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SECTION C

This document covers a shelf stable performance readiness bar fortified with calcium and 

vitamin D.

C-1 ITEM DESCRIPTION

PCR-P-049A, PERFORMANCE READINESS BAR, FORTIFIED WITH CALCIUM 

CARBONATE AND VITAMIN D3, SHELF STABLE

Flavors.

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. Shelf life. The packaged product shall meet the minimum shelf life requirement of 12

months at 80oF.

 C. Appearance.

(1) General. The finished product shall be an intact bar with a smooth to slightly 

rough glossy exterior surface. The interior matrix shall have a dense and slightly porous 

structure. The finished product shall be free from foreign materials.

(2) Flavor I. The chocolate bar shall have a medium to dark brown exterior and 

interior color. The interior matrix shall have intact pieces of light and dark tan crisped cereal 

grains uniformly distributed throughout.

Flavor I – Chocolate

Flavor II – Tart cherry berry 

Flavor III – Salted caramel
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(3) Flavor II. The tart cherry berry bar shall have a medium reddish-pink exterior and 

interior color. The interior matrix shall have intact pieces of light tan crisped cereal grains

and distinct small pieces of dried cranberries uniformly distributed throughout. 

(4) Flavor III. The salted caramel bar shall have a light to medium tan exterior and 

interior color. The interior matrix shall have intact pieces of light and dark tan crisped cereal 

grains uniformly distributed throughout.

 D. Odor and flavor. The bar may have a slight to moderate bicarbonate or leavening agent 

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

(1) Flavor I. The chocolate bar shall have a moderately sweet baking chocolate, cocoa

and toasted grains odor and flavor. 

(2) Flavor II. The tart cherry berry bar shall have a moderate tart cherry, moderately 

sweet, slight cranberry and slight toasted grains odor and flavor. 

(3) Flavor III. The salted caramel bar shall have a moderately sweet, moderate buttery 

caramel and slight toasted grains odor and flavor. The bar shall have a slightly salty flavor. 

 E. Texture. The bar shall be chewy and slightly soft with crispy pieces of cereal grains. The 

Flavor II, tart cherry berry bar shall have soft and chewy pieces of dried cranberries. 

 F. Dimensions. The bar shall be not less than 4-1/4 inches and not greater than 5-1/4 inches 

in length by not less than 1-1/2 inches and not greater than 2 inches in width.

 G. Net weight. The net weight of an individual bar shall be not less than 2.3 ounces (65 

grams).

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

the approved product standard in palatability and overall appearance.

 I. Analytical requirements.

(1) Carbohydrate. The carbohydrate content shall be not less than 35 grams and not 

greater than 43 grams per bar.

(2) Protein. The protein content shall be not less than 8 grams and not greater than 12 

grams per bar. 
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(3) Calories. The calorie content shall be not less than 200 calories and not greater 

than 250 calories per bar.

(4) Calcium. The calcium content shall be not less than 850 milligrams and not 

greater than 1100 milligrams per bar.

(5) Vitamin D. The vitamin D3 content shall be not less than 1400 International Units 

(IU) and not greater than 2000 IU per bar.

(6) Water activity. The water activity (aw) shall be not greater than 0.55 when 

measured at 77oF (25oC).

 J. Microbiological requirements.

(1) Aerobic plate count. The aerobic plate count shall be not greater than 25,000 

Colony Forming Units (CFU) per gram in eight of nine samples and not greater than 50,000 

CFU per gram in any individual sample.

(2) Yeast and mold. The yeast and mold count (combined) shall not exceed 100 CFU 

per gram.

(3) Escherichia coli (E. coli) count. E. coli shall have less than 10 CFU per gram or 

less than 3 Most Probable Number (MPN) per gram, where findings indicate zero colonies 

CFU per plate or zero tubes producing gas for MPN.

(4) Salmonella. The product shall be Salmonella negative for each of nine pouches 

tested per production lot.

 K. Product formulation and ingredients. The following formulas shall be used for Flavor I 

chocolate and Flavor II tart cherry berry. Ingredient suppliers and available specific 

ingredients may change (companies bought out, part numbers change, ingredients no longer 

supplied, etc.). Any changes in formulations and ingredients shall be pre-approved by 

Combat Capabilities Development Command Soldier Center (DEVCOM SC), Combat 

Feeding Division.
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(1) Flavor I, Chocolate.

Ingredients Percent by weight

Corn syrup (DE 42) 19.200

Date plum or Plum/date/grape fruit paste 1/ 14.000

Soy protein cereal crisps 80% protein 2/ 12.300

Confectioners’ sugar 10.000

Maltodextrin (DE 10) 8.220

Crisp rice cereal, tiny round 2/ 8.000

High roast African liquor (chocolate wafers) 3/ 7.250

Dextrose monohydrate powder 5.000

Palm oil shortening 4.300

Vitamin premix 4/ 3.900

Cocoa powder, Red Dutch (10-12 percent fat) 3.000

Whey protein concentrate 80% 2.000

Glycerin USP or food grade 1.900

Lecithin 0.500

Vanilla powder 0.420

Ascorbyl palmitate 0.015

Mixed tocopherols 0.003

NOTE: The corn syrup and maltodextrin percentages may be adjusted to ease process and 

control end item texture. No other percentage adjustments shall be made.

1/ “Fructose, glycerin, date, plum, prep, (40 percent Fructose)” or “Plum/Date/Grape Fruit 

Paste Fat Replacer” from Mariani Ingredient Prod, 500 Crocker Rd., Vacaville, CA

95688.

2/ “Soy protein crisps 639” and “Crisp Rice Tiny Round 200” from Pacific Grain Products 

Inc., P.O. Box 2 Woodland, CA 95776.

3/ “H-365” from Wilbur Chocolate, Lititz, PA 17543.

4/ Vitamin premix shall include calcium carbonate and vitamin D3 and shall be made to 

ensure compliance with requirements as stated in C-2, I(4) and (5). Vendor shall use 

FT150302 from DSM Nutritional Products 2105 Technology Drive Schenectady, NY 12308 

(or equivalent premix).
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(2) Flavor II, Tart cherry berry.

Ingredients Percent by weight

Corn syrup (DE 42) 20.000

 

Tart cherry fruit paste 1/ 16.387

Maltodextrin (DE 10) 10.000

Milk protein cereal crisps 2/ 9.000

Tart cherry powder 3/ 9.000

Dried cranberries (Craisins) 8.430

Palm oil shortening 6.500

Milk protein isolate 90% 4/ 5.000

Instant whole oats 5.000

Isomaltulose (Palatinose) 4.250

Vitamin premix 5/ 3.910

Glycerin USP or food grade 2.000

Sunflower lecithin 0.400

Citric acid 0.100

Ascorbyl palmitate 0.020

Mixed tocopherols 0.003

NOTE: The corn syrup and maltodextrin percentages may be adjusted to ease process and

control end item texture. No other percentage adjustments shall be made.

1/ “Tart Cherry Filling Concentrate (052020-03-ST )” from Steward Ingredient 

Systems, Inc., 1843 W Fulton St., Chicago, IL 60612.

2/ “Crunchie milk protein crisps (74% protein)” from Glanbia Nutritionals, Inc, 

227 W Monroe St. Suite 5100, Chicago, IL 60606.

3/ “Tart Cherry RapiDry Powder N298” from FutureCeuticals, Inc., 2692N. State Rt. 1-17, 

Momence, IL 60954. 

4/ “Barpro 296 (milk protein isolate 90%)” from Glanbia Nutritionals, Inc, 

227 W Monroe St. Suite 5100, Chicago, IL 60606.

5/ Vitamin premix shall include calcium carbonate and vitamin D3. The following premix has 

been show to meet end item analytical requirements: FT150302 from DSM Nutritional 

Products 2105 Technology Drive Schenectady, NY 12308 (or equivalent premix).
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 L. Preparation and processing. The following preparation and processes were used at the 

DEVCOM SC for processing the performance readiness bars fortified with calcium 

carbonate and vitamin D3. Industrial preparation and processing equipment may be used to 

produce product of the same quality as produced at DEVCOM SC.

(1) Liquid mix. The liquid mix may be prepared as follows using a steam-jacketed 

kettle equipped with swept surface agitator.

 a. Add corn syrup and glycerin and heat to 180-200°F (82-93°C).

 b. Add shortening, lecithin, mixed tocopherols and ascorbyl palmitate; mix until 

shortening is melted completely. Allow the product temperature to drop to 160°F (71°C).

 c. Add fruit paste (as applicable) and mix thoroughly for 5 to 10 minutes or until 

uniformly mixed; maintain temperature at 150-160°F (66-71°C).

 

 d. Add chocolate liquor (for Flavor I) and mix thoroughly for 5 minutes until 

uniform; maintain temperature at 140°F (60°C).

 e. Maintain product under low agitation at a temperature not to exceed 140°F 

(60°C). Temperature may be lowered using cold water in kettle jacket if necessary to obtain 

suitable viscosity of final dough for extrusion.

 f. The liquid mix is drawn according to batch size. The liquid mix may be held in 

the kettle under low agitation up to 4 hours.

(2) Matrix mix. The matrix may be prepared as follows using an 80 quart Hobart 

Mixer with standard paddle.

a. Add liquid mix and mix 30 seconds on setting #3 (medium-high speed 183

revolutions per minute (RPM)).

 b. Add dry ingredients (dextrose, maltodextrin, cocoa, vanilla powder, as 

applicable) and mix 2 to 4 minutes on setting #1 (low speed 55 RPM) or until mix appears 

homogeneous.

c. Pre-blend isomaltulose (as applicable) and vitamin premix until uniform and 

then add to batch. Mix on setting #1 or #2 (low to medium speed 55-120 RPM) until 

uniformly distributed throughout the matrix. 
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 d. Add dried cranberries and oats (for Flavor II) and mix for 2 to 4 minutes on 

setting #2 (medium speed 120 RPM) until uniformly dispersed throughout matrix.

 e. Add cereal crisps and mix for 1 - 2 minutes on setting #1 (low speed 55 RPM) 

until crisps are uniformly dispersed throughout matrix. 

NOTE: Caution needs to be taken throughout mixing process to minimize breaking of the 

crisps.

(3) Bar forming. The bar may be formed as follows using a Hosokawa BEPEX 

GmhH Model F 97 265 – 266. Other types of bar forming such as, sheeting and/or slab 

forming equipment are also acceptable. Any type of high shear bar forming shall be avoided 

to maintain rice crisp integrity. 

 a. Product shall be extruded through a nozzle or sheeted/formed and cut to produce 

a bar with nominal dimensions as stated in C-2, F.

 b. Finished product is cooled to less than 90°F (32°C) prior to handling and

packaging.

C-3 MISCELLANEOUS INFORMATION

THE FOLLOWING IS INFORMATION ONLY TO PROVIDE THE BENEFIT OF PAST 

EXPERIENCE. THIS IS NOT A MANDATORY CONTRACT REQUIREMENT.

A. Ingredients and formulation. The ingredients and a generic formulation may be as follows:

(3) Flavor III, Salted caramel.

Ingredients Percent by weight

Flavored bar base 37.000

 

Maltodextrin (DE 10) 19.000

Isomaltulose (Palatinose) 11.000

Protein cereal crisps 10.000

Palm oil shortening 7.000

Milk protein isolate 90% 6.000

Vitamin premix 1/ 4.000

Sunflower lecithin Less than 2%

Ascorbyl palmitate Less than 2%

Mixed tocopherols Less than 2%
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1/ Vitamin premix shall include calcium carbonate and vitamin D3. The following premix 

has been show to meet end item analytical requirements: FT150302 from DSM Nutritional 

Products 2105 Technology Drive Schenectady, NY 12308 (or equivalent premix).

SECTION D

D-1 PACKAGING

 A. Packaging. One bar shall be commercially packaged in a foil or metalized laminate

pouch that will provide an effective light, moisture and oxygen barrier.

D-2 LABELING

 A. Packaged bar. Each packaged bar shall be labeled in accordance with all Food and Drug 

Administration (FDA) laws and regulations for commercially produced food products. In 

addition the commercially packaged product shall be labeled with the following:

(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) “Supplement Facts” label in accordance with the Dietary Supplement Health 

and Education Act (DSHEA) and all applicable FDA regulations

(7) DO NOT CONSUME MORE THAN 1 BAR WITHIN A 15 HOUR TIME 

PERIOD AND NO MORE THAN 2 BARS WITHIN A 24 HOUR TIME 

PERIOD

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 2050 would be coded as 0045. 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 snug-fitting shipping 

container and closed in accordance with good commercial practices. 
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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. 

 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 consumption of the product.

(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 PDM shall be inspected in accordance with the 

provisions of this document and evaluated for overall appearance and palatability. 

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

examination and the methods of inspection cited in this section. The contractor shall submit 

(36) sample bars during the first large scale lot of production as first article samples to be 

evaluated for conformance and comparability to the initial PDM. The selected bars shall be 

submitted to the following address for evaluation:
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COMBAT CAPABILITIES DEVELOPMENT COMMAND (DEVCOM) SOLDIER CENTER

FCDD-SCD-SCR

10 GENERAL GREENE AVENUE

NATICK, MA 01760-5000

E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT)

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

performance requirements specified in Section C of this Product Contract Requirements 

document utilizing the double sampling plans indicated in ANSI/ASQ Z1.4. The sample unit 

shall be one bar. 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.

TABLE I. Product defects 1/ 2/

Category Defect

Major Minor

General

101 Product not performance readiness bar or not flavor specified.

201 Bar not intact. 3/

202 Bar does not have a smooth to slightly rough glossy exterior

surface.

203 Bar interior matrix not a dense or not a slightly porous structure.

Appearance

204 Flavor I chocolate bar not a medium to dark brown exterior or 

interior color.

205 Flavor II tart cherry berry bar not a medium reddish-pink exterior 

or interior color. 

206 Flavor III salted caramel bar not a light to medium tan exterior or 

interior color.
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TABLE I. Product defects 1/ 2/ - Continued

Category Defect

Major Minor

207 Flavor I chocolate or Flavor III salted caramel bar interior matrix 

do not have intact pieces of light or not dark tan crisped cereal 

grains or not uniformly distributed throughout. 4/

208 Flavor II tart cherry berry bar interior matrix does not have intact 

pieces of light tan crisped cereal grains or not distinct small pieces 

of dried cranberries or not uniformly distributed throughout. 4/

Odor and flavor

102 Flavor I chocolate bar not a moderately sweet baking chocolate or 

not cocoa or not toasted grains odor or flavor.

103 Flavor II tart cherry berry bar not a moderate tart cherry or not 

moderately sweet or not slight cranberry or not slight toasted grains 

odor or flavor. 

104 Flavor III salted caramel bar not a moderately sweet or not a 

moderate buttery caramel or not slight toasted grains odor or flavor.

105 Flavor III salted caramel bar does not have a slightly salty flavor.

Texture 

209 Bar not chewy or not slightly soft or not with crispy pieces of 

cereal grains.

210 Flavor II tart cherry berry bar does not have soft or not chewy 

pieces of dried cranberries.

Dimensions

211 Bar is less than 4-1/4 inches or is greater than 5-1/4 inches in 

length by less than 1-1/2 inches or greater than 2 inches in width.

Net weight

212 Net weight of an individual bar less than 2.3 ounces (65 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/ The carbohydrate, protein and calories content shall be verified by the DSHEA 

“Supplement Facts” label. Product not conforming to the carbohydrate, protein or calories 

content requirements as specified in Section C-2, I of this document shall be cause for 

rejection of the lot.

3/ A bar that is broken into two or more pieces will be considered not intact.

4/ At least 50 percent of the crisped cereal grain pieces shall be intact upon visual 

examination of a cross section of the bar.

 B. Methods of inspection.

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

product has a 12 month shelf life when stored at 80°F. 

(2) Net weight. The net weight of the packaged bars shall be determined by weighing 

each sample unit on a suitable scale tared with a representative empty pouch. Results shall be 

reported to the nearest 0.1 ounce or to the nearest 1 gram.

(3) Nutrient content. The contractor shall provide a Certificate of Conformance (CoC)

for the lot including the production formula and premix source formula. Product not 

conforming to the ingredients, including vitamin premix and percentages as specified in 

Section C-2 of this Product Contract Requirements document shall be cause for rejection of 

the lot.

(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

Calcium 984.27, 985.01, or 2011.14 2/

Vitamin D3 2002.05, 2011.11, or 2016.05 2/

Verification will be conducted through actual testing by a third party certified analytical 

laboratory or DEVCOM SC. Test results shall be reported to the nearest milligram or IU, as 
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applicable. Any result not conforming to the vitamin and mineral requirement shall be cause 

for rejection of the lot.

2/ Tests will be conducted for calcium and vitamin D on the PDMs. If the formula is 

changed, then another set of tests shall be conducted by a third party certified analytical 

laboratory or DEVCOM SC, for calcium and vitamin D, and DEVCOM SC will be provided

a copy of the formulation.

(5) Water activity (aw) testing. Eight filled and sealed pouches shall be randomly 

selected from one production lot and tested for aw in accordance with the latest edition of the 

OMA of AOAC International, method 978.18, using an electric hygrometer system selftemperature controlled (at 25°C) or an equivalent instrument. Water activity shall be 

determined not less than 48 hours after packaging to allow moisture equilibration in the 

product. The sample unit shall be a specimen from the center of the product. Test results shall 

be reported to the nearest 0.01. Verification will be conducted through actual testing by a 

third party certified analytical laboratory or DEVCOM SC. Any nonconforming aw result 

shall be cause for rejection of the lot.

(6) Microbiological testing. Nine filled and sealed bars shall be randomly selected 

from one lot regardless of lot size (recommend selecting three bars each from the beginning, 

middle and end of production). The pouched product shall be individually tested for 

microbiological levels in accordance with the latest edition of the OMA of AOAC 

International or the FDA Bacteriological Analytical Manual (BAM). For aerobic plate count 

the average result for all pouched product tested must comply as provided in C-2, J(1). For 

yeast and mold, results for each pouched product must comply as provided in C-2, J(2). For 

E. coli and Salmonella, results for each pouch must comply as provided respectively in C-2, 

J(3) and (4). Verification will be conducted through actual testing by a third party certified 

analytical laboratory or DEVCOM SC. Any result not conforming to the microbiological 

requirements shall be cause for rejection of the lot.

Test Method Number

Aerobic plate count 966.23, 990.12, or BAM Ch. 3 

Yeast and mold 997.02 or BAM Ch. 18 

E.coli 991.14 or 2005.03

Salmonella 994.04, 967.26, 2003.09, 2004.03, or 2013.09
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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

GOVERNMENT PUBLICATION

FOOD AND DRUG 

ADMINISTRATION

Bacteriological Analytical Manual (BAM)

http://www.fda.gov/food/foodscienceresearch/laboratorym

ethods/ucm2006949.htm

NON-GOVERNMENTAL STANDARDS

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

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

AOAC INTERNATIONAL www.aoac.org

Official Methods of Analysis (OMA) of AOAC International