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SECTION C

This document covers shelf stable energy gel packaged in a flexible pouch for use by the 

Department of Defense as a component of operational rations. 

C-1 ITEM DESCRIPTION

PCR-E-018A, ENERGY GEL, PACKAGED IN A FLEXIBLE POUCH, SHELF 

STABLE

Flavors.

Flavor 1 - Raspberry

Flavor 2 - Chocolate

Flavor 3 - Mocha

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 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 glossy and smooth and shall have no 

separation or syneresis. The finished product shall be free from foreign materials. 
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 (2) Flavor 1. The raspberry energy gel shall be a semi-translucent dark pink to red 

color with a syrup-like consistency. 

(3) Flavor 2. The chocolate energy gel shall be a dark brown color with an icing-like 

consistency. 

 (4) Flavor 3. The mocha energy gel shall be a dark brown color with a syrup-like 

consistency. 

 E. Odor and flavor. 

(1) General. The packaged food shall be free from foreign odors and flavors. 

 (2) Flavor 1. The packaged food shall have a slight raspberry odor and a strong 

sugary sweet, fruity sour, raspberry flavor. 

 (3) Flavor 2. The packaged food shall have a moderate to strong sugary sweet, cocoa 

odor and flavor. 

 (4) Flavor 3. The packaged food shall have a moderate sugary sweet, coffee and 

cocoa odor and flavor. 

 F. Texture. 

 (1) Flavors 1 and 3. The raspberry and mocha energy gel shall be smooth and slightly

to moderately thick. 

 (2) Flavor 2. The chocolate energy gel shall be smooth and moderately thick.

 G. Net weight. The net weight of an individual pouch shall be not less than 34 grams. 

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

the approved product standard in palatability and overall appearance. 

 I. Analytical requirements. 

(1) Calories. The calories shall be not less than 100 per serving. 
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 (2) pH. 

a. Flavor 1. The pH shall be not greater than 4.0. 

b. Flavor 2. The pH shall be not greater than 5.8. 

c. Flavor 3. The pH shall be not greater than 6.0. 

 (3) Brix. The Brix measurement shall be not less than 73° and not more than 75°. 

 (4) Caffeine (flavor 3 only). The caffeine content for flavor 3 mocha shall be not less 

than 50 mg per serving. 

SECTION D

D-1 PACKAGING

 A. Packaging. The product shall be packaged in a barrier pouch as described below. 

(1) Pouch. 

 a. Pouch material. The pouch shall be fabricated from 0.002 inch thick polyolefin 

film laminated or extrusion coated to 0.00035 inch thick aluminum foil which is then 

laminated to 0.0005 inch thick polyester. The three plies shall be laminated with the polyester 

on the exterior of the pouch. Tolerances for thickness of plastic films shall be plus or minus 

20 percent and tolerance for the foil layer shall be plus or minus 10 percent. The polyolefin 

layer of bag material shall be suitably formulated for hot fill or post-fill processing. The 

material shall show no evidence of delamination, degradation, or foreign odor. The material 

shall be suitably formulated for food packaging and shall not impart an odor or flavor to the 

product. The complete exterior surface of the pouch shall be uniformly colored and shall 

conform to number 20219, 30219, 30227, 30279, 30313, 30324, or 30450 of SAE-AMSSTD-595, Colors Used in Government Procurement. 

 b. Pouch construction. The pouch shall be a flat style pouch having maximum 

inside dimensions of 2-7/8 inches wide by 5-3/8 inches long. The pouch shall be made by 

heat sealing three edges with 1/4 inch (-1/8 inch, +1/4 inch) wide seals. The pouch shall show 

no aberration in the pouch material or heat seals. The side and bottom seals shall have an 

average seal strength of not less than 6 pounds per inch of width and no individual specimen 
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shall have a seal strength of less than 5 pounds per inch of width when tested. A tear nick,

notch, or serrations shall be provided to facilitate opening of the filled and sealed pouch. 

Excess pouch material at the edges of the pouch shall not exceed 3/16 inch. A 1/8 inch wide 

lip may be incorporated at the open end of the pouch. 

 c. Pouch filling and sealing. The product shall be filled into the pouch and sealed. 

The pouch shall show no aberration in the pouch material or closure seal. The closure seal 

shall be free of entrapped matter that reduces the effective closure seal width to less than 1/16 

inch. Seals shall be free of impression or design on the seal surface that would conceal or 

impair visual detection of seal defects. 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 when tested.

D-2 LABELING

 A. Pouches. Each pouch shall be correctly and legibly labeled. Printing ink shall be 

permanent black ink or other dark contrasting color which is free of carcinogenic elements. 

The label shall contain the following information:

(1) Name and flavor of product (letters not less than 1/8 inch high)

(2) Ingredients

(3) Date 1/ 

(4) Net weight

(5) Name and address of packer

(6) “Nutrition Facts” label in accordance with the Nutrition Labeling and Education 

Act (NLEA) and all applicable FDA regulations 

1/ Each pouch shall have the date of pack noted by using either a four-digit code or five-digit 

code. When using the four-digit code, begin with the final digit of the current year followed 

by the three-digit Julian code. For example, 14 February 2050 would be coded as 0045. 

When using the five-digit code, begin with the decade digit of the current year followed by 

the three-digit Julian code. For example, 14 February 2050 would be coded as 50045. The 

Julian code shall represent the day the product was packaged into the pouch. 

D-3 PACKING 

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

box constructed in accordance with style RSC-L, of ASTM D5118/D5118M, Standard 
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Practice for Fabrication of Fiberboard Shipping Boxes. The fiberboard shall conform to type 

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

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

and Cut Shapes. Each box shall be closed in accordance with ASTM D1974/D4727M, 

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

D-5 MARKING

 A. Shipping containers. Shipping containers shall be marked in accordance with DLA 

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

Perishable and Semiperishable Subsistence.

SECTION E INSPECTION AND ACCEPTANCE

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

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

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

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

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

 A. Definitions. 

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

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

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

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

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

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

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

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

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

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

as follows:

(1) Product standard inspection. The first article or product demonstration model shall 
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be inspected in accordance with the provisions of this document and evaluated for overall 

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: 

COMBAT CAPABILITIES DEVELOPMENT COMMAND (DEVCOM) SOLDIER CENTER

FCDD-SCD-SCR 

10 GENERAL GREENE AVENUE

NATICK, MA 01760-5000 

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

specified in the contract. Three (3) sample units of each item produced shall be randomly 

selected from that one production lot. The three (3) sample units shall be shipped to 

DEVCOM Soldier Center 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.

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

examination 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 

product 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. The sample unit shall be the contents of one 

pouch. The inspection level shall be S-3 and the acceptable quality level (AQL), expressed in 

terms of defects per hundred units, shall be 1.5 for major defects and 4.0 for minor defects. 

Defects and defect classifications are listed in table I. The pouches shall be kneaded prior to 

conducting any portion of the product examination. 
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TABLE I. Product defects 1/ 2/

Category Defect

Major Minor

General

101 Product not energy gel or not flavor specified.

Appearance

201 Finished product not glossy or not smooth.

202 Finished product shows separation or syneresis. 3/

203 Flavor 1 raspberry energy gel not semi-translucent or not a dark pink to 

red color or not with a syrup-like consistency. 

204 Flavor 2 chocolate energy gel not a dark brown color or not with an 

icing-like consistency. 

205 Flavor 3 mocha energy gel not a dark brown color or not with a syruplike consistency. 

Odor and flavor

102 Flavor 1 packaged food not a slight raspberry odor or not a strong 

sugary sweet or not fruity sour or not raspberry flavor. 

103 Flavor 2 packaged food not a moderate to strong sugary sweet or not 

cocoa odor or flavor. 

104 Flavor 3 packaged food not a moderate sugary sweet or not coffee or 

not cocoa odor or flavor. 

Texture

206 Flavors 1 and 3 energy gel not smooth or not slightly to moderately 

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

Category Defect

Major Minor

207 Flavor 2 energy gel not smooth or not moderately thick

Net weight

208 Net weight of an individual pouch less than 34 grams.

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

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

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

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

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

3/ Visually examine product for separation or syneresis after it has been placed on a smooth 

flat surface and not disturbed for at least one minute. 

 B. Methods of inspection. 

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

FDA 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 

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 pouches shall be determined 

by weighing each sample unit on a suitable scale tared with a representative empty pouch. 

Results shall be reported to the nearest 1 gram.
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(4) Analytical. 

 a. Calories. The calorie content shall be verified by the NLEA “Nutrition Facts” 

label. Product not conforming to the calorie content as specified in Section C-2, I of this 

document shall be cause for rejection of the lot.

 b. pH, Brix, and Caffeine. The sample to be analyzed shall be a composite of eight 

filled and sealed pouches which have been selected at random from one 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

pH 981.12

Brix 925.48 or 932.14

Caffeine 980.14

Test results shall be reported to the nearest 1 mg for caffeine. Test results for pH shall be 

reported to the nearest 0.1 and to the nearest whole number for Brix. Government verification 

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

conforming to the analytical requirement shall be cause for rejection of the lot.

E-6 QUALITY ASSURANCE PROVISIONS (PACKAGING AND PACKING 

MATERIALS)

 A. Packaging. 

(1) Pouch material certification. The pouch material shall be tested for these 

characteristics. A Certificate of Conformance (CoC) may be accepted as evidence that the 

characteristics conform to the specified requirements.
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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 SAE-AMS-STD-595 3/

1/ Standard Specification for Polyethylene Film and Sheeting 

2/ Standard Specification for Annealed Aluminum and Aluminum-Alloy Foil for Flexible 

Barrier, Food Contact, and Other Applications 

3/ Colors Used in Government Procurement

(2) 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 acceptable quality 

level (AQL), expressed in terms of defects per hundred units, shall be 0.65 for major defects 

and 2.5 for minor defects. The finding of any critical defect shall be cause for rejection of the 

lot. All exterior surfaces and edges of the filled and sealed pouch shall be examined visually 

for product leakage, width of seals, and delamination while applying a manual kneading 

action which forces the product against the interior surface in the area being observed. 

Alternatively, all surfaces and edges of the filled and sealed pouch may be visually examined 

for product leakage, width of seals, and delamination by placing them in a vacuum chamber, 

dry desiccator, or similar apparatus, and subjecting them to a vacuum of 15 inches of 

mercury (atmospheric pressure is 29.9 inches of mercury) for 30 seconds. Any pouch that 

does not swell to form a tightly distended package having at least one distorted edge during 

the test shall be recorded as a leaker and shall be cause for rejection of the lot. After vacuum 

testing, the pouches shall be visually inspected for table II defects.
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TABLE II. Filled and sealed pouch defects 1/

Category Defect

Critical Major Minor

1 Swollen pouch.

2 Aberrations in pouch material or heat seals resulting from 

heat sealing, pouch fabrication, hot filling or heat 

processing that reduce the effective closure seal width to 

less than 1/16 inch. 2/ 

3 Tear or hole or open seal.

101 Seal width less than 1/16 inch. 3/

102 Presence of delamination. 4/

103 Unclean pouch. 5/

104 Pouch has foreign odor.

105 Any impression or design on the heat seal surfaces which 

conceals or impairs visual detection of seal defects. 6/ 

106 Not packaged as specified.

201 Label missing or incorrect or illegible.

202 Tear nick or notch or serrations missing or does not 

facilitate opening.

203 Seal width less than 1/8 inch but greater than or equal to 

1/16 inch. 

204 Presence of delamination. 4/

205 Excess pouch material at edges exceeds 3/16 inch.

1/ Any evidence of rodent or insect infestation shall be cause for rejection of the lot.
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2/ Aberrations in pouch material or heat seals include:

a. Major fold-over wrinkles or severe wrinkles, that extend into heat seal area and 

reduce effective seal width to less than 1/16 inch; or

 b. Entrapped matter that extends into heat seal area and reduces effective seal width 

to less than 1/16 inch; or 

 c. Severe wrinkles in the body of the pouch along the inside edges of the heat seals. 

Pouches exhibiting one or more of these aberrations shall be tested in accordance with E6,B,(1)b. 

3/ Effective seals are defined as any uncontaminated, fusion bonded, continuous path, 

minimum 1/16 inch wide, that produces a hermetically sealed pouch. 

4/ 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 in the body of the pouch 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 
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evidenced by the delaminated area exceeding the limits of the outlined borders, shall be 

classified as a major defect.

 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. 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.

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

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

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

unclean:

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

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

with a clean dry cloth. 

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

face (localized and aggregate). 

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

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

impression and/or design as a major defect, retain the sample, and contact the Government 

agency supervisor or the contracting officer for instruction. Samples shall be furnished to the 

contracting officer for a determination as to acceptability.

 B. Methods of inspection. 

(1) Pouch integrity testing. The pouch integrity shall be tested as required in a or b, as 

applicable. The lot 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. 

 a. Filled and sealed pouch seal testing. The seals of the pouches shall be tested for 

seal strength in accordance with ASTM F88/F88M. Two adjacent specimens shall be cut 

from the closure and bottom seals and three adjacent specimens shall be cut from the side 

seals of each pouch. The average seal strength of the side seals shall be calculated by 

averaging the three specimens cut from each side seal. The average seal strength of the 

closure and bottom seals shall be calculated by averaging the two specimens cut from each 
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closure and bottom seals. 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. Internal pressure test. The internal pressure resistance shall be determined by 

pressurizing the pouches while they are restrained between two rigid plates. If a three-seal 

tester (one that pressurizes the pouch through an open end) is used, the closure seal shall be 

cut off for testing the side and bottom of the pouch and the distance between restraining 

plates shall be 1/2 inch. For testing the closure seal, the bottom seal shall be cut off. The 

pouches shall be emptied prior to testing. If a four-seal tester (designed to pressurize filled 

pouches by use of a hypodermic needle through the pouch wall) is used, all four seals can be 

tested simultaneously. The distance between rigid restraining plates on the four-seal tester 

shall be equal to the thickness of the product +1/16 inch. Pressure shall be applied at the 

approximate uniform rate of 1 pound per square inch gage (psig) per second until 14 psig 

pressure is reached. The 14 psig pressure shall be held constant for 30 seconds and then 

released. The pouches shall then be examined for material degradation and separation or 

yield of the heat seals. Any rupture of the pouch material exposing the product content area 

to contamination or allowing for leakage or evidence of seal separation greater than 1/16 inch 

in the pouch seals shall be considered a test failure. Any seal separation that reduces the 

effective seal width to less than 1/16 inch shall be considered a test failure. Filled and sealed 

pouches showing aberrations shall withstand a minimum internal pressure of 17 pounds per 

square inch gauge (psig) for 30 seconds to verify pouch integrity. Any rupture of the pouch 

material exposing the product content area to contamination or allowing for leakage or 

evidence of seal separation greater than 1/16 inch in the pouch seals shall be considered a test 

failure. Any seal separation that reduces the effective closure seal width to less than 1/16 inch 

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. 

 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.
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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. 

SECTION J REFERENCE DOCUMENTS

Unless otherwise specified, the issues of these documents are those active on the date of the 

solicitation or contract. 

DLA Troop Support Form

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

Perishable and Semiperishable Subsistence 

NON-GOVERNMENTAL STANDARDS

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

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

Attributes

AOAC INTERNATIONAL www.aoac.org

Official Methods of Analysis (OMA) of the AOAC International
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ASTM INTERNATIONAL www.astm.org

B479 Standard Specification for Annealed Aluminum and 

Aluminum-Alloy Foil For Flexible Barrier, Food 

Contact, and Other Applications 

D1974/D1974M Standard Practice for Methods of Closing, Sealing, and 

Reinforcing Fiberboard Boxes

D2103 Standard Specification for Polyethylene Film and 

Sheeting 

D4727/D4727M Standard Specification for Corrugated Solid Fiberboard 

Sheet Stock (Container Grade) and Cut Shapes

D5118/D5118M Standard Practice for Fabrication of Fiberboard 

Shipping Boxes 

F88/F88M Standard Test Method for Seal Strength of Flexible 

Barrier Materials

SAE INTERNATIONAL

SAE AMS-STD-595 Colors Used in Government Procurement