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 DLA Troop Support -HSQ

 12 Dec 10

APP L

DLA Troop SupportH-4155.2

FOREWORD

(Supplementation is permitted.)

 Appendix L is an aid for the inspection of First Strike Rations (FSR). It provides 

guidelines for sampling, inspecting, classifying defects, and determining lot serviceability

 Users of this publication are encouraged to submit comments and recommended changes to 

improve this publication, through channels, to DLA Troop Support, ATTN: DLA Troop 

Support -FTSA. Changes will be coordinated with the Military Services and implemented as 

appropriate.

BY ORDER OF THE COMMANDER

KATHRYN YONTZ

Chief, Administrative Support &

Base Supply Division

Office of Base Support Services

DISTRIBUTION

 Special 

DLA Troop Support -FTR, FTRB, FTRE, FTRA, FTSA, FTW

VETCOM

This DLA Troop Support Handbook 4155.2 App-L, supercedes DSCP Handbook 4155.2, AppL, Aug 08.
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TABLE OF CONTENTS

PARAGRAPH PAGE

I. GENERAL. 1

A. Purpose and Scope 1

B. Explanation of Inspection Concept 1

C. Receipt Inspection Guidance

D. Cursory Inspections 1

E. Inspection Test Date (ITD) Extensions 1

F. Disposition Recommendations 1

G. Inspection Equipment 2

H. Definitions 3

II. ROUTINE INSPECTION GUIDANCE. 6

A. STEP 1. Cursory or Full Inspection 6 

B. STEP 2. Evaluation of Storage Conditions 6

C. STEP 3. Determine If Grand Lotting Is Appropriate 7 

D. STEP 4. Determine Lot Size 7

E. STEP 5. Inspect Shipping Containers and Select Menu Samples 8

F. STEP 6. Perform Closed Package Inspection of Menus Bag 8

G. STEP 7. Perform Closed Package Inspection of Menu Bag 9

 Contents and Accessory Packets 

H. STEP 8. Perform Destructive Open Package Inspection (DOPI) 9

 I. STEP 9. Recording Results 11

J. STEP 10. Determine if Special Inspection is Required 11

K. STEP 11. Determine Disposition 11

L. STEP 12. Provide Results and Recommendations to 12

 Accountable Officer/Agency

M. STEP 13. Schedule Surveillance Inspection 12

III. SPECIAL INSPECTION GUIDANCE. 12

 A. STEP 1: Determine Lot Size 12

 B. STEP 2: Determine Sample Size for Each Component 12

 C. STEP 3: Perform Inspection of Selected Components 13

 D. STEP 4: Determine Disposition of the Lot 13

 E. STEP 5: Provide Results and Recommendations to Accountable 13

 Officer 
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IV. SAMPLING AND EXAMINATION TABLES. 14

Table A, Sampling Criteria for Inspection of Shipping Containers (Normal Inspection) 14

Table B, Sampling Criteria for Inspection of Shipping Containers (Special Inspection) 14

Table C, Inspection of Shipping Containers 15

Table D, Sampling Criteria for Inspection of Menu Bags and Contents, 15

 Including Accessory Bags and Contents (Normal Inspection)

Table E, Sampling Criteria for Inspection of Menu Bags and Contents 16

 Including Accessory, Accessory Bags and Contents (Special Inspection)

Table F, Inspection of Unopened Menu Bags 16

Table G, Closed Package Inspection of Food Components and Accessory Bag Items 17

Table H, Sampling Criteria for Destructive Open Package Inspection (DOPI) 19

 (Normal Inspection)

Table I, Sampling Criteria for Destructive Open Package Inspection (DOPI) 19

 (Special Inspection) 

Table J, Destructive Open Package Inspection (DOPI) 20

Table K, Specific Defect Codes 21

Table N, Condition Code Criteria Table 23

V. INSPECTION RECORDS. 24

A. Inspection Form 24

B. Database 24

C. Distribution 24

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I. GENERAL. 

 A. Purpose and Scope. This Appendix provides a reference and guide for the surveillance 

inspection of First Strike Rations (FSR) and was written and coordinated to facilitate use on both 

DLA / DLA Troop Support controlled FSRs and those controlled by the individual Military 

Services.

 B. Explanation of Inspection Concept. This Appendix incorporates the concept of 

condition coding a lot based on the serviceability of the various components contained within the 

different menus and their estimated remaining shelf life. Basically, it involves a two step process: 

(1) Determine if any components exceed an action number and if so, (2) classify menus 

containing the defective components using the criteria contained in Table N. 

 C. Receipt Inspection Guidance. For receipt inspections, use the same sampling criteria 

and defect tables as for surveillance. In some cases, a cursory inspection may be performed in 

lieu of a receipt inspection (see guidance on cursory inspections below). In addition, inspectors 

shall advise DLA Troop Support (AFESC / DEHF for Air Force inspection activities) when 

containers/products fail to comply with essential receipt criteria identified in the appropriate 

monographs. Notification should be by the most expeditious means when there is a possibility 

that warranty action can be initiated. Inspectors will be provided additional guidance concerning 

warranty inspection/actions if required.

 D. Cursory Inspections. Cursory inspections are simply the visual inspection of palletized 

load and conveyance to determine if there is any obvious damage or contamination that occurred 

during transport. Cursory examination is only authorized for FSRs received directly from an 

assembly plant, or for loads that received a full (not cursory) inspection at the installation from 

which the FSRs were received within the last 30 days. 

 E. Inspection Test Date (ITD) Extensions. Inspectors may extend an ITD based on their 

estimate of the lot's remaining shelf-life. Table N is provided to aid the inspectors in arriving at 

the best estimate possible without the benefit of laboratory testing. Remarking of the unitized 

loads/cases with a revised ITD will be accomplished in accordance with DLAM 4155.2, 

Appendix S, and/or the appropriate service regulation. Posting of extensions can be 

accomplished by posting stickers containing updated ITD information to each pallet or case.

 F. Disposition Recommendations.

1. The accountable officer/agency will be informed of inspection results by the 

Veterinary/Medical Food Inspector. Inspectors will include (as a minimum): the condition code 

as determined with this Appendix, estimated remaining shelf-life, TTI stage, and a summary of 

general lot characteristics. Inspectors are also encouraged to provide additional comments and 

pictures that will assist the Accountable officer/agency in determining a final disposition.

2. Final disposition instructions for lots placed on medical hold require review and 

approval by the local medical authority.
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3. The points listed below should be considered when developing a disposition 

recommendation. This list is not all inclusive and each point will not always apply.

 a. Can the defective menu(s)/component(s) be removed or replaced just prior to 

consumption?

b. How rapidly is the most defective component expected to deteriorate to the point

that it is likely to become unserviceable?

c. Can the lot be issued and supplemented/substituted with similar commercial items,

Supply catalog items, or operational ration component(s)? Component replacement of FSRs can 

be done successfully, but there have been several instances where inspectors have made this 

recommendation, but the actual soldiers consuming the rations never received the recommended 

supplements/substitutes. In these cases, if possible, inspectors should:

1) Communicate with accountable officer to see if such a substitution is possible. 

(Note: If it can be determined that the substandard components deteriorated through some action

or inaction that occurred prior to the military service taking possession from DLA Troop 

Support, then normally DLA Troop Support will provide replacement rations or ration 

components. If the deterioration took place because of poor storage and transportation after the 

military service took possession of it, then supplements or substitution would be paid for by the 

accountable officer.

2) Follow-up on the supplement or substitution action to see if it was done 

properly. 

 G. Inspection Equipment. The items listed below are recommended as the minimum 

necessary to perform the inspections of FSRs. However, this list is not intended to be all 

encompassing.

1. Adequate lighting.

2. Magnification lens (3 to 5 power recommended) is optional.

3. Metal ruler (32nd inch graduation).

4. Paper plates.

5. Paper cups.

6. Paper towels.

7. Scissors, general use (must be strong enough to easily cut menu bags and retort

 pouches.

8. Tape (for re-taping menu bags and cases).

9. Sharpie Pen.

10. Number 2 stylus.

11. Sharp knife, box cutter, or scalpel that can be sanitized.

12. Alcohol swabs.
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 H. Definitions. 

1. Monograph. An information and instruction sheet that provides the inspection 

activity with a description of a FSR component, including normal characteristics and signs of 

deterioration, as well as special instructions on how to examine the item. Special notes 

concerning inspection techniques are also included in some Monographs. Monographs can be 

accessed at https://www.dscp.dla.mil/subs/support/qapubs/appl/mono-l.asp.

2. Component Classification. The Monograph index (Table M) indicates the 

classification for each component. Component classification is determined by coordination of 

the Surgeon General and the Food Service Headquarters of the Military Services. Table M can 

be accessed at https://www.dscp.dla.mil/subs/support/qapubs/appl/index.asp.

a. Primary. Any individual component in the FSR which, if unserviceable, will

make the meal nutritionally inadequate for any method of intended use.

b. Secondary. Any individual component in the FSR which, if unserviceable, will 

reduce the nutritional value of the meal but will not render the meal unfit for its intended 

purpose. 

c. Ancillary. Any component in the FSR which contributes little or no nutrition to

the meal and if unserviceable, will not cause the meal to be nutritionally deficient for any 

intended use.

3. Major A Defect. This classification should be used for defects that are likely to cause 

hazardous or unsafe conditions for individuals using, maintaining, or dependent upon the 

product. The words “are likely to” are important. They do not mean “could possibly” since it is 

always possible to develop grand scenarios that transform trivial happenings into major 

catastrophes. Therefore, the use of this classification requires experience, prudence and sound 

judgment. 

4. Major B Defect. These are defects that are not hazardous or unsafe. However, they 

may restrict the use of the product or make its consumption unlikely under the conditions for 

which the rations were originally designed. Examples: Extreme color (darkening). odor 

(rancidity), or flavor (bitterness) changes in primary components of a ration that make them 

unlikely to be consumed under normal field conditions where resupply or alternative feeding 

strategies are available. However, under more restrictive conditions the components could be 

consumed without concern that illness could be produced. 

5. Minor Defect. These are defects that make the product less useful than it should be, 

but not seriously so. Minor defects usually do not affect serviceability. However, their 

identification is important since they often reveal early signs of deterioration and can be detected 

before the item reaches a condition that makes its consumption unlikely under conditions of 

normal use. Their early detection may lead to a predictive intervention by the accountable officer 

to ensure consumption before the component or menu loses its serviceability. 
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6. Product Codes. 

a. Assembly code information/Assembler’s lot number: Contract and component

identification markings found on the shipping container, menu bags, and/or accessory bags that 

reflect ration assembly information only (e.g., assembly contractor, date of pack, assembly lot 

numbers, Inspection Test Date (ITD), etc.).

b. Component code information/component lot number: Item identification 

markings found on the primary package and, when applicable, the secondary package (e.g., 

thermostabilized pouch cartons) that reflects the producer's name, the USDA Establishment 

Number, the production lot number of the component, the nomenclature, etc.

7. Action Number (AN). A number which, when reached or exceeded, indicates 

additional inspection is necessary or indicates a component has deteriorated beyond acceptable 

limits. 

8. Condition Coding. Traditionally, condition codes have been based primarily on 

estimates of remaining shelf-life. FSR serviceability will be determined based on the usability 

status of all menus. However, to aid accountable officers in choosing the best disposition option, 

inspectors will provide them the best possible estimate of remaining shelf-life. A list of 

applicable condition codes and their descriptions are as follows:

 a. Condition Code A (issuable without qualification): Refer to Table N.

 b. Condition Code B (issuable with qualification): Refer to Table N. Accountable 

Officers are required to determine what qualifications will be specified in order to issue 

Condition Code B stock (e.g., issue with instructions to consume as soon as possible; or to 

replace specific components with supplements, provided that the inspector has determined that 

supplementary components are available).

 c. Condition Code H (unserviceable - destroy in accordance with local policy): Refer 

to Table N. This classification will be used only when the entire lot has been deemed 

unserviceable.

 d. Condition Code J (laboratory testing, medical hold rework, or reclassification 

hold): Any item on hold pending laboratory analysis, rework, or awaiting authority for disposal.

 

 e. Condition Code L (warranty action hold): Any item placed on hold pending 

warranty action.

9. Thermostabilized Component. Any component subjected to a thermal process in a 

closed retort approved by a process authority.
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10. FSR Lot Serviceability. Two factors are considered when determining the overall 

serviceability of a FSR lot. First the lot is condition coded using Table N and then the integrity of 

the packaging and packing is considered. It is recognized that the status of a FSR lot initially 

declared unserviceable may change as the result of a rework effort or special instructions 

provided by the accountable officer at/prior to issue.

11. Time-Temperature Indicator. A small label attached to the outer case used to

monitor storage conditions. The TTI should be used as a tool only, and shall not be the sole 

factor for determining disposition of rations in storage.

12. Abrasion. A break or crack in the outer lamination of the retort pouch.

13. Foldover wrinkle. Pouch material is overlapped on itself in the seal area that 

reduces the closure seal to less than 1/16 inch. 

14. Entrapped Matter. Foreign material may be trapped in the seal area, when the 

pouch is sealed or bonded. Entrapped matter weakens the seal, but as long as there is 1/16 inch 

of continuous seal all the way across the seal area (i.e. from one side of the pouch seal to the 

other), then the seal is considered acceptable.

15. Delamination. Delamination is the separation of laminated films in a flexible 

laminated pouch. 

16. Stress Crack. It is possible that the foil barrier layer in the FSR pouch material may 

break, but the outer layer (lamination)of polyester is still intact. This would be called a stress 

crack and it is not scored as a defect.

17. Barrier Layer. For an FSR retort pouch this is the lamination (foil) that prevents 

transmission of light, water vapor, or oxygen into out of the retort pouch.

18. Product Contact Layer. For an FSR retort pouch, this would be the inner 

lamination (polypropylene) which is in contact with the food. 

19. Adhesive. Bonding material that binds the laminations (thin sheets of 

Polypropylene, foil, polyester, or nylon) that make up the retort pouch material.

20. Inspection Module. In Operational Rations, the word module typically means a set 

of boxes whose combined content yields the components necessary to feed one meal to a given 

number of soldiers. For the purposes of FSR inspection, we will refer to a full/complete single 

case as an inspection module. This is meant to minimize confusion. The unit of issue is a single 

case (or box). In order to make sure that inspection covers all the menus/components during

inspections, inspectors will make use the term “inspection modules”. An inspection module is a 

full/complete case.
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21. Commercially Sterile. Food that is free of all pathogens and those spoilage 

organisms capable of growth during normal storage and transportation conditions. Normal 

transportation and storage temperature is defined as 80F or less. 

II. ROUTINE INSPECTION GUIDANCE.

 A. STEP 1: Cursory or Full Inspection. A complete receipt inspection is required unless:

1. The FSRs are delivered to the installation directly from the FSR assembly plant; a full 

receipt inspection is not required. Inspect these deliveries only for transportation 

damage/obvious defects. 

2. Normally, rations received will receive a full destination inspection. If the 

depot that the rations were received from performed a cursory inspection, then a full receipt 

inspection shall be performed at destination. The FSRs are delivered from a depot or other 

installation and a current (within the last 30 days) inspection report, completed at the point of 

origin (for example, a depot, not another installation that received the same lot) accompanies the 

shipment. The accompanying inspection report should match the lot number and 

manufacturer/assembler information on the shipping container, plus the delivery origin. 

 B. STEP 2: Evaluation of Storage Conditions (Surveillance).

1. Storage conditions vary significantly. As a minimum FSR storage areas should be 

clean and dry. FSRs should not be stored directly on the floor. The area should be free of pests 

in accordance with:

 a. MIL-STD 904B, Detection, Identification, and Prevention of Pest 

Infestation of Subsistence.

 b. TIM-38, Protecting Meals, Ready-To-Eat Rations (MREs) During

Storage. Although this is written for MREs it is still applicable to FSRs.

2. When multiple pallets of FSRs are warehoused, the storage facility should meet the 

additional standards of MIL-STD 3006C, Guidelines for Auditing Food Establishments, 

Appendix A. FSRs cannot be stacked more than 4 pallets high without the use of storage aids, 

pallet racks/pallet sets, etc. These pallet racks/pallet sets should support the full weight of any

additional pallets. The pallet (s) above shall not be in contact with or supported by the pallets 

beneath. Temperature history of storage locations must also be considered when 

recommending/determining when the next inspection is due.

3. All cases opened for inspection, or damaged, shall be recouped or repaired in a manner 

sufficient to ensure protection of the product during subsequent storage and handling.

Cases should be back filled so that no more than one case will have less than 9 menu bags.

 
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 C. STEP 3: Determine If Grand Lotting Is Appropriate.

1. Lotting procedures will be as follows:

 a. Contractor's lots are composed of rations from the same assembly contractor, 

having the same contract number and lot number, and stored under substantially similar storage 

conditions.

 b. Grand lots for the purpose of FSR inspections will be composed of rations

from the same assembly contractor that have the same contract number. Grand lots will contain 

rations from two or more contractor's lots as long as the contractor (assembler) and production 

year are the same. Additionally, the rations must have been stored under substantially similar 

storage conditions (Check the TTI values on cases from each contractors lot, they should be 

nearly the same). Samples from grand lots must represent all individual lots proportionally, even 

if the next highest sample size must be used. Identity of samples from each sublot must be 

maintained throughout the inspection. This will be done by marking the menu bags with the lot 

code from the case that the menus are drawn from.

2. When the action number is reached or exceeded during normal inspection of a grand

lot, complete the normal inspection of the grand lot and then perform a special inspection of the 

affected component(s) of the nonconforming lot(s).

3. Defective contractor's lots will be segregated from grand lots and inspected

individually when one or more of the following occurs:

 a. A Major A defect is found in the contractor’s lot.

 b. The Major B or Minor defects found seem to be concentrated in one or more of the 

contractor's lots comprising the grand lot.

 c. The inspector determines for any reason, based on initial inspection results, that 

inspection of each contractor's lot is necessary.

 4. Grand Lotting is encouraged (to conserve inspection resources) whenever it is

considered appropriate by the inspection activity. Grand lotting will not be used when 

performing warranty inspections or on inspections of lots reported as possibly having 

wholesomeness deficiencies.

 D. STEP 4: Determine Lot Size. 

1. Lot size is expressed as the total number of inspection modules, menus, or 

components as appropriate:

 a. For inspection of shipping containers, verify total number of modules/cases.
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 b. For inspection of Menu Bags and contents (including accessory bags), the sample 

unit is the menu, and the lot size would be the total number of menu bags in the lot. To 

determine this multiple the total number of inspection modules by 9.

 E. STEP 5: Inspect Shipping Containers and Selection of Menu Samples.

1. IAW Table A, select the appropriate sample size for shipping container examinations.

Obviously damaged shipping cases should not be selected unless they are truly representative of 

the lot. Damaged cases should be set aside, inspected, and salvaged separately.

2. Using the defects listed in Table C, the inspectors should check each sample case

for loose straps, different type straps on one or more cases than those on the majority of the lot, 

or previously opened boxes. While these indicators may be the result of tampering, each may 

also be due to other reasons (e.g., a wholesale rework of a lot). Inspectors should contact their 

supervisors for guidance if pilferage or tampering is suspected.

3. Open the sample cases to determine how many different menus they contain.

While the FSR was designed to have 9 total menus, 3 of each different type of menu, in each 

case, inspectors may encounter double packing of one or more menus.

4. Using defects listed in Table C, observe each case for signs of rodent damage or

insect infestation. Post infestation findings on the inspection report, to include:

 a. Whether or not the pests were alive or dead.

 b. Identification of the pests (preferably based on entomological or laboratory 

identification).

 c. Probable origin of pests (see DLA Troop Support Handbook 4155.2, paragraph 

XIII.).

 d. Probable movement of pests. For example, from outside the shipping

container into the menu bags or vice-versa. 

5. Classify each defective case by the most serious defect it possesses.

 

 F. STEP 6: Perform Closed Package Inspection of Menu Bags.

1. IAW Table D, select the appropriate number of menus being sure the samples are

proportionally representative of the menus in the lot.

2. If the inspection lot has been grand lotted, always mark each menu bag with the
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assemblers lot code from the case from which the menu was taken. Use a sharpie or a selfadhesive label or some other method that will not easily rub off. The assemblers lot code is a 

four digit number (Julian Date) taken from the side panel of the case. In this way, if the action 

number is exceeded, then the inspector can determine whether all the contractor’s lots require a 

Special Inspection. It is also recorded on the inspection report for each defect even if the action 

number is not exceeded. 

3. Inspect for defects listed in Table F.

 G. STEP 7: Perform Closed Package Inspection of Menu Bag Contents and Accessory 

Bag.

 1. Open the menu and accessory bags.

2. Menu bag components will be inspected for defects in accordance with Table G.

Accessory bags will be inspected for defects IAW Table F. When inspecting retort and 

thermostabilized pouches, use the following Non-Destructive Open package Inspection (NDOPI)

method:

 a. Remove pouch from protective carton (if there is one).

 b. Lay pouch on flat surface; check for swelling.

 c. Visually scan both sides of the surface of the pouch. Use the light source by 

changing the position of the pouch in relation to the light source to better spot anomalies, such as 

delamination. Run fingers along both sides of the pouch surface, particularly along the ridges 

of wrinkled areas, feeling for breaks in the outer layer of the laminate. These will feel like small 

snags. Using a nylon is a good way to find abrasions or draw a stylus gently across the possible 

abrasion. It may also be helpful to examine possible abrasions with a magnifying glass.

 d. Press down firmly on the pouch, pushing the food towards the outer edge.

 e. Look at the edge of the pouch, looking for indication that product has leaked

through the pouch seal.

 f. Examine the seal area around the pouch. Look for abnormalities.

3. Thoroughly examine all pouches within the menu bag under a good light source and, if 

available, with the aid of a magnifying glass. When a component exhibits more than one defect, 

it will be classified by the most serious defect it possesses. However, for the purpose of 

gathering additional information, the lesser defects will also be noted. 

 H. STEP 8: Perform Destructive Open Package Inspection (DOPI).
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1. Open package inspection will be performed in accordance with Table H and those 

defects listed in Table J. Select menu bags that did not already have defects noted during the 

closed package inspection. Use the following procedures for inspecting each retort pouch and 

thermostabilized pouch in the DOPI sample:

 a. Lay pouch on flat surface; check for swelling.

 b. Visually scan both sides of the surface of the pouch. Use the light source by 

changing the position of the pouch in relation to the light source to better spot anomalies, such as 

delamination. Run fingers along both sides of the pouch surface, particularly along the ridges 

of wrinkled areas, feeling for breaks in the outer layer of the laminate (abrasions). These will 

feel like small snags. Using a nylon is a good way to find abrasions or draw a stylus gently 

across the possible abrasion. It may also be helpful to examine possible abrasions with a 

magnifying glass. 

 c. Press down firmly on the pouch, pushing the food towards the outer edge.

 d. Look at the edge of the pouch, looking for indication that product has leaked

through the pouch seal.

 e. Examine the seal area around the pouch. Look for abnormalities such as foldover

wrinkles or entrapped matter.

 f. Using a sharp scalpel-type knife that is sanitary, make an “X” incision across

the body cavity. Peel back the flaps.

 g. Look at the food, smell it, and transfer to a plate for sensory exam.

 h. Clean pouch and determine if the seam areas are intact by running a Number

2 stylus down the now exposed inner surface of the pouch seal area, and using a magnifying 

glass if necessary. The purpose of this is to determine if there are weak seal areas or channels

that were plugged by the food inside the pouch.

2. Inspectors should refer to the component monographs for information relative to the 

product's normal characteristics, the most likely deteriorative conditions to be observed and any 

unique inspection information and special notes concerning the item. Monographs containing

the FSR can be accessed at https://www.dscp.dla.mil/subs/support/qapubs/appl/mono-l.asp.

3. Each component of the sample DOPI menus (including all accessory items) will be 

opened and inspected. If no Major A or Major B defects are noted and the action number for 

minor defects is not exceeded during normal open package inspection, this phase of the 

inspection should be considered complete.

4. Classify each defective component by the most serious defect it possesses.
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 I. STEP 9: Recording Results.

1. Record the following information for all defective components:

 a. Menu number. 

 b. Assembler's lot number. 

 c. Component nomenclature and code.

 d. Processor's and/or plant name (if available). 

 e. Defect number.

 f. Specific defect code (if applicable).

 g. Narrative description of defect (if necessary). Note: Anytime an inspector uses 

the defect description for “other”, they will need to enter a description to complete the report.

 h. Tally defects (Major A, Major B, Minor) according to type of components.

2. All components observed during the inspection with Major A or Major B defects

will be discarded (whether they are part of the sample or not). Components not exhibiting defects 

or those exhibiting only minor defects may be reassembled into the lot.

3. Component packages with a Major A or Major B packaging defect (other than 

swelling) should be opened to evaluate the effect the defect has on the product. Any findings 

should be recorded as a note on the inspection record. Do not taste product from defective 

pouches. NOTE: This inspection is an exception to normal destructive open package inspection 

(DOPI), during which product is given a sensory examination and compared to criteria found in 

the applicable monograph.

 J. STEP 10: Determine if Special Inspection is Required. Special inspection is normally 

required when any action number is reached/exceeded. However there are rare occasions when 

an action number may be exceeded and it may be appropriate to waive the Special Inspection. 

This would normally be a situation in which it can be determined that there is degradation 

through out the grand-lot. For example a situation in which the entire lot is heat stressed or 

infested. If the TTI value is 4 or 5 and the Normal Inspection shows that multiple components are 

heat stressed in numbers in excess of the action numbers. If a Special inspection is deemed 

necessary, go to Section III for procedures.

 K. STEP 11: Determine Disposition. Disposition based on routine inspection results will 

be determined when no Major A or Major B defects were noted or the action number for minor 

defects combined has not been reached.

1. The Condition Code of a lot may only be downgraded based on special
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inspection results or if a factor such as heat stress or infestation causes uniform degradation 

throughout the lot.

2. If deemed necessary, samples may be submitted to the appropriate supporting 

laboratory. The lot will then be placed in Condition Code J pending results of the tests.

 L. STEP 12: Provide Results and Recommendations to Accountable Officer/Agency.

1. Complete DLA Troop Support Form 5117, and provide copy of report to accountable 

officer.

2. Currently there is no VETCOM database to report inspection results. You can find a 

writable version of the DLA Troop Support Form 5177 at the following website, 

https://www.dscp.dla.mil/subs/support/qapubs/appa/5117.pdf.

 M. STEP 13: Scheduling the Next Surveillance Inspection.

1. Condition Code A – Reinspect in 6 months if this lot is in stock, If average storage 

temperatures are between 80-100F, inspect within 3 months. If average storage temperatures are 

in excess of 100F, inspect within 1 month.

2. Condition Code B – Reinspect within 3 months if this lot is still in stock, If average 

storage temperatures are between 80-100F. If average storage temperatures are in excess of 

100F, inspect within 1 month.

III. SPECIAL INSPECTION GUIDANCE. During a Special Inspection, the inspector pulls 

an additional quantity of only those components that met or exceeded the Action Numbers during 

the Normal Inspection. All defective samples will be classified by the most serious defect they 

possess. If you are performing a grandlot inspection and defects are present for a particular lot or 

lots, complete the Normal Inspection and then perform a Special Inspection on the lot(s) that 

require further examination. There may be situations in which it is not necessary to perform a 

Special Inspection. Normally this would be due to a deteriorative condition throughout the lot 

that is readily apparent during the Normal Inspection. Possible examples would be heat stress or 

infestation throughout the lot. When Action Numbers are exceeded, but the inspector believes 

that a Special Inspection is not necessary, then the inspector must discuss this with his chain-ofcommand and request approval to forego the Special Inspection. The approving officer and the 

reason for not performing the inspection should be documented on the inspection report. 

 A. STEP 1: Determine Lot Size. Initially determine lot size of the individual suspected 

defective components as determined during routine inspection (reached/exceeded Action 

Number). Each defective component will be inspected as a separate lot. To determine 

component lot size, you must determine which menus contain the defective component(s) 

utilizing Table S and the previous inspection results. These menus will be the only menus 

selected for the special inspection.

 B. STEP 2: Determine Sample Size for Each Component and Select Samples.
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1. Sample size will be determined in accordance with Table B, E or I. Special

Inspections are performed only on contractor’s lots.

2. Inspect IAW applicable defect table (Table F, G or J).

 a. The sample size for each component involved will dictate the minimum number of 

cases that must be selected for special inspections.

 b. Table S on the DLA Troop Support website can be used to determine the menu 

arrangement for the ration lot in question. This way the inspector can determine which lots to 

pull. The website address is: https://www.dscp.dla.mil/subs/support/qapubs/appl/index.asp.

 C. STEP 3: Perform Inspection of Selected Components. This will be done in the same 

manner as performed on individual components during Normal Inspection, to include pouch 

examination, DOPI, and comparison with characteristics in the monographs.

 D. STEP 4: Determine Disposition of the Lot.

1. If none of the Action Numbers (ANs) are reached or exceeded, each menu is 

considered to be fully useable and the Condition Code of the lot may remain unchanged.

 2. Compare defects noted with the ANs for each type of component (primary, secondary, 

ancillary) and use the criteria in Table N to determine the condition code of the lot. 

 E. STEP 5: Provide Results and Recommendations to Accountable Officer/Agency. 

1. Complete DLA Troop Support Form 5117, and provide copy of report to accountable 

officer.

2. Currently there is no VETCOM database to report inspection results. You can find a 

writable version of the DLA Troop Support Form 5177 at the following website, 

https://www.dscp.dla.mil/subs/support/qapubs/appa/5117.pdf.

3. If rations are placed in less than condition code A, notify DLA Troop Support -

FTRE/FTSA telephonically @ (215) 737-7773/4477/7771 (DSN 444).
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IV. SAMPLING AND EXAMINATION TABLES.

TABLE A 1/ 2/

SAMPLING CRITERIA FOR INSPECTION OF

SHIPPING CONTAINERS (NORMAL INSPECTION)

LOT SIZE

(CASES)

SAMPLE SIZE

(CASES)

DEFECT CLASS ACTION NUMBER

1-250 6 Major B

 Minor

1

 3

251-17,500 20 Major B

 Minor

 2

 8

17,501-250,000 32 Major B

 Minor

 3

 11

> 250,000 50 Major B

 Minor

 4

 15

1/ For use with Table C.

2/ American National Standard ANSI/ASQC Z1.4-2003 was the basis for the sampling tables 

within this appendix. 

TABLE B 1/ 

SAMPLING CRITERIA FOR INSPECTION OF SHIPPING CONTAINERS 

(SPECIAL INSPECTION)

LOT SIZE

(CASES)

SAMPLE SIZE

(CASES)

DEFECT CLASS ACTION NUMBER

1-75 3 Major B

 Minor

1

 3

76-250 10 Major B

 Minor

 2

 8

251-600 16 Major B

 Minor

 3

 11

601-1,600 25 Major B

 Minor

 4

 15

1,601-5,000 40 Major B

 Minor

 6

 22

5,001-17,500 63 Major B

 Minor

8

 31

> 17,500 100 Major B

 Minor

 11

 45

1/ For use with Table C.
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TABLE C 1/ 2/

INSPECTION OF SHIPPING CONTAINERS

CATEGORY DEFECT

 MAJ B MINOR

 501 

 502

 601

 616

 

 618

 

619

 620

Evidence of rodent or insect infestation on or in 

the shipping container. 2/ 

Container damaged, contents exposed or 

affected.

Container damaged, contents not exposed or 

affected.

Missing TTI.

Shrink Wrap is torn or does not cover all four 

sides.

TTI is attached to case strap.

Exterior of case shows mold growth.

1/ For use with Table A and B. 

2/ Requires immediate corrective action according to local Pest Management Program.

TABLE D 1/ 2/ 3/

SAMPLING CRITERIA FOR INSPECTION OF

MENU BAGS AND CONTENTS INCLUDING ACCESSORY

BAGS AND CONTENTS (NORMAL INSPECTION)

LOT SIZE

(Menus)

SAMPLE SIZE

(Menus)

DEFECT CLASS

AND ACTION NUMBERS

MAJ A MAJ B MIN

24 - 6, 000 9 1 1 11

> 6, 001 18
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1 1 22

1/ For use with Table F and G.

2/ Sample menus will be selected from the shipping containers selected for the Table A 

examination.

3/ All defects noted on menu bags and contents and accessory bags and contents will be 

combined and compared to the normal inspection action numbers.

TABLE E 1/ 2/

SAMPLING CRITERIA FOR INSPECTION OF MENU BAGS

AND CONTENTS INCLUDING ACCESSORY BAGS

AND CONTENTS (SPECIAL INSPECTION)

LOT SIZE

(Components)

SAMPLE SIZE

(Components)

DEFECT CLASS 

AND ACTION NUMBERS

MAJOR A MAJOR B MINOR

24 – 36 ,000 9 1 2 9

> 36, 001 18 1 3 11

1/ For use with Table F and G.

2/ On special inspections, compare separate component inspection results to the action numbers.

TABLE F 1/ 2/

INSPECTION OF UNOPENED MENU BAGS

CATEGORY DEFECT

MAJOR MAJOR MINOR

 A B

 503

 514

 

 602

Rodent damage/insect infestation of menu bag.2/

Less than 9 menus in a case.

Visible tear/cut/hole/open seam in menu bag. 

1/ For use with Tables D and E.

2/ Requires immediate corrective action according to local Pest Management Programs. 
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TABLE G 1/ 2/ 3/ 4/ 5/ 6/ 7/ 

CLOSED PACKAGE INSPECTION OF FOOD COMPONENTS AND ACCESSORY

BAG ITEMS

CATEGORY DEFECT

 MAJOR MAJOR MINOR

 A B

 401

 402

 

 

 406

 504

 

 505

 506

 507

 

 508 

 

 509

 

 

 

 

 513

 

 

 515

 

Swollen pouch. 3/ 

Tear/cut/hole/open seal in primary package of 

peanut butter cheese spread, or

thermostabilized component.

Menu bag is missing an entrée.

Rodent damage/insect infestation of accessory 

bag. 2/ 

Complete loss of menu. 4/ 

Tear/cut/hole/open seal in primary package

(other than those covered by defect 402 or 

608). 

Inadequate vacuum with moderate to extreme 

effect on product. 6/ 

Foldover wrinkle extending into the seal such 

that the closure seal is reduced to less than 1/16 

inch (retorted and thermostabilized pouches 

only).

Presence of entrapped matter (for example, 

product, moisture, grease, etc.) that reduces the 

closure seal to less than 1/16 inch, or seal area 

width not a continuous 1/16 inch around the 

pouch.

Missing Secondary Component from menu 

bag, or primary component other than the

entrée is missing.

Accessory pouch missing from the menu bag. 
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 603

 

 604

 605

 606

 607

 608

 609

 610

 617

 

 621

Visible tear/cut/hole/open seam in accessory

bag.

Rupture of normal appearing cheese spread or 

peanut butter package when kneaded. 

Presence of delamination when multi-layered 

laminate is used. (not applicable to dehydrated 

components).

Inadequate vacuum, product not affected or

only slightly affected. 6/

Unserviceable carton (e.g., carton missing, 

severely torn, flaps not glued).

Tear/cut/hole/open seal or loose lid (hot sauce) 

in package of ancillary component.

Presence of delamination when multi-layered 

laminate is used. (dehydrated components). 

Abrasion in the exterior surface of retorted or 

thermostabilized pouches.

Ancillary component missing from the menu 

bag.

Missing tear notch on food component or 

accessory bag.

1/ For use with Table D and E.

2/ Requires immediate corrective action according to local Pest Management Programs. 

3/ Cake items often exhibit more internal air than thermostabilized items. Do not score as 

swellers due solely to their naturally puffy appearance. 

4/ Score when one or more defective components cause the entire menu to be unserviceable. For 

example, one or more leaking, ruptured, or contaminated packages may affect the other 

components.

5/ This defect does not apply to inner wrapper of freeze dried components.

6/ See component Monograph (defects 507 and 606 apply to vacuum packaged items only).

7/ See component Monograph. 

 
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TABLE H 1/ 2/ 3/ 

SAMPLING CRITERIA FOR DESTRUCTIVE OPEN

PACKAGE INSPECTION (DOPI) (NORMAL INSPECTION)

LOT SIZE

(Menus)

SAMPLE SIZE

(Menus)

 DEFECT CLASS

AND ACTION NUMBERS

MAJ A MAJ B MINOR

24 - 6, 000 9 1 1 11

6, 000 or more 18 1 1 22

 1/ For use with Table J.

 2/ Sample menus will be selected from those shipping containers selected for the Table A 

 examination. 

 3/ All defects noted will be combined and compared to the normal inspection action 

 numbers.

TABLE I 1/

SAMPLING CRITERIA FOR DESTRUCTIVE OPEN

PACKAGE INSPECTION (DOPI) (SPECIAL INSPECTION)

LOT SIZE

(Components)

SAMPLE SIZE

(Components)

DEFECT CLASS 

AND ACTION NUMBERS

MAJOR A MAJOR B MINOR

1 – 3 ,000 9 1 1 8

3, 001 - 6, 000 18 1 2 9

6, 001 - 36, 000 27 1 3 10

36, 001 or more 36 1 3 11

 1/ For use with Table J.
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TABLE J 1/ 2/ 3/

DESTRUCTIVE OPEN PACKAGE INSPECTION (DOPI)

CATEGORY DEFECT

 MAJOR MAJOR MINOR

 A B

 403

 404

 405

 

 

 510

 

 511

 512

 611

 612

 613

 614 

Evidence of rodent damage/insect infestation in product.

/2 

Product off conditions as evidenced by abnormal odor, 

color, flavor or texture suggesting contamination and/or 

spoilage for no apparent reason (e.g., package failure not 

evident).

Foreign material present, effecting wholesomeness (e.g., 

glass, metal, wire).

Primary component fails to rehydrate (moderate to 

extreme) or dissolve (extreme).

Moderate to extreme texture, odor, color or flavor

change in a primary component not effecting

wholesomeness (product unlikely to be consumed under 

conditions of intended use).

Mechanical damage to primary component significantly 

effecting serviceability.

Slight texture, odor, color or flavor change in a primary 

component not effecting wholesomeness.

Primary component fails to rehydrate (slight) or dissolve 

(slight to moderate).

Moderate to extreme texture, odor, color or flavor

change in a secondary or ancillary component not

affecting wholesomeness.

Secondary or ancillary component fails to rehydrate or 

dissolve (moderate to extreme).
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 615 Evidence of mechanical damage to secondary or

ancillary component significantly affecting

serviceability (e.g., crushed gum).

1/ For use with Table H and I.

2/ Requires immediate corrective action according to local Pest Management Programs.

3/ Specify defect(s) observed. Enter all specific defect codes that apply and a narrative 

description when appropriate.

TABLE K

SPECIFIC DEFECT CODES

 A. INSECT / RODENT

 A1. Rodent.

 A2. Insect.

 A3. Other (describe).

 B. PACKAGING, PACKING, MARKING, LABELING AND UNITIZATION

 B1. Essential case markings missing.

 B2. Essential case markings illegible.

 B3. Essential case markings incorrect.

 B4. Essential Labeling missing.

 B5. Essential Labeling illegible.

 B6. Essential labeling incorrect.

 B7. Improperly unitized load.

 B8. Unit load failure.

 B9. Missing tear notch.

 B10. Tear notches ripped or torn. 

 B11. Sifter (see Monographs).

 B12. Inadequate vacuum.

 B13 Delamination (separation of layers in laminate material).

 B14. Foldover wrinkle.

 B15. Entrapped matter or seal area width not a continuous 1/16 inch around the pouch.

 B16. Abrasion.

 B17. Sweller.

 B18. Leaker.

 B19. Other (describe).

 C. TEXTURE CHANGES

 C1. Too thick or pasty.

 C2. Chewy / gummy.

 C3. Mealy.

 C4. Tough / stringy.

 C5. Caked or hardened.

 C6. Brittle.

 C7. Crumbly, cracking.

 C8. Excessively dry.

 C9. Loss of crispness.

 C10. Soft / mushy.

 C11. Curdled.

 C12. Gritty / grainy.

 C13. Spongy / rubbery.

 C14. Syneresis (The contraction of a gel, or a homogeneous colloid system, when left

 standing separates into two phases: a coherent gel and a liquid. A good example
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 is the separation or weeping of liquid of liquid from a gelatin mold when left 

 sitting in a refrigerator too long.).

 C15. Liquefaction (passing from dry, solid, or semi-solid) to a liquid state (e.g.,

 complete loss of gel structure in jelly component).

 C16. Caramelized.

 C17. Watery gravy or excessive product juices (probably due to product formulation

 and/or time-temperature abuse).

 C18. Honeycombing.

 C19. Coagulation/gelation (beverage base).

 C20. Other (describe).

 D. ODOR CHANGES

 D1. Medicinal, vitamin-like.

 D2. Chemical odor, solvent-like/turpentine/paint-like.

 D3. Plastic-like.

 D4. Hay-like (oxidized).

 D5. Fermented.

 D6. Scorched/burnt.

 D7. Sulfur-like.

 D8. Musty, moldy, mildew.

 D9. Overripe.

 D10. Not ripe.

 D11. Stale.

 D12. Cardboard.

 D13. Soured.

 D14. Putrid.

 D15. Acidic/vinegary.

 D16. Other (describe).

 E. FLAVOR CHANGES

 E1. Loss of flavor, flat, bland.

 E2. Chemical flavor, solvent-like, turpentine/paint-like.

 E3. Medicinal, vitamin-like.

 E4. Plastic-like.

 E5. Hay-like (oxidized).

 E6. Bitter.

 E7. Burnt.

 E8. Soapy.

 E9. Musty, moldy, mildew.

 E10. Rancid (this may also be an odor change).

 E11. Stale.

 E12. Fermented.

 E13. Earthy.

 E14. Tart, acidic.

 E15. Overripe.

 E16. Green, not ripe.

 E17. Tobacco.

 E18. Sweet, perfume like, flowery.

 E19. Metallic.

 E20. Excessively over-processed / scorched.

 E21. Canned.

 E22. Putrid (this may also be an odor change).

 E23. Sour.

 E24. Excessively salty.

 E25. Other (describe).
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 F. APPEARANCE CHANGES

 F1. Darkened.

 F2. Bloomed, blotchy (e.g., chocolate).

 F3. Oily, oiled-off (partial disintegration of an oil in water emulsion whereby a film,

 pockets, or droplets of oil form on the surface of the product or within the product).

 F4. Off-color (e.g., pink, off-white, reddish, green).

 F5. Cloudiness (beverage bases except orange).

 F6. Webbing (caffeine leeching).

 F7. Other (describe).

 G. FOREIGN MATERIAL

 G1. Potentially hazardous (e.g., glass, splinters, metal).

 G2. Not potentially hazardous.

 G3. Other (describe).

 H. COMPLETE LOSS OF MENU (Does Not Consider Caloric Count)

NOTE: The purpose of this defect category is to enable inspectors and evaluators of the inspection data to properly 

identify menus that contained one (or more) leaking component that adversely affected the entire meal. For example, 

if an applesauce pouch leaks, the entire menu may be unfit for use because of the mold growth that would likely 

occur inside the menu bag. 

 H1. Due to one leaking or ruptured component.

 H2. Due to more than one leaking or ruptured component. 

 H3. Due to one or more components contaminated by insecticide/pesticide.

 H4. Due to one or more components contaminated by an unidentified substance.

 H5. Other (describe).

 J. MISSING COMPONENTS/MENUS

 J1. Required component(s) missing from menu.

 J2. Required menus missing.

TABLE N 1/ 2/ 3/ 4/ 5/

CONDITION CODE CRITERIA

DEFECTS FROM SPECIAL INSPECTION RESULTS

(COMPONENTS THAT EQUALS OR EXCEEDS

AN ACTION NUMBER)

 CATEGORY

 CONDITION CODE A MAJOR A MAJOR B MINOR

 Primary

Secondary

Ancillary

0

 0

0

0

 1 

 1

1

 2

 2

CONDITION CODE B

Primary

Secondary

Ancillary

 0

0

 0

1

 2 

 2

2

 3

 3

CONDITION CODE H or J 

(see note 5)

Primary

Secondary

Ancillary

1

 1

 1

2

 3 

 3

NA

 NA 

 NA

1/ Lots determined to be unwholesome will be classified Condition Code J until final disposition 

is made by the responsible veterinarian.
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2/ Each column lists the maximum number of components allowed to equal or exceed an action 

number for that category (Note this is the number of defective components with the same defect, 

not the total number of defects for the same component. For example, multiple observations of 

darkened hot sauce would be counted as one ancillary component with a Major B defect. 

Likewise, components that are identical except for the flavoring are also grouped together. If 

both the jalapeno cheese spread and the bacon cheese spread show significant darkening, that 

would be one secondary component with a Major B defect). 

3/ Each row lists the maximum number of components allowed to equal or exceed an action 

number by component classification.

4/ Compare the number of components from the inspection that equals or exceeds the special 

inspection action numbers for each category. If the number in any row/column intersection is 

exceeded, the lot must be downgraded to the next lower Condition Code.

5/ For lots that fail inspection and do not meet a serviceable condition code, a condition code of 

J or H is assessed. If it is necessary to send samples to the lab for food safety or productionrelated defects, or to investigate the lot further; then assess a condition code of J. If condition J is 

assessed, this will need to revised once the lab evaluation or investigation is complete. Changing 

the condition code after the report is submitted is the responsibility of the report approver. If the 

defects have a readily explainable cause, such as heat stress, physical damage, or infestation, than 

Condition Code H (condemnation) is appropriate. Condition Code L means that warranty action 

is pending. Warranty inspections will be directed by the contracting officer and/or the chain-ofcommand. Inspectors who are asked to perform a warranty inspection will be supplied with 

specific sampling and inspection instructions.

V. INSPECTION RECORDS.

 A. Inspection Form. All inspections will be entered on DLA Troop Support Form 5117. 

Local reproduction of DLA Troop Support Form 5117 is authorized.

 B. Database. There is currently no VETCOM database to report FSR inspection results.

 C. Distribution. For DLA owned/controlled stocks, one copy of DLA Troop Support Form 

5117 will be provided to the accountable officer. Copies of all reports will also be maintained in 

the local quality history files. Inspections resulting in less than Condition Code A status must be 

telephonically reported to DLA Troop Support -FTRE/FTSA (215) 737-7773/4477/7771 (DSN 

444). Other distribution will be according to the directives of the responsible inspection agency 

and/or Military Service.