4.2 Examination of container. After processing, the container shall be visually examined for compli

with 3.1.4, 3.1.5, and 3.1.9. Defects and defect classifications are listed in table II. 

TABLE II. Filled, sealed and processed container defects 1/

1/ The following procedure may be used by inspection personnel to examine for filled, sealed

and processed container defects on a consistent basis:

1. Remove tape from one end of protective sleeve only.

2. Remove tray from open end of protective sleeve.

3. Observe interior of sleeve for signs of food product/wetness as this may indicate a potential

defect.

4. Observe all sides of tray/lid for obvious leaks.

5. Set tray on flat surface, lid up and observe for apparent swelling. As there is a maximum

requirement for allowable residual gas, appearance of the lid should typically range from flush

with the surface of the tray flanges to somewhat concave from applied vacuum.

6. With the tray still on a flat surface, press down on the lid with both hands (palms down) and

apply a medium force (e.g., 30-40 Pounds). Listen and look for signs of air or food product

leakage.

7. Examine lid surface for cuts, holes, leaks, abrasions, seal width, continuous seals, etc. 

Focus attention to where the lid body interfaces the seal area. If the lid material overhangs the

tray flange at the outer edges, lift lid material slightly and examine where the underside of the

lid contacts the tray flange. This area may be slightly wetted if a non-continuous seal or other

defect is present.

8. Hold tray with lid down and examine the tray

body for holes, cuts, cracks, etc. or any areas

where wet or dry food product is apparent.

9. Record any defects in accordance with Table II.

10. Re-insert tray into sleeve and re-tape.

Polymeric Tray With Protective 

Sleeve

ppg ()

Updated to Include Change 03 (13 Jul 07)

POC: Bob Trottier, DoD Combat Feeding Directorate

Tel: (508) 233-5053, E-Mail: robert.trottier@us.army.mil

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p
with 3.1.4, 3.1.5, and 3.1.9. Defects and defect classifications are listed in table II. 

TABLE II. Filled, sealed and processed container defects 1/

Category Defect

Critical Major A Major B Minor

1 Swollen container.

Conforming Container (Non-Scoreable) Swollen Container

2 Tear, crack, cut, hole, or if a multi-layered laminate 

used, abrasion through more than one layer of the tr

or through the barrier (e.g., foil) layer of the lid 

material or leakage through any seal or surface.

Leakage Through Seal Hole in Lid

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General

3 Closure seal not continuous along tray flange surfac

Non-Continuous Seal Leakage Under a Non-Cont. Seal
Non-Continuous Seal Leakage Under same Seal

Category Defect

Critical Major A Major B Minor

4 Foldover wrinkle extending into the seal such that th

closure seal is reduced to less than 1/8 inch.

Foldover Wrinkle Across Seal

5 Presence of delamination when a multi-layered 

laminate is used. 3/

3

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/ Delamination defect classification:

Critical - Evidence of outer ply delamination such that the adjacent ply in the lid body is exposed

or evidence of multi ply delamination such that the food contact layer is exposed. Any evidence

of outer ply delamination of the tray body or internal layer separation within the tray body due to

for example, poor adhesion between layers.

Internal Layer Separation
102 Any impressions or design on the seal surfaces whi

conceals or impairs visual detection of seal defects

151 Presence of delamination when a multi-layered 

laminate is used. 3/

101 Unclean container. 4/

Category Defect

Critical Major A Major B Minor

3/ Delamination defect classification:

Major B - Delamination of the outer ply in the lid seal area that can be propagated to expose

the adjacent ply at the food product edge of the lid. 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 scored as a Major B defect. 

Additionally, spot delamination of the outer ply in the body of the lid that can be propagated 

beyond its initial borders is also a Major B defect. To determine if the delaminated area is a 

defect, use the following procedure: Mark the outside edges of the delaminated area using a 

bold permanent marking pen. Open the tray and remove the contents. Cut the lid on opposing 

sides of the delaminated area not closer than 3/16 inch from the delaminated area. Hold the 

delaminated area 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-counter clockwise directions. After flexing, the 

separated outer ply shall be grasped between thumb and forefinger and gently lifted away from 

the lid surface 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. Any propagation of the delaminated area, as evidenced by the 

delaminated area exceeding the limits of the outlined borders, shall be scored as a Major B 

defect.

Outer- Ply Delamination - Propagated Outer- Ply Delamination - Propagated

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201 Presence of delamination when a multi-layered 

laminate is used. 3/; 7/

Category Defect

Critical Major A Major B Minor

3/ Delamination defect classification (Continued):

Minor - Minor delamination of the outer ply in the lid 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. Isolated spots of delamination in the body of the lid that do not propagate when flexed as 

described above shall be classified as minor. Post-retort wrinkling of the outer ply in the lid sea

area shall also be scored as a minor defect. Note: Post-retort wrinkles of the outer ply are 

typically perpendicular to the flange direction, in a straight line, and extend from within the foo

product area to the outer edges of the lid.

Outer-Ply Delamination – Post-retort

(Non-Scoreable)

Outer-Ply Delamination – Post-retort

The following additional guidance is provided for scoring Minor 201 delamination:

If found within 1/16 inch of the FPE, post-retort wrinkles are technically scoreable as mino

defects. However, USDA and vendors should use their best judgment when scoring these wrink

As such, post-retort wrinkles should be scored as a minor defect only if they span the entire wid

seal.

202 Color does not contribute to woodland camouflage

Color not Woodland Camouflage

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Category Defect

Critical Major A Major B Minor

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203 Presence of any permanent tray body deformation 

such that deformed area is discolored and roughene

in texture.

Tray Body Deformation Tray Body Deformation

204 Areas of “wave-like” striations or wrinkles along th

seal area that span the entire width of seal. 4/; 7/

Wrinkle Across Seal Width – Fingernail 

“Catches”

Striation (Non-Scoreable)

Striation (Non-Scoreable) Wrinkle Across Seal Width, but Fingernail 

Doesn’t “Catch” (Non-Scoreable)
Category Defect

Critical Major A Major B Minor

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The following additional guidance is provided for scoring Minor 204 defects:

Striations or wrinkles that occur during sealing are technically scoreable as minor 204 defe

However, USDA and vendors should use their best judgment when scoring them.

As such, striations or wrinkles should be scored as minor 204 defects only if they:

- extend across the full width of seal, and

- for wrinkles, if running a fingernail across it (along the length of flange), th

fingernail "catches" on one or more of the wrinkles.

Type I Products

6 Abrasion on the lid material within 1/16 inch of food 

product edge of seal such that barrier (e.g., foil) laye

of the lid material is exposed. 7/

Foil Exposed at FPE

7 Presence of entrapped matter within 1/16 inch of the 

food product edge of seal or entrapped moisture or 

vapor within 1/16 inch of the food product edge of 

seal that results in less than 1/16 inch of defect free 

seal width at the outside edge. 2/; 7/

Entrapped Matter Entrapped Matter
Category Defect

Entrapped Matter

Critical Major A Major B Minor

103 Closure seal width less than 1/8 inch. 5/; 7/

Thin Seal - Long Side Thin Seal - Corner

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205 Presence of any seal defect or anomaly (for exampl

entrapped moisture, gases, etc.) within 1/16 inch of 

food product edge of seal. 5/; 7/

5/ The following shall be scored as minor defects if present within 1/16 inch of the food product

edge of seal:

a. Small concave impressions or cavities indicating slight tray imperfections or hard

particulates affixed to the seal head and contacting the lid and tray.

Concave Impression – Tray Imperfection
Category Defect

Critical Major A Major B Minor

b. Small (i.e., 1/32 inch or less in any direction) convex bumps or points on the seal area indica

small imperfections on the seal head. NOTE: This anomaly is typically visible on successive trays

coming off the heat sealer.

Seal Head Imperf. – Outside 1/16” of FPE Seal Head Imperf. – Within 1/16” of FPE 

c. Minor impressions or scorching of the top layer of the lid material on the seal area indicating

soft particulates on the seal head being “burned-off” during sealing. NOTE: This anomaly is

typically visible on successive trays coming off the heat sealer.

Scorching

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Entrapped Moisture or Vapor 

(Non-Scoreable)

d. Anomalies caused by entrapped moisture or vapor (which typically appear as concave spots

on the tray flange surface) that result in less than 1/8” of defect free seal width at the outside edge

of these spots.

Entrapped Moisture or Vapor

(Non-Scoreable)
2/ The following shall be scored as minor defects if present within 1/16 inch of the food product

edge of seal:

Category Defect

Critical Major A Major B Minor

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The following additional guidance is provided for scoring Minor 204d/e defects:

Entrapped matter is scored as before, i.e., if within 1/16 inch of the food product 

edge then it is a critical defect, regardless of defect-free seal width behind it.

Entrapped moisture or vapor within 1/16 inch of the food product edge can be 

scored as no defect, or a minor defect, or a critical defect, based on continuous defect

free seal width outside of the contaminated spot. Specifically, for entrapped moisture 

vapor within 1/16 inch of the FPE:

- if > 1/8 inch of defect free seal outside spot = no defect

- if < 1/8 inch of defect free seal outside spot = minor defect

- if < 1/16 inch of defect free seal outside spot = critical defect

USDA has developed an Excel chart (below) on entrapped matter/moisture 

contamination for additional assistance in scoring Critical 7 and Minor 204d/e defects

e. For solid products only, anomalies caused by entrapped matter that result in less than 1/8" bu

not less than 1/16" of defect free seal width at the outside edge of these spots. Solid products 

would include eggs, stuffing, mashed potatoes, rice, lasagnas, bakes, and other items possessin

minimal or no capability for hydraulic stresses during transport, and would exclude items 

packed in brine, gravy, and/or other low viscosity sauces. 

POLYMERIC TRAY DEFECTS CHART (Type I Products Only)

Based on MIL-PRF-32004A March 05, 2001 Performance Specifications

Updated on 11/02/01 to include Tray Pack PAT Meeting Inspection changes.

Updated on 11-08-01 to include different defect examples (Lee B. - USDA)

Updated on 11-09-01 after discussions between Lee Brothers, Donna McCarter and Robert Trottier

Updated on 04-01-03 to include differentiations between "solid" and "non-solid" product entrapped matter

Updated on 06/21/05 to update the defect name changes. Based on MIL-PRF-32004B w/change 01 24 FEB 05.

 ENTRAPPED MATTER (NON-SOLID PRODUCT) =

# 1 # 2 # 3 # 4 # 5 # 6 # 7 # 8

1/16" 1/32" 1/32"

1/16"

1/16" 1/32" 1/32"

*** measurements in cells represent seal area that is clear of defects.

Critical 7 Critical 7 Critical 7 Non-scorable Non-scorable Critical 7 Critical 7 Critical 7

Spot w /i 1/16" Spot w /i 1/16" Spot w /i 1/16" Spot outside 1/16" Spot outside 1/16" Spot w /i 1/16" Spot w /i 1/16" Spot w /i 1/16"

of FPE of FPE of FPE & total seal w idth & total seal w idth of FPE of FPE of FPE

>1/8" >1/8"

=

# 1 # 2 # 3 # 4 # 5 # 6 # 7 # 8

1/16" 1/32" 1/64" 1/32"

1/16"

1/16" 1/32" 1/64" 1/64"

Non-scoreable Minor 205d/e Critical 7 Non-scorable Non-scorable Critical 7 Minor 205d/e Critical 7

> 1/8" defect free between 1/16" < 1/16" dfs spot occurs spot occurs < 1/16" dfs between 1/16" & < 1/16" dfs

seal outside spot & 1/8" dfs outside outside spot >1/16" from FPE >1/16" from FPE outside spot 1/8" dfs outside outside spot

spot inner spot

1). ARE SEAL WIDTHS ON EITHER SIDE OF A DEFECT ADDED TOGETHER TO DETERMINE TOTAL DEFECT FREE SEAL AREA ?

Seal width is total available width at a particular point along the flange (with or without contamination present).

2). Discuss difference between MAJ A 103 and Minor 205d. (example: why is #2 on first chart different than #2 on second chart?)

Major A 103 is designed to find seal widths that are thin due to poor sealing practices, faulty trays, etc. Entrapped matter (non-solid product) i

before, i.e., if within 1/16" of FPE then it is a critical, regardless of defect-free seal width behind it. The new change is that entrapped moisture o

entrapped matter (solid product) within 1/16"of FPE can be scored as nothing, minor, or critical, based on continuous defect-free seal width out

contaminated spot.

3). DSCP will advise vendors and USDA contractually as to which products are "solid" in nature. Solid products would typically include eggs, stuf

potatoes, rices, lasagnas, bakes, and other items possessing minimal or no capability for hydraulic stresses during transport, and would exclu

packed in brine, gravy, and/or other low viscosity sauces.

FOOD PRODUCT EDGE

OUTSIDE SEAL EDGE

FOOD PRODUCT EDGE

OUTSIDE SEAL EDGE

 ENTRAPPED MOISTURE OR VAPOR ANENTRAPPED MATTER (SOLID PRODUC
3.1.6 Protective sleeve. The sleeve shall protect the tray, lid, and seals from physical damage. The 

maximum height of the filled, sealed and processed tray with protective sleeve shall not exceed 2-1/8 in

The length of the protective sleeve shall cover the entire tray flange, and shall not exceed 12-13/16 inch

The width of the protective sleeve shall fit snugly against the tray flange so as to restrict the sliding mo

of the tray within the sleeve. The top and bottom faces of the sleeve at the open ends shall be compres

such a manner so as to keep the top sleeve face flush against the tray lid and seams (see 6.4). The tray 

be restrained within the sleeve, at both ends, in such a manner so as to prevent the tray from sliding out

sleeve shall provide added stacking strength to the tray. The color of all inside and outside surfaces o

sleeve shall be natural kraft, tan, or dull gray. A label with the following instructions shall be printed, 

stamped, or otherwise applied onto the protective sleeve, in a manner that does not damage the sleeve, 

permanent ink of any contrasting color. Type size of the label shall be no smaller than shown below, b

be larger.

Proper Stack & Restraint Combo Improper Stack & Restraint Combo

4.3.8 Internal pressure.

4.3.8.1 Destructive. Internal pressure resistance... Any rupture of the container (i.e., through tray, lid 

closure seal) or evidence of any seal separation greater than 1/16 inch or minimum closure seal width 

than 1/16 inch shall be considered a test failure.

11 of 12 Seal Creep to less than 1/16”

4.3.8.2 Non-Destructive (Type I only). Internal pressure resistance resistance and container integrity 

be determined by using the approved Non-Destructive Static Compression Tester (ND Tester) or othe

apparatus expressly approved by the Government ...

4.3.8.2.1 Internal pressure resistance. When determining internal pressure resistance in accordance w

4.3.8.2, the following criteria shall apply: (a) Any rupture of the container (i.e., through tray, lid or cl

seal) or evidence of any seal separation greater than 1/16 inch or minimum closure seal width less t

1/16 inch shall be considered a test failure. The tray tested shall be withheld from the lot. (b) Any tr

passing the ND test and possessing a minimum closure seal width greater than 1/8 inch may be placed 

into the lot.
Proper Box & Liner Height Improper Box & Liner Height

Scored as Inadequate Workmanship

D-3 PACKING (From all Poly Tray Food Product PCRs)

• Packing for shipment to ration assembler. Four filled, sealed, processed and sleeved polymeric tra

shall be packed in a snug fitting fiberboard box conforming to style RSC-L, type CF, grade 275 of A

D 5118, Standard Practice for Fabrication of Fiberboard Shipping Boxes. The sleeved trays shall b

placed flat with the first two trays placed with the lids together and the next two trays with the lids tog

The box shall be closed in accordance with ASTM D 1974, Standard Practice for Methods of Closing

Sealing, and Reinforcing Fiberboard Shipping Containers.

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Additional Guidance for Army Veterinary Inspection (AVI) Personnel:

• Lid strain from excessive abuse. Polymeric trays that undergo excessive abuse (e.g., falling off tr

etc.) may exhibit lid strain with or without accompanying product leakage. Lid strain is the internal 

separation of one or more layers of the lid material from the tray flange caused by physical abuse, not 

deficiency of the lid material. Polymeric trays that exhibit lid strain should be examined carefully by 

personnel to determine if any material (product, moisture, oils, etc.) is leaking or has leaked through t

strained area. If there is any signs of leakage, the tray should be disposed of. If there are no signs of 

leakage, the tray should preferably be disposed of. If not, it should be heated and consumed immedia

(and inspected again after heating, prior to opening for consumption). Heated, but unopened trays exh

lid strain should not be reheated.

Lid Strain Without Leakage

Lid Strain Without Leakage