PCR-B-058

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SECTION C

This document covers thermostabilized meatballs and pasta in brown gravy packaged in a

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

C-1 ITEM DESCRIPTION

PCR-B-058, BROWN GRAVY WITH MEATBALLS AND PASTA, PACKAGED IN A 

POLYMERIC TRAY, SHELF STABLE

C-2 PERFORMANCE REQUIREMENTS

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

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

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

The approved sample shall serve as the product standard. Should the contractor at any time 

plan to or actually produce the product using different raw material or process methodologies 

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

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

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

comparability.

 B. Commercial sterility. The packaged product 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 blend of brown gravy with meatballs and 

mafalda noodles. The finished product shall be free from foreign materials.

(2) Gravy. The gravy shall be a medium brown color and may contain visible flecks 

of spices. The gravy shall be moderately thick and glossy.

(3) Meatballs. The meatballs shall be a minimum of 1/8 ounce in weight and shall be

1/2-3/4 inches in size. The cooked meatballs shall be a medium brown color, and shall be a 

uniform shape. The cooked meatballs shall be practically free of bone or bone fragments, 

cartilage, coarse connective tissue, tendons or ligaments, and glandular material.
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(4) Pasta. The mafalda noodles shall be enriched pasta product. The dry mafalda 

noodles shall be broad, flat noodles with ruffled edges. The cooked mafalda noodles shall

have measurements of not less than 1-1/4 inches in length by 3/4 inch in width and shall have 

a cooked pasta color. The pasta may have a brown color from absorbed sauce.

 E. Odor and flavor.

(1) General. The packaged food shall have an odor and flavor of cooked beef in 

gravy. The packaged food shall be free from foreign odors and flavors.

(2) Gravy. The gravy shall have a cooked beef odor and a cooked beef and mild 

mushroom flavor.

(3) Pasta. The mafalda noodles shall have a cooked pasta odor and flavor.

 F. Texture.

(1) Gravy. The gravy shall be smooth and moderately thick.

(2) Meatballs. The cooked meatballs shall be moist and moderately firm and shall not 

be mushy.

(3) Pasta. The cooked mafalda noodles shall be slightly soft to slightly firm and shall 

not be mushy or pasty.

 G. Net weight. The average net weight shall be not less than 92 ounces (2608 grams). The 

net weight of an individual polymeric tray shall be not less than 90 ounces (2552 grams).

 H. Drained weight. The average drained weight of meatballs and mafalda noodles

(combined) shall be not less than 37.0 ounces (1049 grams). The drained weight of intact 

meatballs and mafalda noodles (combined) in an individual polymeric tray shall be not less 

than 35.0 ounces (992 grams).

 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. The protein content shall be not less than 7.0 percent.

(2) Fat. The fat content shall be not greater than 11.0 percent.
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(3) Salt. The salt content shall be not greater than 0.8 percent.

C-3 MISCELLANEOUS INFORMATION

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

CONTRACT REQUIREMENT.

 A. Ingredients. Water, meatballs (beef, chicken, water, textured vegetable protein [soy 

protein concentrate, caramel color], bread crumbs [enriched wheat flour {niacin, iron, 

thiamine mononitrate, riboflavin, folic acid}, durum flour, leavening [sodium bicarbonate, 

sodium acid pyrophosphate, yeast], tomato paste, soy protein concentrate, salt, dehydrated 

Worcestershire sauce [dextrose, dehydrated garlic, salt, cellulose gum, chili pepper, spices, 

mustard, malic acid, natural flavorings, dehydrated onions], flavoring, spice, lemon flavor 

[corn syrup solids, lemon juice solids], dried beef stock, autolyzed yeast, sodium 

phosphates), mafalda pasta (semolina [wheat], egg whites, niacin, ferrous sulfate, thiamin 

mononitrate, riboflavin, folic acid), modified food starch, beef flavoring (roast beef including 

beef juices, autolyzed yeast extract, potato flour, maltodextrin [from corn], natural flavorings, 

caramel color, paprika), contains less than two percent of the following: tomato paste, 

mushroom flavoring ( portabella mushrooms, salt, maltodextrin, olive oil, water, onion, 

mushroom juice concentrate [sunflower oil], dried shitake mushrooms, natural flavorings, 

shallot juice concentrate, potato flour, garlic juice concentrate [sunflower oil], dry porcini 

powder, black pepper, black truffle), unsalted butter (pasteurized cream, natural flavorings), 

sour cream (Grade A Cultured), sugar, soy lecithin, non-fat milk powder (modified food 

starch, dextrose, medium chain triglycerides, natural and artificial flavors). Allergens: wheat, 

milk, soy eggs.

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. Government 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. The polymeric tray body shall be clearly printed or stamped, in a 

manner that does not damage the tray, with permanent ink of any contrasting color, which is 
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free of carcinogenic elements. One end of the polymeric tray (see figure 1 of MIL-PRF32004) shall be marked with the product name and number of portions. If the tray body end 

markings are not readily legible in low light conditions, a small, easily legible label shall be 

applied, but not over any existing tray markings. All other markings may be applied along 

the tray body side. To avoid erroneous marking of trays, the product name, lot number and 

filling equipment number shall be applied prior to processing. Additional tray marking may 

be applied before or after processing. 1/

Tray body markings shall include:

(1) Product name. Commonly used abbreviations may be used.

(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, 

14 February 2014 would be coded as 4045). 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 self-adhering 0.002 

inch thick clear polyester label printed with indelible contrasting color ink may be used.

Note: The font tested by Natick was Microsoft Helvetica. The font used shall be similarly 

clear/easy to read as Helvetica. The recommended font sizes are as follows: 22 for the 

product name, 14 for “yield” and “to heat in water.” If an additional note is required on the 

label, such as “fluff before serving,” it should also be in font size 14. All other information 

should be in font size 9. 
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(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 USDA regulations

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

(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.

BROWN GRAVY WITH MEATBALLS AND PASTA

D-3 PACKING

 A. Packing. Four filled, sealed, processed and sleeved polymeric trays shall be packed in a 

fiberboard box conforming to 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 275 of ASTM D4727/D4727M, Standard Specification for 

YIELD: Serves 9 portions and approximately 1 cup gravy with meatballs and 

pasta.

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.
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Corrugated and Solid Fiberboard Sheet Stock (Container Grade) and Cut Shapes. 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. 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 loads. Boxes shall be arranged in unit loads in accordance with 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.

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:
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(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:

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. Two (2) 

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

The two (2) 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 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. 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/ 4/ 5/

Category Defect

Major Minor

Appearance

101 Product not a blend of meatballs and mafalda noodles in brown gravy.

102 Bone or bone fragment measuring more than 0.3 inch in any dimension.

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

ligaments, and glandular material more than 2.0 ounces (57 grams).

202 Gravy not a medium brown color or not moderately thick or not glossy.

203 Meatballs not a uniform shape.

204 Meatballs not a medium brown color.

205 Mafalda noodles not broad or not flat or not with ruffled edges.

206 Mafalda noodles not a cooked pasta color.

Odor and flavor

103 Product does not have a cooked beef odor or a cooked beef and mild 

mushroom flavored brown gravy.

207 Gravy does not have a cooked beef odor or does not have a cooked beef 

and mild mushroom flavor.

208 Mafalda noodles do not have a cooked pasta odor or flavor.

Texture

209 Gravy is not smooth or not moderately thick.

210 Cooked meatballs not moist or not moderately firm, are mushy.

211 Cooked mafalda noodles not slightly soft to slightly firm, are mushy or 

pasty.
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TABLE I. Product defects 1/ 2/ 3/ 4/ 5/ - Continued

Category Defect

Major Minor

Net weight

212 Net weight of an individual polymeric tray is less than 90 ounces (2552 

grams). 6/

Drained weight

213 Drained weight of intact meatballs and mafalda noodles (combined) in an 

individual polymeric tray less than 35.0 ounces (992 grams). 7/

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

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

rancid, sour, stale, musty or moldy shall be cause for rejection of the lot.

2/ Finished product not equal to or better than the approved product standard in palatability 

and overall appearance shall be cause for rejection of the lot.

3/ Meatball weight and size requirement shall be verified by Certificate of Conformance 

(CoC).

4/ Verification of the malfalda noodle as enriched pasta product shall be with the statement 

of ingredients on the label. Any nonconforming result shall be cause for rejection of the lot.

5/ Size requirement for the mafalda noodle shall be verified by CoC.

6/ Sample average net weight less than 92 ounces (2608 grams) shall be cause for rejection of 

the lot.

7/ Sample average drained weight of meatballs and mafalda noodles (combined) less than 

37.0 ounces (1049 grams) shall be cause for rejection of the lot.

 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 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 
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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.

(3) Net weight. The net weight of the filled and sealed polymeric 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 or to the nearest 1 gram.

(4) Drained weight. To determine drained weight, the contents shall be poured into a 

flat bottom container. A minimum of three times the polymeric tray’s volume of not less than 

140° F and not greater than 190° F water shall be added to the container so as to cover the 

contents. The contents and water shall be agitated so as to liquefy rendered fat and to remove 

the gravy without breaking the meatballs or mafalda noodles. The contents shall then be 

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

sieve without breaking the meatballs or mafalda noodles. 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 two minutes before determining the combined drained weight by subtracting the sieve 

tare weight from the gross weight. The drained weight shall be reported to the nearest 0.5 

ounce or to the nearest 1 gram.

(5) Analytical. The sample to be analyzed shall be a one-pound composite of three 

filled and sealed polymeric trays that have been selected at random from the production lot. 

The composite sample shall be prepared using Method 983.18 and analyzed in accordance 

with the following Official Methods of Analysis (OMA) of AOAC International:

Test Method Number

Protein 984.13, 992.15, or 2011.04

Fat 991.36, or 2008.06

Salt 935.47

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

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
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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 for each of the test characteristics. Any test failure shall be classified 

as a major defect and shall be 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
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(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. 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 or 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.

(3) Label adhesive examination. When self-adhering labels are used, the adhesive 

shall be tested in accordance with ASTM D3330/D3330M, Standard Test Method for Peel 

Adhesion of Pressure-Sensitive Tape. In lieu of testing, a CoC shall be provided.

 B. Packing.

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

containers shall be examined for the defects listed in table IV. 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 missing or incorrect or illegible.

102 Inadequate workmanship. 1/

201 Arrangement or number of polymeric trays not as specified.
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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 DLA Troop Support Form 3507, Loads, Unit: Preparation of Semiperishable 

Subsistence Items. Any nonconformance shall be classified as a major defect.
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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

Form 3507 Loads, Unit: Preparation of Semiperishable Subsistence Items

Form 3556 Marking Instructions for Boxes, Sacks, and Unit Loads of 

Perishable and Semiperishable Subsistence

MILITARY SPECIFICATIONS

MIL-PRF-32004 Packaging of Food in Polymeric Trays

GOVERNMENT PUBLICATIONS

Federal Meat Inspection Act (FMIA) and the Poultry Products Inspection Act (PPIA) 

and regulations promulgated thereunder (9 CFR Parts 300-End)

Food Standards and Labeling Policy Book

NON-GOVERNMENTAL STANDARDS

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

ANSI/ASQ Z1.4 Sampling Procedures and Tables for Inspection by Attributes

ASTM INTERNATIONAL www.astm.org

D1974/1974M Standard Practice for Methods of Closing, Sealing, and 

Reinforcing Fiberboard Boxes

D3330/D3330M Standard Test Method for Peel Adhesion of PressureSensitive Tape

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
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AOAC INTERNATIONAL www.aoac.org

Official Methods of Analysis (OMA) of AOAC International