APP B

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 DLA Troop Support -FTSA

 

 22 Nov 10

FOREWORD

(Supplementation is permitted.)

Appendix B is for the inspection of Unitized Group Ration (UGR) Heat and Serve 

(H&S) modules. It provides guidelines for sampling, inspecting, classifying defects, and 

determining lot serviceability. Prior to using this Appendix, inspectors should be thoroughly 

familiar with DLA Troop Support Handbook 4155.2, Inspection of Composite Operational 

Rations. Users of this publication are encouraged to submit comments and recommended 

changes to improve this publication, through channels, to DLA Troop Support, ATTN: DLA 

Troop Support -FTSA. Changes will be coordinated with the Defense Security Cooperation 

Agency and implemented as appropriate.

BY ORDER OF THE COMMANDER

 KATHRYN YONTZ

Chief, Administrative Support &

Base Supply Division

Office of Base Support Services

DISTRIBUTION

Special

DLA Troop Support - FTR, FTRB, FTRE, FTRA, FTSA/B, 

VETCOM 

This DLA Troop Support Handbook 4155.2, App-B, supersedes DSCP Handbook 4155.2, App 

B, Jan 09.
 

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TABLE OF CONTENTS

PARAGRAPH PAGE

I. GENERAL.

 A. Purpose and Scope 4

 B. Explanation of Inspection Concept 4

 C. Receipt Inspection Guidance 4

 D. Inspection Test Date (ITD) Extensions 4

 E. Inspection Frequencies 4

 F. Disposition Recommendations 5

 G. Inspection Equipment 5

 H. Definitions 6

II. ROUTINE INSPECTION GUIDANCE.

 A. STEP 1: Evaluation of Storage Conditions 9

 B. STEP 2: Determine Lot Size 9

 C. STEP 3: Inspect Modules and Selection of Samples 10

 D. STEP 4: Perform Closed Package Inspection (CPI) of Module Contents 11

 E. STEP 5: Perform Destructive Open Package Inspection (DOPI) of Module 

 Contents 12

 F. STEP 6: Determine if Special Inspection is Required 12

 G. STEP 7: Determine Disposition 13

 H. STEP 8: Provide Results and Recommendations to Accountable Officer/

 Agency 13

III. SPECIAL INSPECTION GUIDANCE.

 Background Information 14

 A. STEP 1: Determine Lot Size 14

 B. STEP 2: Determine Sample Size for Each Component and Select Sample 

 Modules 14

 C. STEP 3: Determine Disposition of the Lot 14

 D. STEP 4: Provide Results and Recommendations to Accountable Officer/

 Agency 14

IV. SAMPLE AND DEFECT TABLES.

 Table A. Sampling Criteria for Inspection of Modules and Module Contents

 (Normal Inspection) 15

 Table B. Sampling Criteria for Inspection of Modules and Module Contents
 

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 (Special Inspection) 15

 Table E. Inspection of Module Boxes 16

 Table F. Inspection of Polymeric Trays 16

 Table G. Inspection of Metal Containers 19

 Table H. Inspection of Plastic/Glass/Fiberboard Containers 20

 Table I. Inspection of Flexible Pouches 20

 Table J. Inspection of Envelopes (Packets) 21

 Table K. Inspection of Nonfood Components 21

 Table L. Destructive Open Package Inspection (DOPI) 22

 Table M. Specific Defect Codes 23

 Table N. Condition Code Criteria Defects From Special Inspection Results

 (Components That Equal of Exceed an Action Number) 26

 

V. INSPECTION RECORDS AND REPORTING.

 A. Inspection Form 27

 B. Database 27

 C. Distribution 27
 

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I. GENERAL.

A. Purpose and Scope. This Appendix is a reference and guide for receipt and surveillance 

inspections of government-owned unitized modules. It was written and coordinated to facilitate 

use on both DLA/ DLA Troop Support controlled stocks and those controlled by the individual

Services.

B. Explanation of Inspection Concept. This Appendix incorporates the concept of 

“Condition Coding” a lot based on the serviceability of the various components contained within 

the different modules and their estimated remaining shelf life. It involves a two step process: (1) 

Determine if any component(s) exceed an action number. (2) Determine the Condition Code. 

 C. Receipt Inspection Guidance. For receipt inspections, use the same sampling criteria

and defect tables as for surveillance. In addition, inspectors shall advise DLA Troop Support

when containers/products fail to comply with other essential receipt criteria identified in the 

appropriate monographs. Notification should be by the most expeditious means when there is a 

possibility that warranty action can be initiated. Inspectors will be provided guidance concerning 

additional requirements for warranty action.

D. Inspection Test Date (ITD) Extensions. Modules estimated shelf life is 18 months at 80 

degrees Fahrenheit. Inspectors may extend an ITD based on their estimate of the lot's remaining 

shelf life. Remarking of the unitized loads/cases with a revised ITD will be accomplished in 

accordance with DLAM 4155.37, Appendix S, and/or the appropriate service regulation. Posting 

of extensions may be accomplished by placing stickers with the updated ITD information on each 

pallet or module.

E. Inspection Frequencies. Inspections of UGR H&S ration modules will be accomplished 

as follows:

1. At receipt:

a. If previous inspection/condition code information accompanies shipment and is 

less than 3 months old, a general inspection for transportation damage and identity will be 

performed.

b. If UGR H&S’s possess obvious defects, mechanical damage, or are more than 3 

months from the last receipt/surveillance inspection, perform a full inspection IAW this 

appendix.

2. Surveillance:

a. One month prior to ITD.
 

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b. After ITD has passed, modules will be inspected at 3-month intervals for 

condition code A stocks, and 1 month intervals for all other condition codes. 

 F. Disposition Recommendations.

 

1. The accountable officer/agency will be informed of inspection results by the 

Veterinary/Medical Food Inspector. Inspectors will include (as a minimum): the condition code 

as determined by this appendix, estimated remaining shelf life, and a summary of general lot 

characteristics. Inspectors are also encouraged to provide additional comments that will assist 

the accountable officer/agency in determining a final disposition.

2. Final disposition instructions for lots placed on medical hold require review and 

approval by the local medical authority.

3. The points listed below should be considered when developing a disposition 

recommendation. This list is not all-inclusive and each point may not always apply.

a. Can the defective module(s)/component(s) be removed just prior to 

consumption?

b. How rapidly is the most defective component expected to deteriorate to the 

point that it is unlikely to be consumed?

c. Can the lot be issued and supplemented with similar commercial items, supply 

catalog items, or operational ration component(s)?

 G. Inspection Equipment. The items listed below are recommended as the minimum 

necessary to perform the inspections of UGR H&S modules. However, this list is not intended to 

be all encompassing.

1. Adequate lighting.

2. Inspection trays and pans, white enamel or plastic.

3. Magnification lens (3 to 5 power recommended) is optional. 

4. Metal ruler (32nd inch graduation). 

5. Spatula(s). 

6. Paper towels.

7. Paper plates.

8. Paper/styrofoam/plastic cups. 

9. Scissors, general use. 

10. Tape (for retaping modules).

11. Can opener.

12. Alcohol swabs/wipes. 

13. Paper, wax impregnated, white roll.

14. Sharp knife, box cutter, or scalpel that can be sanitized.

15. Forceps/petri-dishes/5ml vials.

16. Sharpie pens.

17. Number 2 stylus.
 

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 H. Definitions:

1. Monograph. An information and instruction sheet that provides the inspector with a 

detailed description of an UGR H&S module/component, including normal characteristics and 

signs of deterioration, as well as special instructions on how to examine the item. Special notes 

concerning inspection techniques are also included in some monographs. Monographs can be 

accessed at http://www.dscp.dla.mil/subs/support/qapubs/appb/mono-b.asp.

2. Component Classification. The monograph index indicates the classification for 

each component. Component classification is determined by coordination of the Surgeon 

General and the Food Service Headquarters of the Military Services.

a. Primary. Any individual component in the UGR H&S module that, if 

unserviceable, will make the meal nutritionally inadequate for any method of intended use.

b. Secondary. Any individual component in the UGR H&S module that, if 

unserviceable, will reduce the nutritional value of the meal but will not render the meal unfit for 

its intended purpose. 

c. Ancillary. Any component in the UGR H&S module that contributes little or 

no nutrient value to the meal and if found unserviceable, will not constitute the meal as 

nutritionally deficient for its intended purpose.

3. Major A Defect. This classification should be used for defects that are likely to cause 

hazardous or unsafe conditions for individuals using, maintaining or dependent upon the product. 

The words “are likely to” are important. They do not mean “could possibly” since it is always 

possible to develop grand scenarios that transform trivial happenings into major catastrophes. 

Therefore, the use of this classification requires experience, prudence and sound judgment. 

4. Major B Defect. These are defects that are not hazardous or unsafe. However, they 

may restrict product use or make its consumption unlikely under the conditions for which the 

rations were originally designed. Examples: Extreme color (darkening), odor (rancidity), or 

flavor (bitterness) changes in primary components of a ration that makes them unlikely to be 

consumed under normal field conditions where resupply or alternative feeding strategies are 

available. However, under more restrictive conditions the components could be consumed 

without concern that illness could be produced. 

5. Minor Defect. These are defects that make the product less useful than it should be, 

but not seriously so. Minor defects usually do not affect serviceability. However, their 

identification is important since they often reveal early signs of deterioration and can be detected 

before the item reaches a condition that makes its consumption unlikely under conditions of 

normal use. Their early detection may lead to a predictive intervention by the accountable officer 

to ensure consumption before the component or module loses its serviceability.
 

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6. Module. The unit of issue for UGR H&S menus is a single module (3 boxes). A 

module consists of 3 boxes (boxes 1, 2, and 3) and will contain everything needed to feed 50 

individuals one complete meal. 

7. Product Codes.

a. Assembly code information. Contract and component identification markings 

found on the shipping container, modules, and/or components that reflect ration assembly 

information only (e.g., assembly contractor, date of pack, assembly lot numbers, Inspection Test 

Date (ITD) etc.).

b. Component code information. Item identification markings found on the 

primary package and, when applicable, the secondary package (e.g., thermostabilized trays) that 

reflects the producer's name, the USDA Establishment Number, the production lot number of the 

component, the nomenclature, etc.

8. Action Number (AN). A number which, when reached or exceeded, normally 

indicates additional inspection is necessary or indicates a component has deteriorated beyond 

acceptable limits and the menu that contains it must be evaluated for serviceability. 

9. Condition Coding. Traditionally, condition codes have been based primarily on 

estimates of remaining shelf life. Serviceability will be determined based on the usability status 

of the complete module. However, to aid accountable officers in choosing the best disposition 

option, inspectors will provide them the best possible estimate of remaining shelf life. A list of 

applicable condition codes and their descriptions are as follows:

a. Condition Code A (issuable without qualification): Refer to Table N. 

Modules have more than 6 months shelf life remaining.

b. Condition Code B (issuable with qualification): Refer to Table N (usually 3-6 

months shelf life remaining). Accountable Officers are required to determine what qualifications 

will be specified in order to issue Condition Code B stock (e.g., issue with instructions to 

consume within 60 days; issue with instructions to supplement, etc.).

c. Condition Code H (unserviceable). Refer to Table N. Modules are 

unserviceable and/or unfit for human consumption. This classification will be used only when 

the entire lot has been deemed unserviceable.

d. Condition Code L (warranty action). Any item placed on hold pending 

warranty action.

e. Condition Code J (laboratory testing, medical hold, rework, pest activity, or 

reclassification hold. Any item on hold pending laboratory testing, rework, or awaiting authority 

for disposal.
 

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10. Unit load packing list. A list attached to a unit load of modules that lists the 

components (including contractual identification information) contained in the module.

11. UGR H&S Lot Serviceability. Two factors are considered when determining the 

overall serviceability of a UGR H&S lot. First the lot is condition coded using Table N and then 

the integrity of the packaging and packing is considered. It is recognized that the status of a 

UGR H&S lot initially declared unserviceable may change as the result of a rework effort or 

special instructions provided by the accountable officer at/prior to issue.

12. Entrapped Matter. Foreign material may be trapped in the seal area, when the tray 

and/or pouch is sealed or bonded. Entrapped matter weakens the seal, but as long as there is 1/8

inch of continuous seal all the way across the seal area (i.e. from one side of the pouch/tray seal 

to the other), and then the seal is considered acceptable.

13. Adhesive. Bonding material that binds the laminations (thin sheets of 

Polypropylene, foil, polyester, or nylon) that make up the retort pouch material.

14. Abrasion. A break or crack in the outer lamination of the retort pouch. 

15. Foldover wrinkle. Pouch material is overlapped on itself in the seal area that 

reduces the closure seal to less than 1/16 inch. 

16. Entrapped Matter. Foreign material may be trapped in the seal area, when the 

pouch is sealed or bonded. Entrapped matter weakens the seal, but as long as there is 1/16 inch 

of continuous seal all the way across the seal area (i.e. from one side of the pouch seal to the 

other), and then the seal is considered acceptable.

17. Delamination. Delamination is the separation of laminated films in a flexible 

laminated pouch. 

18. Stress Crack. It is possible that the foil barrier layer in the food packet pouch 

material may break, but the outer layer (lamination) of polyester is still intact. This would be 

called a stress crack and it is not scored as a defect.

19. Barrier Layer. For a food packet retort pouch this is the lamination (foil) that 

prevents transmission of light, water vapor, or oxygen into out of the retort pouch.

20. Product Contact Layer. For a food packet retort pouch, this would be the inner 

lamination (polypropylene) which is in contact with the food. 

21. Inspection Module. In Operational Rations, the word module typically means a set 

of boxes whose combined contents yield the components necessary to feed one meal to a given 

number of soldiers. For the purposes of UGR H&S inspection, we will refer to 3 boxes (box 1, 

2, & 3) an inspection module. This is meant to minimize confusion. The unit of issue is a single 

module (3 boxes). In order to make sure that inspection covers all the menus/components during 
 

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inspections, inspectors will make use the term “inspection modules”. An inspection module is 3 

boxes (box 1, 2, & 3). 

22. Commercially Sterile. Food that is free of all pathogens and those spoilage 

organisms capable of growth during normal storage and transportation conditions. Normal 

transportation and storage temperature is defined as 80F or less. 

II. ROUTINE INSPECTION GUIDANCE.

 A. STEP 1: Evaluation of Storage Conditions.

1. Storage conditions vary significantly. As a minimum UGR H&S module storage 

areas should be clean and dry and not subject to extreme temperatures. UGR H&S modules 

should not be stored directly on the floor. The facility should be free of pests in accordance with:

a. MIL-STD-904B, Detection, Identification, and Prevention of Pest Infestation of 

Subsistence.

 b. TG-38 Protecting Meals Ready-To-Eat Rations (MREs) and Other Subsistence 

During Storage. Although this is primarily written for MREs it is still applicable to UGR H&S. 

2. When UGR H&S modules are warehoused, the storage facility should meet the 

additional standards of MIL-STD-3006C, Requirements for Food Establishments (Appendix A, 

only). UGR H&S modules cannot be stacked more than 2 pallets high without the use of storage 

aids, pallet racks/pallet sets, etc. These pallet racks/pallet sets should support the full weight of 

any additional pallets. The pallet (s) above shall not be in contact with or supported by the 

pallets beneath. Temperature history of storage locations must also be considered when 

recommending final condition codes and dispositions.

3. All modules opened for inspection, or damaged, shall be recouped or repaired in a 

manner sufficient to ensure protection of the product during subsequent storage and handling.

4. All ration food components are shortened by high temperatures. Food packet storage 

temperatures in excess of 80°F should be reported to DLA Troop Support-FTR and DLA Troop 

Support -FTRE.

 B. STEP 2: Determine Lot Size. 

1. The lot size for modules shall be the total number of modules by menu number. The 

sample unit is one complete module (3 boxes, box 1, 2, & 3).

2. Lotting procedures will be as follows:

a. Assembler’s lots are composed of rations from the same assembler that 
 

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have the same contract number, lot number/DOP, menu number, and stored under substantially 

similar conditions.

b. Grand lots for the purpose of UGR H&S inspections will be composed of 

rations from the same assembler, and the same menu number, but will contain more than one lot 

number/DOP. Grand lots will be limited to a 120 day DOP window (earliest to latest DOP shall 

not exceed 120 days). Additionally, the rations must have been stored under substantially similar 

storage conditions. Samples from grand lots must represent all individual lots proportionally, 

even if the next highest sample size must be used. Identity of samples from each sublot must be 

maintained throughout the inspection. 

 c. Defective assembler's lots will be segregated from grand lots and inspected 

individually when one or more of the following occurs:

(1) A Major A defect is found in an assembler’s lot.

(2) The Major B or Minor defects found seem to be concentrated in one or 

more of the assembler’s lots comprising the grand lot.

(3) The inspector determines for any reason, based on initial inspection results, 

that inspection of an individual assembler's lot is justified. 

d. Grand lotting is encouraged (to conserve resources) whenever it is considered 

appropriate by the inspection activity. Grand lotting will not be used when performing warranty 

inspections or on inspections of lots reported as possibly having wholesomeness deficiencies.

 C. STEP 3: Inspect Modules and Selection of Samples.

1. IAW Table A, select appropriate sample size for module examinations. Damaged 

modules should not be selected as samples unless they are truly representative of the lot. In 

addition, damaged modules should be set aside and the contents inspected to determine the extent 

of damage to the food components.

2. Routine inspections will be conducted using a single sampling plan.

3. Using the defects listed in Table E, the inspectors should check each sample Module 

for previously opened boxes. While this may indicate evidence of tampering, each may also be 

due to other reasons (e.g., a wholesale rework of a lot). Inspectors shall contact their supervisors 

for guidance if pilferage or tampering is suspected. 

4. Using defects listed in Table E, observe each Module for signs of rodent damage or 

insect infestation. If either condition is observed, annotate the findings on inspection report, 

accordingly. The notes should include the following:

a. Whether or not the pests were alive or dead.

b. Pest identification (preferably entomological/laboratory identification).

c. Probable origin of Pests (see DLA Troop Support Handbook 4155.2, 

paragraph XIII.).
 

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d. Probable movement of pests. For example, from outside the shipping 

container into the modules or vice-versa.

5. Classify each defective module by the most serious defect it possesses. List each 

defect in the inspection report. If the action number (AN) is not reached or exceeded, the lot 

passes the module inspection.

 D. STEP 4: Perform Closed Package Inspection (CPI) of Module Contents.

1. IAW Table A, select the appropriate number of modules being sure the samples are 

proportionally representative of the modules in the lot.

2. Open the sample modules.

3. Module components will be inspected for defects in accordance with Tables F thru K. 

4. Thoroughly examine all components within the module. Perform this inspection 

under a good light source and, if available, with the aid of a magnification lens. When a 

component exhibits more than one defect, it will be classified by the most serious defect it 

possesses. However, for the purpose of gathering additional information, the lesser defects will 

also be noted. Record the following information for all defective components:

a. Menu number/name. 

b. Assembler's lot number. 

c. Component nomenclature and code (if applicable). 

d. Processor's and/or plant name (if available).

e. Defect number.

f. Specific defect code (if applicable). 

g. Narrative description of defect (if necessary). 

h. Tally defects (Major A, Major B, Minor) according to type of component.

5. All components observed during the inspection with Major A or Major B defects 

will be discarded (whether they are part of the sample or not). Components not exhibiting 

defects or those exhibiting only minor defects may be reassembled into the lot.

 6. Component packages with a Major A or Major B packaging defect should be opened

to evaluate the effect the defect has on the product. Any findings should be recorded as a note 

on the inspection record. This inspection should in no way be confused with the normal open 

package inspection. Open package inspection is a phase of inspection during which only those 

components that did not show any external Major A or Major B packaging defects are 

examined. 

 7. Classify each defective unit by the most serious defect it possesses. Record all 

defects on the inspection report. If none of the Action Numbers are equaled or exceeded, the 
 

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lot passes. CPI inspection does not require a second sample or “special inspection” unless 

requested by the accountable officer or directed by the inspector’s chain-of-command.

 E. STEP 5: Perform Destructive Open Package Inspection (DOPI) of Module Contents.

1. IAW Table A, select the appropriate number of modules being sure the samples are 

proportionally representative of the modules in the lot.

2. Open the sample module(s).

3. Module components will be inspected for defects in accordance with Table L. 

4. Thoroughly examine all items within the module under a good light source and, if 

available, with the aid of a magnification lens. When a component exhibits more than one 

defect, it will be classified by the most serious defect it possesses. However, for the purpose of 

gathering additional information, the lesser defects will also be noted. Record the following 

information for all defective components:

a. Menu number.

b. Assembler's lot number. 

c. Component nomenclature and code (if applicable). 

d. Processor's and/or plant name (if available). 

e. Defect number (Table L).

f. Specific defect code (if applicable). 

g. Narrative description of defect (if necessary). 

h. Tally defects (Major A, Major B, Minor) according to type of component.

5. Inspectors should refer to the component monographs for information relative to the 

product's normal characteristics, the most likely deteriorative conditions to be observed and any 

unique inspection information and special notes concerning the item. Monographs can be 

accessed at http://www.dscp.dla.mil/subs/support/qapubs/appb/mono-b.asp. If monographs are 

not available for a particular item, contact DLA Troop Support -FTSA for information. (Comm: 

(215) 737-8342, DSN: 444-8342).

6. Each component of the food packet will be opened and inspected. If no Major A or 

Major B defects are noted and the action number for minor defects is not exceeded during normal 

open package inspection, this phase of the inspection should be considered complete.

 7. Classify each defective by the most serious defect it possesses. If the action number 

is not reached or exceeded, the lot passes DOPI. 

 F. STEP 6: Determine if Special Inspection is Required. 

Special inspection is required when any action number is reached/exceeded. If a special 

inspection is deemed necessary, go to Section III for procedures.
 

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 G. STEP 7: Determine Disposition.

1. Disposition based on routine inspection results will be determined when no Major A 

or major B defects were noted or the action number for minor defects combined has not been 

reached. 

 2. If the lot passes all three inspections (Module, CPI, DOPI), the lot is fully useable 

and placed in Condition Code A. 

 

 3. If the lot fails the module inspection for minor defects, but has no major defects, the 

lot may be judged to be Condition Code A, if the inspector deems the lot to be fully serviceable.

 

 4. If the lot fails for defects to ancillary components, the lot may be placed in

Condition Code B, so long as the food packets are serviceable.

 

 5. The Condition Code of a lot may only be downgraded based on special inspection 

results.

 6. If deemed necessary, samples may be submitted to the appropriate supporting 

laboratory for testing. The lot will then be placed in Condition Code J pending results of the 

lab testing.

 7. Otherwise recommend destruction, Condition Code H to the accountable officer. If 

the lot may be unwholesome notify the supervising Veterinary Corps Officer, Vet Svcs Warrant 

Officer, or Air Force Preventive Medicine Officer for final disposition approval. 

 8. Complete Inspection Report.

 H. STEP 8: Provide Results and Recommendations to Accountable Officer/Agency.

1. Input data to the appropriate Lotus Notes (LN) database, and provide a copy of 

inspection report to accountable officer.

2. If LN access is not available, complete local DLA Troop Support Form 5117, and 

provide copy of 

report to accountable officer.

3. Local DLA Troop Support Form 5117 can be found at, 

http://www.dscp.dla.mil/subs/support/qapubs/appa/index.asp. 

4. For instructions on filling out local DLA Troop Support Form 5117, see website

https://www.dscp.dla.mil/subs/support/qapubs/appa/5117inst.pdf.

III. SPECIAL INSPECTION GUIDANCE.
 

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 Background Information: When a special inspection is performed, the inspector may 

choose to inspect all of the components in a module during the special inspection if he/she deems 

it necessary to ascertain the true condition of the lot. Otherwise, only the component(s) that 

exhibited the defects that initiated the special inspection will be inspected. All defective samples 

will be classified by the most serious defect they possess. Inspection is based on double 

sampling plan.

 A. STEP 1: Determine Lot Size.

1. Lot size is expressed as the total number of individual suspected defective components 

as determined during routine inspection (reached/exceeded Action Number). Each defective 

component will be inspected as a separate lot. To determine component lot size, you must 

determine which modules contain the defective component(s) utilizing the inspection results. 

These modules will be the only modules selected for the special inspection.

2. All defective samples will be classified by the most serious defect they possess.

 B. STEP 2: Determine Sample Size for Each Component and Select Sample Modules.

1. Sample size will be determined in accordance with Table B for Module inspections

and for module component inspections.

2. Inspect IAW applicable defect tables (Tables E thru L).

a. For special inspections, good sample representation of the lot is extremely 

important to help preclude unnecessary destruction. If routine inspection defects tend to be 

associated with a certain lot or lots, these shall be inspected separately. 

b. The sample size for each component involved will normally dictate the 

minimum number of modules that must be selected for special inspections. The inspector may 

increase the number of modules from which samples are drawn for cogent reasons.

 C. STEP 3: Determine Disposition of the Lot.

1. If none of the action numbers (ANs) are reached or exceeded, each module is 

considered to be fully useable and the Condition Code of the lot may remain unchanged.

2. For each action number equaled or exceeded, determine the Condition Code of the lot. 

Refer to Table N.

 D. STEP 4: Provide Results and Recommendations to Accountable Officer/Agency. 

1. Input data to the appropriate Lotus Notes database and provide a copy of inspection 

report to accountable officer.
 

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2. If LN access is not available, complete local DLA Troop Support Form 5117, and 

provide copy of report to accountable officer.

3. Local DLA Troop Support Form 5117 can be found at, 

http://www.dscp.dla.mil/subs/support/qapubs/appa/index.asp. 

4. For instructions on filling out local DLA Troop Support Form 5117, see website

https://www.dscp.dla.mil/subs/support/qapubs/appa/5117inst.pdf.

5. If rations are placed in less than condition code A and not entered into the LN 

database, notify DLA Troop Support -FTR telephonically @ (215) 737-7802 (DSN 444).

IV. SAMPLING AND DEFECT TABLES.

TABLE A 1/

SAMPLING CRITERIA FOR INSPECTION OF MODULES 

AND MODULE CONTENTS

(NORMAL INSPECTION)

LOT SIZE SAMPLE SIZE ACTION NUMBERS

(Modules) (Modules) MAJ A MAJ B MINOR

50 or less 2 1 1 2

51------500 3 1 1 2

501----35,000 5 1 1 3

35,000 or more 8 1 1 4

1/ For use with Table E thru L.

TABLE B 1/

SAMPLING CRITERIA FOR INSPECTION OF MODULES 

AND MODULE CONTENTS

(SPECIAL INSPECTION)

LOT SIZE SAMPLE SIZE ACTION NUMBERS

(Components) (Components) MAJ A MAJ B MINOR

150 or less 5 1 1 3

151------1,200 20 1 2 8

1,201----10,000 32 1 3 11

10,001 or more 50 1 4 15

1/ For use with Table E thru L.
 

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TABLE E 1/ 2/

INSPECTION OF MODULE BOXES

CATEGORY DEFECT

 MAJ B MINOR

 501 

 502

 

 601

 503 

 602 

Evidence of rodent or insect infestation on or 

in the shipping container. 2/ 

Container damaged, contents exposed or 

affected.

Container damaged, contents not exposed or 

affected.

Essential Markings:

a. Missing

b. Illegible/Incorrect

1/ For use with Table A and B. 

2/ Requires immediate corrective action according to local Pest Management Programs.

TABLE F 1/ 2/ 3/

INSPECTION OF POLYMERIC TRAYS

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B
 

 APP B

 DLA Troop SupportH 4155.2

17

 417

 418

 419

 420

 421

 422

 524

 525

 

 526

 

 622

 623

 

 624

 625

Swollen Container. 

Tear, crack, cut, hole, or if a multi-layered laminate 

is used, abrasion through more than one layer of the 

tray or through the barrier (e.g. foil) layer of the lid 

material or leakage through any seal or surface.

Abrasion on the lid material within 1/16 inch of the 

food product edge of seal.

Closure seal not continuous along tray flange 

surface.

Closure seal width less than 1/8 inch.

Foldover wrinkle extending into the seal such that 

the closure seal is reduced to less than 1/8 inch.

Presence of entrapped matter within 1/16” of 

the food product edge of seal or entrapped 

moisture or vapor within 1/16” of the food

product edge of seal that results in less than 

1/16” of defect free seal width at the outside

edge. 2/ 

Presence of delamination when a multi-layered 

laminate is used. 

Unclean container.

Any impression or design on the seal surfaces

which conceals or impairs visual detection of 

seal defects.

Presence of delamination when a multi-layered

laminate is used.

Presence of delamination when a multi-layered

laminate is used.

Color does not contribute to Woodland 

Camouflage.

Presence of any permanent tray body 

deformation, such that deformed area is 

discolored and roughened in texture.
 

 APP B

 DLA Troop SupportH 4155.2

18

Presence of any seal defect or anomaly

(i.e.: entrapped moisture, gases, etc.) within 1/16”

of food product edge seal.

1/ For use with Table A and B.

2/ The following shall be scored as minor defects if present within 1/16 inch of the food product 

edge of seal:

a. Small concave impressions or cavities indicating slight tray imperfections or hard 

particulates affixed to the seal head and contact the lid and tray.

b. Small (i.e. 1/32 inch or less in any direction) convex bumps or points on the seal area 

indicating small imperfections on the seal head. NOTE: this anomaly is typically visible on 

successive trays coming off the heat sealer.

c. Minor impressions or scorching of the top layer of the lid material on the seal area 

indicating soft particulates on the seal head being “burned-off” during sealing. NOTE: This 

anomaly is typically visible on successive trays coming off the heat sealer.

d. Areas of “wave-like” striations or wrinkles along the seal area indicating slight tray 

imperfection, improper lid tensioning, or vacuum release prior to lid cooling/setting.

e. Anomalies caused by entrapped moisture or vapor (which typically appear as concave 

spots on the tray flange surface) that result in less than 1/8” of defect free seal width at the 

outside edge of these spots.

3/ Delamination Defect classification:

 a. Major A – Evidence of outer ply delamination such that the adjacent ply in the lid body is 

exposed or evidence of multi ply delamination such that the food contact layer is exposed. Any 

evidence of outer ply delamination of the tray body or internal layer separation with the tray body 

due to, (for example) poor adhesion between layers.

 b. Major B – Delamination of the outer ply in the lid seal area that can be propagated to 

expose the adjacent ply at the food product edge of the lid. 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 in 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 scored as a Major B defect. 

Additionally, spot delamination of the outer ply in the body of the lid that can be propagated 

beyond its initial borders is also a Major B defect. To determine if the delaminated area is a 

defect, use the following procedure: Mark the outside edges of the delaminated area using a bold 

permanent marking pen. Open the tray and remove the contents. Cut the lid on opposing sides 

of the delaminated area not closer than 3/16 inch from the delaminated area. Hold the 

delaminated area between the thumb and forefinger of each hand with both thumbs and 

forefingers touching each other. The delaminated area shall than be rapidly flexed 10 times by 

rotating both hands in alternating clockwise-counter clockwise directions. After flexing, the 

separated outer ply shall be grasped between thumb and forefinger and gently lifted away from 

the lid surface 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. Any propagation of the delaminated area, evidenced by the delaminated 

area exceeding the limits of the outlined borders, shall be scored a Major B defect. 
 

 APP B

 DLA Troop SupportH 4155.2

19

 c. Minor – Minor delamination of the outer ply in the lid 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. Isolated spots of delamination in the body of the lid that do not propagate when 

flexed shall be classified as minor. Post-retort wrinkling of the outer ply in the lid seal area shall 

also be scored as a minor defect. NOTE: Post-retort wrinkles of the outer play are typically 

perpendicular to the flange direction, in a straight line, and extend from within the food product 

area to the outer edges of the lid. 

TABLE G 1/

INSPECTION OF METAL CONTAINERS

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 407

 408

 509

 

 609 

 

 510

 

 610

 

 511

 611

 

 512

 

 513

Swell, springer, or flipper (not applicable to 

gas or pressure packed product).

Leaker or blown container.

Closure incomplete, incorrect or not sealed, 

crimped, or fitted properly. 

Corrosion Defects: 

 a. Rust stain.

 b. Pitted rust.

Dents: 

 a. Materially affecting appearance but not 

affecting usability.

 b. Materially affecting usability.

Buckled Containers:

 a. Not involving end seam.

 b. Extending into the end seam.

Collapsed container.

1/ For use with Table A and B.
 

 APP B

 DLA Troop SupportH 4155.2

20

TABLE H 1/

INSPECTION OF PLASTIC/GLASS/FIBERBOARD CONTAINERS

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 409

 514

 

 612 

 

Broken and leaking container.

Closure not sealed, crimped, or fitted properly.

Chip in glass. 

1/ For use with Table A and B.

Table I 1/ 2/ 3/

INSPECTION OF FLEXIBLE POUCHES

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 409

 410

 411

 515

 

 516

 517

 613 

 

Broken and leaking container.

Tear, hole, or open seal.

Swollen pouch.

Rupture of pouch when kneaded IAW the

package instructions or monograph. 2/

Pouch exhibits delamination and ruptures

when tested. 3/

Objectionable odor.

Not clean.

1/ For use with Table A and B.

2/ Pouches exhibiting delamination in the body of the pouch will be examined for rupturing as 

follows: lay the pouch on a flat surface and apply moderate downward pressure with hands on 

both sides of the delaminated area. 

3/ Pouches exhibiting delamination in the seal area will be examined as follows:
 

 APP B

 DLA Troop SupportH 4155.2

21

a. Test for spreading of the delamination by holding the pouch between the thumb and 

forefinger of each hand with the delaminated area located at the contact point between the 

thumbs and forefingers. Flex the delaminated area rapidly while exercising care not to tear the 

pouch with your fingernails.

b. Test for rupturing by laying the pouch on a flat surface and applying moderate downward 

pressure with one hand on the product side of the delaminated area. 

TABLE J 1/

INSPECTION OF ENVELOPES (PACKETS)

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 518

 

 519 

 

 614

Tear, hole, or open seal.

Objectionable odor.

Not clean. 

1/ For use with Table A and B.

TABLE K 1/

INSPECTION OF NONFOOD COMPONENTS

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 521

 

 

 524 

 

 622

Damaged/torn/crushed materially affecting 

usability.

Nonfood Component Missing

 a. Completely.

c. Partially/count not as specified.

1/ For use with Table A and B.
 

 APP B

 DLA Troop SupportH 4155.2

22

TABLE L 1/ 2/ 3/

DESTRUCTIVE OPEN PACKAGE INSPECTION (DOPI)

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 412

 413

 414

 

 520

 615

 522

 523 

 616

 617

 

 618

 619

 620

Evidence of rodent damage/insect infestation in product. 

Product off conditions as evidenced by abnormal odor, 

color, flavor or texture suggesting contamination and/or 

spoilage for no apparent reason

(e.g., package failure not evident).

Foreign material present, affecting wholesomeness (e. g.,

glass, metal, wire).

Component missing

 a. Completely.

 b. Partially/count not as specified.

Moderate to extreme texture, odor, color or flavor 

change in a primary component not affecting 

wholesomeness (product unlikely to be consumed under 

conditions of intended use). 

Component fails to rehydrate or dissolve (extreme).

Slight texture, odor, color or flavor change in a 

component not affecting wholesomeness.

Component fails to rehydrate or dissolve (slight to 

moderate).

Internal container defects

 a. Detinning.

 b. Flaking/scarring of enamel

 c. Faulty coating (tray)
 

 APP B

 DLA Troop SupportH 4155.2

23

 621

 622

 d. Damaged coating (tray)

 e. Other

1/ For use with Table A and B.

2/ Requires immediate corrective action according to local Pest Management Programs.

3/ Specify defect(s) observed. Enter all specific defect codes that apply and a narrative 

description when appropriate.

TABLE M

SPECIFIC DEFECT CODES

 A. INSECT / RODENT

 A1. Rodent.

 A2. Insect.

 A3. Other (describe).

 B. PACKAGING, PACKING, MARKING, LABELING AND UNITIZATION

 B1. Essential case markings missing.

 B2. Essential case markings illegible.

 B3. Essential case markings incorrect.

 B4. Essential Labeling missing.

 B5. Essential Labeling illegible.

 B6. Essential labeling incorrect.

 B7. Pitted rust.

 B8. Rust stains.

 B9. Dents.

 B10. Flat tray (Low vacuum). 

 B11. Loose lid (Flipper).

 B12. Paneling-Affects double seam.

 B13. Paneling-Not affecting seam.

 B14. Incomplete/False seam tray closure.

 B15. Hard sweller.

 B16. Soft sweller.

 B17. Leaker-pinhole.

 B18. Leaker-blown/ruptured container.

 B19. Leaker-seam area.

 B20. Collapsed container-other than trays.

 B21. Incomplete closure-other than trays.

 B22. Sweller, springer, flipper-other than trays.

 B23. Buckled containers-other than trays. 

 B24. Chip in glass.

 B25. Broken of leaking glass/plastic container.

 B26 Tear, hole, leaker-flexible pouches/envelopes/poly trays.

 B27. Swollen flexible pouch.
 

 APP B

 DLA Troop SupportH 4155.2

24

 B28. Pouch ruptures when kneaded.

 B29. Unclean pouches/envelopes/poly trays.

 B30. Delamination. 

 B31. Objectionable odor-flexible pouches/envelopes.

 B32. Damaged/missing food components.

 B33. Damaged/missing non-food components.

 B34. Shipping container damaged, contents exposed.

 B35. Shipping container damaged, contents not exposed.

 B36. Abrasion of lid material-poly trays.

 B37. Foldover wrinkles-poly trays.

 B38. Seal defect or Amanoly-poly trays.

 B39. Tray body deformation-poly trays.

 B40. Color not contributing to Woodland Camouflage-poly trays.

 B41. Impression concealing visual detection of seal defects-poly trays.

 B42. Other, describe.

 C. TEXTURE CHANGES 

 C1. Too thick or pasty.

 C2. Chewy / gummy.

 C3. Mealy.

 C4. Tough / stringy.

 C5. Caked or hardened.

 C6. Brittle.

 C7. Crumbly, cracking.

 C8. Excessively dry.

 C9. Loss of crispness/soft/mushy.

 C10. Lumpy.

 C11. Curdled.

 C12. Gritty / grainy.

 C13. Spongy / rubbery.

 C14. Syneresis (The contraction of a gel, or a homogeneous colloid system, when left 

standing separates into two phases: a coherent gel and a liquid. A good example is the 

separation or weeping of liquid of liquid from a gelatin mold when left sitting in a refrigerator 

too long).

 C15. Liquefaction (passing from dry, solid, or semi-solid) to a liquid state (e.g., complete 

loss of gel structure in jelly component).

 C16. Caramelized.

 C17. Watery gravy or excessive product juices (probably due to product formulation and/or 

time-temperature abuse).

 C18. Honeycombing.

 C19. Coagulation/gelation (beverage base).

 C20. Other, describe.

 D. ODOR CHANGES

 D1. Medicinal, vitamin-like.

 D2. Chemical odor, solvent-like/turpentine/paint-like.

 D3. Plastic-like.
 

 APP B

 DLA Troop SupportH 4155.2

25

 D4. Hay-like (oxidized).

 D5. Fermented.

 D6. Scorched/burnt.

 D7. Sulfur-like.

 D8. Musty, moldy, mildew.

 D9. Overripe.

 D10. Green, not ripe.

 D11. Stale.

 D12. Cardboard.

 D13. Soured.

 D14. Putrid.

 D15. Acidic/vinegary.

 D16. Metallic.

 D17. Rancid.

 D18. Ammonia.

 D19. Loss of spice or product aroma.

 D20. Other, describe.

 E. FLAVOR CHANGES

 E1. Loss of flavor, flat, bland.

 E2. Chemical flavor, solvent-like, turpentine/paint-like.

 E3. Medicinal, vitamin-like.

 E4. Plastic-like.

 E5. Hay-like (oxidized).

 E6. Bitter.

 E7. Burnt.

 E8. Soapy.

 E9. Musty, moldy, mildew.

 E10. Rancid.

 E11. Stale.

 E12. Fermented.

 E13. Earthy.

 E14. Tart, acidic.

 E15. Overripe.

 E16. Green, not ripe.

 E17. Tobacco.

 E18. Sweet, perfume like, flowery.

 E19. Metallic.

 E20. Excessively over-processed / scorched.

 E21. Canned.

 E22. Putrid.

 E23. Sour.

 E24. Excessively salty.

 E25. Other (describe).

 F. APPEARANCE CHANGES

 F1. Darkened.
 

 APP B

 DLA Troop SupportH 4155.2

26

 F2. Bloomed, blotchy (e.g., chocolate).

 F3. Oily, oiled-off (partial disintegration of an oil in water emulsion whereby a film, 

pockets, or droplets of oil form on the surface of the product or within the product).

 F4. Off-color (e.g., pink, off-white, reddish, green).

 F5. Cloudiness (beverage bases except orange).

 F6. Webbing (caffeine leeching).

 F7. Other, describe.

 G. FOREIGN MATERIAL

 G1. Potentially hazardous (e.g., glass, splinters, metal).

 G2. Not potentially hazardous.

 G3. Other, describe.

 H. COMPLETE LOSS OF MENU (Does Not Consider Caloric Count)

NOTE: The purpose of this defect category is to enable inspectors and evaluators of the 

inspection data to properly identify menus that contained one (or more) leaking component that 

adversely affected the entire meal. For example, if an applesauce pouch leaks, the entire menu 

may be unfit for use because of the mold growth that would likely occur inside the menu bag. 

 H1. Due to one leaking or ruptured component.

 H2. Due to more than one leaking or ruptured component. 

 H3. Due to one or more components contaminated by insecticide/pesticide.

 H4. Due to one or more components contaminated by an unidentified substance.

 H5. Other, describe.

 J. MISSING COMPONENTS/MENUS

 J1. Required component (s) missing from menu.

 J2. Required menus missing.

TABLE N 1/ 2/ 3/ 4/ 5/

CONDITION CODE CRITERIA

DEFECTS FROM SPECIAL INSPECTION RESULTS

(COMPONENTS THAT EQUAL OR EXCEED

AN ACTION NUMBER)

CATEGORY

CONDITION CODE A MAJOR A MAJOR B MINOR

Primary

Secondary

Ancillary

0

0

0

0

1

1

1

2

2

CONDITION CODE B

Primary

Secondary

Ancillary

0

0

0

0

2

2

2

3

3

CONDITION CODE H or J

(see note 5)

Primary

Secondary

1

1

2

4

NA

NA
 

 APP B

 DLA Troop SupportH 4155.2

27

Ancillary 1 4 NA

1/ Lots determined to be unwholesome will be classified Condition Code J until final disposition 

is made by the responsible veterinarian.

2/ Each column lists the maximum number of components allowed to equal or exceed an action 

number for that category.

3/ Each row lists the maximum number of components allowed to equal or exceed an action 

number by component classification.

4/ Compare the number of components from the inspection that equals or exceeds the special 

inspection action numbers for each category. If the number in any row/column intersection is 

exceeded, the lot must be downgraded to the next lower Condition Code.

5/ For lots that fail inspection and do not meet a serviceable condition code, a condition code of 

J or H is assessed. If it is necessary to send samples to the lab for food safety or productionrelated defects, or to investigate the lot further; then assess a condition code of J. If condition J is 

assessed, this will need to revised once the lab evaluation or investigation is complete. Changing 

the condition code after the report is submitted is the responsibility of the report approver. If the 

defects have a readily explainable cause, such as heat stress, physical damage, or infestation, than 

Condition Code H (condemnation) is appropriate. Condition Code L means that warranty action 

is pending. Warranty inspections will be directed by the contracting officer and/or the chain-ofcommand. Inspectors who are asked to perform a warranty inspection will be supplied with 

specific sampling and inspection instructions.

V. INSPECTION RECORDS.

 A. Inspection Form. All inspections will be entered on DLA Troop Support Form 5117. 

Local reproduction of DLA Troop Support Form 5117 is authorized.

 B. Database. There is currently a VETCOM database to report UGR H&S inspection results. 

This will be the primary means for documenting inspection results. 

 C. Distribution. For DLA owned/controlled stocks, one copy of DLA Troop Support Form

5117 will be provided to the accountable officer. Copies of all reports will also be maintained in 

the local quality history files. Inspections resulting in less than Condition Code A status must be 

telephonically reported to DLA Troop Support -FTRE/FTSA (215) 737-7773/4477/7771 (DSN 

444). Other distribution will be according to the directives of the responsible inspection agency 

and/or Military Service.