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SECTION C

This document covers thermostabilized chili with beans packaged in a polymeric tray for 

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

C-1 ITEM DESCRIPTION

PCR-C-034A, CHILI WITH BEANS, PACKAGED IN A POLYMERIC TRAY, SHELF STABLE

C-2 PERFORMANCE REQUIREMENTS

 A. Product standard. A sample shall be subjected to first article or product 

demonstration model inspection as applicable, in accordance with the tests and 

inspections of Section E of this Performance-based Contract Requirements document.

 B. Commercial sterility. The packaged food shall be processed until commercially 

sterile.

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

36 months at 80oF.

 D. Appearance.

(1) General. The finished product shall be a mixture of coarsely ground beef, light 

red kidney beans in a tomato based sauce with onions, seasoned with spices. The packaged 

food shall be free from foreign materials. 

(2) Ground beef. The beef shall be typically produced by a 3/8 inch grinder plate, 

and shall be practically free of bone or bone fragments, cartilage, coarse connective 

tissue, tendons or ligaments, and glandular material. The beef shall be a brown, cooked 

beef color.

(3) Kidney beans. The cooked beans shall be light red kidney beans and shall be 

intact.

(4) Sauce. The sauce shall be tomato based and shall be dark red color with pieces 

of tomatoes and onions with flecks of spices. 

 E. Odor and flavor. The packaged food shall have an odor and flavor of ground beef and 

kidney beans in a tomato based sauce with onions and shall elicit a sensation of medium 

to high heat. The packaged food shall be free from foreign odors and flavors. 

 F. Texture. 

(1) Ground beef. The cooked ground beef shall be moist and tender. 

(2) Kidney beans. The kidney beans shall be slightly soft to slightly firm.

(3) Sauce. The sauce shall have pieces of tomatoes and onions with flecks of 

spices.

 G. Net weight. The average net weight shall be not less than 96 ounces. No individual 

polymeric tray shall have a net weight of less than 94 ounces.
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 H. Drained weight. The drained weight of the beef and beans (combined) in an 

individual polymeric tray shall be not less than 52.0 ounces. 

 

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

than the approved product standard in palatability and overall appearance.

 J. Analytical requirements.

(1) Protein content. The protein content shall be not less than 9.0 percent.

(2) Fat content. The fat content shall be not greater than 6.0 percent.

(3) Salt content. The salt content shall be not less than 0.5 percent and not 

greater than 1.3 percent.

C-3 MISCELLANEOUS INFORMATION

THE FOLLOWING IS PROVIDED FOR INFORMATION ONLY TO PROVIDE THE BENEFIT OF PAST GOVERNMENT 

EXPERIENCE. THIS IS NOT A MANDATORY REQUIREMENT.

 A. Ingredients/formulation. Ingredients and formulation percentages may be as follows: 

Ingredients Percent by weight 1/

Beef, ground, blanched 2/ 37.00

Water 2/ 44.53

Tomato paste (24 percent solids) 3/ 5.50

Tomatoes, crushed (8 percent solids) 3/ 4.50

Starch, waxy maize, modified 1.00

Paprika, ground 1.80

Pepper, chili, ground 1.66

Sugar, granulated 1.00

Onions, chopped, dehydrated 1.30

Salt 4/ 1.30

Cumin, ground 0.15

Garlic powder 0.10

Oregano, ground 0.08

Pepper, red, ground 0.08

1/ The product shall consist of 72 percent prepared chili con carne and 28 percent soaked 

beans. The beans shall be combined with the meat sauce mixture and mixed only to the 

extent necessary to ensure a uniform distribution of the beans throughout the product. 

The percent by weight of beans may be adjusted as necessary to ensure compliance with 

finished product drained weight requirements.

2/ The percent by weight of blanched ground beef and the percent by weight of water may 

be adjusted if necessary to ensure compliance with finished product requirements.

3/ If the specified tomato solids are not available, the tomato solids that are used may 

be adjusted to bring the solid level to that specified.

4/ The total amount of salt in the formula may be adjusted as necessary to produce a 

product that complies with the finished product salt requirement.
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SECTION D

D-1 PACKAGING

 A. Preservation. Product shall be filled into polymeric trays and the trays with 

protective sleeves shall conform to the requirements of section 3 of MIL-PRF-32004, 

Packaging of Food in Polymeric Trays. Verification testing and inspection of trays, lids 

and sleeves shall be in accordance with Section 4 of MIL-PRF-32004 and the Quality 

Assurance Provisions of Section E of this Performance-based Contract Requirements 

document.

 B. Polymeric tray closure. The filled, sealed, and processed tray shall be securely 

closed.

D-2 LABELING

 A. Polymeric tray body. One side of each polymeric tray shall be clearly printed or 

stamped, in a manner that does not damage the tray, with permanent ink of any contrasting 

color, which is free of carcinogenic elements. To avoid erroneous marking of trays, the 

product name, lot number and filling equipment number shall be applied prior to 

processing. All other tray marking may be applied before or after processing. If these 

markings are applied along the tray body side (see figure 1 of MIL-PRF-32004), or if 

applied along the tray body end, are not readily legible in low light conditions, a 

small, easily legible label detailing product name and number of portions shall be 

applied along one tray body end, but not over any existing tray markings. 1/ 

Tray body markings shall include:

(1) Product name. Commonly used abbreviations may be used when authorized by 

the inspection agency.

(2) Tray code includes: 2/

 Lot Number

 Filling equipment identification number

 Retort identification number 

 Retort cook number

 Official establishment number

1/ As an alternate method, tray body markings may be clearly printed or stamped onto the 

polymeric tray lid prior to processing, in a manner that does not damage the lid, with 

permanent ink of any contrasting color, which is free of carcinogenic elements, provided 

that the required markings are applied onto the tray body after processing.

 

2/ The lot number shall be expressed as a four digit Julian code. The first digit shall 

indicate the year of production and the next three digits shall indicate the day of the 

year (Example, 12 October 2000 would be coded as 0286). The Julian code shall represent 

the day the product was packaged into the tray and processed. Sublotting (when used) 

shall be represented by an alpha character immediately following the four digit Julian 

code. Following the four digit Julian code and the alpha character (when used), the other 

required code information shall be printed in the sequence as listed above.

 B. Polymeric tray lid. The lid shall be clearly printed or stamped, in a manner that 

does not cause damage. Permanent ink of any contrasting color, which is free of 

carcinogenic elements, shall be used. As an alternate labeling method, a pre-printed 
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self-adhering 0.002 inch thick clear polyester label printed with indelible contrasting 

color ink may be used.

(1) Lid labeling shall include: 

 Product name

 Ingredients

 Net weight

 Name and address of packer

 Official inspection legend

 “Nutrition Facts” label in accordance with the Nutrition Labeling and

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

(2) Lid labeling shall also show the following statements:

TO HEAT IN WATER: Submerge unopened tray in water. Bring water to a boil. Simmer gently 

35-40 minutes. Avoid overheating (tray shows evidence of bulging).

WARNING: Do not heat tray in oven.

TO TRANSPORT AFTER HEATING: Insert tray back into protective sleeve to protect during 

transport. If sleeve is unavailable, stack trays lid-to-lid with fiberboard pads in 

between.

CAUTION: Use care when opening as pressure may have been generated within the tray.

TO OPEN: Using a clean knife, cut the lidding around the inside perimeter of the tray 

seals.

SUGGESTION: Cut lid along 3 sides and fold over uncut portion. Fold back to keep unused 

portions protected.

YIELD: Serves 18 portions of approximately 2/3 cup each.

(3) The product shall be formulated and labeled in accordance with all USDA 

labeling regulations and policies. The lid shall be labeled with the following product 

name:

CHILI WITH BEANS

D-3 PACKING

 A. Packing for shipment to ration assembler. Four filled, sealed, processed and 

sleeved polymeric trays shall be packed in a snug fitting fiberboard box conforming to 

style RSC-L, type CF, grade 275 of ASTM D 5118, Standard Practice for Fabrication of 

Fiberboard Shipping Boxes. The sleeved trays shall be placed flat with the first two 

trays placed with the lids together and the next two trays with the lids together. The 

box shall be closed in accordance with ASTM D 1974, Standard Practice for Methods of 

Closing, Sealing, and Reinforcing Fiberboard Shipping Containers.

D-4 UNITIZATION

 A. Unit loads. Unit loads shall be as specified in DSCP FORM 3507, Loads, Unit: 

Preparation of Semiperishable Subsistence Items.
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D-5 MARKING

 A. Shipping containers and unit loads. Marking of shipping containers and unit loads 

shall be as specified in DPSC FORM 3556 Marking Instructions for Shipping Cases, Sacks 

and Palletized/Containerized Loads of Perishable and Semiperishable Subsistence.

SECTION E INSPECTION AND ACCEPTANCE

The following quality assurance criteria, utilizing ANSI/ASQC Z1.4-1993, Sampling 

Procedures and Tables for Inspection by Attributes, are required. 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 Performance-based Contract 

Requirements document and evaluated for overall appearance and palatability. Any failure 

to conform to the performance requirements or any appearance or palatability failure 

shall be cause for rejection of the lot.

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

and the methods of inspection cited in this section.

E-5 QUALITY ASSURANCE PROVISIONS (PRODUCT)

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

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

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

1993. The lot size shall be expressed in trays. The sample unit shall be the contents of 

one tray. The inspection level shall be S-3 and the acceptable quality level (AQL), 

expressed in terms of defects per hundred units, shall be 4.0 for major defects and 6.5 

for minor defects. Defects and defect classifications are listed in Table I below. The 

trays shall be heated in accordance with the heating instructions from the tray label 

prior to conducting any portion of the product examination. The samples for drained 

weight inspection shall be selected using the same sampling criteria as above.
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TABLE I. Product defects 1/ 2/ 3/

Category Defect

Major Minor

Appearance

101 Bone or bone fragment measuring more than 0.3 inch in any 

dimension.

201 Ground beef is not a brown, cooked beef color.

202 Kidney beans are not light red type or not intact.

203 Sauce is not tomato based or not dark red with pieces of tomatoes 

and onions with flecks of spices. 

204 Total weight of cartilage, coarse connective tissue, tendons or 

ligaments, and glandular material is more than 2.0 ounces.

Odor and flavor

102 The packaged food does not have an odor or flavor of chili with 

beans, or does not elicit a sensation of medium to high heat.

Texture

205 Ground beef is not moist or not tender.

206 Kidney beans are hard or mushy.

207 Sauce does not have pieces of tomatoes and onions. 

Net weight

208 The net weight of an individual polymeric tray is less than 94 

ounces. 4/

Drained weight

209 The drained weight of the beef and beans (combined) in an 

individual polymeric tray is less than 52.0 ounces.

1/ The presence of any foreign material such as but not limited to, dirt, insect parts, 

hair, wood, glass, metal, or mold or the presence of any foreign odors or flavors such 

as, but not limited to burnt, scorched, rancid, sour, or stale shall be cause for 

rejection of the lot.

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/ Grinder plate size requirement for ground beef shall be verified by certificate of 

conformance. 

4/ Sample average net weight less than 96 ounces shall be cause for rejection of the lot. 
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 B. Methods of inspection.

(1) Commercial sterility. Commercial sterility shall be verified in accordance with 

USDA/FSIS regulations. 

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

product has a 3 year shelf life when stored at 800F. Government verification may include 

storage for 6 months at 1000F or 36 months at 800F. 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 hedonic 

scale to be considered acceptable.

(3) Net weight. The net weight of the filled and sealed tray shall be determined by 

weighing each sample unit on a suitable scale tared with a representative empty tray and 

lid. Results shall be reported to the nearest 1 ounce. 

(4) Drained weight. The free liquid in the tray shall be poured off and the 

remaining contents shall be poured into a flat bottom container. A minimum of three times 

the volume of a tray of 140o to 190oF water shall be added to the container so as to cover 

the contents. The contents and water shall be agitated so as to fully dissolve the sauce 

without undue breakup of the beef and beans. The contents shall then be poured into a 

U.S. Standard No. 7 sieve in a manner that will distribute the product evenly over the 

sieve. Sieve area shall be such that the distributed product does not completely cover 

all the openings of the sieve. The sieve shall be tilted at such an angle to assure 

complete drainage of liquid from the product. Drain product for 2 minutes before 

determining the drained weight by subtracting the sieve tare weight from the gross 

weight. The drained weight shall be reported to the nearest 0.5 ounce.

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

sealed polymeric trays which have been selected at random from the lot. The composited 

sample shall be prepared (see NOTE) and analyzed in accordance with the following methods 

of the Official Methods of Analysis of AOAC International:

Test Method Number

Protein 988.05 or 992.15

Fat 985.15 or 2008.06

Salt 935.47 or 971.27

Test results shall be reported to the nearest 0.1 percent. Any nonconforming results 

shall be cause for rejection of the lot.

NOTE: The USDA will use AOAC method 983.18 for preparation of the sample.

E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING MATERIALS, POLYMERIC TRAY)

 A. Packaging and labeling.

(1) Polymeric tray testing. For purposes of clarification, the polymeric tray

without the lid will be referred to as the “tray” and the polymeric tray with the lid 

shall be referred to as the “container”. The polymeric tray with protective sleeve and 

polymeric tray material shall be examined for the characteristics listed in table I of 

MIL-PRF-32004, Packaging of Food in Polymeric Trays. The lot size, sample unit, and 

inspection level criteria are provided in table II below for each of the test 

characteristics. Any test failure shall be classified as a major defect and shall be 
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cause for rejection of the lot. For rough handling survivability at frozen temperature, 

polymeric tray survival rate shall be at least 85 percent. 

TABLE II. Polymeric tray quality assurance criteria

Prior to processing

Characteristic Lot size 

expressed in

Sample

unit

Inspection 

level

Tray configurations and dimensions Trays 1 tray S-1

Oxygen gas transmission rate of tray Trays 1 tray S-1

Oxygen gas transmission rate of lid Yards 1/2 yard S-1

Water vapor transmission rate of tray Trays 1 tray S-1

Water vapor transmission rate of lid Yards 1/2 yard S-1

Camouflage Containers 1 container S-1

After processing

Characteristic Lot size

expressed in

Sample

unit

Inspection 

level

Processing Trays 1 tray S-2

Rough handling survivability Test containers 1 container S-2

Protective sleeve Containers 1 container S-1

Residual gas Containers 1 container S-1

Closure seal Containers 1 container S-1

Internal pressure Containers 1 container S-1

Lid opening Containers 1 container S-1

(2) Examination of container. The container with protective sleeve removed shall be 

examined for the defects listed in table II of MIL-PRF-32004 and the labeling defects 

listed in table III below. The lot size shall be expressed in containers. The sample unit 

shall be one processed and labeled container. The inspection level shall be I and the 

AQL, expressed in terms of defects per hundred units, shall be 0.65 for major A defects, 

2.5 for major B defects and 4.0 for minor defects. Two hundred sample units shall be 

examined for critical defects. The finding of any critical defect shall be cause for 

rejection of the lot.

TABLE III. Container labeling defects

Category Defect

Major A Minor

101 Polymeric tray lid or body labeling missing, incorrect or illegible.

201 When a pre-printed self adhering label is used, the label not 

adhering to tray lid (for example, label raised or peeled back from 

edge to corner) or presence of any areas of gaps along the perimeter 

of the label where the label is not properly adhered.
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 B. Packing.

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

containers shall be examined for the defects listed in table IV below. The lot size shall 

be expressed in shipping containers. The sample unit shall be one shipping container 

fully packed. The inspection level shall be S-3 and the AQL, expressed in terms of 

defects per hundred units, shall be 4.0 for major defects and 10.0 for total defects.

TABLE IV. Shipping container and marking defects

Category Defect

Major Minor

101 Marking omitted, incorrect, illegible, or improper size, location 

sequence or method of application.

102 Inadequate workmanship. 1/

201 Arrangement or number of polymeric trays not as specified.

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.

 C. Unitization.

(1) Unit load examination. The unit load shall be examined in accordance with the 

requirements of DSCP Form 3507, Loads, Unit: Preparation of Semiperishable Subsistence 

Items. Any nonconformance shall be classified as a major defect and shall be cause for 

rejection of the lot.

SECTION J REFERENCE DOCUMENTS

DSCP FORMS

DSCP FORM 3507 Loads, Unit: Preparation of Semiperishable Subsistence Items

DPSC FORM 3556 Marking Instructions for Shipping Cases, Sacks and

Palletized/Containerized Loads of Perishable and Semiperishable 

Subsistence

MILITARY SPECIFICATIONS

MIL-PRF-32004 Packaging of Food in Polymeric Trays

GOVERNMENT PUBLICATIONS

Federal Food, Drug, and Cosmetic Act and regulations promulgated thereunder 

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

NON-GOVERNMENTAL STANDARDS

AMERICAN SOCIETY FOR QUALITY (ASQ)

ANSI/ASQCZ1.4-1993 Sampling Procedures and Tables for Inspection by Attributes
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AMERICAN SOCIETY FOR TESTING AND MATERIALS (ASTM)

D 1974 Standard Practice for Methods of Closing, Sealing, and Reinforcing 

Fiberboard Shipping Containers

D 5118 Standard Practice for Fabrication of Fiberboard Shipping Boxes 

AOAC INTERNATIONAL Official Methods of Analysis of the AOAC International