ACR-F-09__18_Apr_17.pdf

ACR-F-09

18 April 2017

SUPERSEDING

ACR-F-08

9 March 2010

SECTION C

The First Strike Ration® (FSR) provides an assault ration for the individual during short duration, high intensity missions.

C-1 ITEM DESCRIPTION

ACR-F-09, FIRST STRIKE RATION® (FSR) ASSEMBLY REQUIREMENTS

C-2 ASSEMBLY REQUIREMENTS

A. Components. The components are specified in table I.

TABLE I. Components

Component Reference

Entrées

Chicken Breast Fillets, Seasoned

Garlic and Herb Seasonings

Barbecue Sauce

A-A-20361A

Type I

Type II

Chicken Chunks, White, Cooked, Canned or in Flexible

Pouches, 7 oz. Pouch

A-A-20352B, Type VI

Filled Bakery Item

Filled French Toast

Cinnamon Bun

Apple Turnover

Blueberry Turnover

MIL-DTL-32221B

Type I

Type II

Type III

Type IV

Filled Wrap

Barbecued Seasoned Pork

Mexican Style Beef

MIL-DTL-32347

Type I

Type II

Sandwich, Breakfast, Shelf Stable, Bacon Cheddar MIL-DTL-32223

Sandwich, Shelf Stable

Nacho Flavored Beef

Pepperoni

Honey Barbecue Chicken

Honey Barbecue Beef

Italian Style

MIL-DTL-32141

Type I

Type II

Type III

Type IV

Type V

Tuna, Flexible Pouch, Chunk

Light, Water, Lemon Pepper, Regular (no more than 1.5 percent salt)

A-A-20155D, Type B, Form I, Color a, Packing Media 1, Flavor 1, Salt/Sodium Level (a)

SUPERSEDING

TABLE I. Components - Continued

Component Reference

Chunk, Light, Water

Sweet and Spicy, Regular (no more than 1.5 percent salt)

Solid, White (Albacore), Water, Unflavored, Regular Salt, 3 ounce

Form I, Color a, Packing Media 1, Flavor 3, Salt/Sodium Level (a)

Form II, Color b, Packing Media 1, Unflavored, Salt/Sodium Level (a), Option 1

Starches and Soups

Bagel, Plain MIL-DTL-32219, Type I

Crackers, Fortified, Plain PCR-C-037A, Type I

Snack Bread, Fortified

Italian Bread Sticks, Single Pack

Multigrain Snack Bread, Single Pack

PCR-S-009D

Type IV, Style A

Type V, Style A

Spread Soup Mix

Cheddar Potato with Artificial Bacon Bits

PCR-S-023

Type II

Tortillas

Plain

Chipotle

PCR-T-008A

Flavor 1

Flavor 2

Fruits

Fruits, Infused and Dried

Cranberries, Sliced, Unflavored, Not Fortified

Whole Raisins, Not Fortified

A-A-20299C

Type VII, Style B, Flavor 1, Fortification. a

Type IX, Fortification a

Fruits, Wet Pack

Applesauce, Carbohydrate Enhanced, Sweetened, Regular Style, Style 2 or 3 Spout Pouch

Applesauce, Carbohydrate Enhanced, Sweetened, Regular Style, Cinnamon, Style 2 or 3 Spout Pouch

PCR-F-002C

Type VII

Type IX

Desserts and Snacks

Caffeinated Chocolate Pudding

Trans Fat Free, Style 2 or 3 Spout Pouch

PCR-C-081

Cakes, Brownies, Muffin Tops and Filled Cakes

Pound Cake, Lemon Poppy Seed, Trans Fat Free

PCR-C-007F

Type I, Flavor 6, Style 2

Candy and Chocolate Confections

Caffeinated Mints, Round Tablets, Sugar Free

Peppermint

A-A-20177E

Type XII, Style B

SUPERSEDING

Component Reference

Cheese Spread, Cheddar, Fortified

Plain

With Jalapeno Peppers

PCR-C-039A

Type I

Type II

Dessert Bar

Mocha

Peanut Butter

Chocolate Banana Nut

PCR-D-004

Flavor I

Flavor II

Flavor III

Energy Gel, Mixed Berry PCR-E-018, Flavor I

First Strike Bar, Mini

Chocolate

Apple-Cinnamon

Cran-Raspberry

Mocha

PCR-F-001, Style B

Flavor I

Flavor II

Flavor III

Flavor V

Meat and Poultry Snacks, Cured

Beef, Moist Cured/Kippered, Chopped and Formed, Strips

Teriyaki

Barbeque

Beef, Fermented, Chopped and Formed, Sticks

Teriyaki

Turkey, Moist Cured/Lactate, Natural Style, Nuggets

Smoked

A-A-20298C

Variety A, Type II, Style a, Class 1, Package J

Flavor (b)

Flavor (c)

Variety A, Type IV, Style a, Class 2

Flavor (b)

Variety B, Type III, Style b, Class 4, Flavor (a), Package J

Nut and Fruit Mix

Nut and Raisins with Pan Coated Chocolate Disks

PCR-N-003A

Type II

Nuts, Shelled, Roasted

Almonds (Unblanched), Flavored (Smoked)

A-A-20164D

Type IX, Style C

Nut Butters and Nut Spreads

Regular, Stabilized, Fortified, Salted, Conventional

Peanut Butter, Smooth

A-A-20328B, Class A, Type a, Fortification 2, Seasoning (a), Agricultural Practices (1)

Style I, Texture 1

Snack Foods

Pretzels, Sticks, Plain, Salted

Filled Pretzels, Cheddar Cheese

Baked Snack Crackers, Hot and Spicy Cheese

Toasted Corn Kernels, Plain, Salted and Barbecue

Cheese Filled Crackers, Cheddar Cheese

A-A-20195D

Type II, Style C, Flavor 1

Type II, Style F, Flavor 1

Type V, Flavor 2

Type VI, Flavors 1 and 2

Type VII, Flavor 1

SUPERSEDING

Component Reference

Trail Mix, Recovery PCR-T-014

Toaster Pastries, Shelf Stable, Regular, Not Fortified, Rectangular, Enriched Wheat Flour

Single Serving Packet

Frosted Brown Sugar Cinnamon, Without Sprinkles

Frosted Chocolate Chip, With Swirled or Drizzled Icing

A-A-20211C, Type I, Fortification b, Shape i, Grain Composition (1)

Servings (a)

Style B, Flavor 3, Frosting (B)

Style B, Flavor 12, Frosting (C)

Beverages

Beverage Powder, Carbohydrate, Flat Interlocking

Closure Pouch

Fortified with Ascorbic Acid and Enhanced with

Maltodextrin

Fruit Punch

Grape

Lemon-Lime

Orange

Tropical Punch

Lemonade

PCR-B-055, Design B

Formulation b

Flavor 2

Flavor 3

Flavor 4

Flavor 5

Flavor 6

Chocolate Protein Drink Powder PCR-C-082A

Dairyshake Powder, Fortified with Calcium and Vit. D

Trans Fat Free, Flat Interlocking Closure Pouch

Vanilla

Strawberry Banana

PCR-D-002B

Type II, Design B

Flavor I

Flavor IV

Other Items

Barbecue Sauce, Plain/Regular, Without Fruit Purees A-A-20335B, Flavor I, Type B

Chewing Gum 3/

Tablet, Large, or Disk, Regular, with Caffeine, Regular, Peppermint

Cinnamon

A-A-20175E

Type I, Size C, or Type VII, Size B, Style (2), Class 1, Package J

Flavor a

Flavor c

Hot Sauce 2/

Extra Hot 4x, 1/8 fl. oz. pouch

Buffalo Style

A-A-20097F

Type II

Type IX

Mayonnaise, Salad Dressing and Tartar Sauce

Mayonnaise, Fat Free

A-A-20140D

Type I, Style C

SUPERSEDING

Component Reference

Fork, Knife and Spoon, Picnic (Plastic)

High Impact, Spoon, MRE, 7-inch (Brown)

A-A-3109B

Type IV, Item 13

Re-closeable Interlocking Plastic Bag 1/

1/ The plastic bag shall be 0.003” thick, beige, opaque, LDPE, minimum 10 inches wide by

12 inches long, with double track zippers.

2/ Hot sauce may be packaged in the subassembly/accessory packet or loose in the meal bag.

3/ Either Type I (Tablet, Large) or Type VII (Disk, Regular) may be procured for distribution in the Menus listed in TABLE III.

SUPERSEDING

B. Accessory components. Accessory components are specified in table II.

TABLE II. Accessory Components

Component Reference Acc. Pack

Chewing Gum, Tablet, Regular, Without Caffeine, Xylitol Sweetened, Peppermint or Cinnamon 1/

A-A-20175E

Type I, Size B, Style (1), Class 3, Flavor a or c

A, B, C

Hand and Body Wipes, Pre-Moistened, Hand Wipe, Non-antibacterial, Individually Wrapped, Single Pack

A-A-461C, Type I, Style 2, Packaging a, (3 hand wipes per accessory pack)

A, B, C

Matches, Safety A-A-59489A, Type I, Class B A, B, C

Salt, Table, Iodized, 4 grams NaCl Monograph A, B, C

Toilet Tissue, Institutional, Folded, One Ply, Perforated, 4-1/2 by 4-1/2 inches

A-A-59594A, Style II, Type A, Class 1, Sheet size b

A, B, C

Coffee, Soluble

Spray Dried, Agglomerated or Freeze Dried, Regular

A-A-20184C

Type II or Type III, Style A

A

Creamer, Non-Dairy, Dry, Regular, Plain/Unflavored

A-A-20043D, Style I, Flavor A

A

Sugar, White (Refined), Granulated

(fine or extra fine), 1/7 ounce

A-A-20135D, Type I, Style A A

Beverage Base (Powdered) 1/

Sweetened with Non-Nutritive

Sweetener, Lap or Fin Seal Pouch

Lemonade, Non-fortified

Raspberry, Non-fortified

A-A-20098E

Type III

Design D

Flavor 8, Formulation a

Flavor 13, Formulation a

B

1/ Flavors shall be procured in equal quantities and assembled in a uniform distribution

SUPERSEDING

C. Contents. The contents of each meal are specified in table III. Refer to table I for full citation and document number of components.

TABLE III. Contents

Menu #1

Filled French Toast

Sandwich, Breakfast Bac. Ch.

Sandwich, Pepperoni

Cheese Spread, Jalapeno

Italian Bread Sticks

Dessert Bar, Peanut Butter

First Strike Bar, Chocolate

Beef Strips, Barbeque

Beef Strips, Teriyaki

Snack, Pretzels, Sticks

Fruit, Zapplesauce®, Cinnamon

Trail Mix, Recovery

Chocolate Protein Drink

Beverage (1) 1/

Gum, Caffeine, Cinnamon

Re-closeable Plastic Bag

Spoon

Accessory Packet B

Menu #2

Toaster Pastry 1/

Sandwich, Italian Style

Chicken Chunks

Tortillas, Chipotle

Peanut Butter

Crackers, Plain

Dessert Bar, Mocha

First Strike Bar, Apple-

Cinnamon

Beef Strips, Teriyaki

Beef Strips, Barbeque

Fruit, Zapplesauce®

Fruit, Dried, Cranberries

Nuts, Almonds, Smoked

Beverages (2) 1/

Gum, Caffeine, Peppermint

Barbecue Sauce

Re-closeable Plastic Bag

Menu #3

Cake, Lemon Poppy Pound

Sandwich, Honey BBQ Beef

Chicken Chunks

Tortillas, Plain

Cheese Spread, Plain

Crackers, Plain

Dessert Bar, Chocolate Banana Nut

First Strike Bar, Mocha

First Strike Bar, Cran-

Raspberry

Snack, Corn Kernels, Plain

Fruit, Zapplesauce®

Trail Mix, Recovery

Beverages (2) 1/

Candy, Caffeinated Mints

Hot Sauce, Buffalo Style 2/

Re-closeable Plastic Bag

Accessory Packet A

SUPERSEDING

TABLE III. Contents - Continued

Menu #4

Filled Cinnamon Bun

Filled Wrap, Mexican Beef

Chicken, BBQ

Snack Bread, Multigrain

Cheese Spread, Jalapeno

Turkey Nuggets, Smoked

Dessert Bar, Peanut Butter

First Strike Bar, Mocha

Energy Gel, Mixed Berry

Snack, Filled Pretzel, Cheddar

Fruit, Zapplesauce®

Fruit, Raisins

Beverages (2) 1/

Gum, Caffeinated, Cinnamon

Hot Sauce, Extra Hot 2/

Re-closeable Plastic Bag

Menu #5

Toaster Pastry 1/

Sandwich, Honey BBQ

Chicken

Tuna, Lemon Pepper

Peanut Butter, Plain

Crackers, Plain

Beef Stick, Teriyaki

Snack, Corn Kernels, Plain

First Strike Bar, Cran-

Raspberry

Energy Gel, Mixed Berry

Nut Fruit Mix, Type II

Fruit, Zapplesauce®, Cinnamon

Chocolate Protein Drink

Beverage (1) 1/

Candy, Caffeinated Mints

Mayonnaise, Fat Free

Re-closeable Plastic Bag

Spoon

Accessory Packet C

Menu #6

Filled Apple Turnover

Filled Wrap, BBQ Pork

Chicken, Garlic and Herb

Cheese Spread, Plain

Bagel, Plain

Turkey Nuggets, Smoked

Snack, Filled Pretzel, Cheddar

Dessert Bar, Mocha

First Strike Bar, Apple-

Cinnamon

Caffeinated Chocolate Pudding

Fruit, Dried, Cranberries

Dairyshake Powder, Strawberry Banana

Beverage (1) 1/

Gum, Caffeinated, Peppermint

Hot Sauce, Extra Hot 2/

Re-closeable Plastic Bag

Accessory Packet C

SUPERSEDING

TABLE III. Contents - Continued

Menu #7

Filled Blueberry Turnover

Sandwich, Beef Nacho

Tuna, Sweet and Spicy

Tortillas, Plain

Spread, Cheddar Potato Bacon

Crackers, Plain

Baked Snack Crackers, Hot and Spicy Cheese

Beef Stick, Teriyaki

First Strike Bar, Chocolate

First Strike Bar, Apple-

Cinnamon

Nut Fruit Mix, Type II

Fruit, Zapplesauce®

Beverages (2) 1/

Gum, Caffeinated, Cinnamon

Mayonnaise, Fat Free

Re-closeable Plastic Bag

Menu #8

Sandwich, Honey BBQ

Chicken

Tuna, Albacore

Bagel, Plain

Cheese Filled Crackers, Cheddar Cheese

Beef Strips, Barbeque

Beef Strips, Teriyaki

Dessert Bar, Chocolate Banana Nut

First Strike Bar, Mocha

Fruit, Zapplesauce®, Cinnamon

Nut Fruit Mix, Type II

Dairyshake Powder, Vanilla

Beverage (1) 1/

Gum, Caffeinated, Peppermint

Mayonnaise, Fat Free

Re-closeable Plastic Bag

Menu #9

Filled Cinnamon Bun

Sandwich, Italian

Chicken, Garlic and Herb

Tortillas, Plain

Spread, Cheddar Potato Bacon

Crackers, Plain

Corn Kernels, Barbecue

Beef Strips, Barbeque

Beef Strips, Teriyaki

First Strike Bar, Cran-

Raspberry

Caffeinated Chocolate Pudding

Fruit, Dried, Raisins

Dairyshake Powder, Vanilla

Beverage (1) 1/

Candy, Caffeinated Mints

Hot Sauce, Extra Hot 2/

Re-closeable Plastic Bag

1/ Flavors shall be procured in equal quantities and assembled in a uniform distribution.

When menu contains two beverages, they shall be different flavors.

2/ Hot sauce may be packaged in the subassembly/accessory packet or loose in the meal bag.

SUPERSEDING

SECTION D

D-1 PACKAGING

A. Components.

(1) Subassembly packet/accessory packet. The subassembly/accessory packet shall be a preformed pouch or a form-fill-seal pouch. Dimensions shall be sufficient to contain all components. Seals shall be a minimum 1/8 inch wide. A tear nick, notch or serrations shall be provided to facilitate opening of the filled and sealed pouch. The average seal strength of the pouch seals shall be not less than 3.5 pounds per inch of width and no individual specimen shall have a seal strength of less than 3.0 pounds per inch of width. As an alternative to the seal strength requirement, 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. The pouch shall be made from polymeric films or film combinations with adequate strength and thickness to contain and protect the components. The water vapor transmission rate (WVTR) of the film shall not exceed 6.2 gm/m2/24hrs/90%rh/100F when tested in accordance with

ASTM F1249, Standard Test Method for Water Vapor Transmission Rate Through Plastic

Film and Sheeting Using a Modulated Infrared Sensor; ASTM E96/E96M, Standard Test

Methods for Water Vapor Transmission of Materials or Method 3030 of FED-STD-101, Test

Procedures for Packaging Materials. The exterior color of the packet shall be clear or tan.

(2) Time-temperature indicator (TTI) label. The TTI label shall be a 3/4 inch square, bull’s-eye type, pressure sensitive adhesive label. The TTI label shall have an activation energy (Ea) of 24–30 kcal/mole, be protected from ultraviolet radiation and have a shelf life of 1100 days at 80F as pivot point.

(3) Meal assembly packet. The meal assembly packet shall be of sufficient thickness and strength to contain the meal components without tearing or spillage of meal contents throughout assembly, packing and distribution.

B. Assembly.

(1) Subassembly/accessory packet assembly. One of each applicable component as described in table II shall be inserted in a pouch. If a subassembly is used, additional components may also be inserted in the pouch. For a preformed pouch, components shall be inserted in the pouch and the pouch shall be closed with a heat seal not less than 1/8 inch wide. For a form-fill-seal pouch, components shall be placed in the body and the cover

SUPERSEDING

applied by heat sealing with a seal not less than 1/8 inch wide. The closure seal shall be free of foldover wrinkles or entrapped matter that reduces the effective seal width to less than

1/16 inch. The average seal strength of the pouch seals shall be not less than 3.5 pounds per inch of width and no individual specimen shall have a seal strength of less than 3.0 pounds per inch of width. As an alternative to the seal strength requirement, the filled and sealed packet 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) Meal assembly. Each applicable component for each meal as described in table III shall be inserted in a meal assembly packet. The packet shall be a single bag or pouch. The meal assembly packet shall be shrink wrapped or heat-sealed (as applicable). If closed by heat seal, the seal shall be not less than 1/8 inch wide. The sealed assembly packet shall not show any evidence of foreign odor. The size of the finished meal assembly packet shall allow for the packing of nine meals into the box.

D-2 LABELING

A. Subassembly/accessory packet. The subassembly/accessory packet shall be labeled on one face in permanent dark contrasting color ink with ‘A’, ‘B’, or ‘C’, as applicable.

Alternatively, the packet letter may be embossed in the seal of the packet.

B. Meal assembly packet. Each packet shall be correctly and legibly labeled in accordance with the colors and design of the FIRST STRIKE RATION® label shown in figure 1.

(NOTE: The registered label design of the U.S. Army Research, Development and

Engineering Command, Natick Soldier Research, Development and Engineering Center is available electronically.) As an alternate labeling method, a pre-printed self-adhering 0.002 inch thick polyester label may be used.

SUPERSEDING

FIGURE 1. First Strike Ration® Label.

The following information shall also be printed on the packet:

Contractor's name and address

Appropriate menu number and contents

D-3 PACKING

A. Packing. Nine meals, one of each menu, shall be packed in a fiberboard box. The fiberboard box shall conform to RSC-L of ASTM D5118/D5118M, Standard Practice for

Fabrication of Fiberboard Shipping Boxes, grade V2s of ASTM D4727/D4727M, Standard

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

Shapes, except the requirements for dry burst strength shall be minimum 425 psi, the requirement for wet burst strength shall be minimum 250 psi and the laminated board thickness shall be 0.069 inches. [U.S. Army Research, Development and Engineering

SUPERSEDING

Command, Natick Soldier Research, Development and Engineering Center has found that solid fiberboard shipping container material consisting of two outer facings of 90 pound wet strength linerboard and an inner ply of 69 pound linerboard met the performance criteria of this specification.] The box liner shall be a full inside width box liner fabricated from grade

W5c fiberboard in accordance with ASTM D5118/D5118M, except the terminal ends of the liner shall overlap a minimum of 2 inches and no fastening of the overlap is required. The box shall be closed in accordance with closure method 2A1 of ASTM D1974/D1974M, Standard Practice for Methods of Closing, Sealing, and Reinforcing Fiberboard Boxes;

except the gap between the outer flaps shall be not more the 3/4 inch wide. Each box shall be reinforced with two girthwise nonmetallic straps. The inside dimensions of the box shall be

16-11/16 inches in length, 9-1/8 inches in width and 10-1/4 inches in depth.

D-4 UNITIZATION

A. Unit loads. Forty-eight boxes shall be arranged in unit loads in accordance with type I, class C of DLA Troop Support Form 3507, Loads, Unit: Preparation of Semiperishable

Subsistence Items. At least two boxes in each tier shall be oriented to display the TTI label.

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 and as specified in the contract with the following exceptions:

(1) Identification markings normally placed on an end of the shipping container shall read from top to bottom, left to right, when the shipping container is rotated from its upright position onto its side for palletization. The major flaps of the shipping container closure immediately to the right of the marked end of the shipping container shall bear the following marking:

Contract data and other required markings

Date of pack

Lot number

U.S. GOVERNMENT PROPERTY – COMMERCIAL RESALE IS UNLAWFUL

(2) Time Temperature Indicator label shall be centrally positioned on the panel. A minimum distance (quiet zone) of 1/4 inch from the nearest identification marking shall be maintained.

SUPERSEDING

(3) One side panel of shipping container shall be marked “FIRST STRIKE

RATION®” in letters not less than 1-1/4 inches high. Underneath the ration nomenclature, in letters not less than 1/2 inch, the shipping container shall be marked “DO NOT ROUGH

HANDLE WHEN FROZEN (0°F or below)”.

B. Unit loads. Unit loads shall be marked in accordance with DLA Troop Support Form

3556.

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. Conformance inspection. Conformance inspection shall include the examinations/tests and the methods of inspection cited in this section.

SUPERSEDING

C. Packaging examination.

(1) Subassembly/accessory 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.

Requirement Requirement Paragraph Test procedure

Color of subassembly/accessory packet

D-1,A(1) Visual evaluation and

SAE-AMS-STD-595, as applicable 1/

Water vapor transmission rate D-1,A(1) ASTM F1249 2/, ASTM

E96/E96M 3/ or Method

3030 of MIL-STD-3010 4/, FED-STD-101 5/

1/ Colors Used in Government Procurement

2/ Standard Test Method for Water Vapor Transmission Rate Through Plastic Film and

Sheeting Using a Modulated Infrared Sensor

3/ Standard Test Methods for Water Vapor Transmission of Materials

4/ Test Procedures for Packaging Materials and Containers

5/ Test Procedures for Packaging Materials

(2) Unfilled preformed subassembly/accessory packet pouch certification. A CoC may be accepted as evidence that unfilled pouches conform to the requirements specified in

D-1,A(1). When deemed necessary by the USDA, testing of the unfilled preformed pouches for seal strength shall be as specified in E,D(1)a.

(3) Subassembly/accessory packet examination. The filled and sealed packets shall be examined for the defects listed in table IV. The lot size shall be expressed in packets. The sample unit shall be one packet. The inspection level shall be S-4 and the acceptable quality level (AQL), expressed in terms of defects per hundred units, shall be 2.5 for major defects and 4.0 for minor defects.

SUPERSEDING

TABLE IV. Subassembly/accessory packet defects

Category Defect

Major Minor

101 Not clean. 1/

201 Seal width less than 1/16 inch. 2/

202 Tear nick or notch or serrations missing or does not facilitate opening.

203 Tear or hole or open seal.

204 Label missing or incorrect or illegible.

1/ Outer packaging shall be free from foreign matter, which is unwholesome, has the potential to cause package damage (for example, glass, metal fillings, etc.), or generally detracts from the clean appearance of the package. The following examples shall not be scored as defects for unclean:

a. Foreign matter which presents no health hazard or potential package damage and which can be readily removed by gently shaking the package or by gently brushing the package with a clean dry cloth.

b. Localized dried product which affects less than 1/8 of the total surface area of one pouch face, or an aggregate of scattered dried product which affects less than 1/4 of the total surface area of one pouch face.

2/ An effective seal is defined as any uncontaminated, fusion bonded, continuous path, minimum 1/16 inch wide, producing a hermetically sealed pouch.

(4) Subassembly/accessory packet contents examination. The filled and sealed packets shall be examined for the defects listed in table V (this examination may be performed on the preformed pouches after filling and prior to sealing). The lot size shall be expressed in packets. The sample unit shall be one packet open or sealed. The inspection level shall be S-4 and the AQL, expressed in terms of defects per hundred units, shall be 1.5 for major defects and 4.0 for minor defects.

SUPERSEDING

TABLE V. Subassembly/accessory packet contents defects

Category Defect

101 Component not clean. 1/

201 Missing or unserviceable component.

potential to cause package damage (for example, glass, metal filings, etc.), or generally detracts from the clean appearance of the package. The following examples shall not be scored as defects for unclean:

package face, or an aggregate of scattered dried product which affects less than 1/4 of the total surface area of one package face.

(5) Assembled meal packet examination. The filled and sealed meal packets shall be inspected for the defects listed in table VI. The lot size shall be expressed in packets. The sample unit shall be one packet. The inspection level shall be S-4 and the AQL, expressed in terms of defects per hundred units, shall be 2.5 for major defects and 4.0 for minor defects. A minimum of 50 samples shall be examined for critical defects. The finding of any critical defect shall be cause for rejection of the lot. The inspection sample shall contain a proportionate amount of each of the meals.

SUPERSEDING

TABLE VI. Assembled meal packet defects

Category Defect

Critical Major Minor

1 Tear or hole or open seal in sandwich, filled wrap, filled bakery item, cheese spread, tuna or chicken pouch.

2 Swollen sandwich, filled wrap, filled bakery item, cheese spread, tuna or chicken pouch.

101 Menu component missing or incorrect assortment for menu.

102 Meal packet not clean or outer packaging of contents not clean. 1/

103 Foreign odor.

104 Labeling missing or incorrect or illegible.

105 Swollen peanut butter or spread soup pouch.

106 Tear or hole or open seal in component packages.

107 Crushed or broken component. 2/

108 Broken spoon.

201 Tear or hole or open seal in meal packet. 3/

202 Tear or hole or open seal in subassembly/accessory packet.

203 Re-closeable interlocking plastic bag not as specified.

potential to cause package damage (i.e. glass, metal filings, etc.), or generally detracts from the clean appearance of the package. The following examples shall not be scored as defects for unclean:

SUPERSEDING

pouch face, or an aggregate of scattered dried product which affects less than 1/4 of the total surface area of one pouch face.

2/ For definition of crushed or broken, refer to applicable ration component document.

3/ The holes provided in shrink films to allow venting of air to facilitate effective application of shrink wrap film are permitted and shall not be scored as defects. In addition a single vent hole in a preformed bag not greater than 1/4 inch diameter is allowed and shall not be scored a defect.

D. Methods of inspection.

(1) Seal testing. The pouch seals shall be tested for seal strength or internal pressure resistance as required in a or b, as applicable.

a. Unfilled preformed subassembly/accessory packet pouch. The seals of the unfilled preformed pouches for the subassembly/accessory packet shall be tested for seal strength in accordance with ASTM F88/F88M, Seal Strength of Flexible Barrier Materials.

The lot size shall be expressed in pouches. The sample unit shall be one pouch. The inspection shall be level S-1 and the AQL, expressed in defects per hundred units, shall be

10.0. Three 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 results of the three specimens cut from that side. Any test specimen failing to meet a seal strength of 3 pounds per inch of width shall be scored a major defect. Any average seal strength of less than 3.5 pounds per inch of width shall be cause for rejection of the lot. Alternatively, the internal pressure resistance shall be determined by pressurizing the pouches while they are restrained between two rigid plates. 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 side and end of the pouch. 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

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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 IV, 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.

b. Subassembly/accessory packet pouch closure. The closure seals of the pouches for the subassembly/accessory packet 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 inspection level shall be S-1 and the AQL, expressed in defects per hundred units, shall be 10.0. For the closure seal on preformed pouches, three adjacent specimens shall be cut from the closure seal of each pouch in the sample. For the form-fill-seal pouches, three 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 specimens cut from that side, end or closure. Any test specimen failing to meet a seal strength of 3 pounds per inch of width shall be scored a major defect. Any average seal strength of less than 3.5 pounds per inch of width shall be cause for rejection of the lot.

Alternatively, the internal pressure resistance shall be determined by pressurizing the pouches while they are restrained between two rigid plates. 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 side and end of the pouch. 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 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 IV, 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.

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E. Packing.

(1) Shipping container and marking examination. The filled and sealed shipping containers shall be examined for the defects listed in table VII. 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 VII. Shipping container and marking defects

Category Defect

101 Marking missing or incorrect or illegible.

102 Outer flaps do not completely meet, leaving an opening greater than 3/4 inch between flap ends.

103 Inadequate workmanship. 1/

104 Missing meal. 2/

105 Not one of each menu.

201 Time-temperature indicator missing or not centrally located on panel.

202 Time-temperature indicator 1/4-inch quiet zone not maintained.

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.

2/ Each missing meal is a defect.

(2) Flap closure testing. The lot size shall be expressed in shipping containers. The sample unit shall be one shipping container. The inspection level shall be S-2 and the AQL, expressed in terms of defects per hundred units, shall be 4.0. The closure of the four outer flaps of the container shall be tested separately. A 90 degree angular bar with each leg approximately 5 inches long by 3 inches wide by 1/8 inch thick shall be used to test the flap closures. Insert one leg of the angular bar full length under the center of one outer flap.

Insertion shall be made through the open slot between the outer flaps. Lift the container

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vertically by the other leg of the bar until the container is suspended. The complete upper surface of the inserted leg shall be in contact with the inner surface of the flap during the lifting and suspension of the container. Complete separation of the adhesive bond of one or more of the outer flaps, showing no evidence of fiber tear, shall be scored a major defect.

F. Unit load examination. The unit load shall be examined in accordance with the requirements of DLA Troop Support Form 3507. Any nonconformance shall be classified as a major defect.

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SECTION J REFERENCE DOCUMENTS

Unless otherwise specified, the applicable version of these documents is that which is active on the date of the solicitation or contract.

DLA Troop Support Forms

Form 3507 Loads, Unit: Preparation for Semiperishable Subsistence Items

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

Perishable and Semiperishable Subsistence

FEDERAL STANDARDS

FED-STD-101 Test Procedures for Packaging Materials

NON-GOVERNMENTAL STANDARDS

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

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

SAE-AMS-STD-595 Colors Used in Government Procurement www.sae.org

ASTM INTERNATIONAL www.astm.org

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

Reinforcing Fiberboard Boxes

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

E96/E96M Standard Test Methods for Water Vapor Transmission of Materials

F1249 Standard Test Method for Water Vapor Transmission Rate

Through Plastic Film and Sheeting Using a Modulated Infrared

Sensor http://www.asq.org/ http://www.sae.org/ http://www.astm.org/

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F88/F88M Standard Test Method for Seal Strength of Flexible Barrier

Materials