PKG&QAP A-A-20140D 

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SECTION C 

This document covers mayonnaise packaged in a flexible 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 

CID A-A-20140D, MAYONNAISE, SALAD DRESSING, AND TARTAR SAUCE 

Type I - Mayonnaise 

Style C - Fat Free (21 CFR § 101.62) 

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 Packaging Requirements and Quality Assurance Provisions 

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. The finished product shall be homogenous. 

 D. Odor and flavor. The packaged food shall be free from foreign odors and flavors. 

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

the approved product standard in palatability and overall appearance. 

Type and style. 
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 F. Net weight. The net weight of one serving of product shall be 28 grams. 

 G. Analytical requirements. The salt content shall be not less than 1.65 percent and not 

greater than 2.70 percent. The pH requirement, procedure, and testing shall be in accordance 

with A-A-20140D. 

 H. Emulsion stability. The emulsion stability requirements and procedures shall be in 

accordance with A-A-20140D. 

SECTION D 

D-1 PACKAGING 

 A. Packaging. Twenty-eight grams of product shall be filled into a preformed barrier 

pouch. 

(1) Preformed pouch. 

 a. Pouch material. The preformed pouches 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. The polyolefin layer of bag material shall be suitably 

formulated for hot fill or post-fill processing. 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 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 complete exterior 

surface of the pouch shall be uniformly colored in the range of 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 preformed 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) wide 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. 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. A tear nick, notch or serrations 
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shall be provided on one outside edge or two opposite outside edges of the pouch to facilitate 

easy opening of the filled and sealed pouch. A 1/8 inch (+1/16 inch) wide lip may be 

incorporated at the open end of the pouch to facilitate opening and filling of the pouch. 

 c. Pouch filling and sealing Twenty-eight grams of the fat free mayonnaise shall be 

filled into the pouch and the filled pouch shall be 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. 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-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 flavor 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. 

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, 

14 February 2013 would be coded as 3045. 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 
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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 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. 

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 item. 

 (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 
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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. 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: 

US Army Research, Development and Engineering Command 

Natick Soldier Research, Development and Engineering Center 

RDNS-CFF 

15 Kansas Street 

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. 

(2) Conformance inspection. Conformance inspection shall include the product 

examination 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 in A-A-20140D and specified in Section C of this Packaging 

Requirements and Quality Assurance Provisions 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. 
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 TABLE I. Product defects 1/ 2/ 

Category Defect 

Major Minor

 Appearance 

101 Product not type or not style as specified. 

 201 Mayonnaise not homogenous or not off-white to light cream in color 

or does not have a slight surface sheen. 

 Odor and flavor 

102 Not a slight vinegar odor or flavor with a pleasing spice note. 3/ 

 Texture 

 202 Not moderately thick or not creamy smooth. 

 203 Mayonnaise shows evidence of lumps or grittiness or gassiness. 

 Net weight 

 204 Net weight of an individual pouch less than 28 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/ May have egg yolk flavor notes. 

 B. Methods of inspection. 
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(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 examination. The net weight of the filled and sealed pouches shall be 

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

pouch. Results shall be reported to the nearest gram. 

(3) 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 method of the Official Methods 

of Analysis (OMA) of AOAC International: 

Test Method Number

Salt 941.13 or 971.27 

Test results shall be reported to the nearest 0.01 percent. Government verification will be 

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

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

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

characteristics conform to the specified requirements. 

 
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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 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,B(1)a. 

 (3) 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 AQL, expressed in 

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

 
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TABLE II. 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. 

 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: 
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 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 - 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. 
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 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. 

 B. Methods of inspection. 

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

c, 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 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 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 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. 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 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 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 
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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 II, footnote 2/) shall be 

considered a test failure. Any test failure shall be cause for rejection of the lot. 

 B. 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. 
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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 Forms 

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 

 

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 

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

Reinforcing Fiberboard Boxes 

D2103 Standard Specification for Polyethylene Film and 

Sheeting 
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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