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SECTION C

This document covers carbohydrate electrolyte beverage powder, packaged in a pouch for use 

by the Department of Defense as a component of operational rations.

C-1 ITEM DESCRIPTION

PCR-B-013A BEVERAGE POWDER, CARBOHYDRATE ELECTROLYTE, 

PACKAGED IN A POUCH

 Flavors, Designs and Packages

 Flavors

I Fruit Punch

II Grape

III Lemon Lime

IV Orange

 Designs

A Flat pouch

B Flat, interlocking closure pouch

 Packages

Package C Meal, Ready to Eat (MRE)

Package H Food Packet, Carbohydrate Supplement

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 non comparable to the Product 

Standard, the contractor shall arrange for a new or alternate FA or PDM approval. In any 
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event, all product produced must meet all requirements of this document including Product 

Standard comparability.

 B. Shelf life. The packaged food shall meet the minimum shelf life requirement of 36 

months at 80oF.

 C. Powdered product.

(1) Appearance. The beverage powder shall be a free flowing homogenous mixture 

and have a color typical of the flavor specified. The packaged food shall be free from foreign 

materials.

(2) Odor. The packaged food shall have an odor typical of the flavor specified. The 

packaged food shall be free from foreign odors.

(3) Texture. The packaged food shall be free from hard lumps.

 D. Hydrated product. The beverage powder, when hydrated according to directions for use, 

shall dissolve within 2 minutes of constant shaking.

(1) Appearance.

a. Flavor I. The fruit punch shall have a bright red color.

b. Flavor II. The grape shall have a bright blue color.

c. Flavor III. The lemon lime shall have a light yellow/green color.

d. Flavor IV. The orange shall have an orange color.

(2) Odor and flavor. The beverage powder shall be free from foreign odors or flavors.

 a. Flavor I. The odor shall be a well-balanced blend of cherry with orange citrus 

notes. The flavor shall be a moderate strong, artificial cherry/citrus flavor. The product may 

be slightly salty.
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 b. Flavor II. The odor shall be a moderate sweet artificial grape. The flavor shall be 

a moderate sweet grape flavor. The product may be slightly salty.

 c. Flavor III. The odor shall be an artificial lemon lime with some slight citrus 

notes. The flavor shall be a moderate blend of sweet lime and mild lemon citrus notes. The 

product may be slightly salty.

 d. Flavor IV. The odor shall be a moderate orange citrus. The flavor shall be a 

moderate orange with artificial orange notes. The product may be slightly salty.

(3) Texture. The prepared beverage shall have no discernable lumps and shall be 

sediment free.

 E. Net weight. The net weight of the pouch of beverage powder shall be not less than 24 

grams.

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

the approved product standard in palatability and overall appearance.

 G. Analytical requirements.

(1) Moisture content. The moisture content shall be not greater than 3.5 percent.

(2) Nutrient content.

 a. Sodium content. The sodium content shall be not less than 100 mg and not 

greater than 175 mg.

 b. Potassium content. The potassium content shall be not less than 40 mg and not 

greater than 75 mg.

 d. Carbohydrate content. The carbohydrate content shall be not less than 22 grams.

(3) Fructose content. The finished product shall not contain fructose as an ingredient.
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C-3 MISCELLANEOUS INFORMATION

THE FOLLOWING INGREDIENTS ARE FOR INFORMATION ONLY. THIS IS NOT A 

MANDATORY CONTRACT REQUIREMENT.

 A. Ingredients for flavor I may be as follows: Sucrose, dextrose, citric acid, salt, sodium 

citrate, monopotassium phosphate, natural and artificial flavors, calcium silicate, Red 40, 

partially hydrogenated coconut oil.

 B. Ingredients for flavor II may be as follows: Sucrose, dextrose, citric acid, natural and 

artificial grape flavor, salt, sodium citrate, monopotassium phosphate, calcium silicate, 

coconut oil, Blue 1, Red 40.

 C. Ingredients for flavor III may be as follows: Sucrose, dextrose, citric acid, salt, sodium 

citrate, natural lemon and lime flavors with other natural flavors, monopotassium phosphate, 

calcium silicate, Yellow 5.

 D. Ingredients for flavor IV may be as follows: Sucrose, dextrose, citric acid, salt, sodium 

citrate, natural orange flavors with other natural flavors, monopotassium phosphate, calcium 

silicate, partially hydrogenated soybean and cottonseed oils, Yellow 6.

SECTION D

D-1 PACKAGING

 A. Packaging. Twenty-four (24) grams of powdered product shall be packaged in a barrier 

pouch as described below. The pouch will be used as a package and as a hydrating pouch for 

the beverage.

(1) Design A Flat pouch.

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

polyethylene film inner layer 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 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 
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food packaging and shall not impart an odor or flavor to the product. The complete exterior 

surface of the pouch shall be uniformly colored in the range of 20219, 30219, 30227, 30279, 

30313, 30324, or 30450 of FED-STD-595, Colors Used in Government Procurement.

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

inside dimensions of 4-7/8 (+ 1/8 inch) by 8-3/8 inches (+ 1/8 inch). The pouch shall be made 

by heat sealing three edges with 3/8 inch (-1/8, +3/16 inch) wide seals. The side and bottom 

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 when 

tested as specified in E-6,A,(4),a. Alternatively, the pouch shall exhibit no rupture or seal 

separation greater than 1/16 inch when tested for internal pressure resistance as specified in 

E-6,A,(4),c. A tear nick or notch shall be provided on one or two opposite edges of the 

pouch. A 1/8-inch wide lip may be incorporated at the open end of the pouch.

(2) Design B Flat interlocking closure pouch.

 a. Pouch material. The interlocking closure preformed pouch shall be fabricated 

from 0.002 inch thick ionomer or polyethylene film inner layer laminated or extrusion coated 

to 0.00035 inch thick aluminum foil which is then bonded to 0.0005 inch thick polyester. The 

three plies may be laminated with nylon on the exterior of the pouch. Tolerances for 

thickness of plastic films shall be plus or minus 20 percent and tolerance for foil layer shall 

be plus or minus 10 percent. The material shall show no evidence of delamination, 

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

be suitably formulated for food packaging and shall not impart an odor or flavor to the 

product. The complete exterior surface of the pouch shall be uniformly colored in the range 

of 20219, 30219, 30227, 30279, 30313, 30324, or 30450 of FED-STD-595.

 b. Pouch construction. The pouch shall be a flat design preformed pouch with an 

interlocking closure. The design and dimensions shall be as indicated in Figure 1. The pouch 

shall be made by heat sealing the sides and top of the pouch with 3/8-inch (+1/8, -1/4) wide 

seals. The pouch shall exhibit no rupture or seal separation greater than 1/16 inch when tested 

for internal pressure resistance as specified in E-6,A,(4),c. The interlocking closure of the 

pouch shall not leak more than 15 ml when tested in accordance with E-6,A,(5). A tear nick 

or notch shall be provided on one or two opposite edges of the pouch above the interlocking 

closure. A 1/8 inch wide lip may be incorporated at the open end of the pouch.
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(3) Pouch filling and sealing (Design A and B). Product shall be inserted into the 

pouch and the filled pouch shall be sealed with a 1/8 to1 inch wide heat seal. The closure seal 

shall be applied no more than 1/2 inch from the open end of the pouch. 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 when tested as specified in E-6,A,(4),b. Alternatively, 

the pouch shall exhibit no rupture or seal separation greater than 1/16 inch when tested for 

internal pressure resistance as specified in E-6,A,(4),c.

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) Contractor's name and address

(6) “Nutrition Facts” label in accordance with the Nutrition Labeling and 

Education Act (NLEA) and all applicable FDA/USDA regulations.

(7) Directions for Design A flat pouch:

Allow water just chemically purified to stand 30 minutes before adding to 

beverage powder.

TEAR POUCH AT NOTCH, ADD 12 OZ WATER (1/2 CANTEEN CUP) TO 

POUCH. FOLD OVER TOP OF POUCH. FIRMLY HOLDING TOP OF 

POUCH, SHAKE 30 SECONDS.

(8) Directions for Design B flat interlocking closure pouch:

Allow water just chemically purified to stand 30 minutes before adding to 

beverage powder.

TEAR POUCH AT NOTCHES. OPEN ZIPPER, ADD 12 OZ WATER (1/2 

CANTEEN CUP) TO FILL LINE. CLOSE ZIPPER. SHAKE TO MIX. 
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SINGLE USE ONLY.

(9) Fill line for Design B flat interlocking closure pouch: A fill line (not less than 

1/32 inch thick, not less than 2 inches long and centered) shall be placed on the 

pouch/label for 12-ounce fill at 6-1/2 + 1/4 inches from the inside edge of the 

closure seal.

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, 25 

October 2004 would be coded as 4299. The Julian day code shall represent the day the 

product was packaged into the pouch.

D-3 PACKING

 A. Packing for shipment to ration assembler. Not more than 40 pounds of pouched product 

shall be packed in a fiberboard shipping container constructed in accordance with style RSCL, class domestic, variety SW, grade 200 of ASTM D5118/D5118M-95 (2001) Standard 

Practice for Fabrication of Fiberboard Shipping Boxes. Each container shall be securely 

closed in accordance with ASTM D1974-98 (2003) Standard Practice for Methods of 

Closing, Sealing, and Reinforcing Fiberboard Boxes.

D-4 MARKING

 A. Shipping containers. Shipping containers shall be marked in accordance with DSCP 

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/ASQC Z1.4-1993, Sampling 

Procedures and Tables for Inspection by Attributes, are required. Unless otherwise specified, 

Single Sampling Plans indicated in ANSI/ASQC Z1.4-1993 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.
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(1) Critical defect. A critical defect is a defect that judgment and experience indicate 

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

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

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

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

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

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

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

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

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

as follows:

(1) Product standard inspection. The first article or product demonstration model shall 

be inspected in accordance with the provisions of this document and evaluated for overall 

appearance and palatability. Any failure to conform to the performance requirements or any 

appearance or palatability failure, shall be cause for rejection of the lot. The approved first 

article or product demonstration model shall be used as the product standard for periodic 

review evaluations. All food components that are inspected by the USDA shall be subject to 

periodic review sampling and evaluation. The USDA shall select sample units during 

production of contracts and submit them to the following address for evaluation:

DEPARTMENT OF THE ARMY

FCDD-SCC-EMR

COMBAT CAPABILITIES DEVELOPMENT COMMAND-SOLDIER CENTER

10 GENERAL GREENE AVENUE

NATICK, MA 01760-5056

One lot shall be randomly selected during each calendar month of production. Six (6) sample 

units of each item produced shall be randomly selected from that one production lot. The six 

(6) sample units shall be shipped to Natick within five working days from the end of the 

production month and upon completion of all USDA inspection requirements. The sample 

units will be evaluated for the characteristics of appearance, odor, flavor, texture and overall 

quality.
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(2) Conformance inspection. Conformance inspection shall include the examinations 

and the methods of inspection cited in this section.

E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT)

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

performance requirements specified in Section C of this Performance-based Contract 

Requirements utilizing the double sampling plans indicated in ANSI/ASQC Z1.4-1993. The 

lot size shall be expressed in pouches. The sample unit shall be one filled and sealed 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 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

Powdered product

101 Product not carbohydrate electrolyte beverage powder of the flavor 

specified.

102 Product contains fructose. 3/

Appearance

201 Beverage powder not free flowing or not a homogenous mixture.

202 Powder color not typical of flavor specified.

Odor

103 Powdered product not typical of odor specified.

Texture

203 Presence of hard lumps. 4/

Weight

204 Net weight of an individual pouch less than 24 grams.
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TABLE I. Product defects 1/ 2/ - Continued

Category Defect

Major Minor

Hydrated product 5/

Appearance

205 Flavor I not bright red color.

206 Flavor II not bright blue color.

207 Flavor III not light yellow/green color.

208 Flavor IV not orange color.

Odor and flavor

104 Flavor I product odor not a well-balanced blend of cherry with orange 

citrus notes or flavor not a moderate strong, artificial cherry/citrus.

105 Flavor II product odor not a moderate sweet artificial grape or flavor 

not a moderate sweet grape.

106 Flavor III product odor not an artificial lemon lime with some slight 

citrus notes or flavor not a moderate blend of sweet lime and mild 

lemon citrus notes.

107 Flavor IV product odor not a moderate orange citrus or flavor not a 

moderate orange with artificial orange notes.

Texture

108 Product has discernable lumps or exhibits sedimentation.

1/ Presence of any foreign materials such as, but not limited to dirt, insect parts, hair, wood, 

glass, metal, or any foreign odors or flavors such as, but not limited to burnt, scorched, 

rancid, sour, or stale, shall be cause for rejection of the lot. Foreign flavor is not applicable to 

powdered product.
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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. Palatability not applicable to 

powdered product.

3/ The presence of fructose shall be verified with the statement of ingredients on the label.

4/ Lumps that do not fall apart under light pressure between the fingers shall be scored as a 

defect.

5/ Prior to conducting the hydrated product examination, the beverage powder shall be 

reconstituted per label instructions. Product that does not fully dissolve within 2 minutes with 

constant shaking shall be cause for rejection of the lot.

 B. Methods of inspection.

(1) Shelf life. The contractor shall provide a certificate of conformance that the 

product has a 3 year shelf life when stored at 80°F. Government verification may include 

storage for 36 months at 80°F or 6 months at 100°F. Upon completion of 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 hedonic 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. 

Results shall be reported to the nearest 1.0 gram.

(3) Analytical. The sample to be analyzed shall be a composite of eight filled and 

sealed pouches that have been selected at random from the lot. The composited sample shall 

be prepared and analyzed in accordance with the following method of the Official Methods of 

Analysis of AOAC International:

Test Method Number

Moisture 925.45A, or 2007.04

Test results shall be reported to the nearest 0.1 percent. Verification will be conducted 

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

analytical requirements shall be cause for rejection of the lot.
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(4) Nutrient Content. The sodium, potassium and carbohydrate content shall be 

verified by the NLEA “Nutrition Facts” label. Product not conforming to the sodium, 

potassium and carbohydrate content as specified in section C of this document shall be cause 

for rejection of the lot.

E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING 

MATERIALS)

 A. Packaging.

(1) Pouch material certification. Materials listed below may be accepted on the basis 

of a contractor’s certification of conformance to the indicated requirements. In addition, 

compliance to the requirements for inside pouch dimensions and dimensions of the 

manufacturer’s seals may be verified by certification of conformance.

Requirement Requirement paragraph Test procedure

Thickness of laminated material D-1,A,(1),a & D-1,A,(2),a As specified in ASTM 

D2103-03 1/

Aluminum foil thickness D-1,A,(1),a & D-1,A,(2),a As specified in ASTM 

B479-00 2/

Laminated material 

identification and construction

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

Color of laminated material D-1,A,(1),a & D-1,A,(2),a Visual evaluation by 

FED-STD-595 3/

1/ ASTM D2103-03 Standard Specification for Polyethylene Film and Sheeting

2/ ASTM B479-00 Standard Specification for Annealed Aluminum and Aluminum-Alloy 

Foil for Flexible Barrier, Food Contact, and Other Applications

3/ FED-STD-595 Colors Used in Government Procurement
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(2) Unfilled preformed pouch certification. A certification of conformance may be 

accepted as evidence that unfilled pouches conform to the requirements specified in 

D-1,A,(1),a and b and D-1,A,(2), 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,A,(4),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, 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 Fill line missing or does not measure within + 1/4 inch of 6-1/2 inches 

from the inside edge of the closure seal.

108 Not packaged as specified.

201 Label missing, incorrect, or illegible.

202 Tear nick or notch missing.

203 Seal width less than 1/8 inch but greater than 1/16 inch.
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TABLE II. Filled and sealed pouch defects 1/ - Continued

Category Defect

Major Minor

204 Presence of delamination. 3/

205 Design B pouch does not meet design or dimensions cited in Figure 1.

206 Fill line on Design B pouch not required thickness or length.

1/ Any evidence of rodent or insect infestation shall be cause for rejection of the lot.

2/ The effective closure seal is defined as any uncontaminated, fusion bonded, continuous 

path, minimum 1/16 inch wide, from side seal to side seal that produces a hermetically sealed 

pouch.

3/ Delamination defect classification:

Major - Delamination of the outer ply in the pouch seal area that can be propagated to 

expose aluminum foil at the food product edge of the pouch after manual flexing of the 

delaminated area. To flex, the delaminated area shall be held between the thumb and 

forefinger of each hand with both thumbs and forefingers touching each other. The 

delaminated area shall then be rapidly flexed 10 times by rotating both hands in alternating

clockwise- counterclockwise directions. Care shall be exercised when flexing delaminated 

areas near the tear notches to avoid tearing the pouch material. After flexing, the separated 

outer ply shall be grasped between thumb and forefinger and gently lifted toward the food 

product edge of the seal or if the separated area is too small to be held between thumb and 

forefinger, a number two stylus shall be inserted into the delaminated area and a gentle lifting 

force applied against the outer ply. If separation of the outer ply can be made to extend to the 

product edge of the seal with no discernible resistance to the gentle lifting, the delamination 

shall be classified as a major defect. Additionally, spot delamination of the outer ply in the 

body of the pouch that is able to be propagated beyond its initial borders is also a major 

defect. To determine if the laminated area is a defect, use the following procedure: Mark the 

outside edges of the delaminated area using a bold permanent marking pen. Open the pouch

and remove the contents. Cut the pouch transversely not closer than 1/4 inch (+1/16 inch) 

from the delaminated area. The pouch shall be flexed in the area in question using the 

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

c. Water spots.

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.

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

c for Design A, and as required in c for Design B.

 a. Unfilled preformed pouch (Design A). The seals of the unfilled preformed 

pouches for the pouch shall be tested for seal strength in accordance with ASTM F 88, 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 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 results of the three specimens cut from that side. Any average seal strength of less than 6 
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pounds per inch of width or any test specimen with seal strength of less than 5 pounds per 

inch of width shall be a major defect and shall be cause for rejection of the lot.

 b. Pouch closure (Design A). The closure seals of the pouches for the packet shall 

be tested for seal strength in accordance with ASTM F 88. The lot size shall be expressed in 

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

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

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

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

specimens cut from that side, end or closure. Any average seal strength of less than 6 pounds 

per inch of width or any test specimen with seal strength of less than 5 pounds per inch of 

width shall be a major defect and shall be cause for rejection of the lot.

 c. Internal pressure test (Design A and B). The internal pressure resistance shall be 

determined by pressurizing the pouches while they are restrained between two rigid plates. 

The sample size shall be the number of pouches indicated by inspection level S-1. If a three 

seal tester (one that pressurizes the pouch through an open end) is used, the closure seal shall 

be cut off for testing the side and top or of the pouch. For testing the closure seal, when 

applicable, the bottom seal shall be cut off. For Design B pouch, when testing the closure 

seal, the top and interlocking closure shall be cut off. The pouches shall be emptied prior to 

testing. If a four-seal tester (designed to pressurize filled pouches by use of a hypodermic 

needle through the pouch wall) is used, all four seals can be tested simultaneously. The 

distance between rigid restraining plates on the four-seal tester shall be equal to the thickness 

of the product +1/16 inch. Pressure shall be applied at the approximate uniform rate of 1 

pound per square inch gage (psig) per second until 14 psig pressure is reached. The 14 psig 

pressure shall be held constant for 30 seconds and then released. The pouches shall then be 

examined for separation or yield of the heat seals. Any rupture of the pouch or evidence of 

seal separation greater than 1/16 inch in the pouch manufacturer’s seal shall be considered a 

test failure. Any seal separation that reduces the effective closure seal width to less than 1/16 

inch (see table II, footnote 2/) shall be considered a test failure. Any test failure shall be 

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

(5) Interlocking closure test (Design B). The interlocking closure of the pouch shall be 

tested. The lot size is expressed in pouches. The sample size shall be the number of pouches 

indicated by inspection level S-2. Open a filled and sealed interlocking closure pouch and 

prepare beverage in accordance with instructions using 70°F (+5°F) water. Close pouch. 

Invert pouch and suspend pouch for 15 seconds. Collect and measure any water that drips. A 
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pouch that leaks more that 15 ml shall be a major defect and shall be cause for rejection of 

the lot.

 B. Packing.

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

containers shall be examined for the defects listed in Table III below. 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 omitted, incorrect, illegible, or of improper size, location 

sequence or method of application.

102 Inadequate workmanship. 1/

201 More than 40 pounds of product.

1/ Inadequate workmanship is defined as, but not limited to, incomplete closure of container 

flaps, loose strapping, inadequate stapling, improper taping, or bulged or distorted container.
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SECTION J REFERENCE DOCUMENTS

DSCP FORMS

DSCP FORM 3556 Marking Instructions for Boxes, Sacks and Unit Loads of 

Perishable and Semiperishable Subsistence

FEDERAL STANDARD 

FED-STD-595 Colors Used in Government Procurement

NON-GOVERNMENTAL STANDARDS

AMERICAN SOCIETY FOR QUALITY (ASQ)

ANSI/ASQCZ1.4-1993 Sampling Procedures and Tables for Inspection by 

Attributes

AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

B479-00 Standard Specification for Annealed Aluminum and 

Aluminum-Alloy Foil for Flexible Barrier, Food 

Contact, and Other Applications

D1974-98 (2003) Standard Practice for Methods of Closing, Sealing, 

and Reinforcing Fiberboard Boxes

D2103-03 Standard Specification for Polyethylene Film and 

Sheeting

D5118/D5118M-95 (2001) Standard Practice for Fabrication of Fiberboard 

Shipping Boxes 

F88-00 Standard Test Method for Seal Strength of Flexible 

Barrier Materials

AOAC INTERNATIONAL Official Methods of Analysis of the Association of 

Official Analytical Chemists International
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FIGURE 1. Design B Flat Interlocking Closure Pouch

(Not actual size)