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SECTION C

This document covers fortified cheddar cheese spread packaged in a flexible pouch for use 

by the Department of Defense as a component of operational rations. 

C-1 ITEM DESCRIPTION

PCR-C-039A, CHEESE SPREAD, CHEDDAR, FORTIFIED, PACKAGED IN A 

FLEXIBLE POUCH, SHELF STABLE

Types.

Type I - Plain

Type II - With Jalapeno Peppers

Type III - With Bacon

C-2 PRODUCT 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 Product 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. Commercial sterility. The packaged food shall be thermally processed until 

commercially sterile in accordance with 21 Code of Federal Regulations (CFR) Part 113, 

Thermally Processed, Low Acid Food’s Packaged in Hermetically Sealed Containers.

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

months at 80°F.
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 D. Appearance. 

(1) General. The finished product shall show no evidence of excessive heating 

(materially darkened or scorched), mottling, curdling, or oiling off. The cheddar cheese 

spreads shall be smooth, homogenous, slightly plastic, light yellow-orange color (between 

No. 6 and No. 10 of the National Cheese Institute Color Standard), and shall have a uniform 

surface sheen. The finished product shall be free from foreign materials.

(2) Type II. The cheddar cheese spread with jalapeno peppers shall have small specks 

of green jalapeno pepper uniformly dispersed throughout. 

(3) Type III. The cheddar cheese spread with bacon shall have small pieces of brown 

to reddish-brown bacon uniformly dispersed throughout. 

 E. Odor and flavor. 

(1) General. The packaged food may have a slight bitterness from the medium cured 

cheese. The packaged food shall be free from foreign odors and flavors. 

(2) Type I. The plain cheddar cheese spread shall have a medium cured cheddar and 

cooked milk odor and a medium cheddar, salty, slightly buttery flavor.

(3) Type II. The cheddar cheese spread with jalapeno peppers shall have a medium 

cured cheddar, slightly buttery, and jalapeno odor and shall have a medium cheddar, salty, 

slightly buttery, and a moderate jalapeno flavor. The product shall impart a moderate heat or 

mouth burning sensation. 

(4) Type III. The cheddar cheese spread with bacon shall have a medium cured 

cheddar, slightly buttery, slightly meaty, and slightly smoky odor and shall have a medium 

cheddar, slightly buttery, salty, slightly meaty, and slightly smoky flavor. 

 F. Texture. 

(1) General. The cheddar cheese spread, after the pouch has been kneaded, shall have 

a smooth, homogenous, and easily spreadable texture. The cheddar cheese spread shall not 

have a grainy texture. 

 
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(2) Type II. The cheddar cheese spread with jalapeno peppers may have small soft 

specks of jalapeno pepper. 

(3) Type III. The cheddar cheese spread with bacon shall have bacon pieces that are 

soft to slightly firm and may be chewy. 

 G. Emulsion stability. The product shall show no evidence of emulsion separation. 

 H. Net weight. The net weight of an individual pouch shall be not less than 28 grams. 

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

the approved product standard in palatability and overall appearance. 

 J. Analytical requirements. 

(1) Fat. The fat content shall be not less than 38.0 percent and not greater than 43.0 

percent.

(2) Salt. The salt content shall be not less than 1.6 percent and not greater than 2.2 

percent for Types I and II. The salt content shall be not less than 1.8 percent nor greater than 

3.5 percent for Type III. 

(3) Moisture. The moisture content shall be not less than 38.0 percent and not greater 

than 42.0 percent. 

(4) pH. The pH shall be not less than 5.5 and not greater than 5.9.

 (5) Vitamin A. The vitamin A content shall be not less than 2350 International Units 

(IU) and not greater than 2850 IU per 100 grams. 

 (6) Vitamin D3. The vitamin D3 content shall be not less than 4.6 ug and not greater 

than 5.6 ug per 100 grams. 

(7) Calcium. The calcium content shall be not less than 350 mg and not greater than 

425 mg per 100 grams. 
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K. Ingredients. Ingredients shall be as follows: 

(1) Cheddar cheese. The quantity of milled/shredded medium cured cheddar cheese 

used shall be in accordance with the Definitions and Standards of Identity under the Federal 

Food, Drug and Cosmetic Act for pasteurized process cheddar cheese spread (21 CFR Part 

133.176) or pasteurized cheese spread with fruits, vegetables or meats (21 CFR Part 

133.176). 

(2) Butter or plastic cream. Butter or plastic cream, or a combination of both, shall be 

used as a fat standardizing ingredient. Milled cheese and butter or plastic cream, or a 

combination of both, shall be blended together in a steam jacketed vat, kettle, or laydown 

cooker. The mixture shall be heated to a temperature not to exceed 180°F while constantly 

stirring until the cheese and butter have completely melted. Scorching of the mixture shall be 

avoided. 

(3) Water. The amount of water used is dependent on the moisture content of the 

cheddar cheese, butter, and jalapeno peppers (type II only) and the amount of moisture lost 

during processing. The water may be added in several aliquots during the blending process. 

The water shall be used to dissolve the stabilizers, emulsifying agents, salts, and other 

powdered ingredients. 

(4) Stabilizer. Not more than 0.30 percent by weight of the finished product. 

(5) Emulsifying agents. Not less than 1.90 percent nor more than 3 percent by weight 

(anhydrous salts) of the finished product.

(6) Mono and diglycerides. Not more than 0.50 percent by weight of the finished 

product. 

(7) Salt. The amount of salt in the formula is dependent upon the salt content in the 

cheese and butter and jalapeno peppers (type II only). The total salt shall comply with the 

product requirements. 

(8) Cheese coloring. Cheese coloring compounds shall be specifically designed for 

coloring butter and cheese. Cheese coloring shall be added as necessary so that the finished 

product will conform to the color requirement.
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(9) Vitamins and mineral fortification. Vitamin A, vitamin D3, and calcium shall be 

added to the cheddar cheese spread in such quantity to comply with the product 

requirements.

(10) Acidifying agent. The acidifying agent shall be added after all ingredients have 

been blended and in a quantity to achieve a pH that complies with the finished product 

requirements.

(11) Jalapeno peppers. The amount of jalapeno peppers (pepper solids and liquid 

brine) used in type II product shall be of sufficient quantity to achieve a finished product 

odor and flavor. 

(12) Bacon bits. The amount of bacon bits used in type III product shall be of 

sufficient quantity to achieve a finished product odor and flavor. 1/ 

1/ Bacon bits EDP #34743 manufactured by Hormel Foods, Corp., Austin, Minnesota 55912 

performs satisfactorily in this product.

 L. Formulation. Formulations are as follows: 

(1) Type I. Cheddar cheese, butter or plastic cream, water, stabilizer, emulsifying 

agents, mono and diglycerides, salt, cheese color, vitamins, acidifying agent. 

(2) Type II. In addition to the ingredients listed for type I product, jalapeno peppers 

are included.

(3) Type III. In addition to the ingredients listed for type I product, bacon pieces 

cured with water, salt, sodium erythorbate, and sodium nitrite are included. The bacon pieces 

may also contain sugar, dextrose, brown sugar, sodium phosphates, potassium chloride, and 

flavoring. 

 M. Preparation and processing. Processing shall be on a continuous basis. 

(1) Preparation of the cheddar cheese. The cheddar cheese spread shall be produced 

from cheddar cheese (except for finish and appearance) U.S. Grade A medium cured or better

or bulk U.S. Extra Grade medium cured. The finish and appearance shall be U.S. Grade B 

medium cured or better. The cheddar cheese shall be at least 90 days old at time of use and 
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may be colored or uncolored. The medium cured cheddar cheese shall be trimmed and 

cleaned, as necessary, to remove all rind, wax, mold, or any other objectionable materials 

from the surface. The trimmed and cleaned cheddar cheese shall be milled or shredded. The 

milling or shredding of the cheese may be accomplished up to 24 hours prior to the 

preparation of the cheese spread. The milled/shredded cheese shall be protected from 

contamination in the clean covered containers and shall be held under refrigeration until time 

of use. 

(2) Preparation of the cheese spread. The cheddar cheese spread shall be prepared 

using the quantities of ingredients indicated based on the weight of the finished cheddar 

cheese spread and by blending the ingredients in accordance with an established process 

schedule or a method which results in the cheddar cheese spread complying with the product 

requirements. 

(3) Thermal processing. The cheddar cheese spread after blending shall be thermally 

processed in accordance with 21 CFR Part 113, Thermally Processed, Low-Acid Foods 

Packaged in Hermetically Sealed Containers.

 a. Records of processing temperatures. Recording charts of all heating and cooling 

times and temperatures, regardless of type of system used, shall be maintained. The charts 

shall be taken from recorders, which have been accurately calibrated in the applicable 

temperature range and time recording function. The recording clock time and actual time 

shall be synchronized during all processing operations. The charts shall also include the date, 

plant identification, operator, contract number, lot number, and product being run (for 

example, startup water, product, and post rinses). The charts shall be maintained for three 

years and shall be made available for review by the government inspector.

 b. Continuity of preparation, processing, and packaging. The cheddar cheese spread 

shall be prepared, processed, and filled into a pouch in a continuous manner with minimum 

delay between the various stages.

(4) Pouch filling and sealing. The cheese spread shall be aseptically filled (hot-filled) 

into a pouch, fabricated and constructed as specified in D-1,A(1), nitrogen flushed and sealed 

immediately after filling. If the cheddar cheese spread is not filled using an aseptic filler, all 

filling operations shall be conducted in a filling room maintained in a “clean room” 

condition. 
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(5) Filled pouch cooling temperature requirements. The filled and sealed pouch of 

cheddar cheese spread shall be water cooled, air cooled or a combination of both, sufficiently 

to ensure that the product temperature in the center of the pouch shall be below 100°F prior 

to packing for shipment to ration assembler. If water cooling is utilized, the pouches shall be 

thoroughly dry before packing. 

SECTION D

D-1 PACKAGING

A. Packaging. The product shall be packaged in a barrier pouch as described below. 

(1) Pouch. 

 a. Pouch material. The pouch shall be fabricated from 0.002 inch thick polyolefin 

film laminated or extrusion coated to 0.00035 inch thick aluminum foil which is then 

laminated to 0.0005 inch thick polyester. The three plies shall be laminated with the polyester 

on the exterior of the pouch. Tolerances for thickness of plastic films shall be plus or minus 

20 percent and tolerance for the foil layer shall be plus or minus 10 percent. The polyolefin 

layer of bag material shall be suitably formulated for hot fill or post-fill processing. The 

material shall show no evidence of delamination, degradation, or foreign odor. when heatsealed or fabricated into pouches. The material shall be suitably formulated for food 

packaging and shall not impart an odor or flavor to the product. The exterior surface of the 

pouch shall be uniformly colored and shall conform to number 20219, 30219, 30227, 30279, 

30313, 30324, or 30450 of FED-STD-595, Colors Used in Government Procurement. 

 b. Pouch construction. The pouch shall be a flat style pouch having maximum 

inside dimensions of 2-7/8 inches wide by 5-3/8 inches long. The pouch shall be made by 

heat sealing three edges with 3/8 inch (-1/8 inch, +3/16 inch) 1/4 inch (-1/8 inch, +1/4 inch) 

wide seals. The pouch shall show no aberration in the pouch material or heat 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. Alternatively, the pouch shall exhibit no rupture or seal separation greater 

than 1/16 inch or seal separation that reduces the effective closure seal width to less than 1/16 

inch when tested for internal pressure resistance. A tear nick, notch, or serrations shall be 

provided to facilitate opening of the filled and sealed pouch. Excess pouch material at the 
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edges of the pouch shall not exceed 3/16 inch. A 1/8 inch wide lip may be incorporated at the 

open end of the pouch. 

 c. Pouch filling and sealing. The product shall be filled into the pouch, nitrogen 

flushed and the pouch sealed. The pouch shall show no aberration in the pouch material or 

closure seal. 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. Alternatively, the pouch shall exhibit no rupture or seal separation greater than 1/16 

inch or seal separation that reduces the effective closure seal width to less than 1/16 inch 

when tested for internal pressure resistance. The pouch shall show no aberration in the pouch 

material or heat seals. Filled and sealed pouches showing aberrations shall withstand a 

minimum internal pressure of 17 pounds per square inch gauge (psig) for 30 seconds to 

verify package integrity. Not less than 24 hours after hot-filling, the pouches shall withstand 

an internal pressure of 17 psig for 30 seconds without rupture or seal separation greater than 

1/16 inch or seal separation that reduces the effective closure seal width to less than 1/16 inch 

when tested for internal pressure resistance.

D-2 LABELING

 A. Pouches. Each pouch shall be correctly and legibly labeled. Printing ink shall be 

permanent black ink or other dark contrasting color which is free of carcinogenic elements. 

The label shall contain the following information.

(1) Name and type of product (letters not less than 1/8 inch high)

(2) Ingredients

(3) Date 1/

(4) Net weight

(5) Name and address of packer

(6) "Nutrition Facts" label in accordance with the Nutrition Labeling and Education Act 

(NLEA) and all applicable FDA regulations

(7) KNEAD PACKAGE BEFORE OPENING

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

final digit of the current year followed by the three digit Julian day code. For example, 
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14 February 2017 would be coded as 7045. The Julian day code shall represent the day the 

product was packaged into the pouch. 

D-3 PACKING

 A. Packing. Not more than 40 pounds of product shall be packed in a fiberboard shipping 

box constructed in accordance with style RSC-L of ASTM D5118/D5118M, Standard 

Practice for Fabrication of Fiberboard Shipping Boxes. The fiberboard shall conform to type 

CF, class D, variety SW, burst grade 200 or ECT grade 32 of ASTM D4727/D4727M, 

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

and Cut Shapes. Each box shall be closed in accordance with ASTM D1974/D1974M, 

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

D-5 MARKING

 A. Shipping containers. Shipping containers shall be marked in accordance with DLA 

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

Perishable and Semiperishable Subsistence.

SECTION E INSPECTION AND ACCEPTANCE

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

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

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

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

Certificate(s) 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. 

(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. 
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(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 product 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: 

DEPARTMENT OF THE ARMY

FCDD-SCC-EMR

COMBAT CAPABILITIES DEVELOPMENT COMMAND-SOLDIER CENTER

10 GENERAL GREENE AVENUE

NATICK, MA 01760-5056 

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

specified in the contract. Six (6) sample units shall be randomly selected from that one 

production lot. The six (6) sample units shall be shipped to Natick within five (5) working 

days from the end of the production month from which they are randomly selected and upon 

completion of all USDA inspection requirements. The sample units will be evaluated for 

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

(3) Conformance inspection. Conformance inspection shall include the 

examinations/tests and methods of inspection cited in this section.
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E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT). 

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

product requirements specified in Section C of this Product Contract Requirements document 

utilizing the double sampling plans indicated in ANSI/ASQ Z1.4. The lot size shall be 

expressed in pouches. The sample unit shall be the contents of one pouch. The inspection 

level shall be S-3 and the acceptable quality level (AQL), expressed in terms of defects per 

hundred units, shall be 1.5 for major defects and 4.0 for minor defects. Defects and defect 

classifications are listed in table I. The pouches shall be kneaded prior to conducting any 

portion of the product examination. 
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TABLE I. Product defects 1/ 2/ 3/

Category Defect

Major Minor

Appearance

101 Product not fortified cheddar cheese spread or not type specified.

102 Evidence of excessive heating (materially darkened or scorched), 

mottling, curdling, or oiling off. 

201 Cheddar cheese spreads not smooth or not homogenous or not a

slightly plastic appearance. 

202 Cheddar cheese spreads, not a light yellow-orange color (between 

No. 6 and No. 10 of the National Cheese Institute Color Standard) or 

do not have a uniform surface sheen. 

203 Type II cheddar cheese spread with jalapeno peppers does not have 

small specks of green jalapeno pepper uniformly dispersed 

throughout. 

204 Type III cheddar cheese spread with bacon does not have small 

pieces of brown to reddish-brown bacon uniformly dispersed 

throughout. 

Odor and flavor

103 Type I plain cheddar cheese spread not a medium cured cheddar or 

not a cooked milk odor. 

104 Type I plain cheddar cheese spread not a medium cheddar or not 

salty or not a slightly buttery flavor.
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TABLE I. Product defects 1/ 2/ 3/ - Continued

Category Defect

Major Minor

105 Type II cheddar cheese spread with jalapeno peppers not a medium 

cured cheddar or not slightly buttery or not a jalapeno odor. 

106 Type II cheddar cheese spread with jalapeno peppers not a medium 

cheddar or not salty or not slightly buttery or not a moderate 

jalapeno flavor. 

107 Type II cheddar cheese spread with jalapeno peppers does not 

impart a moderate heat or mouth burning sensation. 

108 Type III cheddar cheese spread with bacon not a medium cured 

cheddar or not slightly buttery or not slightly meaty or not a slightly 

smoky odor. 

109 Type III cheddar cheese spread with bacon not a medium cheddar or 

not slightly buttery or not salty or not slightly meaty or not a slightly 

smoky flavor. 

Texture

205 Cheddar cheese spread not smooth or not homogenous or not an 

easily spreadable texture after kneading. 

206 Cheddar cheese spread has a grainy texture.

207 Type III cheddar cheese spread with bacon does not have soft to 

slightly firm bacon pieces. 

Net weight

208 Net weight of an individual pouch less than 28 grams.
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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/ Grade and age requirements of cheddar cheese shall be verified by USDA Grade 

certificate.

 B. Methods of inspection. 

 (1) Commercial sterility. Commercial sterility shall be verified in accordance with 

FDA regulations. 

(2) 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.

(3) Net weight. The net weight of the filled and sealed pouches 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 1 gram. 

(4) Analytical. The sample to be analyzed shall be a composite of eight filled and 

sealed pouches which have been selected at random from the lot. The composite sample shall 

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

of Analysis (OMA) of AOAC International:

Test Method Number

Fat 933.05, 2007.04, 2008.06

Salt 935.47, 971.27

Moisture 925.45D, 2007.04, 2008.06

pH 981.12
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Test results shall be reported to the nearest 0.1 percent for fat, salt, and moisture. Test results 

for pH shall be reported to the nearest 0.1. 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.

Using the same composite sample, vitamin and mineral testing is listed below: 

Test Method Number

Vitamin A 2001.13, 2011.07, or 992.06 1/

Vitamin D3 979.24, or 2002.05 1/

Calcium 985.35, or 2011.14 1/

Test results shall be reported to the nearest milligram, microgram, or IU, as applicable. Any 

result not conforming to the vitamin and mineral requirement shall be cause for rejection of 

the lot.

1/ Tests will be conducted by the contractor for vitamins A, D3, and calcium on the first 

production lot and USDA will perform verification testing and verify the formula. A Certificate of 

Conformance (CoC) will be provided on all future lots. If the formula is changed or a new 

contract starts, then another set of tests shall be conducted, a Certificate of Analysis (CoA) will be 

provided and USDA will verify the formula.

 (5) Emulsion stability. Eight filled and sealed pouches shall be randomly selected by 

USDA from each lot and individually tested for emulsion stability. The samples shall not be 

kneaded at any time during the temperature cycle test. The contractor will subject the 

pouches to the temperature cycles and present the pouches to USDA. USDA will evaluate the 

samples and record the results. Any nonconforming result shall be cause for rejection of the 

lot. The filled and sealed pouches shall be tested as follows:

 a. Hold for 2 days at a temperature of -20°F ± 5°F.

 b. Remove from -20°F and hold for 2 days at 70°F ± 5°F.

 c. Remove from 70°F and hold for 2 days at 100°F ± 5°F.

 d. Cool to 70°F ± 5°F and examine for emulsion separation. Examination for 

emulsion separation shall be performed on samples which have not been kneaded. 
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(6) Pouch filling and sealing. The nitrogen flush process shall be verified by USDA 

on the first production lot. A CoC will be provided on all future lots. If a new contract starts, 

then USDA will verify the nitrogen flush process again. 

E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING 

MATERIALS)

 A. Packaging. 

(1) Pouch material certification. The pouch material shall be tested for these 

characteristics. A CoC may be accepted as evidence that the characteristics conform to the 

specified requirements.

Characteristic Requirement paragraph Test procedure

Thickness of films for laminated 

material

 D-1,A(1)a ASTM D2103 1/

Aluminum foil thickness D-1,A(1)a ASTM B479 2/

Laminated material 

identification and construction 

 D-1,A(1)a Laboratory evaluation

Color of laminated material D-1,A(1)a FED-STD-595 3/

1/ Standard Specification for Polyethylene Film and Sheeting 

2/ Standard Specification for Annealed Aluminum and Aluminum-Alloy Foil for Flexible 

Barrier, Food Contact, and Other Applications 

3/ Colors Used in Government Procurement

(2) Unfilled pouch certification. A CoC may be accepted as evidence that unfilled 

pouches conform to the requirements specified in D-1,A(1)a and b. When deemed necessary 

by the USDA, testing of the unfilled pouches for seal strength shall be as specified in E6,B(1)a.
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(32) Filled and sealed pouch examination. The filled and sealed pouches shall be 

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

sample unit shall be one pouch. The inspection level shall be I and the acceptable quality 

level (AQL), expressed in terms of defects per hundred units, shall be 0.65 for major defects 

and 2.5 for minor defects. The finding of any critical defect shall be cause for rejection of the 

lot. All exterior surfaces and edges of the filled and sealed pouch shall be examined visually 

for product leakage, width of seals, and delamination while applying a manual kneading 

action which forces the product against the interior surface in the area being observed. 

Alternatively, all surfaces and edges of the filled and sealed pouch may be visually examined 

for product leakage, width of seals, and delamination by placing them in a vacuum chamber, 

dry desiccator, or similar apparatus, and subjecting them to a vacuum of 15 inches of 

mercury (atmospheric pressure is 29.9 inches of mercury) for 30 seconds. Any pouch that 

does not swell to form a tightly distended package having at least one distorted edge during 

the test shall be recorded as a leaker and shall be cause for rejection of the lot. After vacuum 

testing, the pouches shall be visually inspected for table II defects.

TABLE II. Filled and sealed pouch defects 1/

Category Defect

Critical Major Minor

1 Swollen pouch.

2 Aberrations in pouch material or heat seals resulting from 

heat sealing, pouch fabrication, hot filling or heat 

processing that reduce the effective closure seal width to 

less than 1/16 inch. 2/ 

3 Tear or hole or open seal.

101 Seal width less than 1/16 inch. 3/

102 Presence of delamination. 4/

103 Unclean pouch. 5/

104 Pouch has foreign odor.
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105 Any impression or design on the heat seal surfaces which 

conceals or impairs visual detection of seal defects. 6/ 

106 Not packaged as specified.

201 Label missing or incorrect or illegible.

202 Tear nick or notch or serrations missing or does not 

facilitate opening.

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

1/16 inch. 3/ 

204 Presence of delamination. 4/

205 Excess pouch material at edges exceeds 3/16 inch.

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

2/ Aberrations in pouch material or heat seals include:

a. Major fold-over wrinkles or severe wrinkles, that extend into heat seal area and 

reduce effective seal width to less than 1/16 inch; or

 b. Entrapped matter that extends into heat seal area and reduces effective seal width 

to less than 1/16 inch; or 

 c. Severe wrinkles in the body of the pouch along the inside edges of the heat seals. 

Pouches exhibiting one or more of these aberrations shall be tested in accordance with E6,B,(1),cb. 

3/ 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. Effective seals are defined as any uncontaminated, fusion bonded, continuous path, 

minimum 1/16 inch wide, that produces a hermetically sealed pouch. 
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4/ 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 in the body of the pouch 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 - 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. 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.

5/ 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:
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 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).

6/ 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 score the impression and/or design as a major defect, retain the sample, and contact 

the Government agency supervisor or the contracting officer for instruction. Samples shall be 

furnished to the contracting officer for a determination as to acceptability.

 B. Methods of inspection. 

(1) Seal Pouch integrity testing. The pouch seals integrity shall be tested for seal 

strength as required in, a or b, or c, as applicable. The lot 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. 

 a. Unfilled pouch seal testing. The seals of the unfilled pouch shall be tested for 

seal strength in accordance with ASTM F88/F88M, Standard Test Method for Seal Strength 

of Flexible Barrier Materials. The lot size shall be expressed in pouches. The sample unit 

shall be one pouch. The sample size shall be the number of pouches indicated by inspection 

level S-1. Three adjacent specimens shall be cut from each of the three sealed sides of each 

pouch in the sample. The average seal strength of any side shall be calculated by averaging 

the three specimens cut from that side. Any average seal strength of less than 6 pounds per 

inch of width or any test specimen with a seal strength of less than 5 pounds per inch of 

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

 b. Pouch closure seal testing. The closure seals of the pouches shall be tested for 

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

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

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

closure seal of each pouch in the sample. The average seal strength of the closure shall be 

calculated by averaging the three specimens cut from that 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 
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5 pounds per inch of width shall be classified as a major defect and shall be cause for 

rejection of the lot.

 

 a. Filled and sealed pouch seal testing. The seals of the pouches shall be tested for 

seal strength in accordance with ASTM F88/F88M. Two adjacent specimens shall be cut 

from the closure and bottom seals and three adjacent specimens shall be cut from the side 

seals of each pouch. The average seal strength of the side seals shall be calculated by 

averaging the three specimens cut from each side seal. The average seal strength of the 

closure and bottom seals shall be calculated by averaging the two specimens cut from each

closure and bottom seals. 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.

 cb. 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 end bottom of the pouch and the distance between restraining plates shall 

be 1/2 inch. 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 material degradation and separation or yield of the heat 

seals. Any rupture of the pouch material exposing the product content area to contamination 

or allowing for leakage or evidence of seal separation greater than 1/16 inch in the pouch 

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

effective seal width to less than 1/16 inch (see table II, footnote 2/) shall be considered a test 

failure. Filled and sealed pouches showing aberrations shall withstand a minimum internal 

pressure of 17 pounds per square inch gauge (psig) for 30 seconds to verify pouch integrity. 

Any rupture of the pouch material exposing the product content area to contamination or 

allowing for leakage or evidence of seal separation greater than 1/16 inch in the pouch seals 

shall be considered a test failure. Any seal separation that reduces the effective closure seal 
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width to less than 1/16 inch 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. 

 C. Packing. 

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

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

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

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

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

TABLE III. Shipping container and marking defects

Category Defect

Major Minor

101 Marking missing or incorrect or illegible.

102 Inadequate workmanship. 1/

201 More than 40 pounds of product.

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

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

SECTION J REFERENCE DOCUMENTS

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

on the date of the solicitation or contract.

DLA Troop Support Form

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

Perishable and Semiperishable Subsistence

FEDERAL STANDARD 

FED-STD-595 Colors Used in Government Procurement
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GOVERNMENT PUBLICATIONS

 Federal Food, Drug, and Cosmetic Act and regulations promulgated thereunder (21 

CFR Parts 1-199) 

U.S. Standards for Grades of Cheddar Cheese

NON-GOVERNMENTAL STANDARDS

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

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

Attributes

 ASTM INTERNATIONAL www.astm.org

B479 Standard Specification for Annealed Aluminum and 

Aluminum-Alloy Foil For Flexible Barrier, Food 

Contact, and Other Applications 

D1238 Standard Test Method for Melt Flow Rates of 

Thermoplastics by Extrusion Plastometer

D1505 Standard Test Method for Density of Plastics by the 

Density-Gradient Technique 

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

Reinforcing Fiberboard Boxes

D2103 Standard Specification for Polyethylene Film and 

Sheeting 

D4727/D4727M Standard Specification for Corrugated Solid Fiberboard 

Sheet Stock (Container Grade) and Cut Shapes
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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