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SECTION C

This document covers beverage powder, carbohydrate, packaged in a flexible pouch for use 

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

C-1 ITEM DESCRIPTION

PCR-B-055, BEVERAGE POWDER, CARBOHYDRATE, PACKAGED IN A 

FLEXIBLE POUCH, SHELF STABLE

Flavors.

Flavor 1 - Fruit Punch

Flavor 2 - Grape

Flavor 3 - Lemon-lime

Flavor 4 - Orange

Flavor 5 - Tropical punch

Flavor 6 - Lemonade 

Formulations.

Formulation a - Fortified with ascorbic acid and enhanced with maltodextrin 

 Ascorbic acid – Not less than 45 milligrams per serving 

 Maltodextrin – Not less than 13 grams per serving 

Formulation b - Fortified with ascorbic acid and enhanced with maltodextrin 

 Ascorbic acid – Not less than 30 milligrams per serving 

 Maltodextrin – Not less than 30 grams per serving 

Formulation c - Fortified with ascorbic acid, vitamin D, and fiber, and enhanced 

with maltodextrin 

 Ascorbic acid – Not less than 30 milligrams per serving

 Maltodextrin – Not less than 30 grams per serving

 Vitamin D – Not less than 260 IU per serving

 Dietary fiber – Not less than 2 grams per serving

Designs.

Design B - Flat interlocking closure pouch

Design E - Small flat pouch
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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. Shelf life. The packaged product shall meet the minimum shelf life requirement of 36 

months at 80oF.

 C. Powdered product.

(1) Appearance. The beverage powder shall be a uniformly blended, free flowing,

homogenous, dry mixture. The packaged food shall be free from foreign materials.

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

packaged food shall be free from foreign odors.

(3) Texture. The packaged food shall be free from hard lumps.

 D. Hydrated product. The beverage powder, when hydrated according to label instructions

shall dissolve within 2 minutes.

(1) Appearance. The hydrated product shall be a clear to slightly cloudy, sedimentfree liquid and shall have a color as specified below.

 a. Flavor 1. The fruit punch beverage shall be a reddish-orange color.

 b. Flavor 2. The grape beverage shall be a purple color.

 c. Flavor 3. The lemon-lime beverage shall be a bright pale green color.

 d. Flavor 4. The orange beverage shall be a bright orange color.

 e. Flavor 5. The tropical punch beverage shall be a light red color.

 f. Flavor 6. The lemonade beverage shall be a pale yellow color.

(2) Odor and flavor. The hydrated product shall be free from foreign odors and 

flavors and shall have an odor and flavor as specified below.
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 a. Flavor 1. The fruit punch beverage shall have a sweet fruit blend odor and flavor.

 b. Flavor 2. The grape beverage shall have a sweet grape odor and flavor.

 c. Flavor 3. The lemon-lime beverage shall have a sweet, sour, lemon-lime odor 

and flavor.

 d. Flavor 4. The orange beverage shall have a sweet, sour, distinct orange odor and 

flavor.

 e. Flavor 5. The tropical punch beverage shall have a tropical fruit blend odor and 

flavor.

 f. Flavor 6. The lemonade beverage shall have a sweet, sour, lemon odor and 

flavor.

 E. Net weight.

(1) Formulation a, design E. The net weight of an individual pouch shall be not less 

than 34 grams.

(2) Formulation b, design B. The net weight of an individual pouch shall be not less 

than 47 grams.

(3) Formulation c, design B. The net weight of an individual pouch shall be not less 

than 49 grams.

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

the approved product standard in palatability and overall appearance.

 G. Analytical requirements. 

(1) Moisture. 

 a. Formulation a. The moisture content shall be not greater than 3.5 percent.

 b. Formulation b. The moisture content shall be not greater than 6.0 percent.

 c. Formulation c. The moisture content shall be not greater than 5.0 percent.

(2) Nutrient content. The packaged product per serving shall contain not less than the 

following amounts: 
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Fortification Formulation

a b c

Ascorbic acid (milligrams) 45 30 30

Maltodextrin (grams) 13 30 30

Vitamin D (IU) - - 260

(3) Dietary fiber. For Formulation c, the dietary fiber content of the packaged product 

shall be not less than 2 grams per serving. 

SECTION D

D-1 PACKAGING

 A. Packaging.

(1) Design B, Flat interlocking closure pouch. When specified, the powdered product 

shall be filled into a preformed barrier pouch. The pouch is to be used as a package and a 

hydrating pouch for the beverage powder.

 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. The three plies may be laminated with nylon on 

the exterior of the pouch. 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 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 formfill-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 
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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 E, Small flat pouch. When specified, the powdered product shall be filled

into a small flat pouch.

 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 

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 style preformed or vertical formfill-seal pouch. The pouch shall have maximum inside dimensions of 3-7/8 by 4-3/4 inches. 

The pouch shall be made by heat sealing three edges with 3/8 (-1/8, +3/16) inch wide seals. 

A tear nick or notch shall be provided 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. 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 sealed pouch shall 

not leak when tested in accordance with E-6,B(3).

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

(7) Directions for Design B flat interlocking closure pouch:
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Allow water just chemically purified to stand 30 minutes before adding to powder.

Tear pouch at notch. Open zipper, add 12 ounces of water (about 1/2 canteen cup) to 

fill line. Close zipper, shake to mix. Single use only.

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/label for 12 ounce fill at 6-1/2 ± 1/4 inches from the inside edge of the 

bottom closure seal.

(8) Directions for Design E small flat pouch:

Allow water just chemically purified to stand 30 minutes before adding to powder.

Add 12 ounces of water (about 1/2 canteen cup) to contents and stir.

1/ Each pouch 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 2013 would be coded as 3045. The Julian day 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 

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-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.
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(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. 

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:

DEPARTMENT OF THE ARMY

FCDD-SCC-EMR

COMBAT CAPABILITIES DEVELOPMENT COMMAND-SOLDIER CENTER

10 GENERAL GREENE AVENUE

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.

(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 
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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 one filled and sealed 

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.

TABLE I. Product defects 1/ 2/ 

Category Defect

Major Minor

Powdered product

General

101 Not carbohydrate beverage powder flavor, formulation or design as 

specified.

Appearance

201 Not a uniformly blended, free flowing, homogenous, dry mixture.

Odor

102 Not odor typical of flavor specified.

Texture

202 Presence of hard lumps. 3/

Net weight

203 Net weight of an individual pouch for formulation a, design E, less 

than 34 grams. 

204 Net weight of an individual pouch for formulation b, design B, less 

than 47 grams.

205 Net weight of an individual pouch for formulation c, design B, less 

than 49 grams.
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TABLE I. Product defects 1/ 2/ - Continued

Category Defect

Major Minor

Hydrated product 4/

Appearance

206 Not a clear to slightly cloudy, sediment-free liquid.

207 Flavor 1 fruit punch beverage not a reddish-orange color.

208 Flavor 2 grape beverage not a purple color.

209 Flavor 3 lemon-lime beverage not a bright pale green color.

210 Flavor 4 orange beverage not a bright orange color.

211 Flavor 5 tropical punch beverage not a light red color.

212 Flavor 6 lemonade beverage not a pale yellow color.

Odor and flavor

103 Flavor 1 fruit punch beverage not a sweet fruit blend odor or flavor.

104 Flavor 2 grape beverage not a sweet grape odor or flavor.

105 Flavor 3 lemon-lime beverage not a sweet, sour, lemon-lime odor or 

flavor.

106 Flavor 4 orange beverage not a sweet, sour, distinct orange odor or 

flavor.

107 Flavor 5 tropical punch beverage not a tropical fruit blend odor or 

flavor.

108 Flavor 6 lemonade beverage not a sweet, sour, lemon odor or flavor.

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.
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3/ Lumps that do not fall apart under light pressure shall be scored as a defect.

4/ Prior to conducting the hydrated product examination, the beverage powder shall be 

hydrated 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.

 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 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.

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

sealed pouches which 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 925.45A, or 2007.04 1/

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 requirement shall be cause for rejection of the lot.

1/ Applicable for Flavors 1-5, Formulation a only.

(4) Nutrient content. The sample to be analyzed shall be a composite of eight filled 

and sealed pouches which 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 1/

Ascorbic Acid (Vitamin C) 984.26 or 967.21

Vitamin D 2002.05, 2011.12 or 2011.13

1/ Tests will be conducted on formulations a, b and c for Vitamin C and on formulation c for

Vitamin D on the first production lot of a contract cycle. USDA will perform the verification 
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testing and obtain a copy of the formulation used in the production of that lot. A Certificate 

of Conformance (CoC) for nutrient content for Vitamin C and Vitamin D will be provided on 

all future lots produced using the same formulation. If the formula is changed or a new 

contract starts, then another set of tests shall be conducted by USDA, for Vitamin C and 

Vitamin D, and USDA will obtain a copy of the formulation.

(5) Dietary fiber content. For Formulation c, the dietary fiber content shall be 

verified by the NLEA “Nutrition Facts” label. Product not conforming to the fiber content as 

specified in Section C of this document 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. 

Characteristic Requirement paragraph Test procedure

Thickness of film for laminated 

material

D-1,A(1)a and D-1,A(2)a ASTM D2103 1/

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

Laminated material

identification and construction

D-1,A(1)a and D-1,A(2)a Laboratory evaluation

Color of laminated material D-1,A(1)a and D-1,A(2)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 and D-1,A(2)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) Pouch material certification. For design E, all material, construction and sealing 

requirements shall be verified by a CoC.
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(4) 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.

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 Design B fill line missing or does not measure 6-1/2 + 1/4 inches from 

the inside edge of the bottom 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.

1/ Any evidence of rodent or insect infestation shall be cause for rejection of the lot.
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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 

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).
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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 design E, small flat 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 

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 
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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) Leakage test. For design E, filled and sealed pouches shall be tested by placing 

them in a dry desiccator, or similar apparatus, and subjecting them to a vacuum of 26 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. After vacuum testing, the pouches shall be visually 

inspected for evidence of delamination and for seal separation. Any leakage, any 

delamination, or any seal separation of more than 1/16 inch from the product edge of any seal 

shall be recorded 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.
16

PCR-B-055

7 November 2012

W/Change 02 3 Feb 21 ES21-016 (DSCP-SS-21-00238)

FIGURE 1. Design B, Flat Interlocking Closure Pouch

(Not actual size)
17

PCR-B-055

7 November 2012

W/Change 02 3 Feb 21 ES21-016 (DSCP-SS-21-00238)

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

Perishable and Semiperishable Subsistence

FEDERAL STANDARD 

FED-STD-595 Colors Used in Government Procurement

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

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 and 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

AOAC INTERNATIONAL www.aoac.org

Official Methods of Analysis (OMA) of AOAC International