
A A A
A A A
A A A
A A A

See also the next page.

96


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

12.

Count the number of spears in the sample that are
adversely affected by trimming (not each container).
Use the USDA photoguides, if available. The trim
classification of each broccoli spear is one of the
following:

a.

be

Well trimmed (grade A trim) - not a defect in
any grade;

Reasonably well trimmed (grade B trim) - a defect
only in grade A; or

Poorly trimmed (Substandard trim) - a major defect
in grade A and a minor defect in grade B. Record
on the defect tally the total number of spears in
the sample that are either "reasonably well trimmed"
or "poorly trimmed" (not each container).

If the sample fails requirements for grade A, adjust
the defect tally by: (1) dropping all “reasonably
well trimmed" spears from the defects counted against
grade B; and (2) striking out the major defects
against grade A and moving them to minor defects

to be counted against grade B.

See also the next page.

75


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

16.

17.

18.

Count the number of pieces of harmless extraneous
material (HEM). The expected frequency of occurrence
for HEM should be low. Count pieces of other similar
plants, such as cauliflower or brussels sprouts, as
class 1 HEM. Record on the defect tally the number
of pieces of HEM as follows:

a. Severe; or
b. Critical.

If 25 broccoli spears are being used for inspection,
rather than 50 spears, 0.4 AQL is the smallest AQL in the
25 plan. This doesn't cover grade A critical defects
(class 2 HEM) which has an AQL of 0.25; thus, you're
left without S, T and L values for critical defects in
grade A if you're using the 25 plan. This shouldn't
cause a problem given the small chance of class 2 HEM
occurring in the sample unit. However, if you do

find class 2 HEM in a sample unit of 25 spears, it fails
grade A (S=0; T=0; L=0).

Cook a representative portion of the spears as outlined
in File Code 130-A-38. You may wish to select only
"suspect" spears for the cooking test. Also, it isn't
necessary to cook each sample unit unless = problem
develops, such as fibrous spears.

Evaluate the cooked broccoli for flavor and odor.

Assign the letter grade (A, B or SSTD) for flavor and

odor in the section for "prerequisites." Consider any
objectionable "off~flavor" ("hay-like," "straw-like,"
"smoke," "chemical," or "sour"), but edible sample unit,

as Substandard. Permit a slight "hay-like" or "straw-like"
odor in grade B.

23


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CUT BROCCOLI (continuation).

7.

Separate all of the pieces of harmless extraneous material
(HEM) into 2 categories as follows:

a. Severe (Class 1); or
b. Critical (Class 2).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Place each piece of
HEM, by class, end-to-end (use the longest dimension) in
a continuous row. Measure each class separately. Record
on the defect tally the number of HEM defects (each 2.5 cm
increment is 1 defect).

Example 28:

HEM (Class 2)

TOTAL CRITICAL

cUSUM |

Grade A
Grade B

Bee dem | PeeH|

Blemished (Seriously)

Fiber (Woody)

HEM (Class 1)

TOTAL SEVERE

CUSUM

Grade A
Grade B

3 cm

Class 1 ==," -—--~--—~- ~~ _ _

2.5

48


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

BROCCOLI PIECES (continuation).

3. Prerequisites, container-by-container (continuation).

e.

Evaluate the broccoli for development (head and

bud cluster stages of maturity). Even though the
USDA phetoguides which show various stages of
development, cover only spears, you may use these
Photoguides as an indication of the cut-off point
between "reasonably well developed" and "poorly
developed."

The development classifications of broccoli pieces
are as follows:

a. Grade A - the broccoli may be only "reasonably
well developed" (grade B); or

b. Grade B - the broccoli may be only "poorly
developed" (SSTD) if the appearance is not
materially affected. Poorly developed means
the individual buds are in the flowering stage.

Assign the letter grade (A, B or SSTD) for development
in the prerequisites section of the defect tally.

If any container is "suspect" because of "brightness,"
"odor," "grit" or "development," identify the container
and its product for further examination.

Example 67: (Prerequisites on a container-by-container basis)

Carton No. 1 Carton No. 2 Carton No. 3, etc.

Similar Varietal Char. A A A
Brightness A A A
Flavor and Odor A A A
Grit and Silt A A A
Development A A A

See also the next page.

117


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI

1.

Select at random a 250 g sample unit from the processing
line (either before freezing or after freezing). You may
also use the following optional sample unit size:

500 g (200-2.5 g increments - use the 200 plan in §2852.38b).

You should remember that larger sample units require more
time to grade. Regardless of the sample unit size that
you chose, keep it constant for each basic grading period.
You may vary the sample unit size between style compliance
and quality compliance.

Example 32:

Sample Unit Size Head/Leaf Material Other Style Quality
250 g 50 g 250 g 250 g
250 g 100 g 250 g 250 ¢
500 g 50 g 250 g 500 g
500 g 100 g 250 g 500 g
500 g 250 g 500 g 500 g

Arrange the sample unit of chopped broccoli on a grading
tray to make each unit visible to you.

Evaluate "brightness" and record the letter grade (A, B or
SSTD) in the "prerequisites" section of the defect tally.
The overall brightness may be slightly dull in grade B.
Count "off-color" (yellowish or brownish discoloration) as
Substandard.

At the same time that brightness is evaluated, record the
letter grade (A or SSTD) in the "prerequisites" section of
the defect tally for similar varietal characteristics.

Evaluate the chopped broccoli for development (head and bud
cluster stages of maturity). Even though the USDA photo-
guides which show various stages of development, cover
only spears, you may use these photoguides as an indication
of the cut-off point between "reasonably well developed"
and "poorly developed."

See also the next page.

53




Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SPEARS (continuation).
13. Development (continuation).

Example 47: (Failed grade A, check against grade B).

Color (Reas. Good) In grade A
‘Size (Length)
‘Detached Fragments
Blemished (Materially)
‘Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)
| TOTAL MAJOR
‘Grade A
Grade B

RPOUPER

CUSUM

Size (Diameter) _

Loose Leaves

Broken

Damaged

Blemished (Slightly) _
irim (Reas. Well) In grade A
Trim (Poor) In grade B

Development (Reas. Well) In r:
TOTAL MINOR

RPOSHR

TOTAL ALL CLASSES
Grade A
eee HOME Bo ww. . !
SAMPLE UNIT GRADE |
FINAL GRADE B

CUSUM

OPHOH

me ee LLL

Drop the defects that are counted only against grade A, before /
checking for compliance with grade B-- -—--~-- -~ =a

78


Frozen Broccoli
July 980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SHORT SPEARS OR FLORETS (continuation).

9. Count the number of broken short spears. These should
be the same short spears that were reassembled in step 5,
if any. Record on the defect tally the total number
of br_«e short spears in the sample (not each container).

10. Count the number of short spears with mechanical damage
to the head of the unit. Don't be overly critical.
Don't count broken short spears (step 9) or trimmed
short spears (step 12) as damaged, or vice versa. Record
on the defect tally the total number of damaged short
spears 1 the sample (not each container).

11. Count the number of short spears in the sample that are
blemished (not each container). Blemished broccoli

is the most common defect. Usually, blemishes are:

a. Discolored hollow or pithy stalks (Don't count
hollow or pithy stalks unless they're associated
with discoloration);

b. Yellow leaves;

ce. Orange buds (6 or more orange buds in a single area
of the head is the cut-off point between blemished
and nonblemished) ;

d. Olive-green leaf stem (petiole); and

e. Record on the defect tally the total number of
blemished short spears as follows:

i. Minor;
ii. Major; { “@--—Use photoguides for spears, if available.

iii. Severe.

88


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).

15. Count the number of pieces of harmless extraneous
material (HEM). The expected frequency of occurrence
for HEM should be low. Count pieces of other similar
plants, such as cauliflower or brussels sprouts, as
class 1 HEM. Record on the defect tally the number
of pieces of HEM as follows:

a. Severe; or
b. Critical.

If 25 short spears are being used for inspection,

rather than 50 short spears, 0.4 AQL is the smallest

AQL in the 25 plan. This doesn't cover grade A critical
defects (class 2 HEM) which has an AQL of 0.25; thus,
you're left without S, T and L values for critical defects
in grade A if you're using the 25 plan. This shouldn't
cause a problem given the small chance of class 2 HEM
occurring in the sample unit. However, if you do find
class 2 HEM in a sample unit of 25 spears, it fails grade A
(s=0; T=0; L=0).

16. Cook a representative portion of the short spears as
outlined in File Code 130-A-38. You may wish to select
only "suspect" short spears for the cooking test. Also,
it isn't necessary to cook each sample unit unless a
problem develops, such as fibrous short spears.

17. Evaluate the cooked broccoli for flavor and odor.
Assign the letter grade (A, B or SSTD) for flavor and
odor in the section for "prerequisites." Consider any
objectionable "off-flavor" ("hay-like," "straw-like,"
"smoke," "chemical," or "sour"), but edible sample unit,
as Substandard. Permit a slight "hay-like" or "straw-like"
odor in grade B.

43


Frozen Broccoli
July 1980

Example 74: (Originally designated grade B, reevaluated against a

tighter grade B) Thy

8 cs xX x Herds, Tip B kab

Similar Varietal Characteristics AA
| Brightness
Flavor/Odor
Grit/Silt
TOTAL CRITICAL
cusuM Grade A
_ Grade B
Color (Poor)
Blemished (Seriously)
Fiber (Woody)

HEM (Class 1)
TOTAL SEVERE

| FARO] sO mt wy

AAA daH

Color (Reas. Good) In grade A
Size (Length) [1
Detached Fragments 1
Blemished (Materially) 13 205
Trim (Poor) In grade A i
Development (Poor) 1 1 2
Fiber (Nonwoody) 1 1
TOTAL MAJOR | 4 4 5

crade A Lia
cusum [§&
Grade B AOL = £5" 1!

Size (Diameter) _

Loose Leaves

APOour sz

Broken
‘Damaged
Blemished (Slightly)
Trim (Reas. Well) In grade A

Trim (Poor) In grade B

Development (Reas. Well) In A |
TOTAL MINOR

TOTAL ALL CLASSES
Grade A

Grade B AQA=90,0 1 2 lival 751 0 o | o
SAMPLE UNIT GRADE B B
FINAL GRADE

BPOBAH SE

CUSUM

PPHOHW

128


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CHOPPED BROCCOLI (continuation).

8. Check the sample unit for style compliance. It isn't
necessary to use the same sample size that you're
using for the other factors. You may use a smaller
sample size for style. The smaller sample size makes
grading faster. This procedure would be the same as
drawing a subsample. For example, if you're using
7250 g (29 x 100-2.5 g increments) for the other factors,
you could use 5250 g (21 x 100-2.5 g increments); or
3250 g (13 x 100-2.5 g increments); or 1500 g (6 x 100-2.5 g
increments) for style. If you do chose a smaller sample
size for style, be sure and note on the tally the size
that you've used for style. Otherwise, it's difficult
to reevaluate the tally.

To check for style, do the following:
a. Disregard leaf material, pieces of leaves and HEM;

b. Consider the product for the style that it is
offered for even though you may disagree with the
declaration of style;

ce. Separate all cuts in the sample unit that are longer
than 2 cm and place them on a suitable scale. Record
the composite weight. Count each 2.5 g increment of
this weight as 1 minor style defective;

d. Record the number of minor style defectives in the
style section of the defect tally. If a style
failure occurs, certify the style as "pieces."

Example 65:

| S (Minor (Longer than 2 cm)
: cusum |
L (Head Material L
LE Leaf Material ——-} |
1
/
Longer than 2 cm= 12 g- - ~-—-—- -~--—--— 77

113


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

BROCCOLI

7.

10.

PIECES (continuation). .
Cook a representative portion of the broccoli as
outlined in File Code 130-A-38. You may wish to
select only "suspect" units (step 3) for the cooking
test. Also, it isn't necessary to cook the entire
sample.

Evaluate the cooked broccoli to verify the
tentative grade given for odor in step 3.

Evaluate the cooked broccoli by chewing representative
Portions. This should verify the tentative

grade given for grit and silt in step 3.

Evaluate the cooked broccoli for fiber. Be alert for
fiber located in the pieces that are made from the
base end of the stalk. Fiber is a "fooler." It's
usually more tender after cooking than would be
expected. Cook enough of the "suspect" pieces to

set your sights.

If any detectable fiber is to be counted against the
sample, cook all of the "suspect" units. Follow this
Procedure:

a. Separate all of the pieces with major fiber (nonwoody-
noticeable fiber but can be eaten without difficulty)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 major defect;

b. Separate all of the pieces with severe fiber (woody)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 severe defect; and

c. Record on the defect tally the number of major and
severe defects.

See also the next page.

122


Frozen Broccoli
July 1980

Example 75: (Originally designated grade B, reevaluated against
bottom grade A)

Similar Varietal Characteristics

Brightness

Flavor/ Odor
Grit/silt

CUSUM -~
, Grade B

|elor oor)
Blemished (Seriously)
Fiber (Woody)
HEM (Class 1)

TOTAL SEVERE

Grade A _
cusuM =
veegen i Grade Bo.

4

ine

HAH dH bn wo “Om wd

Good) In grade A

Color (Reas.
Size .
Detached Fragments
Blemished (Materially)
) In grade A
Development (Poor) __
Fiber (Nonwoody) _
| “TOTAL MAJOR
cusum |Stade A
\ iGrade B

BOouPrk
i
!

RIP DN |

Size (Diameter) _
| Loose Leaves

Broken

“Record kept but ndt counted- against~ grade~

BR

'
1
t
_ '
Blemished (Slightly) '
Trim (Reas. Well) In grade A \
Trim (Poor) In grade Bo
|\Development (Reas. Well) In A
____ TOTAL MINOR
__ TOTAL ALL CLASSES
iGrade A
cusiM |”
me Grade B
SAMPLE UNIT GRADE
FINAL GRADE _

DPOBH

EPHOH

“U.S. GOVERNMENT PRINTING OFFICE : 1980 0-310-945/Fsqs-164


Frozen Broccoli
July 1980

This manual is designéd for Processed Products Branch personnel
of the U.S. Department of Agriculture. Its purpose is to give
background information and guidelines to assist in the uniform
application and interpretation of U.S. grade standards, other
similar specifications and special procedures.

The citation of any data, criteria, techniques, illustrations,
copyrighted material, or pictorial representation accredited to
private authorship is used with the permission of the individuals
or sources cited. Unless a specific reference is cited, the
information in this manual has been compiled or developed from
sources available to the public as well as from technical
knowledge of personnel in the Department.

Compliance with the suggested guidelines in this manual does
not excuse failure to comply with the Federal Food, Drug, and
Cosmetic Act or any other applicable Federal or State laws or
regulations.

Except for official USDA inspection aids or devices and color
guides (or standards) produced under license of the Department,
the mention of any supplier, patented device, product, brand-
name or equipment does not imply endorsement by the Department
over any other similar, or equally effective, material.

This manual is for sale to the public. Address inquiries to:

Chief, Processed Products Branch

Fruit and Vegetable Quality Division, FSQS
U.S. Department of Agriculture
Washington, DC 20250


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CHOPPED BROCCOLI

1.

3.

Follow the procedure outlined in File Code 120-A-7
(Lot Single Sampling Plan [Attributes]).

Use the same defect tally sheet for lot inspection as
you would use for on-line inspection. Ignore the section
of the tally devoted to CUSUM values.

Open each individual container that you have drawn for
the sample. Keep the product in its container. Ona
container-by-container basis, without sorting through
the product, tentatively evaluate the following
prerequisites:

a. Evaluate "brightness" and record the letter grade
(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard).

b. At the same time that brightness is evaluated, record
in the "prerequisites" section of the defect tally
the letter grade (A or SSTD) for similar varietal
characteristics.

c. Evaluate the broccoli for odor. Assign the letter
grade (A, B or SSTD) for odor in the section for
“prerequisites.” Consider any objectionable
"off-odor" ("hay-like," "straw-like," "smoke,"
"chemical" or "sour") as Substandard. But the sample
must be edible in step 10. Permit a slight "hay-like"
or "straw-like" odor in grade B.

d. Assign the letter grade (A, B or SSTD) for freedom
from grit in the section for "prerequisites."

See also the next page.

106


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
BROCCOLI PIECES (continuation).
11. Fiber (continuation).
b. Separate all of the units with severe fiber (woody)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this

weight as 1 severe defect;

c. Record the number of major and severe fiber defects
on the defect tally.

Example 40:

Blemished (Seriously)

Fiber (Woody) _ /

HEM (Class 1) 5
TOTAL SEVERE

Grade A 0.4 |0.8 |1.6

Grade B 1 152

CUSUM

Amada H

Blemished (Materially)
| Fiber (Nonwoody)

Grade A 1.5/1.5. 3
Grade B iz 3.3

RPOUP kz

CUSUM

TOTAL MAJOR TT
:
f
1

Woody fiber = 5 g---------~~——~—--
5

Nonwoody fiber = 10 g--— -~-~— —-
5

66


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
CUT BROCCOLI (continuation).
12. Fiber (continuation).

b. Separate all of the units with severe fiber (woody)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 severe defect;

c. Record on the defect tally the number of minor and
major fiber defects. A

Example 31:

Blemished (Seriously) _
Fiber (Woody)
HEM (Class 1)
TOTAL SEVERE
[Grade A
Grade B

BP dao

CUSUM

iBlemished (Materially)
Fiber (Nonwoody)
|____ TOTAL MAJOR
1
cusum )Grade A

I Grade B

| FOUb>R

.

1

7

4

t

}

i)

Woody fiber = 38 ~~~ _o Le '
|

7

Nonwoody fiber = 10 g- __ _ __ -
5

13. ‘Total the classes of defects on the defect tally and
compute the CUSUM values as outlined in File Code 120-A-6.

52


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

7.

Separate all of the pieces of harmless extraneous
material (HEM) into 2 categories as follows:

a. Severe (Class 1); or

b. Critical (Class 2).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Place each piece
of HEM, by class, end-to-end (use the longest dimension)
in a continuous row. Measure each class separately.
Record on the defect tally the number of HEM defects
(each 2.5 cm increment is 1 defect).

Example 58:

HEM (Class 2)

TOTAL CRITICAL

CUSUM

Grade A
Grade B

t

Bow et dot © [le oHaHE]

Blemished (Seriously) oo.

(Woody)

cusuM Grade A
Grade B
Class 1 = 10 em —~_ —__ _ _ -- eH ee
2.5
Class 2=4cm 2 Le”
2.5

101


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).
7. Color of individual short spears (continuation).

Example 19: (Designated grade B production).

Color (Poor)
Blemished (Seriously)
_Fiber (Woody) _
HEM (Class 1)
TOTAL SEVERE
\Grade A
Grade B

Aa damn

CUSUM

| Color (Reas. Good) In grade A
Detached Fragments _
Blemished (Materially)
Trim (Poor) In grade A
‘Development (Boor) Oe
| Fiber (Nonwoody)

TOTAL MAJOR

Grade A__
Grade B

(tome a cases et

| cUSUM |Grade A 2 12 5
| \crade B 2 14 7 2)
__SAMPLE UNIT GRADE ___ a

DPoupr

| cusUM

CP HOH |

Don't count defects that are counted only against grade A ~

33


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

13.

Count the number of short spears that are adversely
affected by trimming. Use the USDA photoguides, if
available. The trim classification of each broccoli
short spear is one of the following:

a. Well trimmed (grade A trim) - not a defect in any
grade:

b. Reasonably well trimmed (grade B trim) - a defect

only in grade A; or

c. Poorly trimmed (Substandard trim) - a major defect
in grade A and a minor defect in grade B.

Record on the defect tally the number of short spears
that are either "reasonably well trimmed" or "poorly
trimmed." If the sample unit fails requirements for
grade A, adjust the defect tally by: (1) dropping all
“reasonably well trimmed" short spears from the defects
counted against grade B; and (2) striking out the
number of "poorly trimmed" short spears counted as

major defects against grade A and moving them to minor
defects to be counted against grade B. If the broccoli
is designated as grade B by the processor, it would be
necessary to count only the “poorly trimmed" short spears
in each sample unit. Place the number of "poorly trimmed"
short spears directly in the minor defect category.
Remember, however, the tally could never be reevaluated
for grade A.

See also the next page.

37


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

13. Compare the total number of defects that you've found in
the sample with the acceptance number for the applicable
AQL and sample size in the "Regulations" (File Code
109-A-1, Tables XV-XIX).

14. Assign a grade to the sample based on the procedure
outlined in File Code 120-A-7 (Lot Single Sampling Plan).

105


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS

1.

2.

3.

Select at random 50 short spears from the processing line
(either before freezing or after freezing). You may use
25 short spears as an optional sample unit size. Unless
the quality is borderline, 25 short spears should be
adequate. Also if you're grading several other products
at the same time, 25 short spears would save time in
grading. In either case, 25 short spears or 50 short
spears, you must keep the sample unit size constant
during each basic grading period.

Reassemble any broken short spear. Count each reassembled
short spear as a single unit.

Arrange all of the short spears in the sample unit ina
continuous row with the base end of each short spear
against the bottom rim of the grading tray. If you're
using 50 short spears, butt each unit against a straight
edge on top of the grading table. As the short spears
are being arranged in a row, place them in order of size
from the longest to the shortest, or vice versa.

a. Disregard loose leaf material, pieces of leaves, EVM
and detached fragments;

b. Locate the point in the continuous row where the short
spears are longer than 9.5 cm, if any. Count the number
of short spears that are longer than 9.5 cm;

c. Locate the point in the continuous row where the spears
are shorter than 2 cm, if any. Count the number of
short spears that are shorter than 2 cm;

d. The standards require that each short spear weigh more
than 6 g but don't provide acceptance criteria for
these small units. Do this: If any floret weighs 6 g
or less and is not counted in the less than 2 cm
defectives, count it as a "minor" style defective,
regardless of the length; and

e. Record the number of defective spears in b, c and d
above in the style section of the defect tally. Short
spears that fail style requirements aren't "pieces."
If a style failure occurs, certify the grade but
show: "Fails style compliance for short spears."

See also the next page.
25


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CHOPPED BROCCOLI (continuation).
12. Fiber (continuation).

Example 66:

Blemished (Seriously)

Fiber (Woody) |e /F |

HEM (Class 1)

TOTAL SEVERE
cusum [Stade A 0.5) 1.5
| ‘Grade B 1212 \

|Blemished (Materially) |

Fiber (Nonwoody) a U BE |
TOTAL MAJOR a A

1

T

\

\

1

ho

AWE don

cusum Grade A 1 : 3/3
| [Grade B 15614

RPOUP x

Woody fiber = 47 g —~~-~-—-—-—W-— ~-—-”
2.5
Nonwoody fiber = 93 g—--~—-- a

13. Compare the total number of defects that you've found in
the sample with the acceptance number for the applicable
AQL and sample size in the "Regulations" (File Code
109-A-1, Tables XV-XIX).

14. Assign a grade to the sample based on the procedure
outlined in File Code 120-A-7 (Lot Single Sampling Plan).

115


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI (continuation).

8. Style (continuation).

e. Separate the stalk material and ignore it;

f. Separate the head material and weigh ("Bald" units
completely stripped of flower buds should not be
considered as head material);

g- Separate the leaf material and weigh;

h. Allow, regardless of sample unit size, the following:
Average: Head material not less than 25% (12.5 g/50 g)

Leaf material not more than 25% (12.5 g/50 g)
Individual sample unit:

Head material not less than 15% (7.5 g/50 g)

Leaf material not more than 35% (17.5 g/50 g)

Example 36:

Ard

‘Minor (Longer than 2 cm)

cusum |
Head Material 50g 3L 755)
Leaf Material a

58


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CHOPPED BROCCOLI (continuation).

7. Separate all of the pieces of harmless extraneous
material (HEM) into 2 categories as follows:

a. Severe (Class 1); or.
b. Critical (Class 2).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Place each piece
of HEM, by class, end-to-end (use the longest dimension)
in a continuous row. Measure each class separately.
Record on the defect tally the number of HEM defects
(each 2.5 cm increment is 1 defect).

Example 64:
g [HEM (Class 2)
i TOTAL CRITICAL
é “cusum Grade A
! Grade B

| Blemished (Seriously)

s
E Fiber (Woody)
Vv |HEM (Class 1)
E TOTAL SEVERE
R j
E  cUSUM | Grade A

| _Grade B
Class 1=12cem_ ~~~ _ __ _

2.5
/
Class 2=6 cm—— ~~ ~ nd

2.5

112


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).
12. Trim (continuation).

Example 46: (Failed grade A, check against

Color (Reas. Good) In grade A
Size (Length)

Detached Fragments

Blemished (Materially)

Trim (Poor) In grade A
[Development (Poor)

Fiber (Nonwoody)

TOTAL MAJOR

RPOUPRE

grade B)

SOK/8 = CSO

Grade A

|CUSUM

Grade B

[Size (Diameter)
Loose Leaves
Broken _
Damaged
Blemished (Slightly)

(rim (Reas. Well) In grade A
(rim (Poor) In grade B
Development (Reas. Well) In A
TOTAL MINOR

RDOBH ES

T

Q |..TOTAL ALL CLASSES
A Grade A

L

Grade B
SAMPLE UNIT GRADE

CUSUM

uw lz

Drop the defects that are counted only against grade
checking for compliance with grade B

76



Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).

5. Evaluate "brightness" and record the letter grade
(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard.

6. At the same time that brightness is evaluated, record
the letter grade (A or SSTD) in the "prerequisites"
section of the defect tally for similar varietal
characteristics.

7. Evaluate the color of the individual broccoli short spears.
The color classification of each short spear is one of
the following:

a. Good color (grade A color) - not a defect in any
grade;

b. Reasonably good color (grade B color) - a defect
only in grade A; or

ce. Poor color (Substandard color) - a defect in grade A
and grade B.

If a short spear is blemished because of orange buds,
olive-green leaf stem (petiole), etc., ignore the blemished
areas for purposes of color evaluation. In other words,
don't count a short spear as "reasonably good" color or
"poor" color because it is blemished. Record on the
defect tally the number of short spears that are either
"reasonably good" or "poor" color. If the sample unit
fails requirements for grade A, adjust the tally by
dropping the number of "reasonably good" short spears
from the grade B defects. Reasonably good color (grade B
color) is not a defect in a grade B sample unit. Count
only "poor" color short spears as defects in a grade B
sample unit.

If the frozen broccoli is designated as grade B by the
processor, it would be necessary to count only the number
of "poor" color short spears. Remember, however, the
tally could never be reevaluated for grade A.

See also the next page.

31


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

17.

18.

19.

20.

21.

22.

Cook a representative portion of the short spears as
outlined in File Code 130-A-38. You may wish to select
only "suspect" (step 3) short spears for the cooking
test. Also, it isn't necessary to cook all of the short
spears.

Evaluate the cooked broccoli for flavor to verify
the tentative grade given for odor in step 3.

Evaluate the cooked broccoli by chewing. This should
verify the tentative grade given for grit in
step 3.

Evaluate the cooked broccoli for fiber. Only fiber
which is detectable in the cooked broccoli should be
counted. It is not necessary to cook all of the short
spears that are suspected of having tough fiber if
enough of the short spears are cooked to accurately
set your sights.

Compare the total number of defects that you've found
in the sample with the acceptance number for the
applicable AQL and sample size in the "Regulations"
(File Code 109-A-1, Tables XV-XIX).

Assign a grade to the sample based on the procedure
outlined in File Code 120-A-7 (Lot Single Sampling Plan).

94


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

5.

While the spears are arranged in a continuous row, check
for uniformity of diameter. Uniformity of diameter is
separate from the style defectives done in step 3, and
uniformity of length done in step 4, previously. Don't
be overly critical. If it is apparent that the spears
are reasonably similar in diameter, accept them as
meeting requirements. If some spears are obviously
larger or smaller than others, do the following:

a. Locate the apparent spears that are outside an
acceptable 2 cm range in diameter between the
large diameters and the small diameters;

b. Determine diameter variation so that only the
least number of defects are tallied against size.
This may be only the small diameter spears, only
the large diameter spears, or both the small
spears and the large spears; and

c. Record the number of diameter defects on the defect
tally as minor defects.

See also the next page.


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

13.

Count the total number of spears in the sample that are
adversely affected by development (head and bud cluster
stages of maturity). Use the USDA photoguides, if
available. The development classification of each
broccoli spear is one of the following:

a. Well developed (grade A development) - not a defect
in any grade;

b. Reasonably well developed (grade B development) - a

defect only in grade A; or

c. Poorly developed (Substandard development) - a defect
in grade A and grade B.

Record on the defect tally the total number of spears that
are either "reasonably well developed" or "poorly
developed." If the sample fails requirements for grade A,
adjust the tally by dropping all "reasonably well
developed" spears from the number of defects that are to
be counted against grade B. Reasonably well developed
(grade B development) isn't a defect in a grade B sample.
Count only "poorly" developed spears as defects in a
grade B sample.

See also the next page.

77


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

Example 48: (Prerequisites on a container-by-container basis)

Carton No. 1 Carton No. 2 Carton No. 3, etc.

Similar Varietal Char. A A A
Brightness A A A
Flavor and Odor A A A
Grit and Silt A A A

The grade for a lot of broccoli short spears may not be
higher than the grade of any "prerequisite" grade for

any individual sample unit in the sample, If the sample
should fail the anticipated grade because of a prerequisite
factor, don't skip the other factors. Continue grading

the sample but don't spend a lot of time with problem areas,
such as uniformity of size, borderline trim, borderline
development, etc.

Assemble (physically or mentally) all of the short spears
from all of the containers into one sample. Adjust the
total number of short spears in the sample to meet the lot
single sampling plan that you're using. If any of the
cartons are "suspect" in step 3, you may wish to assemble
the short spears mentally into one sample. This procedure
would enable you to retain the identity of the "suspect"
cartons.

See also the next page.

83


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).

4. While the spears are arranged in a continuous row, check
for uniformity of size. Uniformity of size is separate
from the style defectives done in step 3, previously.
Don't be overly critical. If it is apparent the
spears are reasonably similar in length, accept them as
meeting requirements. If some spears are obviously
shorter or longer than others, do the following:

a. Locate the point in the row where the spears vary
more than 5 cm from the predominant length;

b. Determine size variation so that only the least
number of defects are tallied against size. This
may be only the short spears, only the long spears,
or both the long spears and the short spears; and

c. Record the number of size defects on the defect
tally as major defects.

See also the next page.


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CHOPPED BROCCOLI (continuation).

6. Blemished (continuation).

Example 63:

[rH Ora | [at HS

Blemished (Seriously)

Fiber (Woody)

HEM (Class 1)

TOTAL SEVERE

Heide

Grade A

CUSUM
Grade B

Blemished (Materially)

Fiber (Nonwoody)

TOTAL MAJOR

‘Grade A

WDOUP

CUSUM |
_--.Grade B_____.

Blemished (Slightly)

TOTAL MINOR

TOTAL ALL CLASSES

Grade A

| CUSUM

Grade B

SAMPLE UNIT GRADE

FINAL GRADE

Slightly = 53 g—--—--—---— —-

35

111



Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SPEARS (continuation).
22. Compare the total number of defects that you've found in
the sample with the acceptance number for the applicable
AQL and sample size in the "Regulations" (File Code
109-A-1, Tables XV-XIX).

23. Assign a grade to the sample based on the procedure
outlined in File Code 120-A-7 (Lot Single Sampling Plan).

81


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CHOPPED BROCCOLI (continuation).

3. Prerequisites, container-by-container (continuation).

e. Evaluate the chopped broccoli for development (head
and bud cluster stages of maturity). Even though

the USDA photoguides which show various stages of
development, cover only spears, you may use these
photoguides as an indication of the cut-off point
between "reasonably well developed" and “poorly
developed." :

The development classifications of chopped broccoli

are as follows:

a. Grade A - the broccoli may be only "reasonably
well developed" (grade B); or

b. Grade B - the broccoli may be only "poorly
developed" (SSTD) if the appearance is not
materially affected. Poorly developed means
the individual buds are in the flowering stage.

Assign the letter grade (A, B or SSTD) for development
in the "prerequisites" section of the defect tally.

f. If any container is "suspect" because of "brightness,"

"odor,"

"grit" or "development," identify the container

and its product for further examination.

Example 61:

Similar Varietal Char.

Brightness
Flavor and Odor
Grit and Silt

Development

(Prerequisites on a container—by-container basis)

Carton No. 1 Carton No. 2 Carton No. 3, etc.

A A A
A A A
A A A
A A A
A A A

See also the next page.

107


Frozen Broccoli
July .1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

13. Development (continuation).

Example 54: (Failed grade A, check against grade B).

0x13 2656 dhe

Color (Reas. Good) In grade A

Detached Fragments

Blemished (Materially)
Trim (Poor) In grade A

Development (Poor)
Fiber (Nonwoody)
TOTAL MAJOR

RPOUP

cusum | Grade A
Grade B

Size (More Than 4X)

Loose Leaves

Broken

Damaged

(Blemished (Slightly)

(Trim (Reas. Well) In grade A
jIrim (Poor) In grade B
Development (Reas. Well) In A
TOTAL MINOR

RPOBAHR

TOTAL ALL CLASSES
Grade A 12 1215

CUSUM

e>PHOH

Grade B [2 | 14/7

i
SAMPLE UNIT GRADE —_
FINAL GRADE

Drop the defects that are counted only against grade A, before
checking for compliance with grade B —~-—- - — - - ~- --=-

92

— eee eee

/
4


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI (continuation).

12. Fiber (continuation).

b. Separate all of the units with severe fiber (woody)
and place them on a suitable scale. Record the
composite weight. Count each 2.5 g increment of
this weight as 1 severe defect;

c. Record on the defect tally the number of major and
severe fiber defects,

Example 37:

Blemished (Seriou:
Fiber (Woody)
HEM (Class 1)
TOTAL SEVERE
Grade A

Grade B

CUSUM

BAe <M

Blemished (Materially)
Fiber (Nonwoody)
TOTAL MAJOR

cusm Stade A
1

Grade B

ROUP x

Woody fiber = 5 g~— —— — —

Nonwoody fiber = 8 g—-~-—---~--— —-
2.5

13. Total the classes of defects on the defect tally and
compute the CUSUM values as outlined in File Code 120-A-66

60


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI (continuation).

7. Separate all of the pieces of harmless extraneous material
(HEM) into 2 categories as follows:

a. Severe (Class 1); or
b. Critical (Class 2).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Place each piece of
HEM, by class, end-to-end (use the longest dimension) in
a continuous row. Measure each class separately. Record
on the defect tally the number of HEM defects (each 2.5 cm
increment is 1 defect).

Example 34:

HEM (Class 2)

TOTAL CRITICAL
Grade A
TL Grade B

CUSUM

Ip POHHrEA|

Blemished (Seriously) i
Fiber (Woody) !
HEM (Class 1)

Grade A 0.5/1.5 2
Grade B 1/2 /)2

AAR Ada

CUSUM

| Az.
TOTAL SEVERE 4
'
i
i
:
7

Class 1 = 3 em~---_.~~.~ ~~ ____--
2.5

Class 2 =,¢,--------- --7

56


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-

SPEARS (continuation) .

14. Trimming (cont inuation).

LINE INSPECTION

Example 10: (Designated grade A production)

Color (Reas. Good) In grade A
Size (Length)
Detached Fragments
_Blemished shed (Materially)

M

‘ ‘Trin, (Poor) In grade A
(e)

R

Development (Poor)
(Fiber (Nonwoody)
TOTAL MAJOR

Grade A
Grade B

 CUSUM

Size (Diameter)
Loose Leaves
| Broken _

'Blemished Slight1. _
Trim (Reas. Well) In grade A
Trim (Poor) In grade B
Development (Reas. Well) InA
i TOTAL MINOR

TOTAL ALL CLASSES

L _. —— a /3 |
[Grade A 2 112 |5 2 3

CUSUM

SAMPLE. UNIT GRADE _

[Grade B_ _ te tua JZ

Drop the defects that are counted only against grade A, before

checking for compliance with grade B-- — - ~

18


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
CUT BROCCOLI (continuation).
6. Blemished (continuation).

e. Record on the defect tally the number of blemished
defects (each 5 g increment is 1 defect) as follows:

i. Minor; or
ii. Major; or }<—Use photoguides for spears, if available.
iii. Severe.

Example 27:

Blemished (Seriously)
Fiber (Woody)
HEM (Class 1)

TOTAL SEVERE
cusuM Grade A
Grade B

Blemished (Materially)
Fiber (Nonwoody)
TOTAL MAJOR

CUSUM Grade A
Grade B

Blemished (Slightly)
TOTAL MINOR

1

PHO BHR jy OUP Ril wm am

TOTAL ALL CLASSES
Grade A

Grade B

SAMPLE UNIT GRADE

CUSUM

|

Slightly = 9 g------- ee eee

47


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CUT BROCCOLI (continuation).

9.

lo.

11.

12.

After the sample unit has been evaluated for style, or

if the sample unit is skipped for style evaluation,

cook a representative portion of the cut broccoli as
outlined in File Code 130-A-38. You may wish to select
only "suspect" units for the cooking test. Also, it
isn't necessary to cook each sample unit unless a problem
develops, such as fibrous units or grit.

Evaluate the cooked broccoli for flavor and odor. Assign
the letter grade (A, B or SSTD) for flavor and odor in

the section for "prerequisites." It isn't necessary to
cook each sample unit unless a problem develops. Consider
any objectionable "off-flavor" ("hay-like," "straw-like,"
"smoke," "chemical," or "sour"), but edible sample unit,

as Substandard. Permit a slight "hay-like" or "straw-like"
odor in grade B.

Evaluate the cooked broccoli for grit or silt. Assign
the letter grade (A, B or SSTD) for freedom from grit in
the section for "prerequisites." It isn't necessary to
cook each sample unit for the grit evaluation unless a
problem develops.

Evaluate the cooked broccoli for fiber. Be alert for
fiber located in the pieces (cuts) that are made from
the base end of the stalk. Fiber is a "fooler." It's
usually more tender after cooking than would be expected.
It isn't necessary to cook each sample unit unless a
problem develops. However, cook enough of the "suspect"
cuts to set your sights.

If any detectable fiber is to be counted against the
sample unit, cook the entire sample unit. Follow this
procedure:

a. Separate all of the units with major fiber (nonwoody-
noticeable fiber but can be eaten without difficulty)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 major defect;

See also the next page.

51


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

17.

18.

19.

20.

21.

Evaluate the sample for compliance with style require-
ments.

a. Disregard loose leaf material, pieces of leaves,
EVM and detached fragments;

b. Determine the total number of spears in the sample
(mot each container) that are longer than 15.5 cm;

c. Determine the total number of spears in the sample
(not each container) that are shorter than 8.5 cm;

d. Record the number of defective spears in b and c above
in the style section of the defect tally. Spears
that fail style requirements aren't "pieces." If a
style failure occurs, certify the grade but show:
"Fails style compliance for spears."

See also example 1, page 4.

Cook a representative portion of the spears as outlined
in File Code 130-A-38. You may wish to select only
"suspect" (step 3) spears for the cooking test. Also,
it isn't necessary to cook all of the spears.

Evaluate the cooked broccoli for flavor to verify
the tentative grade given for odor in step 3.

Evaluate the cooked broccoli by chewing. This should verify
the tentative grade given for grit in step 3.

Evaluate the cooked broccoli for fiber. Only fiber which

is detectable in the cooked broccoli should be counted.
It is not necessary to cook all of the spears that are
suspected of having tough fiber if enough of the spears
are cooked to accurately set your sights.

80


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).
8. Color of individual spears (continuation).

Example 7: (Designated grade B production).

Color (Poor) |
§ | Blemished (Seriously) Li
Fiber (Woody)
Vv —
— | HEM (Class 1)
R TOTAL SEVERE a
Ey cusum | Stade 4 0.5 | 0.5/1.5
Grade B "1.5 11.5] 3 ya
{ Color (Reas. Good) In grade A | , I band nd
Size (Length) | ! f
j Detached Fragments __ i !
| M |Blemished (Materially) 1
; ‘ Trim (Poor) In grade A !
19 Development (Poor) ya !
' g | Fiber (Nonwoody) t
j TOTAL MAJOR J 5 |!
Grade A $1,413 |
i CUSUM [Grade B Fii 6 4 eit
i § TOTAL ALL CLASSES { _ ] 1% |!
Grade A 2 5112 [5 '
A
| 1 (CUS Jorade B 2{ui7 [ol
SAMPLE UNIT GRADE 6 |
| \
|

ce

Don't count defects that are counted only against grade A~


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI (continuation).

6. Blemished (continuation).

e. Record on the defect tally the number of blemished
defects (each 2.5 g increment is 1 defect) as follows:

i. Minor; or |
ii. Major; or «@—Use photoguides for spears, if available.
iii. Severe. J

Example 33:

Ss |Blemished (Seriously)

E |Fiber (Woody)

v |HEM (Class

E TOTAL SEVERE

R \cusut Grade A

E Grade B

M Blemished (Materially)

A |Fiber (Nonwoody)

J TOTAL MAJOR

° |cusum Grade A

R Grade B
| M Blemished (Slightly)
LON TOTAL MINOR _
| TOTAL ALL CLASSES
{
| T cusum Grade A
Lo Grade Boo _ -

SAMPLE UNIT GRADE

55




Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SPEARS (continuation).

7. Weigh all of the detached fragments, if any, in the
sample (not each container). Don't include loose leaves
or pieces of leaves in the weight, these are minor defects.
Ignore any chaff. Don't be overly critical but count
each 28 g increment of the composite weight ( all of
the detached fragments in the sample) as 1 major defect.
Record on the defect tally the total number of detached
fragment defects as follows:

0 - 28 g=1 defect
29 - 56 g = 2 defects
57 - 84 g = 3 defects, etc.

Example 44:

50K /3= 650

Color (Reas. Good) In grade A

Size (Length)
Detached Fragments
Blemished (Materially)

Trim (Poor) In grade A
Development (Po
[Fiber (Nonwoody)
TOTAL MAJOR
Icusum (Grade A
Grade B
. TOTAL ALL CLASSES
cus [Grade A
rade B
SAMPLE UNIT GRADE
[___FINAL

DPoupre

Do PHOH

Detached Fragments = 300 g-- —- ~ —_._ _~-
28

72


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

7. Color of individual short spears (continuation).

Example 18: (Designated grade A production).

| color (Poor)
Blemished (Seriously)
Fiber (Woody)
HEM (Class 1)
TOTAL SEVERE
\Grade A
[Grade B

MAdmin

CUSUM

Color (Reas. Good) In grade A_

Detached Fragments _

Blemished (Materially)

Trim (Poor) In grade A

Development (Poor)

Fiber (Nonwoody)
TOTAL MAJOR

cusum Grade A 1 4
fa le

BOUD>

iGrade B

TOTAL ALL CLASSES /1
lcrade A 2 i122 [5 / /
[crade B [2 jaa [7

SAMPLE UNIT GRADE

| CUSUM

A > HI ORF

Drop the defects that are counted only against grade A, before
checking for compliance with grade B——-— —-—— —-—-— — —

32


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

4. Assembling the sample (continuation) .
Example 42:
NUMBER OF CARTONS
6 13 21 29
(Number of Spears)

s
P 6 36 78 126 174
E
A
R 13 78 169 273 377
s
P 25 150 325 525 725
E
R

50 300 650 1050 1450
Cc
A
R 100 600 1300 2100 2900
T
0
N

5. Reassemble any broken spear. Count each reassembled

spear as a single unit.
6. Evaluate the color of the individual broccoli spears.

The color classification of each broccoli spear is one

of the following:

a. Good color (grade A color) - not a defect in any grade;

b. Reasonably good color (grade B color) - a defect in

grade A only; or

c. Poor color (Substandard color) - A defect in grade A

and grade B.

See also the next page.

70



Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
BROCCOLI PIECES (continuation).
6. Blemished (continuation).

e. Record on the defect tally the number of blemished
defects (each 5 g increment is 1 defect) as follows:

i. Minor; or
ii. Major; or )—Use photoguides for spears, if available.
iii. Severe.

Example 38:

Blemished (Seriously)
Fiber (Woody)

HEM (Class 1)
TOTAL SEVERE

Grade A
Grade B

CUSUM

Arad

Blemished (Materially)
Fiber (Nonwoody)
TOTAL MAJOR.
‘Grade A
Grade B

Blemished (Slightly)
TOTAL MINOR
| TOTAL ALL CLASSES
Grade A

rade B

‘CUSUM

POURS

Lesa

{
|

i SAMPLE UNIT GRADE

PPO || 2H

Slightly = 20 g—-—-— —~~-~~—~—--~--——~—-—v7 \ 1
5
Materially = 10 g-— -—- - ---+-/7 ;
5

Seriously = 3 g--- -~
5

63


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).
14. Trimming (continuation).

Example 11: (Designated grade B production).

Color (Reas. Good) In grade A |
Size (Length)
Detached Fragments
Blemished (Materially)
Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)

TOTAL MAJOR
Grade A
i CUSUM | Grade B

DOoUPR

.Size_(Diameter) 00.
Loose Leaves

Broken

ROBMHS

Damaged

Blemished (Slightly)

Trim (Reas. Well) In grade A
| Trim (Poor) In grade B

| Development (Reas. Well) In A
TOTAL MINOR

TOTAL ALL CLASSES
Grade A
Grade B

SAMPLE UNIT GRADE

f

- cusUM

PHO

i
Don't tally defects that are counted only against grade A’

19


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-
SPEARS (continuation) .
15. Development (continuation).

Example 13: (Designated grade B Producti

Color (Reas. Good) In grade A
| Size (Length)
Detached Fragments -|
‘Blemished (Materially)
Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)

TOTAL MAJOR

Grade A

DOUDP =e

a
us|

LINE INSPECTION

on)

; .
i i
CUSUM Grade B i116 4

i | Size (Diameter)

BPOAwH ze

‘Trim “(Poor) In ; In grade } B
Development (Reas. Well) INA
TOTAL MINOR

§ | TOTAL ALL CLASSES
L

CUSUM

Grade A 22 [5
Grade B _ 2/4 [7

SAMPLE UNIT GRADE

1
2] |
Biot

Don't tally defects that are counted only against

22

grade A -


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CHOPPED BROCCOLI (continuation).

8.

At a sampling frequency outlined in File Code 120-A-5,

check the sample unit for style compliance. (NOTE: It

isn't necessary to check the style of each sample unit
drawn for quality).

a. Disregard leaf material, pieces of leaves and EVM;

b. Consider the product for the style that it is
offered for even though you may disagree with
the declaration of style;

c. Separate all cuts in the sample unit that are longer
than 2 cm and place them on a suitable scale. Record
the composite weight. Count each 2.5 g increment of
this weight as 1 minor style defective;

d. Record the number of minor style defectives in |
the style section of the defect tally. If a style
failure occurs, certify the style as "pieces";

Example 35:

Minor (Longer than 2 cm)

cust | oS0Oy (2 {10 | 5
7

mrt

Head Material
Leaf Material

Longer than 2 cm= 12 g-_--~-~-~---~~—---

See also the next page.

57


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

10.

il.

12.

Count the number of broken short spears. These should
be the same short spears that were reassembled in step 2,
if any. Record on the defect tally as minor defects the
number of broken spears (each reassembled short spear is
counted as only 1 defect).

Count any mechanical damage to the head material of the
short spear as a defect. Don't be overly critical --
only materially damaged, or worse, is counted. Don't
count broken short spears (step 10) or trimmed short
spears (step 13) as damaged, or vice versa. Record on
the defect tally as minor defects the number of damaged
short spears.

Count the number of short spears that are blemished.
Blemished broccoli is the most common defect. Usually,
blemishes are:

a. Discolored hollow or pithy stalks (Don't count
hollow or pithy stalks unless they're associated
with discoloration) ;

b. Yellow leaves;

c. Orange buds (6 or more orange buds in a single area
of the head is the cut-off point between blemished
and nonblemished) ;

d. Olive-green leaf stem (petiole); and

&. Record on the defect tally the number of blemished
short spears as follows:

i. Minor; or
ii. Major; or ) #—Use photoguides, if available.

iii. Severe.

36


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

12.

Count the number of short spears in the sample that

are adversely affected by trimming (not each container).
Use the USDA photoguides, if available. The trim
classification of each short spear is one of the
following:

a.

Well trimmed (grade A trim) - not a defect in any

grade;

Reasonably well trimmed (grade B trim) - a defect

only in grade A; or

Poorly trimmed (Substandard trim) - a major defect
in grade A and a minor defect in grade B. Record
on the defect tally the total number of short spears
in the sample that are either "reasonably well
trimmed" or "poorly trimmed" (not each container).

If the sample fails requirements for grade A, adjust
the defect tally by: (1) dropping all "reasonably

well trimmed" short spears from the defects counted
against grade B; and (2) striking out the major defects
counted against grade A and moving them to minor
defects to be counted against grade B.

See also the next page.

89


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).

18. Evaluate the cooked broccoli for grit or silt. Assign
the letter grade (A, B or SSTD) for freedom from grit
in the section for "prerequisites."

19. Evaluate the cooked broccoli for fiber. Be alert for
fiber located at the base end of the short spear. Any
detectable fiber should be classified as follows:

a. Major (nonwoody - noticeable fiber but can be
eaten without difficulty); or

b. Severe (woody).

20. Total the classes of defects on the defect tally and
compute CUSUM values as outlined in File Code 120-A-6.


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

6.

Color of the individual short spears (continuation).

If a short spear is blemished because of orange buds,
olive-green leaf stem (petiole), etc., ignore the
blemished areas for the purpose of color evaluation.
Don't count a short spear as "reasonably good" color
or "poor" color because it is blemished. Record on the
defect tally the total number of short spears in the
sample that are either "reasonably good" or "poor"
color (not each container). If the sample fails
requirements for grade A, adjust the tally by dropping
the number of "reasonably good" short spears from the
grade B defects. Reasonably good color (grade B color)
is not a defect in a grade B sample. Count only "poor"
color against a grade B sample.

Example 50:

SOKIB = 650 heat dptaed

Color (Reas. Good) In grade A

[Detached Fragments

M |Blemished (Materially) VAL,
4 (Trim (Poor) In grade A |
9 (Development (oor) —-——-
R [Fiber (Nonwoody) _ - 2.
TOTAL MAJOR 30 bo*
. 1
cusum fesse A 14 |3 | a
i rade B 16/54
z TOTAL ALL CLASSES [10 _L40|
T f i
cusum Grade A 2112 [5 De
‘ rade B 2114 17

SAMPLE UNIT GRADE

FINAL GRADE B 3

Drop the defects that are counted only against grade A, before
checking for compliance with grade B -—--—--—-—--— - --

85

\— ——-Failed grade A


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

BROCCOLI PIECES (continuation).

5.

Development (continuation).

The development classifications of broccoli pieces are
as follows:

a. Grade A - the broccoli may be only "reasonably
well developed" (grade B); or

b. Grade B - the broccoli may be only "poorly
developed" (SSTD) if the appearance is not
materially affected. Poorly developed means
the individual buds are in the flowering stage.

Record the letter grade (A, B or SSTD) for development
in the "prerequisites" section of the defect tally.

Separate all of the blemished units into 3 categories:

a. Slightly; or
b. Materially; or
c. Seriously.

Place each category on a suitable scale. Record the
weight. Each 5 g increment of this weight is 1 defect.

Blemished broccoli is the most common defect. Usually
blemishes are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration) ;

b. Yellow leaves;

c. Orange buds (3 or more orange buds in a single area
is the cut-off point between blemished and nonblemished);

d. Olive-green leaf stem (petiole);

See also the next page.

62


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE.UNDER LOT INSPECTION
SHORT SPEARS OR FLORETS (continuation).

7. Weigh all of the detached fragments, if any, in the
sample (not each container). Don't include loose leaves
or pieces of leaves in the weight, these are minor
defects. Ignore any chaff. Don't be overly critical
but count each 28 g increment of the composite weight
(all of the detached fragments in the sample) as 1 major
defect. Record on the defect tally the total number
of detached fragments as follows:

0 - 28 g =1 defect

29 - 56 g = 2 defects

57 - 84 g = 3 defects, etc.

Example 51:

Color (Reas.
Detached Fragments
Blemished (Materially)
Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)
oe TOTAL MAJOR
cusum [Grade A 1) 4 3
rade B 1 6 4

|____ TOTAL ALL CLASSES 2 ee ee

Grade A 2\12 15 a
Oe forage 8 at Ta |
__SAMPLE UNIT GRADE
FINAL GRADE

RPOUP

Db >HOH

a en

Detached Fragments = 300 g - — ~- ~~ ~~~ ---
28

86


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

BROCCOLI PIECES (continuation)’.

6. Separate all of the pieces of harmless extraneous
material (HEM) into 2 categories as follows:

a. Severe (Class 1); or
b. Critical (Class 2).

Count pieces of other similar plants, such as
cauliflower or brussels sprouts, as class 1 HEM.
Place each piece of HEM, by class, end-to-end (use
the longest dimension) in a continuous row. Measure
each class separately. Record on the defect tally
the number of HEM defects (each 2.5 cm increment

is 1 defect).

Example 70:

HEM (Class 2) _ 2
TOTAL CRITICAL

Grade A 0.5 10.5
| Grade B [0.4/0.8 (1.6

Blemished (Seriously)

CUSUM

BPO HE HE

HEM (Class 1), a a
‘TOTAL SEVERE

CUSUM

Grade A : 0.4/0.8 (1.6
Grade B 1/1 /2

mA dM

121


Frozen Broccoli
July 1980

SPECIAL LOT INSPECTION SITUATIONS

1.

INSPECTION OF LARGE CARTONS (2-1/2 1b., etc.) OR OTHER
LARGE CONTAINERS.

File Code 120-A-6 permits you to drawn a minimum of

3 cartons for inspection of small lots if Inspection
Aid No. 42 specifies the 3 sample size. Although the
lot single sampling plan is designed for a minimum

of 6 sample units, you may use the maximum number

of units of broccoli in the 3 cartons and adjust the
sample to 36, 78, 126, 150, 169, etc., or more units.
However, you must have at least 36 units in the sample
to perform a lot inspection. If 3 cartons give fewer
than 36 units, draw 4 or more cartons. The same thing
would hold true for a sample drawn by weight. For
example, for "cut" or "pieces," adjust the sample to
180 g, 390 g, 630 g, 845 g, 870 g or more. Or, for
"chopped," adjust the sample to 90 g, 195 g, 315 g,
423 g, 435 g or more.

CAUTION: REMEMBER THAN INSPECTION AID NO. 42
SPECIFIES ONLY THE MINIMUM SAMPLE
SIZE. YOU MAY INCREASE THE SAMPLE
SIZE FOR "SUSPECT" OR BORDERLINE LOTS.

INSPECTION OF SMALL CARTONS (8 oz or 10 oz) OR LARGE
UNITS (Spears) PACKED IN SMALL CARTONS.

If lot inspection covers small cartons or large units
packed in small cartons, it may be necessary to increase
the number of cartons that are to be drawn from the lot.
Without the increase in sample size, you would not have
enough product to meet the minimum sample size, such

as 36 broccoli spears. If the approximate number of
broccoli units in each carton is unknown, open one
carton at the sampling point to get this information.

HOW TO ADJUST A DEFECT TALLY.

If a sample fails to meet the requirements of grade A,
adjust the defect tally before comparing the defects
against the acceptance numbers for grade B. This must
be done because "reasonably good" defects are not
counted against grade B. A grade B lot could have all
"reasonably good" defects. The preceding examples in
this manual have been simple -- the following example
is complex.

See also the next page.

124


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

4. Uniformity of size (continuation).

Example 15:

Acceptable 4X variation ~,

(largest)
creer,
‘ ~
? pte,
| a 3 \—)
? :

4
/

Count only 1 defect -- ~ —-

28


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).
4. Uniformity of length (continuation).

Example 3:

oO

NO

Acceptable 5 cm variation —- -.

\
(largest)

Ne eee

(smallest)

eee ee ee Count only 1 defect


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

CUT BROCCOLI (continuation).

5.

6.

Development (continuation).

The development classifications of cut broccoli are as
follows:

a. Grade A - the broccoli may be only "reasonably
well developed" (grade B); or

b. Grade B - the broccoli may be only "poorly
developed" (SSTD) if the appearance is not
materially affected. Poorly developed means
the individual buds are in the flowering stage.

Record the letter grade (A, B or SSTD) for development
in the "prerequisites" section of the defect tally.

Separate all of the blemished units into 3 categories:

a. Slightly; or
b. Materially; or
c. Seriously.

Place each category on a suitable scale. Record the
weight. Each 5 g increment of this weight is 1 defect.

Blemished broccoli is the most common defect. Usually
blemishes are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration);

b. Yellow leaves;

c. Orange buds (3 or more orange buds in a single area
is the cut-off point between blemished and nonblemished) ;

d. Olive-green leaf stem (petiole); and

See also the next page.

46


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).
4. Uniformity of length (continuation).

Example 2:

Acceptable 5 cm variation ----___ aan
t

(largest)

ry
/
Count only 1 defect -- ~-


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

14.

Count the number of short spears that are adversely
affected by development (head and bud cluster stages
of maturity). Use the USDA photoguides, if available.
The development classification of each short spear is
one of the following:

a. Well developed (grade A development) - not a defect
in any grade;

b. Reasonably well developed (grade B development) - a
defect only in grade A; or

c. Poorly developed (Substandard development) - a defect
in grade A and grade B.

Record on the defect tally the number of short spears that
are either "reasonably well developed" or "poorly
developed." If the sample unit fails requirements for
grade A, adjust the tally by dropping all "reasonably
well developed" spears from the number of defects counted
against grade B. Reasonably well developed (grade B
development) isn't a defect in a grade B sample unit.
Count only "poorly developed" short spears as defects

in a grade B sample unit. If the frozen broccoli is
designated as grade B by the processor, it would be
necessary to count only the number of "poorly developed"
short spears. Remember, however, the tally could never
be reevaluated for grade A.

See also the next page.

40


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
BROCCOLI PIECES (continuation).
5. Blemished (continuation).

Example 69:

Blemished (Seriously)
Fiber (Woody)

HEM (Class 1)
__._TOTAL SEVERE
Grade A

Grade B

AA dH

CUSUM

Blemished (Materially)
Fiber (Nonwoody)
TOTAL MAJOR

cusum Grade A
Grade B

RPOUuUrR

Blemished (Slightly)
TOTAL MINOR

TOTAL ALL CLASSES
cusuM Grade A
dion wun. |Grade B
SAMPLE 1
FINAL GRADE

ror |e

Slightly = 100g ----~-~-~~____._____e \
5
/
Materially = 50 g-—~-~—~--~— ~~ __/
5

Slightly = 20 g---~-- —
5

120


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

15.

Count the number of spears that are adversely affected
by development (head and bud cluster stages of maturity).
Use the USDA Photoguides, if available. The development
classification of each broccoli spear is one of the
following:

a. Well developed (grade A development) - not a defect
in any grade;

b. Reasonably well developed (grade B development) - a
defect only in grade A; or

c. Poorly developed (Substandard development) - a defect

in grade A and grade B.

Record on the defect tally the number of spears that are
either "reasonably well developed" or "poorly developed."
If the sample unit fails requirements for grade A, adjust
the tally by dropping all "reasonably well developed"
spears from the number of defects counted against grade B.
Reasonably well developed (grade B development) isn't

a defect in a grade B sample unit. Count only "poorly
developed" spears as defects in a grade B sample unit.

If the frozen broccoli is designated as grade B by the
Processor, it would be necessary to count only the number
of "poorly developed" spears. Remember, however, the
tally could never be reevaluated for grade A.

See also the next page.

20


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

9.

Weigh the detached fragments, if any, in the sample unit.
Don't include loose leaves or pieces of leaves in the
weight, these are minor defects. Ignore any chaff.
Don't be overly critical but count each 28 g increment
of detached fragments as 1 major defect. Record on the
defect tally the number of detached fragments as follows:

0 - 28 g = 1 defect

29 - 56 g = 2 defects

57 - 84 g=3 defects, etc.

Example 8:

RPoupr

Color (Reas. Good) In grade

Size (Length)

Detached Fragments

Blemished (Materially)

Trim (Poor) In grade A

Development (Poor)

Fiber (Nonwoody)

TOTAL MAJOR

cusum |Grade A

Grade B

Detached fragments = 335 g-----~------

14


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS

1.

2.

3.

Select at random 50 spears from the processing line (either

before freezing or after freezing). You may use 25 spears
as an optional sample unit size. Unless the quality is
borderline, 25 spears should be adequate. Also if you're
grading several other products at the same time, 25 spears
would save some grading time. In either case, 25 spears
or 50 spears, you must keep the sample unit size constant
during each basic grading period.

Reassemble any broken spear. Count each reassembled spear
as a single unit.

Arrange all of the spears in the sample unit in a continuous
row with the base end of each spear against the bottom rim
of the grading tray. If you're using 50 spears, butt each
spear against a straight edge on top of the grading table.
As the spears are being arranged in a row, place them in
order of size from the longest. to the shortest, or vice
versa.

a. Disregard loose leaf material, pieces of leaves, EVM
and detached fragments;

Db. Locate the point in the continuous row where the spears
are longer than 15.5 cm, if any. Count the number of
spears that are longer than 15.5 cm;

c. Locate the point in the continuous row where the spears
‘are shorter than 8.5 cm, if any. Count the number of
spears that are shorter than 8.5 cm; and

d. Record the number of defective spears in b and c above
in the "style" section of the defect tally. Spears
that fail style requirements aren't "pieces." If a
style failure occurs, certify the grade but show:
"Fails style compliance for spears."


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CHOPPED BROCCOLI (continuation)

6.

Separate all of the blemished units into 3 categories:

a. Slightly; or
b. Materially; or
ce. Seriously.

Place each category, separately, on to a suitable scale.
Record the weight. Each 2.5 g increment of this weight
is 1 defect.

Blemished broccoli is the most common defect. Usually
blemishes are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration);

b. Yellow leaves;

c. Orange buds (3 or more orange buds in a single area
is the cut-off point between blemished and
nonblemished) ;

d. Olive~green leaf stem (petiole);

e. Record on the defect tally the number of blemished
defects (each 2.5 g increment is 1 defect) as follows:

i. Minor; or
ii. Major; or / “#— Use photoguides for spears, if available.
iii. Severe. )

See also the next page.

110


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SPEARS (continuation).

Example 41: (Prerequisites on a container-by-container basis)

Carton No. 1 Carton No. 2 Carton No. 3, etc.

Similar Varietal Char. A A A
Brightness A A A
Flavor and Odor A A A
Grit and Silt A A A

The grade for a lot of broccoli spears may not be higher
than the grade of any "prerequisite" grade for any
individual sample unit in the sample. If the sample
should fail the anticipated grade because of a prerequisite
factor, don't skip the other factors. Continue grading
the sample but don't spend a lot of time with problem
areas, such as uniformity of size, borderline trim, border-
line development, etc.

Assemble (physically or mentally) all of the spears from

all of the containers into one sample. Adjust the total
number of spears in the sample to meet the lot single
sampling plan that you're using. If any of the cartons
are "suspect" in step 3, you may wish to assemble the
spears mentally into one sample. This procedure would
enable you to retain the identity of the "suspect"
cartons.

See also the next page.

69


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).

9. Weigh the loose leaves and pieces of leaves, if any, in
the sample unit. Count each 14 g increment of loose
leaf material as 1 minor defect. Record on the defect
tally the number of loose leaf defects as follows:

0 - 14 g =1 defect
15 - 28 g = 2 defects
29 - 42 g = 3 defects, etc.

Example 21:

Size (More than 4X)
Loose Leaves
Broken

Damaged 4

Blemished (Slightly) _—_
Trim (Reas. Well) In grade A

Trim (Poor) In grade B

RBOBAHE

Development
TOTAL MINOR

Loose leaves = 20 g —----—-—-— — — _

35


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

5. Uniformity of diameter (continuation).

Example 5:

Measure here
7 x

= 265 He ee ee

4

i

{

I 2.5 cm

'

I

T

1

|

t

1

\

heteieinelied Acceptable - — ~ — -

10


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-
SHORT SPEARS OR FLORETS (continuation).

4. Uniformity of size (continuation) .

Example 17:

Acceptable 4X variation

(Omen a

)a-----------

|

| fn

LINE INSPECTION

ve

(smallest)



Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
CULT BROCCOLI (continuation).

5. Assemble (physically or mentally) all of the cut broccoli
from all of the cartons that were drawn into one sample.
Adjust the entire sample (either by randomly removing cuts
or adding cuts) to meet the closest weight possible in
the lot single sampling plan. If any of the cartons
are "suspect" in step 3, you may wish to assemble the
broccoli mentally into one sample. This procedure would
enable you to retain the identity of the "suspect"

cartons.
Example 56:
NUMBER OF CARTONS
6 13 21 29
Total Weight of Broccoli 1/
(grams)

6 180 390 630 870
5
&

L 13 390 845 1365 1885
N

c .
R

E 25 750 1625 2625 3625
M
E
N

T 50 1500 3250 5250 7250
s

100 3000 6500 10500 14500

1/ Sample size x 5 g increments = weight of cut broccoli
equivalent to the number of sample units times the
standard sample unit size.

98


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SHORT SPEARS OR FLORETS (continuation).

13. Count the total number of short spears in the sample
that are adversely affected by development (head and
bud cluster stages of maturity). Use the USDA
Photoguides, if available. The development classification
of each broccoli short spear is one of the following:

a. Well developed (grade A development) - not a defect
in any grade;

b. Reasonably well developed (grade B development) - a
defect only in grade A; or

c. Poorly developed (Substandard development) - a defect
in grade A and grade B.

Record on the defect tally the total number of short spears
that are either "reasonably well developed" or "poorly
developed." If the sample fails requirements for grade A,
adjust the tally by dropping all “reasonably well developed"
short spears from the number of defects that are to be
counted against grade B. Reasonably well developed

(grade B development) isn't a defect in a grade B sample.
Count only "poorly" developed short spears as defects in

a grade B sample.

See also the next page.

91


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).

6. Evaluate "brightness" and record the letter grade
(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard.

7. At the same time that brightness is evaluated, record
the letter grade (A or SSTD) in the "prerequisites"
section of the defect tally for similar varietal
characteristics.

8. Evaluate the color of the individual broccoli spears.
The color classification of each broccoli spear is one
of the following:

a. Good color (grade A color) - not a defect in any
grade;

b. Reasonably good color (grade B color ) - a defect

only in grade A; or

c. Poor color (Substandard color) - a defect in grade A
and grade B.

If a spear is blemished because of orange buds, olive-green
leaf stem (petiole), etc., ignore the blemished areas for
purposes of color evaluation. In other words, don't
count a spear as "reasonably good" color or "poor" color
because it is blemished. Record on the defect tally the
number of spears that are either "reasonably good" or
"poor" color. If the sample unit fails requirements for
grade A, adjust the tally by dropping the number of
"reasonably good" spears from the grade B defects.
Reasonably good color (grade B color) is not a defect

in a grade B sample unit. Count only "poor" color spears
as defects in a grade B sample unit.

If the frozen broccoli is designated as grade B by the
processor, it weuld be necessary to count only the number
of "poor" color spears. Remember, however, the tally
could never be reevaluated for grade A.

See also the next page.

11


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

3.

Prerequisites, container-by-container (continuation).

The grade for a lot of cut broccoli may not be higher
than the grade of any "prerequisite" grade for any
individual sample unit in the sample. If the sample
should fail the anticipated grade because of a
prerequisite factor, don't skip the other factors.
Continue grading the sample but don't spend a lot of
time with style or problem areas, such as blemishes
or fiber.

While the cut broccoli is identified by individual
containers, determine compliance with head material
and leaf material. It isn't necessary to check each
individual carton but enough cartons should be checked
to satisfy yourself the requirements are either met or
failed. In the cartons that are selected for the
check, do the following:

a. Separate the head material and weigh ("Bald" units
completely stripped of flower buds should not be
counted as head material);

b. Separate the leaf material and weigh;

c. Allow the following:

’ Average: Head material not less than 25%.
Leaf material not more than 25%.
Individual sample cartons:

Head material not less than 15%.

Leaf material not more than 35%.

97


Frozen Broccoli
Revised
November 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

8.

Check the sample for style compliance. It isn't necessary to
use the same sample size that you're using for the other
factors. You may use a smaller sample size for style. The
smaller sample size makes grading faster. This procedure would
be the equivalent of drawing a subsample. For example, if
you're using 14500 g (29 x 100-5 g increments) for the other
factors, you could use 10500 g (21 x 100-5 g increments); or
6500 g (13 x 100-5 g increments); or 3000 g (6 x 100-5 g
increments) for style. If you do chose a smaller sample size
for style, be sure and note on the tally the size that you've
used for style. Otherwise, it's difficult to reevaluate the
tally.

To check for style, do the following:
a. Disregard leaf material, pieces of leaves and EVM;

b. Consider the product for the style that it is offered for
even though you may disagree with the declaration of
style;

Cc. Separate all cuts in the sample that are longer than 5S cm
and place them on a suitable scale. Record the composite
weight. Count each 5 g increment of this weight as 1
major style defective;

d. Separate all cuts in the sample that are shorter than
T.5 cm (exclusive of chaff) and place them on a suitable
scale. Record the composite weight. Count each 5 g
increment of this weight as 1 minor style defective;

e. Record the number of minor and major style defectives in
the style section of the defect tally. If a style failure
occurs, certify the style as "pieces";

See also the next page.

* Change

102


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

BROCCOLI PIECES (continuation).

3. Prerequisites, container-by—container (continuation).

The grade for a lot of broccoli pieces may not be higher

than the grade of any "prerequisite" grade for any
individual sample unit in the sample. If the sample
should fail the anticipated grade because of a
prerequisite factor, don't skip the other factors.
Continue grading the sample but don't spend a lot of
time on problem areas, such as blemishes or fiber.

_ lis

1/ Sam

weight

ple size x 5 g increments

of broccoli pieces equal to the number
of sample units times the standard

sample unit size.

4. Assemble (physically or mentally) into one sample all of
the broccoli pieces from all of the cartons that were
drawn. Adjust the entire sample (either by randomly
removing pieces or adding pieces) to meet the closest
Possible weight in the lot single sampling plan. If
any of the cartons are "suspect" in step 3, you may
wish to assemble the broccoli mentally into one sample.
This procedure would enable you to retain the identity
of the "suspect" cartons.

Example 68:
NUMBER OF CARTONS
6 13 21 29
Total Weight of Broccoli 1/
(grams)

5 6 180 390 630 870
g
I 13 390 845 1365 1885
N
. 25 750 1625 2625 3625
E
x 50 1500 3250 5250 7250
N
: 100 3000 6500 10500 14500


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

BROCCOLI PIECES (continuation).

8.

10.

11.

Cook a representative portion of the broccoli as outlined
in File Code 130-A-38. You may wish to select only
"suspect" units for the cooking test. Also, it isn't
necessary to cook each sample unit unless a problem
develops, such as fibrous units or grit.

Evaluate the cooked broccoli for flavor and odor. Assign

the letter grade (A, B or SSTD) for flavor and odor in
the section for "prerequisites." It isn't necessary to
cook each sample unit unless a problem develops. Consider
any objectionable “off-flavor" ("hay-like," "straw-like,"
"smoke," "chemical," or "sour"), but edible sample unit,
as Substandard. Permit a slight "hay-like" or "straw-
like" odor in grade B.

Evaluate the cooked broccoli for grit or silt. Assign

the letter grade (A, B or SSTD) for freedom from grit
in the section for "prerequisites." It isn't necessary
to cook each sample unit for the grit evaluation unless
a problem develops.

Evaluate the cooked broccoli for fiber. Be alert for

fiber located in the pieces that are cut from the base
end of the stalk. Fiber is a "fooler." It's usually
more tender after cooking than would be expected. It
isn't necessary to cook each sample unit unless a
problem develops. However, cook enough of the "suspect
units to set your sights. The expected incidence of
fiber may be higher in broccoli "pieces" than in any
other style because of the absence of any head material
requirement; thus, "pieces" may be composed of all stalk
material.

If any detectable fiber is to be counted against the
sample unit, cook the entire sample unit. Follow this
procedure.

a. Separate all of the units with major fiber (nonwoody-
noticeable fiber but can be eaten without difficulty)
and place them on a suitable scale. Record the
composite weight. Count each 5 g increment of this
weight as 1 major defect;

See also the next page.

65


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION
SPEARS (continuation).

6. Color of the individual spears (continuation).

If a spear is blemished because of orange buds, olive-green
leaf stem (petiole), etc., ignore the blemished areas for
the purpose of color evaluation. Don't count a spear as
"reasonably good" color or "poor" color because it is
blemished. Record on the defect tally the total number of
spears in the sample that are either "reasonably good"

or "poor" color (not each container). If the sample

fails requirements for grade A, adjust the tally by
dropping the number of "reasonably good" spears from the
grade B defects. Reasonably good color (grade B color)
is not a defect in a grade B sample. Count only "poor"
color against a grade B sample.

Example 43:
Ahh <
a a
\ gy
Size (Length) 10 \ 5
Detached Fragments J t a
M |Blemished (Materially) 10 t 2
A |Trim (Poor) In grade A lod
3 Development (Foor) . ' "
R |Fiber (Nonwoody) a ' |
_. TOTAL MAJOR _ 30 LO “-- -
rade A 4 3 t
cusum [?"3 - 44 13
rade B 1/16 4 {
(§ TOTAL ALL CLASSES 10 {
| ft rade A 2 |12 | 5 | |
i ICUSUM a
£ rade B 2 ta | 7 ——SS |
SAMPLE UNIT GRADE i
‘FINAL GRADE B
\

Drop the defects that are counted only against grade A, before

checking for compliance with grade B—- — ~ —- ~— — — -- fe

71


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

ll.

12.

13.

Count ‘the number of broken spears. These should be the
same spears that were reassembled in step 2, if any.
Record on the defect tally as minor defects the number
of broken spears (each reassembled spear is counted as
only 1 defect).

Count any mechanical damage to the head material of the
spears as a defect. Don't be overly critical -- only
materially damaged, or worse, are counted. Don't count
broken spears (step 11) or trimmed spears (step 14) as
damaged, or vice versa. Record on the defect tally as
minor defects the number of damaged spears.

Count the number of spears that are blemished. Blemished
broccoli is the most common defect. Usually, blemishes
are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration);

b. Yellow leaves;

c. Orange buds (6 or more orange buds in a single area
of the head is the cut-off point between blemished
and nonblemished);

d. Olive-green leaf stem (petiole); and

e. Record on the defect tally the number of blemished
spears as follows:

i. Minor; or
ii. Major; or })<—Use photoguides, if available.

iii. Severe.

16


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

6.

Separate all of the blemished units into 3 categories:

a. Slightly; or
b. Materially; or

c. Seriously.

Place each category, separately, on to a suitable scale.
Record the weight. Each 5 g increment of this weight
is 1 defect.

Blemished broccoli is the most common defect. Usually
blemishes are:

a. Discolored hollow or pithy stalks (Don't count hollow
or pithy stalks unless they're associated with
discoloration);

b. Yellow leaves;

c. Orange buds (3 or more orange buds in a single area
is the cut-off point between blemished and
nonblemished) ;

d. Olive-green leaf stem (petiole);

e. Record on the defect tally the number of blemished
defects (each 5 g increment.is 1 defect) as follows:

i. Minor; =|
ii. Major; or “@-—Use photoguides for spears, if available.

iii. Severe. J

See also the next page.

99


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).
13. Trimming (continuation).

Example 22: (Designated grade A production).

-Golor_(Reas. Good) In grade A|

Detached Fragments

Blemished (Materially)

Trim (Poor) In grade A

Development (Poor)

Fiber (Nonwoody)
TOTAL MAJOR

Grade A
| CUusUM Grade B

WOU

Size (More than 4X)

Loose Leaves

_Broken

Damaged

Blemished (Slightly)

Trim (Reas. Well) In grade A

_Trim (Poor) In grade B _

Development (Reas. Well) In A
TOTAL MINOR

TOTAL ALL CLASSES
d

| custm | Stade 4

| Grade B

SAMPLE UNIT GRADE

ROBAHR

PHO [~

Drop the defects that are counted only against grade A, before /
checking for compliance with grade B——~- --—~ ~ ~— —~ ~=-7”

38


Frozen Broccoli
Revised
November 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
CUT BROCCOLI (continuation).
8. At a sampling frequency outlined in File Code 120-A-5, check
the sample unit for style compliance. (NOTE: It isn't
necessary to check the style of each sample unit drawn for

quality).

a. Disregard leaf material, pieces of leaves and EVM;

be Consider the product for the style that it is offered for
even though you may disagree with the declaration of
style;

Cc. Separate all cuts in the sample unit that are longer than
5 cm and place them on a suitable scale. Record the

composite weight. Count each 5 g increment of this weight
as 1 major style defective;

d. Separate all cuts in the sample unit that are shorter than
T.5 cm (

* exclusive of chaff) and place them on a suitable
scale. Record the composite weight. Count each 5 g
increment of this weight as 1 minor style defective;

e. Record the number of minor and major style defectives in
the style section of the defect tally. If a style failure
occurs, certify the style as "pieces";

Example 29:

S | Major (Longer than 5 cm)

T [ cusum | A50g

y [Minor (Shorter than 1.5 cm) 7 116

L [cusim | 2509 4 tia

& [Head Material T Ls

Leaf Material cil
a)
an
Longer than 5 cm = +H al v4
i
7
Shorter than 1.5 cm = 38a .-

58

See also next page.

* Change


Frozen Broccoli
July 1980

sd

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI

1.

2.

Follow the procedure outlined in File Code 120-A-7 (Lot
Single Sampling Plan [Attributes]).

Use the same defect tally sheet for lot inspection as
you would use for on-line inspection. Ignore the section
of the tally devoted to CUSUM values.

Open each individual container that you have drawn for
the sample. Keep the product in its container. On a
container-by-container basis, without sorting through
the product, tentatively evaluate the following
prerequisites:

a. Evaluate "brightness" and record the letter grade
(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard.

b. At the same time that brightness is evaluated, record
in the "prerequisites" section of the defect tally
the letter grade (A or SSTD) for similar varietal
characteristics.

c. Evaluate the broccoli for odor. Assign the letter
grade (A, B or SSTD) for odor in the section for
"prerequisites." Consider any objectionable
"off-odor" ("hay-like," "straw-like," "smoke,"
"chemical" or "sour") as Substandard. But the sample
must be edible in step 10. Permit a slight “hay-like"
or "straw-like" odor in grade B.

d. Assign the letter grade (A, B or SSTD) for freedom
from grit in the section for "prerequisites."

See also the next page.

95


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SHORT SPEARS OR FLORETS (continuation).
3. Style defectives (continuation). -

Example 14:

Each short spear longer than 9.5 cm is one defective
unit for style

,

Each short spear shorter than 2 cm
is one defective unit for style x
\

\

on
ene

i

i
i
/

é

pO

Don't include leaf material
in the measurement ~— - - ~ ~


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).

14.

Count the number of spears that are adversely affected by
trimming. Use the USDA photoguides, if available. The
trim classification of each broccoli spear is one of

the following:

a. Well trimmed ade A trim) - not a defect in any grade;

.b. Reaso’ ly well trimmed rade B trim) - a defect only

in grade A; or

ec. Poorly trimmed (Substandard trim) - a major defect in
grade A and a minor defect in grade B.

Record on the defect tally the number of spears that are
either "reasonably well trimmed" or "poorly trimmed."

If the sample unit fails requirements for grade A, adjust
the defect tally by: (1) dropping all "reasonably well
trimmed" spears from the defects counted against grade B;
and (2) striking out the number of "poorly trimmed" spears
counted as major defects against grade A and moving them
to minor defects to be counted against grade B. If the
broccoli is designated as grade B by the processor, it
would be necessary to’count only the "poorly trimmed"
spears in each sample unit. Place the number of "poorly
trimmed" spears directly in the minor defect category.
Remember, however, the tally could never be reevaluated
for grade A.

See also the next page.

17


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

BROCCOLI PIECES

1.

2.

3.

Select at random a 250 g sample unit from the processing
line (either before freezing or after freezing). You may
also use the following optional sample unit sizes:

a- 500 g (100 - 5 g increments - use the 100 plan §2852.38b); or
b. 1000 g (200 - 5 g increments - use the 200 plan §2852.38b).

You should remember that larger sample unit sizes require
more time to grade. Regardless of the sample unit size
that you chose, keep it constant for each basic grading
period.

Arrange the sample unit of broccoli on a grading tray to
make each unit visible to you.

Evaluate "brightness" and record the letter grade (A, B or
SSTD) in the "prerequisites" section of the defect tally.
The overall brightness may be slightly dull in grade B.
Count "off-color" (yellowish or brownish discoloration) as
Substandard.

At the same time that brightness is evaluated, record the
letter grade (A or SSTD) in the "prerequisites" section
of the defect tally for similar varietal characteristics.

Evaluate the broccoli for development (head and bud
cluster stages of maturity). Even though the USDA photo-
guides which show various stages of development, cover
only spears, you may use these photoguides as an indication
of the cut-off point between "reasonably well developed"
and "poorly developed."

See also the next page.

61


Example 73:

Frozen Broccoli
July 1980

(Originally designated grade A, reevaluated against a

tighter grade A) XXX Arocle, hp A Loti

Om wd

| Similar Varietal Characteristics

_Brightness

_Flavor/Odor

Grit/Silt

HHBA

OD [> [> Pp

| TOTAL CRITICAL { :

cust | Grade B t

|Grade A 0.
0

AA adm HM

| Color (Poor)

Fiber (Woody)

HEM (Class 1)
TOTAL SEVERE

SS ae

cUSUM \Grade A

| [Grade B |

DAOoure

|Color (Reas. Good) In grade A..
Size (Length)

Detached Fragments
Blemished (Materially)
Trim (Poor) In grade A __

Development (Poor)
Fiber (Nonwoody)
____ TOTAL MAJOR

cusum -tade_A AQ4L=5.0

: eter)
Loose Leaves
Broken _
Damaged
Blemished (Slightly)

Trim (Reas. Well) In grade A
Trim (Poor) In grade B _d
jPevelopment (Reas. Well) In A

‘ MINOR

|

TOTAL ALL CLASSES

CUSUM

i Grade B |

‘ence 12 9
Grade A AGL=/STO ZI Yt 4
2

SAMPLE UNIT GRADE

FINAL GRADE

127



Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CHOPPED BROCCOLI (continuation).

9.

10.

11.

12.

After the sample has been evaluated for style, cook
a representative portion of the chopped broccoli as
outlined in File Code 130-A-38. You may wish to
select only "suspect" units (step 3) for the cooking
test. Also, it isn't necessary to cook the entire
sample.

Evaluate the cooked broccoli to verify the
tentative grade given for odor in step 3.

Evaluate the cooked broccoli by chewing representative

portions. This should verify the tentative grade
given for grit and silt in step 3.

Evaluate the cooked broccoli for fiber. Be alert for
fiber located in the units that are made from the base
end of the stalk. Fiber is a "fooler." It's usually
more tender after cooking than would be expected.

Cook enough of the "suspect" units to set your sights.

If any detectable fiber is to be counted against the
sample, cook all of the "suspect" units. Follow this
procedure:

a. Separate all of the units with major fiber (nonwoody-
noticeable fiber but can be eaten without difficulty)
and place them on a suitable scale. Record the
composite weight. Count each 2.5 g increment of this
weight as 1 major defect;

b. Separate all of the units with severe fiber (woody)
and place them on a suitable scale. Record the
composite weight. Count each 2.5 g increment of this
weight as 1 severe defect;

c. Record the number of major and severe fiber defects
on the defect tally.

See also the next page.

114


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

BROCCOLI PIECES

1. Follow the procedure outlined in File Code 120-A-7 (Lot
Single Sampling Plan [Attributes]).

2. Use the same defect tally sheet for lot inspection as
you would use for on-line inspection. Ignore the section
of the tally devoted to CUSUM values.

3. Open each individual container that you've drawn for
the sample. Keep the product in its container. Ona
container—by-container basis, without sorting through
the product, tentatively evaluate the following
prerequisites:

a.

d.

Evaluate "brightness" and record the letter grade

(A, B or SSTD) in the "prerequisites" section of the
defect tally. The overall brightness may be slightly
dull in grade B. Count "off-color" (yellowish or
brownish discoloration) as Substandard.

At the same time that brightness is evaluated, record
in the "prerequisites" section of the defect tally
the letter grade (A or SSTD) for similar varietal
characteristics.

Evaluate the broccoli for odor. Assign the letter
grade (A, B or SSTD) for odor in the section for
"prerequisites." Consider any objectionable
"off-odor," ("hay-like," “straw-like," "smoke,"
“chemical” or "sour") as Substandard. But the sample
must be edible in step 8. Permit a slight "hay-like"
or "straw-like" odor in grade B.

Assign the letter grade (A, B or SSTD) for freedom
from grit in the section for "prerequisites."

See also the next page.

116


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION
SPEARS (continuation).
3. Style defectives (continuation).

Example 1:

Each spear longer than 15.5 cm is one defective spear
for style - - an

Each spear shorter than 8.5 cm
is one defective spear for style .

aa

5
uss 4 ? ~~
\

Don't include leaf material
in the measurement ~~ - - - - -—


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

SHORT SPEARS OR FLORETS (continuation).

14.

15.

16.

Count the total number of pieces of harmless extraneous
material (HEM) in the sample (not each container).

Count pieces of other similar plants, such as cauliflower
or brussels sprouts, as class 1 HEM. Record on the defect
tally the total number of pieces of HEM as follows:

a. Severe; or
b. Critical.

Establish by. observation the predominant weight of the
short spears in the sample. Don't be overly critical.
If it is apparent the short spears vary less than

4 times (4X) from the predominant weight, accept them
as meeting requirements. If some short spears obviously
vary more than 4X from the predominant weight, do the
following:

a. Determine size variation so that the least number
of defects are tallied against size; and

b. Record on the defect tally the number of size
defects in the sample (not each container).

See also example 15, page 28; example 16, page 29; and
example 17, page 30.

Evaluate the sample for compliance with style:

a. Disregard loose leaf material, pieces of leaves,
EVM and detached fragments;

b. Determine the total number of short spears in the
sample (not each container) that are longer than
9.5 cm;

ec. Determine the total number of short spears in the
sample (not each container) that are shorter than
2 cm; and

d. Record the number of defective short spears in b and c
above in the style section of the defect tally. If a
style failure occurs, certify the grade but show:
"Fails style compliance for short spears." See also
example 14, page 26.

93


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SPEARS (continuation).
15. Development (continuation).

Example 12:

Color (Reas. Good) In grade A
Size (Length)
Detached Fragments
Blemished (Materially)
Trim (Poor) In grade A
Development (Poor)
Fiber (Nonwoody)

TOTAL MAJOR

Grade A

WDOUP ET

(Designated grade A production).

CUSUM

Grade B

| Size (Diameter) an
Loose Leaves

| Broken

Damaged

Blemished (Slightly)

Trim (Reas. Well) In grade A
Trim (Poor) In grade B
Development (Reas. Well) In A
i TOTAL MINOR

ROAHE

TOTAL ALL CLASSES
Grade A 2 12

HOH

CUSUM

i

Grade B 2

SAMPLE UNIT GRADE

{
t
i

A

Drop the defects that are counted only against grade A, before

checking: for compliance with grade B

21


Frozen Broccoli
July 1980

HOW TO REEVALUATE A DEFECT TALLY

It is possible to reevaluate a defect tally for frozen broccoli.
You may encounter this situation if past production is compared
against a more restrictive specification, such as a buyers'

specification, after the original inspection has been completed.

Use the general procedure to reevaluate a defect tally as
outlined in File Code 120-A-6 (Appendix). However, with frozen
broccoli, it is not possible to reevaluate against all grade
levels. This will depend upon the processors designated grade.

If the original grade was against designated grade A, it is
possible to reevaluate the tally for grades A and B. This is
because all of the "reasonably good" units have been tallied
against grade A.

If the original grade was against designated grade B, it is
not possible to reevaluate the tally against grade A -- only
grade B. This is because the "reasonably good" units have not
been tallied against grade A. .

If there is any chance the processor would ask that a tally

be reevaluated against a grade higher than the designated grade,
it would be well to prepare for this situation. You could keep a
record of all "reasonably good" units, even though the broccoli
is graded against grade B, but figure the CuSum values against
grade B only for the original grade. If the tally is to be
reevaluated later, figure the CuSum values against grade A by
including all "reasonably good" units in the tally.

See also the next page.

126


Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNDER LOT INSPECTION

CUT BROCCOLI (continuation).

6. Blemished (continuation)

Example 57:

Blemished (Seriously)

Fiber (Woody)

HEM (Class 1)

TOTAL SEVERE

AAS H

Grade A

0.4 (0.8 [1.6

CUSUM
Grade B

(Fiber (Nonwoody)

\Blemished (Materially)

TOTAL MAJOR

Grade A
CUSUM

i Grade B

i
|

ZH si wPoUuP

‘Blemished (Slightly). 7
{TOTAL MINOR

TOTAL ALL CLASSES

G
icUSUM rade A
| Grade B

It HOR

SAMPLE UNIT GRADE

FINAL GRADE

Slightly = 100 g-—— - - -—- -

100

Seriously = 20 g- —- - -
5



Frozen Broccoli
July 1980

SUGGESTED ORDER OF GRADING A SAMPLE UNIT UNDER ON-LINE INSPECTION

SHORT SPEARS OR FLORETS (continuation).

14. Development (continuation).

Example 24: (Designated grade A production).

Color (Reas. Good) In grade A

Detached Fragments
Blemished (Materially)

Trim (Poor) In grade A

Development (Poor)
Fiber (Nonwoody)

HOUrE

TOTAL MAJOR

Grade A

CUSUM

413
Grade B ileéla |

Size (More than 4X)
Loose Leaves

Broken

Damaged
Blemished (Slightly)

RPOBAHR

Trim (Reas. Well) In grade A

Trim (Poor) In grade B __
Development (Reas. Well) In A

i TOTAL MINOR
TOTAL ALL CLASSES
Grade A 2 | 12 | 5

46

CUSUM

i PHO

Grade B | 2 4114 | 7
SAMPLE UNIT GRADE

=

41@)
B

A |B)

Drop the defects that are counted only against grade A, before

checking for compliance with grade B ~~ - - - - -

41

<~

------

¢
-