PKG&QAP STAND UP POUCH

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SECTION C

This document covers product packaged in a stand up pouch for use by the Department of 

Defense as a component of operational rations. 

C-1 ITEM DESCRIPTION 

PACKAGING REQUIREMENTS AND QUALITY ASSURANCE PROVISIONS FOR 

PRODUCT PACKAGED IN A STAND UP POUCH

SECTION D

D-1 PACKAGING

 A. Packaging. The specified net weight of product (see Section C of applicable product 

document) shall be packaged and sealed in a stand up pouch. 

(1) Pouches. The pouch is to be used as a unit pack and as a rehydrating pouch for 

consumption of the product. 

 a. Pouch material. The pouch shall be fabricated from a laminated film that 

includes a polyethylene sealant layer, aluminum foil barrier layer, and an outer layer suitable 

for printing, resulting in a structure that is 0.0055 inches thick. The polyethylene sealant film 

shall be heat sealable and capable of producing a fusion seal. Tolerances for the thickness of 

plastic films shall be plus or minus 20 percent. The material shall show no evidence of 

delamination, degradation, or foreign odor when heat sealed or fabricated into pouches. The 

material shall be suitably formulated for food packaging and shall not impart an odor or 

flavor to the product. The material shall be approved for addition of hot water (less than or 

equal to 212°F). 

 b. Pouch construction. The pouch shall be a prefabricated, stand up pouch with an 

interlocking closure to facilitate product preparation. The pouch shall have an outside 

dimension of 7-1/2 inches (+ 1/8 inch) for the face width and 9-1/2 inches (+ 1/8 inch) for the 

face height and a gusset of not less than 1-1/2 inches (+ 1/8 inch) and not greater than (2-1/2 

inches (+ 1/8 inch) (see figure 1). Heat seals shall have a minimum width of 1/8 inch. The 

fusion heat seal shall have an average seal strength of not less than 7 pounds per linear inch 

and no individual specimen shall have a seal strength of less than 6 pounds per linear inch. 

Fusion heat sealed pouches shall be provided with appropriate tear nick, notch, or serrations 

to facilitate opening of the filled and sealed pouch. The interlocking closure of the pouch 
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shall not fail to remain closed/locked during the interlocking closure test. Pouches may also 

have a hang hole centered in the top of the front panel. 

 c. Pouch filling and sealing. The product and one oxygen scavenger shall be 

inserted into the pouch. The sealed pouch shall show no evidence of material degradation or 

delamination. The closure seal shall be applied not more than 1-1/2 inch from the open end 

of the pouch. The full width of the pouch closure seal shall be applied not equal or lower than 

the tear nick, notch, or serrations. 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 fusion heat seal strength shall be not less than 7 pounds 

per linear inch of width and no individual specimen shall have a seal strength of less than 6 

pounds per linear inch of width. The filled and sealed pouch shall have a minimum 1/8 inch 

width heat seal. Alternatively, the filled and sealed pouch shall exhibit no rupture or seal 

separation greater than 1/16 inch or seal separation that reduces the effective closure seal 

width to less than 1/16 inch when tested for internal pressure resistance. 

 d. 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 Food and Drug Administration (FDA) regulations. 

D-2 LABELING

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

permanent ink in a contrasting color which is free of carcinogenic elements. The information 

shall be located on the body of the pouch opposite the fin seal, and not closer than 1/16 inch 

to any seal. If a non-contact type printer is used, the information may be located anywhere on 

the pouch (in one complete print), except the fin seal face and the closure seal area. The use 

of commercial graphics is permitted. The label shall contain the following information:

(1) Product name (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/USDA regulations

(7) Directions for preparation: The directions for preparation shall be as specified 

in the applicable product document 
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1/ Each stand up 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 stand up pouch. 

NOTE: Commercial pouch graphics (colors, design and labeling) shall be submitted to the 

Contracting Officer for review and approval and to the Combat Capabilities Development 

Command (DEVCOM) Soldier Center (FCDD-SCD-SCR) for review.

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

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

metal fasteners are used in the box manufacturer’s joint or set-up, the fasteners on the inside 

of the box shall be covered with tape to protect the contents from mechanical damage.

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.

E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING 

MATERIALS) 

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

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

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

the performance of the major end item, i.e., the consumption of the ration. 

(2) Major defect. A major defect is a defect, other than critical, that is likely to result 

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

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

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

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

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

as follows:

(1) Conformance inspection. Conformance inspection shall include the 

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

 C. Packaging. 

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

characteristics. A Certificate of Conformance (CoC) may be accepted as evidence that the 

characteristics conform to the specified requirements. Compliance to 21 CFR substances in 

contact with near boiling water (< 212°F) may be verified by CoC. In addition, compliance to 

the requirements for inside pouch dimensions and dimensions of manufacturer's seals may be 

verified by CoC. 

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

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

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

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

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

 (3) Interlocking closure certification. A CoC may be accepted as evidence that the 

interlocking closure of the pouches conform to the requirements specified in D-1,A(1)b. 

When deemed necessary by the USDA, testing of the interlocking closure shall be as 

specified in E-6,D(1)d. 

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

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

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

terms of defects per hundred units, shall be 0.65 for major defects and 2.5 for minor defects.

TABLE I. Filled and sealed 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/ 

107 Not packaged as specified.

201 Label missing or incorrect or illegible.

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

opening (applicable to fusion sealed pouches only). 

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

inch.
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TABLE I. Filled and sealed pouch defects 1/ - Continued

Category Defect

Major Minor

204 Presence of delamination. 3/

205 Pouch does not meet design or dimensions as specified.

206 Pouch closure seal more than 1-1/2 inch from the open end of the 

pouch. Full width of the pouch closure seal is equal or lower than 

the tear nick or notch or serrations.

207 Interlocking closure fails to remain closed/locked.

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

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

defect.

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

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

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

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

described above shall be classified as minor defects.

4/ Outer packaging shall be free from foreign matter which is unwholesome, has the potential 

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

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

unclean:

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

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

with a clean dry cloth. 

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

(localized and aggregate). 

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

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

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

 D. Methods of inspection. 

(1) Seal testing. The pouch seals shall be tested for seal strength, internal pressure 

resistance, and interlocking closure test as required in a, b, c, or d, as applicable. 

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

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

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

The sample unit shall be one 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 or end. When testing the end 

seal of the pouch, one of the three specimens shall be cut from the center of the seal 

incorporating the folded fin seal juncture of the heat seal. For fusion heat seals, any average 
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seal strength of less than 7 pounds per linear inch of width or any test specimen with a seal 

strength of less than 6 pounds per linear inch of width shall be classified as a major defect 

and shall be cause for rejection of the lot.

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

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

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

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

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

average seal strength of any side, end or closure shall be calculated by averaging the three 

specimens cut from that side, end or closure. For fusion heat seals, any average seal strength 

of less than 7 pounds per linear inch of width or any test specimen with a seal strength of less 

than 6 pounds per linear inch of width shall be classified as a major defect and shall be cause 

for rejection of the lot.

 c. Internal pressure test. The internal pressure resistance shall be determined by 

pressurizing the pouches while they are restrained between two rigid plates. 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 sides and end of the pouch. When testing the closure seal, the top and interlocking 

closure 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 I, 

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. Interlocking closure test. The interlocking closure of the pouches shall be tested. 

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-2. Open a filled and 

sealed stand up pouch and rehydrate entree in accordance with the label directions for 

preparation. Close pouch. Invert pouch and suspend for 15 seconds. Interlocking closures 

that fail to remain closed/locked and spill contents out when inverted shall be classified as a 

minor defect and shall be cause for rejection of the lot.
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 E. Packing. 

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

containers shall be examined for the defects listed in table II. 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 II. 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. 
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FIGURE 1. Stand Up Pouch 

(Not actual size)
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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

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 

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

Reinforcing Fiberboard Boxes

D2103 Standard Specification for Polyethylene Film and Sheeting

D4727/D4727M Standard Specification for Corrugated and Solid Fiberboard 

Sheet Stock (Container Grade) and Cut Shapes

D5118/D5118M Standard Practice for Fabrication of Fiberboard Shipping 

Boxes 

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

Materials