PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

1

SECTION C

This document covers a shelf stable recovery bar packaged in a flexible pouch for use by the 

Department of Defense as a component of operational rations. 

C-1 ITEM DESCRIPTION

PCR-R-016, RECOVERY BAR, PACKAGED IN A FLEXIBLE POUCH, SHELF 

STABLE 

Flavor

Flavor I - Salted caramel marshmallow crisp

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 Performance-based 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 36 

months at 80oF. 

 C. Appearance. 

(1) Flavor I. The finished product shall be a rectangular bar with a slightly rough 

glossy surface. The bar shall have a moderately porous structure and small intact pieces of 

off-white and light tan crisped cereal grains. The finished product shall be free from foreign 

materials.

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

(1) Flavor I. The packaged food shall have a moderate buttery caramel and slight 

vanilla odor and flavor and a moderately sweet, marshmallow, toasted grain and slightly salty

flavor. 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

2

 E. Texture. The bar shall be cohesive, soft, pliable and chewy with crispy cereal grains. 

 F. Dimensions. The bar shall be not greater than 4 inches in length and not greater than 2-

1/2 inches in width. 

 G. Net weight. The net weight of an individual bar shall be not less than 2.2 ounces (62 

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 45 grams per bar. 

(2) Protein. The protein content shall be not less than 8 grams and not greater than 14 

grams per bar.

(3) Fat. The fat content shall be not greater than 7 grams per bar. 

(4) Moisture. The moisture content shall be not greater than 9.0 percent.

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

measured at 77oF (25oC). 

(6) Oxygen. The oxygen content of the filled and sealed pouch shall not exceed 0.30 

percent.

 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 four of five 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. 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

3

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

tested per production lot. 

C-3 MISCELLANEOUS INFORMATION

THE FOLLOWING IS INFORMATION ONLY TO PROVIDE THE BENEFIT OF PAST 

GOVERNMENT EXPERIENCE. THIS IS NOT A MANDATORY CONTRACT 

REQUIREMENT.

A. Ingredients and formulation. Ingredients and formulation may be as follows:

Ingredients Percent by weight

Mix #1

Mini marshmallows 39.62

Sunflower oil 1.00

Butter or margarine (no partially 

hydrogenated oils) 

13.36

Mix #2

Salt 0.62

Whey protein isolate 2.56

Maltodextrin 7.18

No-calorie sweetener, granulated 

(maltodextrin and sucralose)

0.62

Mix #3

Caramel flavor 1.03

Vanilla extract 0.82

Mix #4

Crisp rice #200 Crisp rice cereal, tiny round 

1/

12.24

Soy protein crisps #639-IP 2/ 20.95

1/ 2/ “Crisp rice cereal, tiny round 200” and “soy protein crisps 639-IP” sourced from Pacific 

Grain Products Inc., P.O. Box 2060 Woodland, CA 95776. 

 

SECTION D

D-1 PACKAGING

 A. Packaging. One bar or one commercially prepackaged bar and one intact oxygen 

scavenger shall be packed in a preformed or form-fill-seal barrier pouch.
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

4

(1) Preformed pouch. 

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

ionomer or polyethylene 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 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 and shall conform to number 20219, 30219, 

30227, 30279, 30313, 30324, or 30450 of SAE AMS-STD-595, Colors Used in Government 

Procurement. 

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

inside dimensions of 4-1/2 inches wide by 7 inches long (± 1/8 inch in each dimension). 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 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. A 1/8 inch wide lip may be incorporated at the open end of the 

pouch. 

 c. Pouch filling and sealing. One bar or one commercially prepackaged bar, and 

one oxygen scavenger shall be inserted into the pouch. The filled pouch shall be sealed. The 

closure seal width shall be a minimum of 1/8 inch. 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 of the closure seal 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.

(2) Horizontal form-fill-seal pouches. 

 a. Pouch material. The horizontal form-fill-seal pouch shall consist of a formed 

tray-shaped body with a flat sheet, heat sealable cover or a tray-shaped body with a tray-
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

5

shaped heat sealable cover. The tray-shaped body and the tray-shaped cover shall be 

fabricated from a 3-ply flexible laminate barrier material consisting of, from outside to 

inside, 0.0009 inch thick oriented polypropylene bonded to 0.0007 inch thick aluminum foil 

with 10 pounds per ream pigmented polyethylene or adhesive and bonding the opposite side 

of the aluminum foil to 0.003 inch thick ionomer or a blend of not less than 50 percent linear 

low density polyethylene and polyethylene. The linear low density polyethylene portion of 

the blend shall be the copolymer of ethylene and octene-1 having a melt index range of 0.8 to 

1.2 g/10 minutes in accordance with ASTM D1238, Standard Test Method for Flow Rates of 

Thermoplastics by Extrusion Plastometer and a density range of 0.918 to 0.922 g/cc in 

accordance with ASTM D1505, Standard Test Method for Density of Plastics by DensityGradient Technique. Alternatively, 0.0005 inch thick polyester may be used in place of the 

oriented polypropylene as the outer ply of the laminate. The flat sheet cover shall be made of 

the same 3-ply laminate as specified for the tray-shaped body except the aluminum foil 

thickness may be 0.00035 inch. 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 color 

requirements of the exterior (oriented polypropylene or polyester side) of the laminate shall 

be as specified in D-1,A(1)a. 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 any odor or flavor to the 

product. 

 b. Pouch construction. The tray-shaped body and the tray-shaped cover shall be 

formed by drawing the flexible laminate material into an appropriately shaped cavity. The 

flat cover shall be in the form of a flat sheet of the barrier material taken from roll stock. One 

bar or one commercially prepackaged bar, and one oxygen scavenger shall be placed into the 

tray-shaped body of the pouch. Pouch closure shall be effected by heat sealing together the 

cover and body along the entire pouch perimeter. The closure seal width shall be a minimum 

of 1/8 inch. The closure seal 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. The maximum 

outside dimensions of the sealed pouch shall be 6 inches wide by 8-1/4 inches long. A tear 

nick, notch or serrations shall be provided to facilitate opening of the filled and sealed pouch. 

The sealed pouch shall not show any evidence of material degradation, aluminum stress 

cracking, delamination or foreign odor. Heat seals shall be free of 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.
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

6

(3) 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 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 2/ 

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 2030 would be coded as 0045. The Julian day code shall represent the day the 

product was packaged into the pouch. 

1/ Each pouch shall have the date of pack noted by using either a four-digit code or five-digit 

code. When using the four-digit code, begin 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. 

When using the five-digit code, begin with the decade digit of the current year followed by 

the three-digit Julian code. For example, 14 February 2050 would be coded as 50045. The 

Julian 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, 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. 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

7

D-4 UNITIZATION

 A. Unit loads. Unit loads shall be as specified in accordance with DLA Troop Support 

Form 3507, Loads, Unit: Preparation of Semiperishable Subsistence Items. 

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. 

(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 performance 

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 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

8

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: 

COMBAT CAPABILITIES DEVELOPMENT COMMAND (DEVCOM) SOLDIER CENTER

FCDD-SCD-SCR 

10 GENERAL GREENE AVENUE

NATICK, MA 01760-5000 

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

specified in the contract. Three (3) sample units shall be randomly selected from that one 

production lot. The three (3) 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. 

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 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. 

TABLE I. Product defects 1/ 2/ 

Category Defect

Major Minor

General

101 Product not flavor specified.

102 Pouch does not contain one bar and one intact oxygen scavenger. 3/
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

9

TABLE I. Product defects 1/ 2/

Category Defect

Major Minor

201 The finished product not a rectangular bar or does not have a 

slightly rough or not a glossy surface. 

202 The bar does not have a moderately porous structure or not small 

intact pieces of off-white or not light tan crisped cereal grains. 

Odor and flavor

103 Flavor I does not have a moderate buttery caramel or not a slight 

vanilla odor or flavor. 

104 Flavor I does not have a moderately sweet or not a marshmallow or 

not a toasted grain or not a slightly salty flavor.

Texture 

203 Bar not cohesive or not soft or not pliable or not chewy or not with 

crispy cereal grains.

Dimensions

204 Dimensions not as specified.

Net weight

205 Net weight of an individual bar less than 2.2 ounces (62 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/ Construction of the oxygen scavenger and compliance with FDA regulations shall be 

verified by a Certificate of Conformance (CoC). 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

10

 B. Methods of inspection. 

(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. 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 and 

oxygen scavenger. Results shall be reported to the nearest 0.1 ounce or to the nearest 1 gram. 

(3) Analytical. 

 a. Nutrients. The carbohydrate, protein, and fat content shall be verified by the 

NLEA “Nutrition Facts” label. Product not conforming to the carbohydrate, protein or fat

content as specified in Section C of this document shall be cause for rejection of the lot. 

 b. 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 

Official Methods of Analysis (OMA) of AOAC International, method 978.18, using an 

electric hygrometer system self-temperature 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. Test results shall be reported to the nearest 0.01. Verification 

will be conducted through actual testing by a government laboratory. Any nonconforming aw

result shall be cause for rejection of the lot. 

 c. Moisture testing. The moisture content shall be determined in accordance with 

the OMA of AOAC International method 925.45A or 925.09B. Results shall be reported to 

the nearest 0.1 percent. The lot size shall be expressed in pouches. The sample unit shall be 

one filled and sealed pouch. The inspection level shall be S-2 and the AQL, expressed in 

terms of defects per hundred units, shall be 2.5. Any result not conforming to the analytical 

requirement shall be cause for rejection of the lot. 1/ 

 d. Oxygen testing. Eight filled and sealed pouches shall be randomly selected from 

one production lot and individually tested for oxygen content. Testing shall be accomplished 

after the filled and sealed pouches have been allowed to equilibrate at room temperature for 

not less than 48 hours from the time of sealing. Test results shall be reported to the nearest 

0.01 percent. Government verification will be conducted through actual testing by a 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

11

Government laboratory. Any individual result not conforming to the oxygen content 

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

(4) Microbiological testing. Five filled and sealed pouches shall be randomly selected 

from the lot regardless of lot size. 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 results for each 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 respectively 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). Any result not conforming to the microbiological requirements shall be 

cause for rejection of the lot. 1/ 

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, 996.08, 2003.09, 2004.03, or 2013.09

1/ NOTE: The following conditions apply for analytical water activity, moisture, oxygen 

testing and microbiological testing:

 a. For prepackaged product received from a supplier that is not further processed, 

the contractor will furnish a Certificate of Analysis (CoA) providing test results showing that 

the product meets all analytical water activity, moisture, oxygen testing and microbiological 

requirements. No additional testing is required. 

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.
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

12

Characteristic Requirement paragraph Test procedure

Thickness of films for laminated 

material

D-1,A(1)a and D-1,A(2)a ASTM D2103 1/

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

Laminated material 

identification and construction 

D-1,A(1)a and D-1,A(2)a Laboratory evaluation

Color of laminated material D-1,A(1)a and D-1,A(2)a SAE AMS-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 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. 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

13

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.

108 Presence of stress cracks in the aluminum foil. 6/ 7/

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:

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 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

14

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. 

 b. Dried product which affects 1/8 inch by 1/8 inch or equivalent area or less 

(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.

6/ Applicable to form-fill-seal pouches only. 

7/ The initial examination shall be a visual examination of the closed package. Any suspected 

visual evidence of stress cracks in the aluminum foil (streaks, breaks, or other disruptions in 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

15

the laminated film) shall be verified by the following physical examination. To examine for 

stress cracks, the inside surface of both tray-shaped bodies shall be placed over a light source 

and the outside surface observed for the passage of light. Observation of light through the 

pouch material in the form of a curved or straight line greater than 2 mm in length shall be 

evidence of the presence of stress cracks. Observation of light through the pouch material in 

the form of a curved or straight line 2 mm in length or smaller or of a single pinpoint shall be 

considered a pinhole. Observation of ten or more pinholes per pouch shall be evidence of 

material degradation.

 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 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. 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. For the closure seal on preformed pouches, three 

adjacent specimens shall be cut from the closure seal of each pouch in the sample. For formfill-seal pouches, three adjacent specimens shall be cut from each side and each end 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 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 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 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

16

testing the side and end 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 rate of 1- 2 

pounds 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 and 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 Forms
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

17

Form 3507 Loads, Unit: Preparation of Semiperishable Subsistence 

Items

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/FoodScienceRese

arch/LaboratoryMethods/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

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 
PCR-R-016

5 August 2020 

W/Change 03 9 Jan 24 ES24-012 (DSCP-SS-24-00182)

18

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

SAE INTERNATIONAL www.sae.org

SAE-AMS-STD-595 Colors Used in Government Procurement