PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

1

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-008B, TORTILLAS, PACKAGED IN A FLEXIBLE POUCH, SHELF 

STABLE

Flavors.

Flavor 1 – Plain

Flavor 2 – Chipotle

Flavor 3 – Whole grain

Types.

Type I – (2 count individual serving package)

Type II – (50 count group serving package)

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 80°F.
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

2

 C. Appearance.

(1) General. For type I, the finished product shall be two baked intact tortillas 

prepared from enriched wheat flour. For type II, the finished product shall be 50 baked intact 

tortillas prepared from enriched wheat flour. The tortillas 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. 

(4) Flavor 3. The whole grain tortillas shall be a light to medium tan color with brown 

flecks typical of whole grain flour.

 D. Odor and flavor. 

(1) General. The tortillas may have a slightly uncooked wheat dough flavor.

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. 

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

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

sensation of moderate heat. 

(4) Flavor 3. The whole grain tortillas shall have a cooked whole grain wheat flour,

slightly sweet, slightly sour odor and flavor and a slightly bitter 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) Type I. 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 1.9 ounces (54 grams). 
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

3

(2) Type II. The average net weight shall be not less than 52.5 ounces (1488 grams). 

No individual pouch shall have a net weight of less than 47.5 ounces (1347 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) 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 for the two tortillas shall be not less than 220.

SECTION D

D-1 PACKAGING

 A. Packaging. For type I, 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 type II, 50

tortillas (packed flat in two stacks of 25 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 
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

4

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. Type I

shall have maximum inside dimensions of 5 inches wide by 7-3/4 inches long. Type II shall 

have maximum inside dimensions of 10 inches wide by 16-1/4 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 type I, 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 type II, 50 tortillas (packed flat in two stacks of 25 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 type II 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 
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

5

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 

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

type I, two tortillas (folded in half) and one oxygen scavenger shall be placed into the trayshaped body of the pouch. For type II, 50 tortillas (packed flat in two stacks of 25 tortillas) 

and oxygen scavenger(s) shall be inserted into the tray-shaped body of the pouch. For type II, 

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 type I, the maximum outside 

dimensions of the sealed pouch shall be 6 inches wide by 8-1/4 inches long. For type II, the 

maximum outside dimensions of the sealed pouch shall be 10-1/2 inches wide by 17 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.
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

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 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

(7) For type II only:

Optional heating instructions: 

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

Yield: Serves 25 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 2030 would be coded as 0045. The Julian day code shall represent the day the 

product was packaged into the pouch.

D-3 PACKING

 A. Packing. Not more than 40 pounds of product shall be packed in a 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-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

7

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 

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 
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

8

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. For type I, three (3) sample units shall be randomly selected from 

that one production lot. For type II, 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 type I, the sample unit shall be the contents of 

one pouch. For type II, the sample unit shall consist of two tortillas from each pouch obtained

as follows: Take each of the 2 stacks of 25 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.
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

9

TABLE I. Product defects 1/ 2/ 3/

Category Defect

Major Minor

101 Product not flavor as specified.

102 Type I product not two baked intact tortillas.

Type II product not 50 baked intact tortillas.

103 Oxygen scavenger(s) missing. 4/

Appearance

201 Tortillas not thin or not round. 5/

202 Tortillas not easily separable.

203 Flavor 1 plain tortillas not an off-white color.

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

color.

205 Flavor 3 whole grain tortillas not a light to medium tan color or 

not with brown flecks typical of whole grain flour.

Odor and flavor

104 Flavor 1 plain tortillas do not have a cooked wheat flour or not a 

slightly sweet or not a slightly sour odor or flavor.

105 Flavor 2 chipotle tortillas do not have a cooked wheat flour or 

not a slightly sweet or not a slightly sour or not a slightly smoky 

or not a chipotle odor or flavor. 

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

moderate heat.

107 Flavor 3 whole grain tortillas do not have a cooked whole grain 

wheat flour or not a slightly sweet or not a slightly sour odor or 

flavor or not a slightly bitter flavor. 
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

10

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

Category Defect

Major Minor

Texture

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

Size

206 Tortillas greater than 7.0 inches in diameter.

Net weight

207 Type I net weight of an individual pouch less than 1.9 ounces 

(54 grams). 6/

208 Type II net weight of an individual pouch less than 47.5 ounces 

(1347 grams). 7/

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

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

verified by Certificate of Conformance (CoC).
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

11

5/ 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

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

the lot. 

7/ Sample average net weight less than 52.5 ounces (1488 grams) 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 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.
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

12

(3) Moisture and pH testing. For type I, 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 type II, 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 type I, eight filled and sealed pouches shall be 

selected at random from the lot regardless of lot size. For type II, 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 type I shall be a composite specimen made 

from the center of both tortillas in the pouch. For type II, the sample unit shall consist of two 

tortillas from each pouch obtained as follows: Take each of the 2 stacks of 25 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. Government verification will be conducted through actual 

testing by a Government laboratory. 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 requirement as specified in Section C of this 

document shall be cause for rejection of the lot.

(6) 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-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

13

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 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 AQL, expressed in 

terms of defects per hundred units, shall be 0.65 for major defects and 2.5 for minor defects.
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

14

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:
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

15

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

delaminated area exceeding the limits of the outlined borders, shall be classified as a major 

defect.

Minor - Minor delamination of the outer ply in the pouch seal area is acceptable and 

shall not be classified as a minor defect unless it extends to within 1/16 inch of the food 

product edge of the seal. All other minor outer ply delamination in the pouch seal area or 

isolated spots of delamination in the body of the pouch that do not propagate when flexed as 

described above shall be classified as minor defects.

4/ Outer packaging shall be free from foreign matter which is unwholesome, has the potential 

to cause pouch damage (for example, glass, metal filings) or generally detracts from the clean 

appearance of the pouch. The following examples shall not be classified as defects for 

unclean:

a. Foreign matter which presents no health hazard or potential pouch damage and 

which can be readily removed by gently shaking the package or by gently brushing the pouch 

with a clean dry cloth.

b. Dried product which affects less than 1/8 of the total surface area of one pouch face 

(localized and aggregate).
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

16

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 

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 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 
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

17

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 

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.
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

18

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 Form

Form 3556 Marking Instructions for Boxes, Sacks, and Unit 

Loads of Perishable and Semiperishable Subsistence

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
PCR-T-008B

21 December 2020

SUPERSEDING

PCR-T-008A

30 July 2013

19

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

SAE INTERNATIONAL www.sae.org

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