PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

1

SECTION C

This document covers instant fruit juice, packaged in a flexible pouch or metal can for use by 

the Department of Defense as a component of operational rations.

C-1 ITEM DESCRIPTION

PCR-J-002A, JUICE, FRUIT, INSTANT

Types, styles, designs and packages.

 

Types.

Type I – Grape

Type II – Orange

Styles.

Style A – Sweetened

Style B – Unsweetened

Designs.

Design B – Flat interlocking closure pouch

Design F – Metal can

Packages.

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

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

Package K – Unitized Group RationTM-ExpressTM (UGR-ETM)

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 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

2

from the approved product standard, which result in a product noncomparable to the product 

standard, the contractor shall submit a replacement FA or PDM for approval. In any event, all 

product produced must meet all requirements of this document including product standard 

comparability.

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

months at 80oF.

 C. Standards. 

 

(1) Ungraded. 

 a. Type I. Grape juice shall be a dried grape juice powder.

(2) Graded. The grade standard for type II shall conform to the following standard as 

an ingredient prior to dehydration.

 a. Type II. Orange juice shall be U.S. Grade A of the United States Standards for 

Grades of Orange Juice.

 D. Powdered product.

(1) Appearance. The finished product shall be a uniform, free flowing, dry mixture. 

The orange juice powder shall be a yellow-orange color and the grape juice powder shall be a

purple color. The finished product shall be free from foreign materials and foreign colors.

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

food shall be free from foreign odors.

(3) Texture. The instant fruit juice powder shall be free from hard lumps.

 E. Hydrated product. The instant fruit juice, when hydrated according to directions for use, 

shall dissolve within 2 minutes of constant stirring or shaking.

(1) Appearance. 

a. Type I, style A. The hydrated grape juice shall have a purple color.

b. Type II, style B. The hydrated orange juice shall have an orange color.
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

3

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

a. Type I, style A. The hydrated grape juice shall have a sweetened grape odor 

and flavor.

b. Type II, style B. The hydrated orange juice shall have an unsweetened orange 

odor and flavor.

(3) Texture. The hydrated fruit juice shall have no discernible lumps and shall be 

sediment free.

 F. Net weight.

 a. Type I, style A, design B. The net weight of the pouch of instant grape juice 

shall be not less than 34 grams.

 b. Type II, style B, design B. The net weight of the pouch of instant orange juice 

shall be not less than 31 grams.

 

 c. Type II, style B, design F. The net weight of the can of instant orange juice 

shall be not less than 16.5 ounces (468 grams).

 d. Type I, style A, design F. The net weight of the can of instant grape juice shall 

be not less than 19.0 ounces (539 grams).

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

the approved product standard in palatability and overall appearance. 

 H. Analytical requirements.

(1) Moisture.

 a. Design B. The moisture content shall be not greater than 2.0 percent.

 b. Design F. The moisture content shall be not greater than 1.5 percent. 

(2) Oxygen (design F only). The oxygen content of the headspace gas shall not 

exceed 2.0 percent. 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

4

(3) Sulfite (design F only). Sulfite compounds, not more than 250 ppm, may be added 

to the product.

C-3 MISCELLANEOUS INFORMATION

THE FOLLOWING IS FOR INFORMATION ONLY. THIS IS NOT A MANDATORY 

CONTRACT REQUIREMENT.

 A. Ingredients for type I, style A may be as follows: Concentrated Concord grape juice,

essence or natural flavor from Concord grapes, white refined granulated cane or beet sugar, 

dextrose, corn syrup or corn syrup solids, (used singly or in combination, sodium sulfite or 

sodium bisulfite), defoaming agents, foam stabilizers, vegetable gums or 

carboxymethylcellulose, tartaric, citric, malic acid, anticaking agents. 1/

1/ Dextrose, corn syrup and corn syrup solids, if used, should not exceed 1/2 by weight, of 

the total sweetening ingredient on a dry solids basis.

 B. Ingredients for type II, style B may be as follows: Orange juice concentrate, oil of 

orange, entrapped orange oil granules, sodium sulfite, sodium bisulfite, foam stabilizers, 

vegetable gums, carboxymethylcellulose, and anticaking agents.

SECTION D

D-1 PACKAGING

 A. Packaging. 

(1) Design B, Flat interlocking closure pouch. For type I, style A, design B, 34 grams

or for type II, style B, design B, 31 grams of fruit juice shall be filled into a preformed pouch 

as described below. The pouch shall be used as a package and for hydration of the fruit juice.

 a. Pouch material. The 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 bonded 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 food 

packaging and shall not impart an odor or flavor to the product. The complete exterior 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

5

surface of the pouch shall be uniformly colored and shall conform to number 20219, 30219, 

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

Procurement.

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

form-fill-seal pouch with an interlocking closure. The design and dimensions shall be as 

specified in figure 1. The pouch shall be made by heat sealing the sides and top of the pouch 

with 3/8 (+1/8,-1/4) inch wide seals. The pouch shall exhibit no rupture or seal separation 

greater than 1/16 inch when tested for internal pressure resistance. The interlocking closure 

of the pouch shall not leak more than 15 ml. A tear nick or notch shall be provided on one or 

two opposite edges of the pouch above the interlocking closure 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. Product shall be inserted into the pouch and the filled 

pouch shall be sealed with a 1/8 to 1 inch wide heat seal. The closure seal shall be applied not

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. 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) Design F Metal can. For type I, style A, a net weight of 19.0 ounces (532 grams) or 

for type II, style B, a net weight of 16.5 ounces (462 grams) shall be unit packed in a size 401 

by 411 or 401 by 602 metal can in accordance with good commercial practice. After filling, 

the can shall be hermetically sealed under conditions which will result in a vacuum of not 

less than 15 inches of mercury or sealed under an atmosphere of nitrogen so that the oxygen 

content of the gases in the filled and sealed container does not exceed 2.0 percent. The filled, 

sealed, and processed can shall conform to the United States Standards for Condition of Food 

Containers. The can shall not leak when tested in accordance with E-6,B(5). Each can shall 

have a moisture content not greater than 1.5 percent. A desiccant may be used. An oxygen 

scavenger may be used.

 (3) Oxygen scavenger for Design F Metal can. The oxygen scavenger shall be 

constructed of materials that are safe for direct and indirect food contact and shall be 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

6

suitable for use with edible products. The oxygen scavenger shall be in compliance with all 

applicable FDA regulations.

 (4) Desiccant for Design F Metal can. The desiccant shall be constructed of materials 

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

products. The desiccant 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) 1/

(2) Ingredients

(3) Date 2/ 

(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) Directions for design B flat interlocking closure pouch: Allow water just 

chemically purified to stand 30 minutes before adding to the instant fruit juice

powder. Tear pouch at notch. Open zipper, add 8 ounces of cold water (1/3 canteen 

cup) to fill line. Close zipper. Shake to mix. SINGLE USE ONLY.

(8) 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 or 

label for 8-ounce fill at 4-1/2 ± 1/4 inches from the inside edge of the closure seal.

1/ Type I, Style A, Design B, product name shall be referred to as instant grape juice and 

shall include percent juice.

2/ Each pouch or envelope shall have the date of pack noted by using a four digit code 

beginning with the final digit of the current year followed by the three digit Julian day code. 

For example, 14 February 2014 would be coded as 4045. The Julian day code shall represent 

the day the product was packaged into the pouch.
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

7

 B. Metal cans (Design F). Labeling of metal cans shall be as specified in DLA Troop 

Support Form 2997, Labeling of Metal Cans for Subsistence Items. The label shall include 

the following information as:

 1. Type I, Style A, Design F.

GRAPE JUICE, INSTANT, SWEETENED

GAS PACKED (when applicable)

Preserved with Sulfur Dioxide (when applicable)

Directions for use

IMPORTANT: DISCARD DESICCANT BAG OR OXYGEN SCAVENGER 

Place contents in a gallon measure and add 1-7/8 quarts of water while stirring. Makes 1/2 

gallon (sixteen 4-fluid ounce servings) of grape juice. 

To make grape juice drink, add an additional 1/2 gallon of water and stir. Makes 1 gallon 

(16, 8-fluid ounce servings) of grape juice drink.

NOTE: When a calcium oxide (CaO) desiccant is used, the following statement shall be 

printed on the packet:

DO NOT DISCARD DESICCANT PACK. Fill empty beverage can with water and

submerge desiccant pack for 30 minutes before discarding. The spent desiccant may be 

disposed of with general trash.

 2. Type II, Style B, Design F.

JUICE, ORANGE, INSTANT, UNSWEETENED

GAS PACKED (when applicable)

Preserved with Sulfur Dioxide (when applicable)

Directions for use

IMPORTANT: DISCARD DESICCANT BAG OR OXYGEN SCAVENGER 

Pour approximately a quart of cold water into a gallon measure. While whipping water, 

gradually add product. When product has dissolved, add water to make one gallon of juice 

and stir. If desired, 1/4 cup of sugar may be added. Makes sixteen 8-fluid ounce servings of 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

8

orange juice. When preparing juice in quantity, add contents of each can to 3-3/4 quarts of 

cold water and stir briskly.

NOTE: When a calcium oxide (CaO) desiccant is used, the following statement shall be 

printed on the packet:

DO NOT DISCARD DESICCANT PACK. Fill empty beverage can with water and

submerge desiccant pack for 30 minutes before discarding. The spent desiccant may be 

disposed of with general trash.

D-3 PACKING

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

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

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

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

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

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

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

D-4 UNITIZATION

 A. Unit load examination. The unit load shall be examined in accordance with the 

requirements of DLA Troop Support Form 3507, Loads, Unit: Preparation of Semiperishable 

Subsistence Items. 

D-5 MARKING

 A. Shipping containers and unit loads. Shipping containers and unit loads shall be marked 

in accordance with DLA Troop Support Form 3556, Marking Instructions for Boxes, Sacks,

and Unit Loads of Perishable and Semiperishable Subsistence. In addition, the following 

markings (for design F, metal can only) shall appear upon the top of each shipping container 

in letters not less than 1 inch high.

STORE IN COOL, DRY PLACE

PRODUCT DETERIORATES 

RAPIDLY ABOVE 80oF
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

9

SECTION E INSPECTION AND ACCEPTANCE

The following quality assurance criteria, utilizing ANSI/ASQ Z1.4, Sampling Procedures and 

Tables for Inspection by Attributes, are required. Unless otherwise specified, single sampling 

plans indicated in ANSI/ASQ Z1.4 will be utilized. When required, the manufacturer shall 

provide the Certificate(s) of Conformance to the appropriate inspection activity. 

Certificate(s) of Conformance not provided shall be cause for rejection of the lot.

 A. Definitions.

(1) Critical defect. A critical defect is a defect that judgment and experience indicate 

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

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

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

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

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

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

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

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

 

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

as follows:

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

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

appearance, odor, flavor, and texture. Any failure to conform to the performance

requirements or any appearance or palatability failure shall be cause for rejection of the lot. 

(2) Periodic review evaluation. The approved first article or product demonstration 

model shall be used as the product standard for periodic review evaluations. All food 

components that are inspected by the USDA shall be subject to periodic review sampling and 

evaluation. The USDA shall select sample units during production of contracts and submit 

them to the following address for evaluation:
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

10

US Army Research, Development and Engineering Command

Natick Soldier Research, Development and Engineering Center

RDNS-CFF

15 Kansas Street

Natick, MA 01760-5056

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

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

production lot. The three (3) sample units shall be shipped to Natick within five (5) working 

days from the end of the production month from which they are randomly selected and upon 

completion of all USDA inspection requirements. The sample units will be evaluated for 

overall quality against the current first article or product demonstration model.

(3) Conformance inspection. Conformance inspection shall include the 

examinations/tests and methods of inspection cited in this section.

E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT)

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

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

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

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

sealed pouch or one filled and sealed can. 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.
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

11

TABLE I. Product defects 1/ 2/ 3/

Category Defect

Major Minor

Powdered product

101 Product not type or style or design as specified.

Appearance

201 Not a uniform, free flowing, or dry mixture.

202 Orange juice powder not a yellow-orange color.

203 Grape juice powder not a purple color.

Odor

102 Not odor of type specified.

Texture

204 Presence of hard lumps. 4/

Net weight

205 Type I, style A, design B net weight of an individual pouch less than 34 

grams.

206 Type II, style B, design B net weight of an individual pouch less than 

31 grams.

207 Type II, style B, design F net weight of an individual can less than 16.5 

ounces (468 grams).

208 Type I, style A, design F net weight of an individual can less than 19.0 

ounces (539 grams).
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

12

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

Category Defect

Major Minor

Hydrated product 5/

Appearance

209 Type I, style A hydrated grape juice not a purple color.

210 Type II, style B hydrated orange juice not an orange color.

Odor and flavor

103 Type I, style A does not have a sweetened grape odor or flavor.

104 Type II, style B does not have an unsweetened orange odor or flavor.

Texture

105 Product has discernible lumps or not sediment free.

Desiccant bag or oxygen scavenger (for Design F metal can only)

106 Desiccant bag or oxygen scavenger missing or damaged. 6/

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. Foreign flavors not 

applicable to powdered product.

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/ Failure of the juice ingredient for Type II to meet the U.S. Grade A requirements verified 

with a USDA Grade Certificate, shall be cause for rejection of the lot.

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

defect. 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

13

5/ Prior to conducting the hydrated product examination, the instant fruit juice shall be 

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

constant stirring or shaking shall be cause for rejection of the lot.

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

verified by a Certificate of Conformance (CoC).

 B. Methods of inspection.

(1) Shelf life. The contractor shall provide a Certificate of Conformance that the 

product has a 36 month shelf life when stored at 80°F. Government verification may include 

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

period, the product will be subjected to a sensory evaluation panel for appearance and 

palatability and must receive an overall score of 5 or higher based on a 9 point quality scale 

to be considered acceptable.

(2) Net weight. The net weight of the filled and sealed pouch or can shall be 

determined by weighing each sample unit on a suitable scale tared with a representative 

empty pouch or can and lid. Results shall be reported to the nearest 0.1 ounce or gram.

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

sealed pouches or cans that have been selected at random from the lot. The composite sample 

shall be prepared and analyzed in accordance with the following methods of the Official 

Methods of Analysis (OMA) of AOAC International:

Test Method Number

Moisture in sugars 925.45A, 934.06

Sulfites in foods (Design F metal can only) 990.28

The test results for moisture shall be reported to the nearest 0.1 percent for moisture. The test 

results for sulfites in foods shall be reported to the nearest 1 ppm. Government 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.

(4) Oxygen content testing (design F metal can). Eight filled and sealed cans shall be 

randomly selected from one production lot and individually tested for oxygen content. 

Testing shall be accomplished after the filled and sealed cans 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 0.1 percent. Government verification will be 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

14

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

conforming to the oxygen content requirement 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 CoC may be accepted as evidence that the characteristics listed below 

conform to the specified requirements.

Characteristic

Requirement

paragraph Test procedure

Thickness of films for laminated 

material

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

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

Laminated material identification 

and construction

D-1,A(1)a Laboratory evaluation

Color of laminated material D-1,A(1)a FED-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 or b.

(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-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

15

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 Leakage. 6/

108 Fill line missing or does not measure within 4-1/2 + 1/4 inches 

from the inside edge of the closure seal.

109 Not packaged as specified.

201 Label missing or incorrect or illegible.

202 Tear nick or notch 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/

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

figure 1.

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

207 Design B pouch closure seal more than 1/2 inch from the open 

end of the pouch.
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

16

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 

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 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

17

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

unclean:

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

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

with a clean dry cloth.

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

face (localized and aggregate).

5/ If doubt exists as to whether or not the sealing equipment leaves an impression or design 

on the closure seal surface that could conceal or impair visual detection of seal defects, 

samples shall be furnished to the contracting officer for a determination as to acceptability.

6/ Examine pouch after removal from leakage test apparatus.

 B. Methods of inspection.

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

c, as applicable.

 a. Unfilled preformed pouch seal testing. The seals of the unfilled preformed 

pouch shall be tested for seal strength in accordance with ASTM F88/F88M, Standard Test 

Method for Seal Strength of Flexible Barrier Materials. The lot size shall be expressed in 

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

pouches indicated by inspection level S-1. Three adjacent specimens shall be cut from each 

of the three sealed sides of each pouch in the sample. The average seal strength of any side 

shall be calculated by averaging the three specimens cut from that side. Any average seal 

strength of less than 6 pounds per inch of width or any test specimen with a seal strength of 

less than 5 pounds per inch of width shall be classified as a major defect and shall be cause 

for rejection of the lot.

 b. Pouch closure seal testing. The closure seals of the pouches shall be tested for 

seal strength in accordance with ASTM F88/F88M. The lot size shall be expressed in 

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

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

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

pouch in the sample. The average seal strength of any side, end or closure shall be calculated 

by averaging the three adjacent specimens cut from that side, end or closure. Any average 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

18

seal strength of less than 6 pounds per inch of width or any test specimen with a seal strength 

of less than 5 pounds per inch of width shall be classified as a major defect and shall be cause 

for rejection of the lot.

 c. Internal pressure test. For design B, 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 sides and end of the pouch. 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.

(2) Interlocking closure test. For design B, the interlocking closure of the pouch shall 

be tested. 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-2. Open a filled 

and sealed interlocking 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 liquid that drips. Pouches that leak more than 15 ml shall be classified as a

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

(3) Can condition examination. Examination of filled and sealed cans shall be in 

accordance with the United States Standards for Condition of Food Containers. In addition, 

scratches, scuffs or abrasions that occur on the outside coating as a result of the filling, 

sealing, and processing of the cans shall not be scored as a defect.

(4) Can closure examination. Can closures shall be examined visually and by 

teardowns in accordance with the can manufacturer's requirement and 21 CFR, Part 113, 

Subpart D, or 9 CFR, Part 318, Subpart G, as applicable. Any nonconformance based on 
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

19

observation of can seam teardowns or on record of can seam teardowns shall be classified as 

a major defect and shall be cause for rejection of any involved product.

(5) Can leakage examination. Cans shall be inspected for leakage. The sample unit 

shall be one filled and sealed can. The lot size shall be expressed in cans. The sealed cans 

shall be examined for leakage by submerging the can in water contained in a vacuum 

desiccator, Mead Tester, or equivalent device, and drawing a vacuum of not less than 10 

inches of mercury (atmospheric pressure 29.9 inches of Hg) for at least 30 seconds. A leak is 

indicted by a steady progression of bubbles and is a major defect. Isolated bubbles caused by 

air entrapped in the double seam are not considered signs of leakage. The inspection level 

shall be S-3 and the AQL, expressed as defects per hundred units, shall be 1.5.

(6) Vacuum test. The vacuum level in the cans shall be determined by use of a 

puncture vacuum gauge. The sample unit shall be one filled and sealed can. The lot size 

shall be expressed in cans. The inspection level shall be S-3. No vacuum or a vacuum level 

less than 15 inches of mercury shall be a failure and classified as a major defect.

 C. Packing.

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

containers shall be examined for the defects listed in table III. The lot size shall be expressed 

in shipping containers. The sample unit shall be one shipping container fully packed. The 

inspection level shall be S-3 and the AQL, expressed in terms of defects per hundred units, 

shall be 4.0 for major defects and 10.0 for total defects.

TABLE III. Shipping container and marking defects

Category Defect

Major Minor

101 Marking missing or incorrect or illegible.

102 Inadequate workmanship. 1/

201 More than 40 pounds of product.

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

flaps, loose strapping, inadequate stapling, improper taping, or bulged or distorted container.
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

20

FIGURE 1. Design B Flat, Interlocking Closure Pouch

(Not actual size)
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

21

SECTION J REFERENCE DOCUMENTS

Unless otherwise specified, the applicable version of these documents is that which is active 

on the date of the solicitation or contract.

DLA Troop Support Forms

DLA Troop Support Form 2997 Labeling of Metal Cans for Subsistence Items

DLA Troop Support 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

GOVERNMENT PUBLICATIONS

U.S. STANDARDS FOR GRADES

United States Standards for Grades of Orange Juice

Federal Food, Drug, and Cosmetic Act and regulations promulgated there under 

(21 CFR Parts 1-199) and (9 CFR Parts 1-391)

U.S. Standards for Condition of Food Containers

NON-GOVERNMENTAL STANDARDS

AMERICAN SOCIETY FOR QUALITY (ASQ) www.asq.org

ANSI/ASQ Z1.4-2003 Sampling Procedures and Tables for Inspection 

by Attributes
 PCR-J-002A

 10 January 2014

SUPERSEDING

PCR-J-002

15 November 2006

22

ASTM INTERNATIONAL www.astm.org

D1974/D1974M Standard Practice for Methods of 

Closing, Sealing, and Reinforcing 

Fiberboard Boxes

D4727/D4727M Standard Specification for Corrugated and 

Solid Fiberboard Sheet Stock (Container 

Grade) and Cut Shapes

D5118/D5118M Standard Practice for Fabrication of Fiberboard 

Shipping Boxes

B479 Standard Specification for Annealed 

Aluminum and Aluminum-Alloy Foil 

for Flexible Barrier, Food Contact, and 

Other Applications

F88/F88M Standard Test Method for Seal Strength 

of Flexible Barrier Materials

D2103 Standard Specification for Polyethylene 

Film and Sheeting 

AOAC INTERNATIONAL www.aoac.org

Official Methods of Analysis (OMA) of AOAC International