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SECTION C

This document covers shelf stable sweet rolls packaged in a polymeric tray for use by the 

Department of Defense as a component of operational rations.

C-1 ITEM DESCRIPTION

PCR-S-007A, SWEET ROLLS, PACKAGED IN A POLYMERIC TRAY, SHELF 

STABLE 

Flavor.

Flavor 1 - Cinnamon with white icing

C-2 PERFORMANCE REQUIREMENTS

 A. Product standard. A sample shall be subjected to first article (FA) or product 

demonstration model (PDM) inspection as applicable, in accordance with the tests and 

inspections of Section E of this Performance-based Contract Requirements (PCR) document. 

The approved sample shall serve as the product standard. Should the contractor at any time 

plan to or actually produce the product using different raw material or process methodologies 

from the approved product standard, which result in a product noncomparable to the product 

standard, the contractor shall submit a replacement FA or PDM for approval. In any event, all 

product produced must meet all requirements of this document including product standard 

comparability.

 B. Shelf life. The packaged product shall meet the minimum shelf life requirement of 36 

months at 80°F.

 C. Appearance.

(1) General. The finished product shall be fully baked sweet rolls. The product shall 

show no evidence of excessive baking (materially darkened or scorched). There shall be no 

evidence of compression streaks when broken by hand. The finished product shall be free 

from foreign materials.

(2) Flavor 1. Fifteen cinnamon rolls shall have a medium golden tan to brown exterior 

color with a dark brown cinnamon filling swirl. The interior shall be a light tan to yellow 

color with medium to dark brown cinnamon distributed throughout. The icing shall be white, 

smooth and glossy. The icing shall be packaged separately. 
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 D. Odor and flavor. 

(1) General. The packaged food shall be free from foreign odors and flavors.

(2) Flavor 1. The packaged food shall have a sweet, baked yeast dough and a

cinnamon odor and flavor. The white icing shall have a sweet odor and flavor. 

 E. Texture.

(1) Flavor 1. The cinnamon rolls shall have a soft and tender interior with a slightly

firm exterior. The icing shall be easily spreadable and smooth.

 F. Net weight.

(1) Flavor 1. The average net weight, without icing, shall be not less than 30 ounces 

(850 grams). The net weight of an individual polymeric tray, without icing, shall be not less 

than 29 ounces (822 grams). The average net weight of icing shall be not less than 6.0 ounces

(170 grams).

 G. Palatability and overall appearance. The finished product shall be equal to or better than 

the approved product standard in palatability and overall appearance.

 H. Analytical requirements. 

(1) Fat. The fat content shall be not less than 8.0 percent.

(2) Water activity. The water activity (aw) for the sweet rolls (without icing) shall be 

not greater than 0.89.

(3) Oxygen. The oxygen content of the filled and sealed polymeric tray shall not 

exceed 0.30 percent.

SECTION D

D-1 PACKAGING

 A. Preservation. Product as specified plus the appropriate number of oxygen scavengers 

and ovenable tray insert, if applicable, shall be filled and sealed into polymeric trays within 4 

hours of baking and the trays shall conform to the requirements of section 3 of MIL-PRF32004, Packaging of Food in Polymeric Trays, Type II Oven-baked products. Government 

verification testing and inspection of trays, lids, and fiberboard pads shall be in accordance 
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with section 4 of MIL-PRF-32004 and the Quality Assurance Provisions of Section E of this 

Performance-based Contract Requirements document. The requirement for protective sleeves 

shall not apply to Type II Oven-baked products.

 B. Component. For flavor 1, one pouch containing icing shall be provided for each 

polymeric tray of product. The following materials and processing requirements are for icing 

in a pouch prior to packaging with the product:

(1) Icing pouch.

 a. Material and construction. The preformed pouch shall be fabricated from 

material suitably formulated for food packaging and shall be in compliance with all 

applicable Food and Drug Administration (FDA) and United States Department of 

Agriculture (USDA) regulations. The material shall show no evidence of delamination, 

degradation, or foreign odor when heat-sealed or fabricated into pouches. The material shall 

not impart an odor or flavor to the product after filling and sealing. The pouch shall be made 

by heat sealing three edges with 3/8 inch (-1/8 inch, +3/16 inch) wide seals. The heat seals 

shall be made in a manner that will assure hermetic seals. The side and bottom seals shall 

have an average seal strength of not less than 6 pounds per inch of width and no individual 

specimen shall have a seal strength of less than 5 pounds per inch of width when tested as 

specified in E-6,B(1). Alternatively, the filled and sealed pouch shall exhibit no rupture or 

seal separation greater than 1/16 inch or seal separation that reduces the manufacturer’s seals 

to less than 1/16 inch when tested as specified in E-6,C(1)b. A tear notch shall be present in 

one or both side seals to facilitate opening.

b. Filling and sealing. Six ounces of icing shall be filled into the pouch and the 

filled pouch shall be heat sealed. The closure seal shall be free of foldover wrinkles or 

entrapped matter that reduces the effective closure seal width to less than 1/16 inch. Seals 

shall be free of impression or design on the seal surface that would conceal or impair visual 

detection of seal defects. The average seal strength shall be not less than 6 pounds per inch of 

width and no individual specimen shall have a seal strength of less than 5 pounds per inch of 

width when tested as specified in E-6,C(1)b. Alternatively, the filled and sealed pouch shall 

exhibit no rupture or seal separation greater than 1/16 inch or seal separation that reduces the 

effective closure seal width to less than 1/16 inch when tested as specified in E-6,C(1)c.

Residual headspace in the filled and sealed pouch shall be minimized to facilitate packing.

c. Pouch size. The filled and sealed pouch shall be a size that fits within the void 

created between the tray lid material and fiberboard pad added during packing.
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 C. Oxygen scavenger. The oxygen scavenger shall be constructed of materials that are safe 

for direct food contact. The oxygen scavenger shall be in compliance with all applicable 

FDA regulations.

 D. Ovenable tray insert. The ovenable tray insert (if utilized) shall be constructed of 

materials that are safe for direct food contact. The ovenable tray insert shall be in compliance 

with all applicable FDA and USDA regulations.

D-2 LABELING

 A. Polymeric tray body. The polymeric tray body shall be clearly printed or stamped, in a 

manner that does not damage the tray, with permanent ink of any contrasting color, which is 

free of carcinogenic elements. One end of the polymeric tray (see figure 1 of MIL-PRF32004) shall be marked with the product name and number of portions. If the tray body end 

markings are not readily legible in low light conditions, a small, easily legible label shall be 

applied, but not over any existing tray markings. All other markings may be applied along 

the tray body side. The marking of trays with the product name and lot number shall be 

applied at the time of tray scaling. 1/

Tray body markings shall include:

(1) Product name. Commonly used abbreviations may be used.

(2) Tray code includes: 2/

 Lot number

1/ As an alternate method, tray body markings may be clearly printed or stamped onto the 

polymeric tray lid at the time of tray sealing, in a manner that does not damage the lid, with 

permanent ink of any contrasting color, which is free of carcinogenic elements, provided that 

the required markings are applied onto the tray body prior to packing for shipment to ration 

assembler.

2/ The lot number shall be expressed as a four-digit Julian code. The first digit shall indicate 

the year of production and the next three digits shall indicate the day of the year (Example, 

14 February 2050 would be coded as 0045). The Julian code shall represent the day the 

product was packaged into the tray and the tray sealed. Sublotting (when used) shall be 

represented by an alpha character immediately following the four-digit Julian code. 

Following the four-digit Julian code and the alpha character (when used), the other required 

code information shall be printed in the sequence as listed above.
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 B. Polymeric tray lid. The lid shall be clearly printed or stamped in a manner that does not 

cause damage. Permanent ink of any contrasting color, which is free of carcinogenic 

elements, shall be used. As an alternate labeling method, a pre-printed self-adhering 0.002 

inch thick clear polyester label printed with indelible contrasting color ink may be used.

Note: The font tested by DEVCOM Soldier Center was Microsoft Helvetica. The font used 

shall be similarly clear/easy to read as Helvetica. The recommended font sizes are as follows: 

22 for the product name, 14 for “yield” and “to heat in water.” If an additional note is 

required on the label, it should also be in font size 14. All other information should be in 

font size 9.

(1) Lid labeling shall include: 

 Product name and flavor

 Ingredients

 Net weight

 Name and address of packer

 “Nutrition Facts” label in accordance with the Nutrition Labeling and Education 

 Act (NLEA) and all applicable FDA regulations

(2) Lid labeling shall also show the following statements:

 a. For flavor 1:

YIELD: Serves 15 portions; when cut 3 rows by 5 rows.

WARNING: Do not heat pouch or tray in oven.

TO OPEN: Using a clean knife, cut the lidding around the inside perimeter of 

the tray seals.

SUGGESTION: Cut lid along 3 sides and fold over uncut portion. Fold back 

to keep unused portions protected.

ICING: Icing is packaged in a separate pouch. Knead icing packet. Spread 

icing evenly on the surface of the sweet rolls using a spatula or knife. 

 C. Icing pouch. Each pouch shall be clearly printed or stamped, in a manner that does not 

damage the pouch. Permanent black ink or other contrasting color which is free of 

carcinogenic elements shall be used. The information may be located anywhere on the pouch 

(in one complete print).
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(1) Icing labeling shall include:

 Product name

 Ingredients

 Date 1/

 Net weight

 Name and address of manufacturer

1/ Each pouch shall have the date of pack noted by using a four-digit code beginning with the 

final digit of the current year followed by the three-digit Julian code. For example, 14 

February 2050 would be coded as 0045. The Julian code shall represent the day the product 

was packaged into the pouch.

(2) Pouch labeling shall also show the following statements: 

Knead pouch to soften icing.

 Apply icing in accordance with tray label instructions.

CAREFULLY PEEL POUCH AWAY FROM TRAY LID 

PRIOR TO SERVING

D-3 PACKING

 A. Packing. Four filled and sealed polymeric trays shall be packed with fiberboard pads in 

a fiberboard shipping container constructed in accordance with style RSC-L of ASTM 

D5118/D5118M, Standard Practice for Fabrication of Fiberboard Shipping Boxes. The 

fiberboard shall conform to type CF, class D, variety SW, minimum burst grade 200 or ECT 

32 of ASTM D4727/D4727M, Standard Specification for Corrugated and Solid Fiberboard 

Sheet Stock (Container Grade) and Cut Shapes. Type II oven baked product trays shall be 

stacked with lids oriented upright. Fiberboard pads shall be placed between the trays and on 

the top and bottom of the stacked trays. The pad dimensions shall be not less than 1/8 inch of 

the full length and width inside dimensions of the box and shall be fabricated of class D, 

minimum burst grade 200 fiberboard. Each box shall be closed in accordance with ASTM 

D1974/D1974M, Standard Practice for Methods of Closing, Sealing, and Reinforcing 

Fiberboard Boxes.

 B. Packing of icing pouches. In addition to the packing requirements in D-3,A, the 

following shall apply. One filled and sealed icing pouch shall be provided for each polymeric 

tray of specified product. The filled and sealed icing pouch shall be placed between the 

polymeric tray lid and fiberboard pad and secured to the tray lid using a food grade, peelable 
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adhesive or alternate method of attachment. The icing pouch shall peel away easily from the 

tray lid.

D-4 UNITIZATION

 A. Unit loads. Unit loads shall be as specified in accordance with DLA Troop Support 

Form 3507, Loads, Unit: Preparation of Semiperishable Subsistence Items.

D-5 MARKING

 A. Shipping containers and unit loads. Shipping containers and unit loads shall be marked 

in accordance with DLA Troop Support Form 3556, Marking Instructions for Boxes, Sacks, 

and Unit Loads of Perishable and Semiperishable Subsistence.

D-6 MISCELLANEOUS INFORMATION

THE FOLLOWING IS INFORMATION ONLY TO PROVIDE THE BENEFIT OF PAST 

GOVERNMENT EXPERIENCE. THIS IS NOT A MANDATORY CONTRACT 

REQUIREMENT.

 A. Icing pouch material. It has been found that a pouch with minimum inside dimensions of 

8-3/4 inches in length by 6-5/8 inches in width and fabricated from a 3-ply laminate 

constructed of, from inside to outside, 0.002 inch thick linear low density polyethylene, 

extrusion coated or laminated to 0.00035 inch thick aluminum foil, and extrusion coated or 

laminated to 0.0006 inch thick biaxially oriented nylon, meets the performance requirements 

of this document.

SECTION E INSPECTION AND ACCEPTANCE

The following quality assurance criteria, utilizing ANSI/ASQ Z1.4, Sampling Procedures and 

Tables for Inspection by Attributes, are required. Unless otherwise specified, single sampling 

plans indicated in ANSI/ASQ Z1.4 will be utilized. When required, the manufacturer shall 

provide the Certificate(s) of Conformance to the appropriate inspection activity. 

Certificate(s) of Conformance not provided shall be cause for rejection of the lot.

 A. Definitions.

(1) Critical defect. A critical defect is a defect that judgment and experience indicate 

would result in hazardous or unsafe conditions for individuals using, maintaining, or 

depending on the item; or a defect that judgment and experience indicate is likely to prevent 

the performance of the major end item, i.e., the consumption of the ration.
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(2) Major defect. A major defect is a defect, other than critical, that is likely to result 

in failure, or to reduce materially the usability of the unit of product for its intended purpose. 

(3) Minor defect. A minor defect is a defect that is not likely to reduce materially the 

usability of the unit of product for its intended purpose, or is a departure from established 

standards having little bearing on the effective use or operation of the unit.

 B. Classification of inspections. The inspection requirements specified herein are classified 

as follows:

(1) Product standard inspection. The first article or product demonstration model shall 

be inspected in accordance with the provisions of this document and evaluated for 

appearance, odor, flavor, and texture. Any failure to conform to the performance 

requirements or any appearance or palatability failure shall be cause for rejection of the lot. 

(2) Periodic review evaluation. The approved first article or product demonstration 

model shall be used as the product standard for periodic review evaluations. All food 

components that are inspected by the USDA shall be subject to periodic review sampling and 

evaluation. The USDA shall select sample units during production of contracts and submit 

them to the following address for evaluation:

COMBAT CAPABILITIES DEVELOPMENT COMMAND (DEVCOM) SOLDIER CENTER

FCDD-SCD-SCR

10 GENERAL GREENE AVENUE

NATICK, MA 01760-5000

One lot shall be randomly selected during each calendar month of production or as otherwise 

specified in the contract. Two (2) sample units shall be randomly selected from that one 

production lot. The two (2) sample units shall be shipped to DEVCOM Soldier Center within 

five (5) working days from the end of the production month from which they are randomly 

selected and upon completion of all USDA inspection requirements. The sample units will be 

evaluated for overall quality against the current first article or product demonstration model.

(3) Conformance inspection. Conformance inspection shall include the 

examinations/tests and the methods of inspection cited in this section.

E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT)

 A. Product examination. The finished product shall be examined for compliance with the 

performance requirements specified in Section C of this Performance-based Contract 

Requirements document utilizing the double sampling plans indicated in ANSI/ASQ Z1.4. 
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The lot size shall be expressed in trays. The sample unit shall be the contents of one tray, and 

the contents of the associated icing pouch, as applicable. The inspection level shall be S-3 

and the acceptable quality level (AQL), expressed in terms of defects per hundred units, shall 

be 4.0 for major defects and 6.5 for minor defects. Defects and defect classifications are 

listed in table I. The filled and sealed polymeric trays shall be brought to room temperature 

(65°F to 75°F).

TABLE I. Product defects 1/ 2/ 3/

Category Defect

Major Minor

Appearance

101 Product not flavor as specified.

102 Product not fully baked.

103 Evidence of excessive baking (materially darkened or scorched).

201 Evidence of compression streaks. 4/

104 Polymeric tray does not contain intact oxygen scavenger(s). 5/

105 Tear or hole or open seal in oxygen scavenger.

202 Evidence of delamination by ovenable tray insert (if utilized).

106 Less than 15 sweet rolls in a polymeric tray.

203 Flavor 1 cinnamon rolls not a medium golden tan to brown exterior 

color or not with a dark brown cinnamon filling swirl.

204 Flavor 1 cinnamon rolls interior not a light tan to yellow color or not 

with medium to dark brown cinnamon distributed throughout.

205 Icing pouch missing.

206 Icing pouch leaking.

207 Icing pouch not secured to tray lid.

208 Icing pouch does not peel away easily from lid.
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TABLE I. Product defects 1/ 2/ 3/ - Continued

Category Defect

Major Minor

209 Icing not white or not smooth or not glossy.

Odor and flavor

107 Flavor 1 packaged food not a sweet or not a baked yeast dough or not a 

cinnamon odor or flavor.

210 White icing not a sweet odor or flavor.

Texture

211 Flavor 1 cinnamon rolls not a soft or not a tender interior or not with a 

slightly firm exterior.

212 Icing not easily spreadable or not smooth.

Net weight

213 Net weight of an individual polymeric tray, without icing, less than 29.0

ounces (822 grams). 6/

214 Icing pouch net weight less than 6.0 ounces (170 grams).

1/ Presence of any foreign materials such as, but not limited to dirt, insect parts, hair, glass, 

wood, or metal, or any foreign odors or flavors such as, but not limited to burnt, scorched, 

rancid, sour, stale, musty or moldy shall be cause for rejection of the lot.

2/ Finished product not equal to or better than the approved product standard in palatability 

and overall appearance shall be cause for rejection of the lot.

3/ As applicable, bisect sweet rolls vertically in the center with a sharp knife to inspect for 

defects.

4/ When broken by hand.

5/ Construction of the oxygen scavenger and compliance with FDA regulations will be 

verified by Certificate of Conformance (CoC).
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6/ Sample average net weight, without icing, less than 30.0 ounces (850 grams) shall be 

cause for rejection of the lot.

 B. Methods of inspection.

(1) Shelf life. The contractor shall provide a Certificate of Conformance that the 

product has a 36 month shelf life when stored at 80°F. Government verification may include 

storage for 6 months at 100°F or 36 months at 80°F. Upon completion of either storage 

period, the product will be subjected to a sensory evaluation panel for appearance and 

palatability and must receive an overall score of 5 or higher based on a 9 point quality scale 

to be considered acceptable.

(2) Net weight. 

 a. Flavor 1. The net weight of the filled and sealed polymeric tray shall be 

determined by weighing each sample unit on a suitable scale tared with a representative 

empty tray, ovenable tray insert (if utilized), appropriate number of oxygen scavengers, and 

lid. Results shall be reported to the nearest 1 ounce or to the nearest 1 gram.

 b. Icing. The net weight of the filled and sealed pouch shall be determined by 

weighing each sample unit on a suitable scale tared with a representative empty pouch. 

Results shall be reported to the nearest 0.1 ounce or to the nearest 1 gram.

(3) Analytical. The sample to be analyzed shall be a one-pound composite of three 

filled and sealed polymeric trays that have been selected at random from one production lot. 

The sample to be analyzed shall not include the icing. The composite sample shall be 

prepared and analyzed in accordance with the following methods of the Official Methods of 

Analysis (OMA) of AOAC International:

Test Method Number

Fat 922.06, 991.36, 2008.06 or AACC 30-10

Moisture 925.45A or 2008.06

Test results shall be reported to the nearest 0.1 percent. Government verification will be 

conducted through actual testing by a Government laboratory. Any result not conforming to 

the analytical requirement shall be cause for rejection of the lot.

(4) Water activity. Eight filled and sealed polymeric trays shall be selected at random 

from one production lot regardless of lot size. Water activity (aw) shall be determined not less 

than 4 days but not more than 14 days after baking to allow moisture equilibration in the 

product. The product shall be individually tested for water activity in accordance with the 
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Official Methods of Analysis of the AOAC method 978.18, using an electric hygrometer 

system self-temperature controlled at 25°C or an equivalent instrument. The sample unit shall 

be a specimen from the center of the product. The results of each aw determination shall be 

reported to the nearest 0.01. Any result not conforming to the aw requirement shall be cause 

for rejection of the lot. The samples to be tested shall not include the icing.

(5) Oxygen testing. Eight filled and sealed polymeric trays shall be randomly selected 

from one production lot and individually tested for oxygen content. Testing shall be 

accomplished after the filled and sealed polymeric trays have been allowed to equilibrate at 

room temperature for not less than 72 hours from the time of sealing. Test results shall be 

reported to the nearest 0.01 percent. Any individual result not conforming to the oxygen 

content requirement specified in Section C of this Performance-based Contract Requirements 

document shall be classified as a major defect and shall be cause for rejection of the lot.

E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING 

MATERIALS)

 A. Packaging and labeling.

(1) Polymeric tray testing. For purposes of clarification, the polymeric tray without 

the lid will be referred to as the “tray” and the polymeric tray with the lid shall be referred to 

as the “container”. The tray, container and packaging materials, as applicable, in accordance 

with the lot size, sample unit, and inspection level criteria shall be examined for the 

performance characteristics listed in table I of MIL-PRF-32004, Packaging of Food in 

Polymeric Trays. Any test failure shall be classified as a major defect and shall be cause for 

rejection of the lot.

(2) Examination of container. The container shall be examined for the defects listed in 

table II of MIL-PRF-32004. The lot size shall be expressed in containers. The sample unit 

shall be one processed and labeled container. The inspection level shall be I and the AQL, 

expressed in terms of defects per hundred units, shall be 0.65 for major A defects, 2.5 for 

major B defects and 4.0 for minor defects. Two hundredFifty sample units shall be examined 

for critical defects. The finding of any critical defect shall be cause for rejection of the lot. 

The labeling defects are listed in table II as follows:

TABLE II. Container labeling defects

Category Defect

Major A Minor

101 Polymeric tray lid or body labeling missing or incorrect or 

illegible.
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201 When a pre-printed self-adhering label is used, the label not 

adhering to tray lid (for example, label raised or peeled back 

from edge to corner) or presence of any areas of gaps along the 

perimeter of the label where the label is not properly adhered.

(3) Label adhesive examination. When self-adhering labels are used, the adhesive 

shall be tested in accordance with ASTM D3330/D3330M, Standard Test Method for Peel 

Adhesion of Pressure-Sensitive Tape. In lieu of testing, a CoC shall be provided.

 B. Component. Inspection for icing pouch shall be as follows:

(1) Unfilled preformed icing pouch certification. A CoC may be accepted as evidence 

that unfilled pouches conform to the requirements specified in D-1,B(1)a. When deemed 

necessary by the USDA, testing of the unfilled preformed pouches for seal strength shall be 

as specified in E-6,C(1)a.

(2) Filled and sealed icing pouch examination. The filled and sealed pouches shall be 

examined for the defects listed in table III. The lot size shall be expressed in pouches. The 

sample unit shall be one pouch. The inspection level shall be S-3 and the AQL, expressed in 

terms of defects per hundred units, shall be 4.0 for major defects and 6.5 for minor defects.

TABLE III. Filled and sealed icing pouch defects 1/

Category Defect

Major Minor

101 Tear or hole or open seal.

102 Seal width less than 1/16 inch. 2/

103 Presence of delamination. 3/

104 Unclean pouch. 4/

105 Pouch has foreign odor.

106 Any impression or design on the heat seal surfaces which conceals 

or impairs visual detection of seal defects. 5/

201 Label missing or incorrect or illegible.

202 Tear nick or notch or serrations missing or does not facilitate 

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

2/

204 Presence of delamination. 3/

1/ Any evidence of rodent or insect infestation shall be cause for rejection of the lot.

2/ The effective closure seal is defined as any uncontaminated, fusion bonded, continuous 

path, minimum 1/16 inch wide, from side seal to side seal that produces a hermetically sealed 

pouch.

3/ Delamination defect classification:

Major - Delamination of the outer ply in the pouch seal area that can be propagated to 

expose aluminum foil at the food product edge of the pouch after manual flexing of the 

delaminated area. To flex, the delaminated area shall be held between the thumb and 

forefinger of each hand with both thumbs and forefingers touching each other. The 

delaminated area shall then be rapidly flexed 10 times by rotating both hands in alternating 

clockwise-counterclockwise directions. Care shall be exercised when flexing delaminated 

areas near the tear notches to avoid tearing the pouch material. After flexing, the separated 

outer ply shall be grasped between thumb and forefinger and gently lifted toward the food 

product edge of the seal or if the separated area is too small to be held between thumb and 

forefinger, a number two stylus shall be inserted into the delaminated area and a gentle lifting 

force applied against the outer ply. If separation of the outer ply can be made to extend to the 

product edge of the seal with no discernible resistance to the gentle lifting, the delamination 

shall be classified as a major defect. Additionally, spot delamination of the outer ply in the 

body of the pouch that is able to be propagated beyond its initial borders is also a major 

defect. To determine if the laminated area is a defect, use the following procedure: Mark the 

outside edges of the delaminated area using a bold permanent marking pen. Open the pouch 

and remove the contents. Cut the pouch transversely not closer than 1/4 inch (+1/16 inch) 

from the delaminated area. The pouch shall be flexed in the area in question using the 

procedure described above. Any propagation of the delaminated area, as evidenced by the 

delaminated area exceeding the limits of the outlined borders, shall be classified as a major 

defect.

Minor - Delamination of the outer ply in the pouch seal area is acceptable and shall 

not be classified as a minor defect unless it extends to within 1/16 inch of the food product 

edge of the seal. All other minor outer ply delamination in the pouch seal area or isolated 

spots of delamination in the body of the pouch that do not propagate when flexed as 

described above shall be classified as minor defects.
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4/ Outer packaging shall be free from foreign matter which is unwholesome, has the potential 

to cause pouch damage (for example, glass, metal filings) or generally detracts from the clean 

appearance of the pouch. The following examples shall not be classified as defects for 

unclean:

 a. Foreign matter which presents no health hazard or potential pouch damage and 

which can be readily removed by gently shaking the package or by gently brushing the pouch 

with a clean dry cloth.

 b. Dried product which affects less than 1/8 of the total surface area of one pouch 

face (localized and aggregate).

5/ If doubt exists as to whether or not the sealing equipment leaves an impression or design 

on the closure seal surface that could conceal or impair visual detection of seal defects, 

samples shall be furnished to the contracting officer for a determination as to acceptability.

 C. Methods of inspection. 

(1) Seal testing. The icing pouch seals shall be tested for seal strength as required in a, 

b or c, as applicable.

 a. Unfilled preformed icing pouch seal testing. The seals of the unfilled preformed 

pouch shall be tested for seal strength in accordance with ASTM F88/F88M, Standard Test 

Method for Seal Strength of Flexible Barrier Materials. The lot size shall be expressed in 

pouches. The sample unit shall be one unfilled pouch. The sample size shall be the number of 

pouches indicated by inspection level S-1. Three adjacent specimens shall be cut from each 

of the three sealed sides of each pouch in the sample. The average seal strength of any side 

shall be calculated by averaging the three specimens cut from that side. Any average seal 

strength of less than 6 pounds per inch of width or any test specimen with a seal strength of 

less than 5 pounds per inch of width shall be classified as a major defect and shall be cause 

for rejection of the lot.

 b. Icing pouch closure seal testing. The closure seals of the pouches shall be tested 

for seal strength in accordance with ASTM F88/F88M. The lot size shall be expressed in 

pouches. The sample unit shall be one pouch. The sample size shall be the number of 

pouches indicated by inspection level S-1. For the closure seal on preformed pouches, three 

adjacent specimens shall be cut from the closure seal of each pouch in the sample. The 

average seal strength shall be calculated by averaging the three specimens cut from the 

closure. Any average seal strength of less than 6 pounds per inch of width or any test 

specimen with a seal strength of less than 5 pounds per inch of width shall be classified as a 

major defect and shall be cause for rejection of the lot.
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 c. Internal pressure test. The internal pressure resistance shall be determined by 

pressurizing the pouches while they are restrained between two rigid plates. The lot size shall 

be expressed in pouches. The sample unit shall be one pouch. The sample size shall be the 

number of pouches indicated by inspection level S-1. If a three-seal tester (one that 

pressurizes the pouch through an open end) is used, the closure seal shall be cut off for 

testing the side and bottom seals of the pouch. For testing the closure seal, the bottom seal 

shall be cut off. The pouches shall be emptied prior to testing. If a four-seal tester (designed 

to pressurize filled pouches by use of a hypodermic needle through the pouch wall) is used, 

all four seals can be tested simultaneously. The distance between rigid restraining plates on 

the four-seal tester shall be equal to the thickness of the product +1/16 inch. Pressure shall be 

applied at the approximate uniform rate of 1 pound per square inch gage (psig) per second 

until 14 psig pressure is reached. The 14 psig pressure shall be held constant for 30 seconds 

and then released. The pouches shall then be examined for separation or yield of the heat 

seals. Any rupture of the pouch or evidence of seal separation greater than 1/16 inch in the 

pouch manufacturer’s seal shall be considered a test failure. Any seal separation that reduces 

the effective closure seal width to less than 1/16 inch (see table III, footnote 2/) shall be 

considered a test failure. Any test failure shall be classified as a major defect and shall be 

cause for rejection of the lot.

 D. Packing.

(1) Shipping container and marking examination. The filled and sealed shipping 

containers shall be examined for the defects listed in table IV. The lot size shall be expressed 

in shipping containers. The sample unit shall be one shipping container fully packed. The 

inspection level shall be S-3 and the AQL, expressed in terms of defects per hundred units, 

shall be 4.0 for major defects and 10.0 for total defects.

TABLE IV. Shipping container and marking defects

Category Defect

Major Minor

101 Marking missing or incorrect or illegible.

102 Inadequate workmanship. 1/

201 Arrangement or number of polymeric trays not as specified.

1/ Inadequate workmanship is defined as, but not limited to, incomplete closure of container 

flaps, loose strapping, inadequate stapling, improper taping, or bulged or distorted container.
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 E. Unitization.

(1) Unit load examination. The unit load shall be examined in accordance with DLA 

Troop Support Form 3507, Loads, Unit: Preparation of Semiperishable Subsistence Items. 

Any nonconformance shall be classified as a major defect.

SECTION J REFERENCE DOCUMENTS

Unless otherwise specified, the applicable version of these documents is that which is active 

on the date of the solicitation or contract.

DLA Troop Support Forms 

Form 3507 Loads, Unit: Preparation of Semiperishable Subsistence Items 

Form 3556 Marking Instructions for Boxes, Sacks, and Unit Loads of 

Perishable and Semiperishable Subsistence 

DEPARTMENT OF DEFENSE SPECIFICATION

MIL-PRF-32004 Packaging of Food in Polymeric Trays

GOVERNMENT PUBLICATIONS

Federal Food, Drug, and Cosmetic Act and regulations promulgated thereunder 

(21 CFR Parts 1 - 199) and (9 CFR Parts 1 - 391)

NON-GOVERNMENTAL STANDARDS

AMERICAN SOCIETY FOR QUALITY (ASQ) www.asq.org

ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes

ASTM INTERNATIONAL www.astm.org

D1974/D1974M Standard Practice for Methods of Closing, Sealing, and 

Reinforcing Fiberboard Boxes

D3330/D3330M Standard Test Method for Peel Adhesion of PressureSensitive Tape
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D4727/D4727M Standard Specification for Corrugated and Solid Fiberboard 

Sheet Stock (Container Grade) and Cut Shapes

D5118/D5118M Standard Practice for Fabrication of Fiberboard Shipping 

Boxes 

F88/F88M Standard Test Method for Seal Strength of Flexible Barrier 

Materials

AOAC INTERNATIONAL www.aoac.org

Official Methods of Analysis (OMA) of AOAC International 

AMERICAN ASSOCIATION OF CEREAL CHEMISTS (AACC)

 Approved Methods of the American Association of Cereal Chemists 

 (Application for copies should be addressed to: American Association of Cereal Chemists, 

3340 Pilot Knob Road, St. Paul, MN 55121.)