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SECTION C

This document covers tortillas packaged in a flexible pouch for use by the Department of Defense 

as a component of operational rations.

C-1 ITEM DESCRIPTION

PCR-T-008A, TORTILLAS, PACKAGED IN A FLEXIBLE POUCH, SHELF 

STABLE

 Flavors.

Flavor 1 – Plain

Flavor 2 – Chipotle

 Packages.

Package C – Meal, Ready-to-EatTM (MRETM)

Package E – Unitized Group RationTM (UGRTM)-Heat & ServeTM (UGR-H&STM)

Package I – Unitized Group RationTM-B (UGR-BTM)

Package J – First Strike Ration® (FSRTM) 

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 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.

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(1) General. For packages C and J, the finished product shall be two baked intact 

tortillas prepared from enriched wheat flour. For package E and I, the finished product shall 

be 36 baked intact tortillas prepared from enriched wheat flour. The product may have small 

tan to amber spots (less than one inch) randomly dispersed on the surface. The tortillas shall 

be thin, round, and easily separable.

(2) Flavor 1. The plain tortillas shall be an off-white color. 

(3) Flavor 2. The chipotle tortillas shall be a light to medium tan-orange color and 

may contain orange to red flavor specs. 

 D. Odor and flavor. 

(1) General. The packaged food shall be free from foreign odors and flavors.

(2) Flavor 1. The plain tortillas shall have a cooked wheat flour, slightly sweet, 

slightly sour odor and flavor. The tortillas may have a slightly uncooked wheat dough flavor.

(3) Flavor 2. The chipotle tortillas shall have a cooked wheat flour, slightly sweet, 

slightly sour, slightly smoky, chipotle odor and flavor. The tortilla shall elicit a late sensation 

of moderate heat. The tortillas may have a slightly uncooked wheat dough flavor.

 E. Texture. The tortillas shall be soft, pliable, and slightly chewy.

 F. Size. The tortillas shall be not greater than 7.0 inches in diameter. 

 G. Net weight.

(1) Package C and J. The average net weight shall be not less than 2.1 ounces (60 

grams). No individual pouch shall have a net weight of less than 54 grams. 

(2) Package E and I. The average net weight shall be not less than 39.5 ounces (1120 

grams). No individual pouch shall have a net weight of less than 35.2 ounces (998 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.

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(1) Moisture. The moisture content shall be not greater than 26.0 percent.

 (2) pH. The pH shall be not less than 4.8 and not greater than 5.7.

(3) Water activity. The water activity (aw) shall be not greater than 0.85 when 

measured at 77.0°F (25°C).

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

percent.

(5) Calories. The calories content for the two tortillas shall not be less than 220.

(6) Trans fat. The trans fat content shall be not greater than 0 grams per serving.

SECTION D

D-1 PACKAGING

 A. Packaging. For package C and J, two tortillas (folded in half) and one oxygen scavenger 

shall be packaged in a preformed or form-fill-seal barrier pouch as described below. For 

package E and I, 36 tortillas (packed flat in two stacks of 18 tortillas) and oxygen 

scavenger(s) shall be packaged in a preformed or form-fill-seal barrier pouch as described 

below. 

(1) Preformed pouches.

 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. 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 FED-STD-595, Colors 

Used in Government Procurement. 

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

and J shall have maximum inside dimensions of 5 inches wide by 7-3/4 inches long. Package 

E and I shall have maximum inside dimensions of 9-1/2 inches wide by 15-3/4 inches long. 

The pouch shall be made by heat sealing three edges with 3/8 inch (±1/8 inch in any 

dimension) 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 to 

less than 1/16 inch when tested for internal pressure resistance. A tear nick, notch or 

serrations shall be provided to facilitate opening of the filled and sealed pouch. A 1/8 inch 

wide lip may be incorporated at the open end of the pouch.

 c. Pouch filling and sealing. For package C and J, two tortillas (folded in half) and

one oxygen scavenger shall be inserted into the pouch in a manner so as to avoid 

contamination of the closure seal area. For package E and I, 36 tortillas (packed flat in two 

stacks of 18 tortillas) and oxygen scavenger(s) shall be inserted into the pouch in a manner so 

as to avoid contamination of the closure seal area. For package E and I only, the filled pouch 

shall be sealed under a vacuum level of 8 to 12 inches of mercury. 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.

(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 trayshaped 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 Melt Flow 

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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 the

Density- Gradient 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. For

packages C and J, two tortillas (folded in half) and one oxygen scavenger shall be placed into 

the tray-shaped body of the pouch. For package E and I, 36 tortillas (packed flat in two stacks 

of 18 tortillas) and oxygen scavenger(s) shall be inserted into the tray-shaped body of the 

pouch. For package E and I only, the filled pouch body shall be sealed under a vacuum level 

of 12 to 14 inches of mercury. 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. For packages C and 

J, the maximum outside dimensions of the sealed pouch shall be 6 inches wide by 8-1/4 

inches long. For package E and I, the maximum outside dimensions of the sealed pouch shall 

be 10 inches wide by 16-1/2 inches long. A tear nick, notch or serrations shall be provided on 

one or more edges of the pouch 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.

(3) Oxygen scavenger. The oxygen scavenger shall be constructed of materials that 

are safe for direct and indirect food contact, and shall be suitable for use with edible 

products. The oxygen scavenger shall be in compliance with all applicable FDA regulations.

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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

(7) For Package E and I only:

Optional Heating Instructions: 

Tortillas may be heated in the pouch in boiling water for 5-10 minutes.

Yield: Serves 18 portions of 2 tortillas each.

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 2014 would be coded as 4045. The Julian day code shall represent the day the 

product was packaged into the pouch.

D-3 PACKING

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

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

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

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

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

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

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

D-5 MARKING

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 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 

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:

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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. For package C and J, three (3) sample units shall be randomly 

selected from that one production lot. For package E and I, two (2) sample units shall be 

randomly selected from that one production lot. The 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 Performance-based Contract 

Requirements document utilizing the double sampling plans indicated in ANSI/ASQ Z1.4. 

The lot size shall be expressed in pouches. For package C and J, the sample unit shall be the 

contents of one pouch. For package E and I, the sample unit shall consist of two tortillas from 

each pouch obtained as follows: Take each of the 2 stacks of 18 tortillas from each pouch and 

separate them into approximately equal halves. Take the right side tortilla from each half. 

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/ 3/ 4/

Category Defect

Major Minor

101 Package C and J product not two baked intact tortillas.

Package E and I product not 36 baked intact tortillas.

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TABLE I. Product defects 1/ 2/ 3/ 4/ - Continued

Category Defect

Major Minor

102 Oxygen scavenger(s) missing. 45/

Appearance

201 Product not thin or not round.

202 Tortillas not easily separable.

203 Flavor 1 tortillas not an off-white color.

204 Flavor 2 tortillas not a light to medium tan-orange color.

Odor and flavor

103 Flavor 1 plain tortillas do not have a cooked wheat flour, 

slightly sweet, slightly sour odor or flavor.

104 Flavor 2 chipotle tortillas do not have a cooked wheat flour, 

slightly sweet, slightly sour, slightly smoky, chipotle odor or

flavor. 

105 Flavor 2 chipotle tortillas do not elicit a late sensation of 

moderate heat.

Texture

106 Tortillas not soft or not pliable or not slightly chewy.

Size

205 Tortillas greater than 7.0 inches in diameter. 56/

Net weight

206 Package C and J net weight of an individual pouch less than 54 

grams. 67/ 

207 Package E and I net weight of an individual pouch less than 

35.2 ounces (998 grams). 78/ 

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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 mold, or any foreign odors or flavors such as, but not limited to burnt, 

scorched, rancid, 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/ The enriched wheat flour shall be verified with the statement of ingredients on the label.

4/ The trans fat content shall be verified by the NLEA “Nutrition Facts” label. Product not 

conforming to the trans fat content as specified in Section C of this document shall be cause 

for rejection of the lot.

45/ Construction of the oxygen scavenger and compliance with FDA regulations will be 

verified by Certificate of Conformance (CoC).

56/ The difference (Delta) between the X and Y measurements of the diagram shall not be 

greater than 0.75 inches. If the difference (Delta) is less than 0.75 inches, these out of round 

tortillas shall be acceptable.

 Y

 

 X

67/ Sample average net weight less than 2.1 ounces (60 grams) shall be cause for rejection of 

the lot. 

78/ Sample average net weight less than 39.5 ounces (1120 grams) shall be cause for 

rejection of the lot.

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 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 shall be determined by weighing each sample unit on 

a suitable scale tared with a representative empty pouch and appropriate number of oxygen 

scavenger(s). The results for the average net weight shall be reported to the nearest 0.1 ounce 

or to the nearest 1 gram. The results for the individual net weight shall be reported to the 

nearest 0.1 ounce or to the nearest 1 gram.

(3) Moisture content and pH. For package C and J, the sample to be analyzed shall be 

a composite of eight filled and sealed pouches that have been selected at random from one 

production lot regardless of lot size. For package E and I, the sample to be analyzed shall be 

a composite of three filled and sealed pouches that have been selected at random from one 

production lot. The product shall be analyzed for moisture content in accordance with the 

Official Methods of Analysis (OMA) of AOAC International, method 925.09, and for pH 

concentration in accordance with the OMA of AOAC International method 943.02. The 

sample unit shall be one filled and sealed pouch. Test results shall be reported to the nearest 

0.1 percent for moisture and to the nearest 0.1 value for pH level. Government verification 

will be conducted through actual testing by a Government laboratory. Any result not 

conforming to the analytical requirement shall be cause for rejection of the lot.

(4) Water activity (aw) testing. For package C and J, eight filled and sealed pouches 

shall be selected at random from the lot regardless of lot size. For package E and I, three 

filled and sealed pouches shall be selected at random from the lot regardless of lot size. 

Water activity (aw) shall be determined not less than 4 days but not more than 14 days after 

packaging the end item to allow moisture equilibration in the product. The pouched product 

shall be individually tested for water activity in accordance with the OMA of AOAC

International, method 978.18, using an electric hygrometer system self temperature 

controlled (at 25oC) or an equivalent instrument. The sample unit for package C and J shall

be a composite specimen made from the center of both tortillas in the pouch. For package E

and I, the sample unit shall consist of two tortillas from each pouch obtained as follows: Take 

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each of the 2 stacks of 18 tortillas from each pouch and separate them into approximately 

equal halves. Take the right side tortilla from each half. A composite specimen shall be made 

from the center of the two tortillas (one from each half) that were adjacent to each other. The 

results of each aw determination shall be reported to the nearest 0.01. Any individual result 

not conforming to the requirement shall be classified as a major defect and shall be cause for 

rejection of the lot.

(5) Calories. The calorie content shall be verified by the NLEA “Nutrition Facts” 

label. Product not conforming to the calorie content as specified in Section C of this 

document shall be cause for rejection of the lot.

(6) Oxygen content 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 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.

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. 

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 FED-STD-595 3/

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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.

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/

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TABLE II. Filled and sealed pouch defects 1/ - Continued

Category Defect

Major Minor

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 

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) 

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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 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.

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 

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 

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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 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 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 the 

form-fill-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 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 

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 

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 

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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.

 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

Form 3556 Marking Instructions for Boxes, Sacks, and Unit 

Loads of Perishable and Semiperishable Subsistence

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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

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

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

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For DLA Troop Support Website Posting

RDNS-SEC-F 23 January 2015

TO: DLA Troop Support - Subsistence

SUBJECT: ES15-017 (DSCP-SS-15-00444); Request change to Fat content requirements for 

Performance-based Contract Requirements (PCR) document PCR-T-008A, Tortillas, 

Packaged in a Flexible Pouch, Shelf Stable, to incorporate a new Trans Fat Free requirement 

1. Natick has initiated an Engineering Support change to incorporate a new requirement for 

Trans Fat Free in PCR-T-008A, Tortillas, Packaged in a Flexible Pouch, Shelf Stable.

2. Research indicates that there may be a correlation between dietary intake of Trans Fatty 

Acid (TFA) and coronary heart disease (CHD), weight control, inflammatory response and 

immune dysfunction.

3. TFAs are formed when liquid oils are made into solid fats like shortening and hard 

margarine. However, a small amount of TFAs are found naturally, primarily in animal-based 

foods, including beef, butter and milk, although most TFAs in the diet come from partially 

hydrogenated oils.

4. TFAs have many functional benefits in food processing, particularly for baked products, 

including: increased oxidative stability; improved texture; and extended shelf life; all of 

which are extremely important to combat ration components. 

5. CFD initiated research to assess the occurrence and reduction of TFAs in combat ration 

components. Newly formulated TFA free products were produced and subjected to 

accelerated storage studies (6 months at 100°F) to determine the effect of the new 

formulation on quality, acceptability, and shelf life.

6. Samples for bakery items that had been stored for 6 months at 100o

F were evaluated by 

trained sensory panelists and results indicated the TFA free samples met shelf life 

performance requirements. 

7. Based on these findings, Natick recommends the addition of a requirement for Tortillas to 

have a trans fat content not greater than 0 grams per serving. The recommended change will 

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not impact other standards related to product and performance, which will continue to be 

required to be met satisfactorily.

8. Natick submits the following changes to the subject document for all current, pending, 

and future procurements until the document is formally amended or revised.

a. page 3, Paragraph C-2, I(5), after I(5), insert the following new requirement “(6) Trans 

fat. The trans fat content shall be not greater than 0 grams per serving.”

b. page 9, Paragraph E-5, Table I Header, insert a new footnote “4/”. 

c. page 9, Paragraph E-5, Table I, major defect 102, delete footnote “4/” insert footnote 

“5/”.

d. page 9, Paragraph E-5, Table I, minor defect 205, delete footnote “5/” insert footnote 

“6/”.

e. page 9, Paragraph E-5, Table I, minor defect 206, delete footnote “6/” insert footnote 

“7/”.

f. page 9, Paragraph E-5, Table I, minor defect 207, delete footnote “7/” insert footnote 

“8/”.

g. page 10, Paragraph E-5, Table I, Footnotes, after footnote 3/ insert the following new 

footnote “4/ The trans fat content shall be verified by the NLEA “Nutrition Facts” label. 

Product not conforming to the trans fat content as specified in Section C of this document 

shall be cause for rejection of the lot.” Renumber footnotes 4/ through 7/ accordingly.

9. Attached is Change 01, PCR-T-008A, Tortillas, Packaged in a Flexible Pouch, Shelf 

Stable, dated 23 January 2015, with the changes highlighted.

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