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WILS
PEL
GOVU
D 106.21 : 75-64 - FEL * AD

27 Natish Lor

TECHNICAL REPORT

75-64- FEL

EFFECT OF STORAGE CONDITIONS

ON THE QUALITY OF

COMPRESSED FOOD BARS

By

Y A Abdul R. Rahman ,
SIT S OT
ER NE
IV N
UN OF MI TS Harold Gorfien ,
E N
C UM Donald E. Westcott ,
DO S
S IE
UL M PU A R
BR Glenn Schafer,
ST. PA CA 9 LI
7 I
N - 19 David DuBose
JA 29

Series : FEL -28

Approved for public release ;

D
AN

distribution unlimited .
January 1975
MM
ROOP

us U.S. ARMY
CO

UNITED STATES ARMY

NATICK LABORATORIES S
U
P
P
Natick , Massachusetts 01760 O

T
R

Food Engineering Laboratory

Approved for public release ; distribution unlimited .

Citation of trade names in this report does not

constitute an official indorsement or approval of the
use of such items .

Destroy this report when no longer needed . Do not

return it to the originator .
 Unclassified
SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered)
READ INSTRUCTIONS
REPORT DOCUMENTATION PAGE BEFORE COMPLETING FORM
1. REPORT NUMBER 2. GOVT ACCESSION NO. 3. RECIPIENT'S CATALOG NUMBER
Technical Report No. FEL- 28
4. TITLE (and Subtitle) 5. TYPE OF REPORT & PERIOD COVERED
EFFECT OF STORAGE CONDITIONS ON THE QUALITY
Technical Report
OF COMPRESSED FOOD BARS
6. PERFORMING ORG. REPORT NUMBER
TR-75-64
7. AUTHOR( ) 8. CONTRACT OR GRANT NUMBER(*)
Abdul R. Rahman , Harold Gorfien ,
Donald E. Westcott , Glenn Schafer , David DuBose

9. PERFORMING ORGANIZATION NAME AND ADDRESS 10. PROGRAM ELEMENT, PROJECT , TASK
AREA & WORK UNIT NUMBERS
Plant Products Branch , Food Technology Division ,
6.2
Food Engineering Laboratory
1T762724AH99 - BB1003
US Army Natick Laboratories , Natick , MA 01760
11. CONTROLLING OFFICE NAME AND ADDRESS 12. REPORT DATE
US Army Natick Laboratories December 1974
Kansas Street , Natick , MA 01760 13. NUMBER OF PAGES
26
14. MONITORING AGENCY NAME & ADDRESS(if different from Controlling Office) 15. SECURITY CLASS. (of this report)
UNCLASSIFIED

15a. DECLASSIFICATION / DOWNGRADING

SCHEDULE

16. DISTRIBUTION STATEMENT (of this Report)

Approved for public release

Distribution is unlimited

17. DISTRIBUTION STATEMENT (of the abstract entered in Block 20, if different from Report)

18. SUPPLEMENTARY NOTES

19. KEY WORDS (Continue on reverse side if necessary and identify by block number)
STORAGE FOOD BARS REHYDRATION COLOR
QUALITY CONCENTRATED FOODS RATIONS TEXTURE
COMPRESSED FOODS PACKAGING MATERIALS FOOD PACKETS FLAVOR
COMPRESSION MATERIALS CONTAINERS TESTS
FOOD PACKAGING RATION PACKET
20. ABSTRACT (Continue on reverse side if necessary and identify by block number)
Four prototype compressed bars - cherry , beef noodle soup , corn flake and bean
salad - were developed in the laboratory . They were then produced by commer-
cial firms and were evaluated in prototype individual ration packets in the
field . Storage studies indicate that the average technological ratings for
color , flavor and texture of dry as well as rehydrated bars were not adversely
affected after storage for 3 , 6 and 12 months at 4 , 21 or 38°C or for 18 months
at 4 or 21 °C . The ratings of beef noodle soup were somewhat lower than the
rest of the bars throughout the storage tests .
FORM
DD 1 JAN 73 1473 EDITION OF 1 NOV 65 IS OBSOLETE
Unclassified
SECURITY CLASSIFICATION OF THIS PAGE (When Data Entered)
 FOREWORD

Reducing the volume of foods saves military cargo and storage space ,
lessens the requirements for packaging materials , and hence decreases waste .
Recently a new approach to this problem of reducing volume was undertaken ;
namely , examining the possibility of developing techniques for compressing
certain formulated foods and subsequently restoring them to their original
state by rehydration . Such compressed foods offer higher caloric value per
unit volume than the uncompressed product and can be consumed without any
further preparation , which is the utmost in convenience , or rehydrated to
familiar type foods . In addition , they provide definite logistic advantages
not only in operational rations , especially where resupply is not possible
but also where space is critical , such as in submarines and space capsules .

This work was perfromed under project 1T762724AH99 , Military Food

Service and Subsistence Technology .

ii
 TABLE OF CONTENTS

Page

List of Tables iv

Introduction 1

2
Experimental Procedures

3
Results and Discussion

References 4

Appendix A

Appendix B

Appendix C

Appendix D

Appendix E

iii
 LIST OF TABLES

Table Page

1 Average Technological Ratings of Flavor of Compressed 5

Corn Flake Bars as Affected by Storage Conditions

2 Average Technological Ratings of Color of Compressed 5

Corn Flake Bars as Affected by Storage Conditions

3 Average Technological Ratings of Texture of Compressed 6

Corn Flake Bars as Affected by Storage Conditions

4 Average Technological Ratings of Flavor of Compressed 6

Beef Noodle Soup Bars as Affected by Storage Conditions

5 Average Technological Ratings of Texture of Compressed 7

Beef Noodle Bars as Affected by Storage Conditions

6 Average Technological Ratings of Color of Compressed 7

Beef Noodle Soup Bars as Affected by Storage Conditions

7 Average Technological Ratings of Color of Compressed 8

Cherry Bars as Affected by Storage Conditions

8 Average Technological Ratings of Flavor of Compressed 8

Cherry Bars as Affected by Storage Conditions

9 Average Technological Ratings of Texture of Compressed ୨

Cherry Bars as Affected by Storage Conditions

10 Average Technological Ratings of Color of Compressed 9

Bean Salad Bars as Affected by Storage Conditions

11 Average Technological Ratings of Flavor of Compressed 10

Bean Salad Bars as Affected by Storage Conditions
10

12 Average Technological Ratings of Texture of Compressed 10

Bean Salad Bars as Affected by Storage Conditions

iv
 INTRODUCTION

Compressed foods which can be eaten " out -of -hand " or rehydrated to a
familiar product are of significant importance in feeding the military man
in non-resupply operational situations . The need for such acceptable and
stable foods has been expressed by the Armed Services . Land Warfare Laboratory
order #71-09 asked for the exploratory development and production of prototype
bars for a potential seven -day strategic operations patrol ration packet .

This paper describes the development of four such prototype bars ; noodle ,
corn flake , cherry and bean salad bars .

Nonreversibly compressed foods which can be eaten without rehydration ,

such as cereal bars and beef jerky bars , previously have been successfully
developed ( Helmer and Tuomy , 1969) . Various single foods in the fruit ,
vegetable & meat category have been " reversibly" compressed and subsequently
restored to their normal appearance and texture through rehydration . However ,
research on the variables affecting the compression of formulated foods has
not been extensive .

Fitzmaurice , et al . ( 1969 ) indicated that compressed bars produced from

freeze -dried meat balls and pork sausage links show promise for use in
operational rations . Compression ratios of 3.7 : 1 for meat balls and 4.5 : 1
for pork sausage links were obtained . Reduction in volume of up to 8 - fold
was obtained by compressing dehydrated vegetables ( Gooding and Rolfe , 1957) .
Hamdy ( 1962 ) stated that the achievement of acceptable products from the
compressed form varies considerably . Ishler ( 1962 ) in his patented process
reported that spraying the rehydrated food with water , glycerine or propylene
glycol before compression produced bars with excellent rehydration
characteristics . Brockmann ( 1966) reported that freeze -dried foods properly
preconditioned can be compressed with little or no fragmentation and that
most foods so compressed can be restored to their precompression characteristics .
Rahman , et al . ( 1969 ) reported that freeze -dried peas , corn , sliced onions ,
spinach , carrots , and green beans were successfully compressed , and compression
ratios of 4 : 1 , 4 : 1 , 5 : 1 , 11 : 1 , 14 : 1 , and 16 : 1 were obtained respectively .
Compressed discs approximately 3-3/4 inch diameter have been developed from
freeze -dried blueberries and red tart pitted ( RTP ) cherries . They can be
successfully rehydrated and used in the preparation of pies (Rahman , et al .
1969 ) . However , the products mentioned above are designed to be rehydrated
rather than to be eaten "out of hand" . Tuomy ( 1971 ) indicated that six combination
meat prototype reversibly compressed bars were developed which are considered
candidates for use in individual ration packets which can be eaten " out of
hand" or rehydrated to their familiar form .

1
 EXPERIMENTAL PROCEDURES

Four compressed food bars , namely , kidney bean salad bar , cherry bar,
beef noodle soup bar and corn flake bar were commercially prepared in accordance
with production guides in Appendix A , B , C and D, respectively . They were
packaged in accordance with the packaging production guide in Appendix E.
These guides were prepared as a result of research and development work
performed at the US Army Natick Laboratories , Food Engineering Laboratory .

The compressed packaged food bars were delivered to the US Army Natick
Laboratories and were immediately placed in storage at 4° , 21 ° and 38°c .
Bars stored at 4° or 21°C were evaluated by a technological panel consisting
of ten ( 10) experienced judges for color , odor , flavor , texture and appearance
using a nine ( 9 ) point scale (9 -Excellent to 1 -Extremely Poor ) at 3 , 6 , 12
and 18 month intervals . Bars stored at 38°C were similarly tested at 3 ,
6 and 12 month intervals .

The bars were evaluated in the dry form as well as in the rehydrated
Rehydration was performed in accordance with the production guides
using cold water . Data obtained was statistically evaluated by analysis
of variance .

2ལ
 RESULTS AND DISCUSSION

Corn Flake Bars : Average technological panel ratings of flavor of dry as

well as rehydrated corn flake bars , as shown in Table 1 , indicate that storage
time and temperature did not have significant effect . Flavor ratings of both
rehydrated and dry bars after 12 months storage at 4° , 21° and 37°C or 18 months
at 40 and 21°C were not significantly different from those of the initial
samples . Results also indicate no significant difference between dry and
rehydrated samples regardless of the time and temperature of storage . Average
technological ratings of color and texture , as shown in Tables 2 and 3 , indicate
similar results as that obtained for the flavor .

Beef Noodle Soup Bars : Results shown in Tables 4 and 5 indicate that
the average technological ratings for flavor and texture were rather low
throughout these studies ; therefore , storage studies were limited to 12 months
only . The flavor and texture of rehydrated bars after storage for 3 and 6
months at 21° or 38°C were significantly lower than the initial samples
(Tables 4 and 5 ) , whereas the color was not affected by storage time and
temperature , as shown in Table 6. In general , the quality of this food bar
needs to be improved .

Cherry Bar : Results shown in Tables 7, 8 and 9 indicate that the color ,
flavor and texture were not affected by storage time and temperature . Average
technological panel ratings of color , flavor or texture after 3 , 6 and 12
months at 4° , 21° and 38°C or 18 months at 4° and 21° C were not significantly
different from the initial samples . No significant differences between dry
or rehydrated samples were shown throughout the storage studies .

Bean Salad Bars : Results shown in Tables 10 and 11 indicate that the color
& flavor of dry or rehydrated bean salad bars were not affected by storage time
and temperature . Average technological ratings of color and flavor of these
bars after 12 months storage at 4° , 21° or 38°C or 18 months at 4° or 21 °C
were not significantly different from the initial dry or rehydrated samples .
No significant difference was shown in the color & flavor of dry or rehydrated
samples throughout the storage tests . However , the texture of rehydrated
samples after storage for 3 or 6 months at 21°C were significantly lower than
the initial samples or samples stored for 12 or 18 months ( Table 12 ) . This
seems to be unusual and may be due to faulty packaging or incorrect rehydration
procedures . Otherwise the texture results were similar to that obtained for
the flavor & color .

Conclusion

Compressed food bars which can be eaten as is or rehydrated to a familiar food

and which offer acceptability and stability can be commercially produced for
use in individual ration packets . However , further work is recommended to develop
objective measurements so that assurance for reproducibility of high quality
product can be attained .

3
 REFERENCES

1. Helmer , H.L. and J. M. Tuomy . Compressed Beef Jerkey . Technical Report

FL - 98 , U.S. Army Natick Laboratories , Natick , Massachusetts , 1969 .

2. Fitzmaurice , W.J. , R. L. Helmer and J.

J. M. Tuomy . Compressed Freeze Dried
Meat Balls and Pork Sausage Links . Technical Report FL - 104 ,
U.S. Army Natick Laboratories , Natick , Massachusetts , 1969 .

3. Gooding, E. G. B. and E. J. Rolfe . Some Recent Work on Dehydration in the

United Kingdom . Food Technology 11 : 302-6 , 1957 .

4. Hamdy , M.M. Compression of Dehydrated Foods , Final Report , Contract

No. DA 19-129 -QM - 1899 . Quartermaster Food and Container Institute
for the Armed Forces , Chicago , Illinois , 1962 .

5. Ishler , N. I. Methods for Controlling Fragmentation of Dried Foods During

Compression , Final Report Contract No. DA 19-129 -AMC -2 . Technical
Report D- 13 , U.S. Army Natick Laboratories , Natick , Massachusetts
1965 .

6. Brockmann , M.C. Compression of Foods . Activities Report 18 ( 2 ) , 173-177 ,

1966 .

7. Rahman , A.R. , G. Schafer , G.R. Taylor and D. E. Westcott . Studies on

Reversible Compression of Dehydrated Vegetables . Technical
Report FL -102 , U.S. Army Natick Laboratories , Natick , Massa-
chusetts , 1969 .

8. Rahman , A.R. , G. R. Taylor , G. Schafer and D. E. Westcott . Studies on

Reversible Compression of Freeze -Dried RTP Cherries and Blue-
berries . Technical Report FL-105 , U. S. Army Natick Laboratories ,
Natick , Massachusetts , 1969 .

9. Tuomy , J. M. Development of Reversibly Compressed Freeze - Dried Foods for

Use in Individual Ration Packets . Technical Report FL- 135 ,
U.S. Army Natick Laboratories , Natick , Massachusetts , 1971 .

4
 Table 1 - Average Technological Ratings of Flavor of
Compressed Corn Flake Bars as Affected by
Storage Conditions

Temperature
Time 4 °C 21°C 38°C
(Months) Dry Rehyd . Dry Rehyd . Dry Rehyd .

6.4 6.6 6.4 6.6 6.4 6.6

3 5.8 6.6 6.1 6.2 5.9 6.2

6 6.2 5.9 5.8 5.7 5.8 5.6

12 6.3 5.9 6.1 6.7 5.5 5.6

11
18 6.4 6.4 6.1 6.0

No significant difference at the 5 percent level

Table 2 - Average Technological Ratings of Color of

Compressed Corn Flake Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21 °C 38°C
(Months ) Dry Rehyd . Dry Rehyd . Dry Rehyd .

6.3 6.7 6.3 6.7 6.3 6.7

3 6.8 6.8 6.4 6.4 6.5 6.6

6 6.6 6.1 6.5 6.4 6.4 5.9

24

12 6.2 6.2 6.4 6.6 5.8 6.4

18 6.7 6.8 6.7 6.2

No significant difference at the 5 percent level

5
 Table 3 - Average Technological Ratings of Texture of
Compressed Corn Flake Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

0 5.9 5.2 5.9 5.2 5.9 5.2

3 5.9 6.1 6.0 5.1 6.2 5.7

69

5.6 6.0 6.1 5.2 5.8 4.9

12 6.1 5.9 6.0 5.7 5.7 5.3

18 6.2 5.7 6.5 5.4

11
No significant different at the 5 percent level

Table 4 - Average Technological Ratings of Flavor of

Compressed Beef Noodle Soup Bars as Affected
by Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months ) Dry Rehyd . Dry Rehyd . Dry Rehyd .

0 5.4 5.5 5.4 5.5 5.4 5.5

3 5.8 5.3 4.9 4.6 3.9* 4.5

6 4.0* 3.6* 4.4 3.7* 4.5 3.6*

12 5.4 5.1 5.4 4.5 4.6 404

*Significant difference at the 5 percent level

6
 Table 5 - Average Technological Ratings of Texture of
Compressed Beef Noodle Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

5.2 4.8 5.2 4.8 5.2 4.8

3 5.3 5.1 5.3 4.3 5.3 5.3

6 4.0 3.5* 5.7 3.7* 5.2 3.6*

12 5.9 5.1 5.0 4.7 4.9 404

* Significant difference at the 5 percent level

Table 6 - Average Technological Ratings of Color of

Compressed Beef Noodle Soup Bars as Affected
by Storage Conditions

Temperature
Time 4°C 21 °C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

5.6 5.5 5.6 5.5 5.6 5.5

3 6.6 6.3 5.4 5.3 5.6 6.1

6 5.3 4.9 5.2 5.1 5.9 4.8

12 5.9 5.8 5.5 5.9 5.1 6.3

No significant difference at the 5 percent level

7
 Table 7 - Average Technological Ratings of Color of
Compressed Cherry Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

0 6.1 6.2 6.1 6.2 6.1 6.2

3 5.4 5.7 6.2 6.1 6.4 6.5

6 6.3 5.9 6.4 6.1 6.6 5.8

12 6.3 6.4 6.4 6.9 6.2 6.3

18 6.7 7.1 6.8 6.8

No significant difference at the 5 percent level

Table 8 - Average Technological Ratings of Flavor of

Compressed Cherry Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

O 6.0 5.5 6.0 5.5 6.0 5.5

3 409 5.2 5.7 5.2 5.8 5.3

6 5.9 5.0 5.3 4.9 5.3 5.2

12 5.5 5.1 5.7 6.2 6.5 5.8

18 6.4 6.4 6.2 5.8

No significant difference at the 5 percent level

8
 Table 9 - Average Technological Ratings of Texture of
Compressed Cherry Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months ) Dry Rehyd . Dry Rehyd . Dry Rehyd .

0 5.9 5.0 5.9 5.0 5.9 5.0

3 5.4 5.0 5.9 4.9 5.9 5.3

6 5.5 4.7 5.8 4.7 5.9 4.8

12 5.8 5.1 6.1 6.0 6.8 5.8

18 6.4 6.2 6.6 5.6

No significant difference at the 5 percent level

P.

Table 10 - Average Technological Ratings of Color of

Compressed Bean Salad Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months ) Dry Rehyd . Dry Rehyd . Dry Rehyd .

6.2 6.5 6.2 6.5 6.2 6.5

3 6.5 6.7 6.2 6.1 6.4 6.3

6 5.8 5.9 6.3 5.6 6.2 5.7

12 6.2 6.2 6.3 6.7 5.6 6.1

18 6.1 6.7 6.8 6.5

No significant difference at the 5 percent level

9
 Table 11 - Average Technological Ratings of Flavor of
Compressed Bean Salad Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

O 6.2 6.5 6.2 6.5 6.2 6.5

3 6.5 6.9 6.0 5.9 6.4 6.3

6 5.3 5.8 5.5 5.2 6.0 5.7

12 5.7 5.9 6.2 6.7 5.1 6.0

::
18 5.8 6.4 6.7 6.5

11
No significant difference at the 5 percent level

Table 12 · Average Technological Ratings of Texture of

Compressed Bean Salad Bars as Affected by
Storage Conditions

Temperature
Time 4°C 21°C 38°C
(Months Dry Rehyd . Dry Rehyd . Dry Rehyd .

0 5.6 5.8 5.6 5.8 5.6 5.8

3 6.1 6.6 5.8 4.3

* 5.8 6.2

6 5.5 4.9 5.9 4.2* 5.7 5.2

12 5.1 5.9 6.2 6.0 5.2 6.1

18 5.8 6.1 6.3 5.9

¦

* Significant difference at the 5 percent level

10
 APPENDIX A

Production Guide
Compressed Food Bar Prototype
US Army Natick Laboratories
June 1971

KIDNEY BEAN SALAD BAR

1. This product is a compressed salad bar containing dark red kidney beans ,
celery , eggs , vinegar , sweet relish , salad dressing, green bell peppers , onion ,
salt , and black pepper .

2. All material shall be in excellent condition , clean , sound , wholesome and

free from evidence of insect infestation , foreign and undesireable odors , flavors ,
colors and extraneous materials .

2.1 Kidney Beans , Dark Red , Canned in Sauce . The beans shall be washed free
of sauce , drained , and slit in a slitting machine with an opening of 3/16"
(pea size ) .

2.2 Celery . Fresh celery shall be chopped or diced to a dimension range of

" x 1" to 3/16" x 2/16" .

2.3 Eggs . Fresh eggs shall be placed in water , brought to boiling , and
allowed to remain for 10 minutes in the hot ( not boiling ) water . The eggs
shall be cooled immediately , peeled , and chopped to a dimension range of
½" x 1 " to 1/8 " x 1/8 " .

2.4 Vinegar . White vinegar of 5 percent acidity shall be used .

2.5 Sweet Relish . Good quality sweet relish shall be used .

2.6 Salad Dressing . Miracle Whip salad dressing was used in the developmental
work . Salad dressing of equivalent quality shall be used .

2.7 Green Bell Peppers . Fresh green bell peppers shall be cored and chopped
to a dimension range of " x 1" to 1/8 " x 1/8 " .

2.8 Onion . Fresh onions shall be washed after skin and outer layer are
discarded . They shall be chopped to a dimension range of 3/16 " x 3/16" to
1/16 " x 1/16" .

2.9 Salt . Salt shall be non -iodized .

2.10 Black Pepper . Pure ground black pepper shall be used in foods .

A- 1
3. Formula .

Percent By Weight

Kidney Beans 61.6

Celery 8.1
Eggs 7.3
Vinegar 7.1
Relish , sweet 5.5
Salad Dressing 5.4
Green Bell Peppers 2.7
Onion 2.0
Salt 0.26
Pepper , black 0.04

4. Preparation .

4.1 Washing . All vegetables shall be thoroughly washed in cold water prior
to processing .

4.2 Mixing . All ingredients shall be combined , beans and eggs last . Gently
fold in beans and eggs so as not to fracture . Spread on trays and freeze at
a temperature not more than -10°F . Freeze - dry at a temperature not higher
than 120° F . and at a maximum pressure of 1.5 mm . A fine cold water spray shall
be applied to the dry product until a level of 10 percent increase in weight
of the dry product is reached . Several mixings shall be included to expose
dry surfaces and assure uniform application of water . The product shall be
placed in covered containers and allowed to equilibrate overnight .

4.3 Bar Formation . Thirty ( 30 ) grams of conditioned salad shall be compressed

in a 3" x 1 " mold at a pressure of 1200 + 100 p.s.i. with a 5 second dwell
period . The bar shall be redried in a vacuum at 120°F . and packaged . The
bar shall be sufficiently strong to be handled during processing and packaging
without breaking apart .

5. Finished Product .

5.1 Physical Requirements . The finished product shall comply with the following
physical requirements :
a. There shall be no foreign material .
10. When 30 grams of product is rehydrated with 40 cc of cool water
(70°F . ) for 10 minutes , the product shall be rehydrated completely .
C. When rehydrated , the product shall have a pleasing flavor and odor .
There shall be no off flavors or odors .

5.2 Moisture Requirements . The finished product shall contain not more than
2.5% of moisture when tested as follows :

Weigh 10 grams of the ground material into a dry aluminum weighing

dish (approximately 3 3/4 inches in diameter and 3/4 inch in depth ) . Place
the dish in a rapid moisture tester for 20 minutes at 130°C . After 20 minutes
read percent moisture directly from rapid moisture tester .

A- 2
 APPENDIX B

Production Guide
Compressed Food Bar Prototype
US Army Natick Laboratories
June 1971

CHERRY BAR

1. This product is a compressed fruit bar containing dehydrated applesauce ,

sugar , freeze -dried lemon flavored potatoes , textured sour cherry flavored
soy flour , slivered blanched almonds , freeze - dried cherry powder , dehydrated
maraschino cherries and silica gel .

2. Material . All material shall be in excellent condition , clean , sound ,

wholesome and free from evidence of insect infestation , foreign and undesirable
odors , flavors , colors and extraneous materials .

2.1 Apple Powder . Apple powder shall be prepared as follows :

McIntosh or Cortland variety apples shall be peeled and cored ; then they
shall be diced or sliced and blanched for 2 to 5 minutes in boiling water .
Blanch time should be based on piece size . After blanching , the apples shall
be cooled with tap water and drained . Next the blanched apples shall receive
a one -minute dip in sodium bisulfite solution containing 1500+ 200 ppm
available SO2 . After dipping , the fruit shall be drained . Next the apple
pieces shall be pressed to extract 45-55 percent of the juice by weight . The
pressed apples shall be frozen; then freeze -dried at a pressure not to exceed
1.0 millimeter and a surface temperature not to exceed 120°F . The freeze-
dried product shall be mechanically ground to a particle size that will rehydrate
readily .

2.2 Sugar . Refined granulated sugar shall be used .

2.3 Freeze -dried Lemon Flavored Potatoes . Fresh potatoes ( in season ) shall be
peeled , diced to a dimension of 3/8 " x 3/8 " x 1/4 " and blanched in water in
which lemon crystals are dissolved at the rate of 5.95 oz . avd . per gallon of
water . Prior to blanching , the potatoes shall be kept submerged in water
containing sodium meta -bisulfite at the rate of 1 gram per gallon of water .
The blanching water shall be brought to a boil and the lemon crystals dissolved .
The diced potatoes shall be blanched for 2 minutes in water which is not returned
to the boiling point (2000+ 5°F . ) . The potatoes shall be drained and potatoes
and solution quickly cooled . The potatoes shall then be soaked for 2 hours in
the cooled solution , drained , frozen and freeze -dried at 120°F . (Lemon crystals
used in developmental work were manufactured by Plant Industries . ) Comparable
varieties of lemon crystals may be substituted for those used in the developmental
work .

2.4 Textured Soy Flour , Sour Cherry Flavored . Blend sour cherry flavor and
vegetable oil in a 1 to 1 ratio . Blend 4 parts textured soy flour and 1 part
cherry -oil . Shake the cherry flavor -oil blend before use . (In the developmental
work , Food Material Corp. Sour Cherry Flavor #8139 , Durkex 500 oil , Glidden-
Durkee , and Texgran #10900 , manufactured by Swift Chemical Co. , were used .
Equivalent products may be used . ) B-1
2.5 Almonds , Slivered . Almonds shall be fresh , blanched , and slivered .

2.6 Cherry Powder , Freeze - dried . Freeze -dried , R.T.P. cherries shall be
powdered without introducing heat , and kept from caking by canning with desiccant
bags .

2.7 Maraschino Cherries , Dehydrated . Maraschino cherries shall be washed ,

drained , chopped to a dimension range of 1/2 " x 1/2 " to 3/16 " x 3/16" , and
air dried at 125° . ( 60-70 minutes ) to a moisture content of 10.25 + 0.25% .

2.8 Silica Gel . Syloid 244 was used in the developmental stage . Comparable
varieties may be used .

3. Formula .

Percent By Weight

Apple Powder , with sucrose 25.8

and malic acid
Sugar 22.7
Potatoes , lemon flavored , freeze - dried 15.6
Textured Soy Protein , sour cherry flavored 15.1
Almonds , slivered 10.9
Cherry Powder , freeze -dried 4.5
Cherries , Maraschino , dehydrated 3.9
Silica Gel 1.5

4. Preparation .

4.1 Mixing . The apple powder shall be blended with sugar and malic acid in the
following proportion :

Apple Powder 100 parts

Sugar 150 parts
Malic Acid 1.5 parts

The potatoes shall be sprayed with cold water to a level 12% greater than the
freeze - dried potato weight ; allowed to equilibrate in covered containers
(overnight ) and blended into the formula . The silica gel shall be placed in
the mixing bowl first and all other ingredients added except the potatoes .
The mixture shall be blended and the potatoes added and blended . Blending
shall be accomplished at slow speed . A Varistat may be required to obtain
slow speed . The formula shall be placed in a tightly covered container until
compressed .

4.2 Bar Formation . Thirty grams of formula shall be placed in a 3 " x 1 " mold
and compressed at 950 p.s.i. with a 10 second dwell period . The bars shall be
redried in a vacuum at 120° F . The bars shall be sufficiently strong to be
handled during processing and packaging without breaking apart .

B -2
5. Finished Product .

5.1 Physical Requirements . The finished product shall comply with the following
physical requirements :

a. There shall be no foreign material .

b. When 30 grams of product is rehydrated with 50 cc of cool water
( 70°F . ) for 10 minutes , the product shall be completely rehydrated .
C. When rehydrated , the product shall have a pleasing odor and
flavor . There shall be no off flavors or odors .

5.2 Moisture Requirements . The finished product shall contain not more
than 2.5% moisture when tested as follows :

Weigh 10 grams of the ground material into a dry aluminum weighing

dish ( approximately 3 3/4 inches in diameter and 3/4 inch in depth ) . Place
the dish in a rapid moisture tester for 20 minutes at 130°C . After 20
minutes read percent moisture directly from rapid moisture tester .

B- 3
 APPENDIX C

Production Guide
Compressed Food Bar Prototype
US Army Natick Laboratories
June 1971

BEEF NOODLE SOUP BAR

1. This product is a beef noodle soup containing freeze - dehydrated beef ,

noodles and mushrooms . Brand names of ingredients or equipment were those
used in development work and no indorsement of these items over other similar
items is stated or implied .

2. Applicable documents .

2.1 The following documents of the issue in effect on date of invitation

for bids or request for proposal , form a part of this production guide to the
extent specified herein .

SPECIFICATIONS
FEDERAL
N-M- 591- Noodles
EE -S -631 · Spices , Ground and Whole
MILITARY
IP/DES S - 18-0 Food Packet , Long Range Patrol

THE UNITED STATES PHARMACOPOEIAL CONVENTION , INC .

Pharmacopoeia of the United States .

3. Material . All material shall be in excellent condition , clean , sound ,

wholesome and free from evidence of insect infestation , foreign and undesirable
odors , flavors , colors and extraneous materials .

3.1 Ground Beef Raw. As specified in paragraph 3.2.2 and 3.2.2.2 of IP/DES
S - 18-0 · Food Packet , Long Range Patrol .

3.1.1 Beef , Cooking . Beef shall be placed in stainless steel pans , covered ,
and cooked in steam under 5 pounds pressure . The center temperature of the
ground beef shall be 165°F . or higher upon completion of the cooking . While
still hot , the beef shall be drained of fat and other liquids using a stainless
steel straining device with holes 1/8 inch in diameter . The beef shall be
chilled and then chopped in such a manner that particle sizes will not exceed
by by inch . Fat content of the cooked beef shall not exceed 15 percent .
The beef particles shall then be spread on dehydrator trays and frozen .

3.2 Noodles . Enriched egg noodles ( " fine " as specified in N -N - 591 Noodles )
shall be cooked in an excess of water until tender (at least 30 minutes simmering
boil ) . The cooked noodles shall be drained and rinsed at least three times
with cold water . The noodles shall then be spread on dehydrator trays and
frozen .
C -1
3.2.1 Mushrooms . Mushrooms shall be sliced into bits and pieces no larger
than 1/2 by 1/2 by 1/8 inch . Commercial methods used for cooking and preparing
mushrooms for freeze dehydration shall be used . The mushrooms shall then be
spread on dehydrator trays and frozen .

3.2.2 Pepper , white , ground . High quality ground white pepper shall be used .

3.2.3 Celery Seed . High quality celery seed shall be used .

3.2.4 Parsley Flakes . High quality parsley flakes shall be used .

3.2.5 Monosodium glutamate . Shall be of edible grade monosodium glutamate .

3.2.6 Caramel Color #800 . (Miles Lab . , or Sethness ) .

3.2.7 Maltrin -10 . A hydrolyzed cereal solid of high viscosity , low hygro-
scopicity and low dextrose equivalent . This product shall be readily soluble
in both cold and hot water , have no sweetness and be resistant to caking . It
shall have a dextrose equivalent of 9-12 , a maximum moisture content of 5.0%
and a pH equal to approximately 4.0 . It shall have a carbohydrate profile
(approximate ) of dextrose - 0.5% , disaccharide - 3.5% , trisaccharide - 6.5%
tetrasaccharide - 5.5% , pentasaccharide - 4.5% , and hexasaccharide and
·
above 79.50%.

3.2.8 Ribotide . A mixture of disodium 5 - inosinate and disodium 5 - guanylate .

3.2.9 Hydrolyzed Protein (Maggi Super BE ) . A hydrolyzed plant protein with

partially hydrogenated vegetable oil added . Typical analysis is as follows :
total solids - 96.0% , ash - 34.5%, organic solids - 61.5% , chloride calculated
-
as sodium chloride 27.6%, total nitrogen 7.73%, protein (Nx6.25 ) - 48.3%,
- 25.6% ,
monosodium glutamate - 25.6%, ammonium chloride - - 3.74%,
3.74% , pH - 5.3 , hydrogenated
vegetable oil 1.5% .

3.2.10 Glycerin , USP . Glycerin shall meet the requirements of the Pharmacopoeia
of the United States .

3.2.10.1 Glycerin Solution . A glycerin solution shall be prepared by mixing

5 parts of water by volume with 95 parts of glycerin by volume .

3.3 Dehydration . The beef , noodles , and mushrooms shall be freeze dehydrated
by the method described in paragraph 3.4 of IP/DES S - 18-0 " Food Packet , Long
Range Patrol " , except that the temperature of each product shall not exceed
130°F .

e s
304 Time and Temperatur Limitation . The materials and products shall be so
s
handled as to comply with the limitation defined in paragraph 3.5 of IP/DES
S -18 -0 " Fo od Pa ck et , Lo n g Ra ng e Pa tr ol ".

3.5 Particle Size Reduction . After freeze dehydration , the noodles shall be re-
duced in size to individual pieces between 1/4 inch and 1 inch in length . After
dehydration , the portion of the beef to be used as powdered beef shall be reduced
in size to a powder with individual particles no larger than 1/16 inch in diameter .

C -2
4. Preparation .

4.1 Beef Noodle Soup . Beef noodle soup shall be prepared in accordance with the
following formula :

Percent by weight

Beef , freeze dried , ground , cooked 31.40

Noodles , freeze dried 9.10
Mushrooms , freeze dried 9.40
Hydrolyzed Protein 4.74
White pepper 0.08
Celery seed 0.14
Parsley flakes 0.14
Caramel color 0.31
Ribotide 0.15
Monosodium glutamate 0.61
Maltrin -10 25.10
Beef, freeze dried , powdered ground , cooked 9.40
Glycerin solution ( 5 parts water and 95 parts
glycerin by volume ) 9.43
100.00

A matrix shall be prepared from Maltrin -10 , freeze dried powdered ground cooked
beef, and the glycerin solution . The matrix shall be prepared in the following
manner :

Freeze dried powdered ground cooked beef shall be preblended uniformly with
maltrin - 10 . The glycerin solution shall be heated to 70°C . and then sprayed
in a fine mist on to the preblended powdered beef and maltrin , while blending
in an exclosed mixer . Temperature of the glycerin solution shall not fall
below 54°C . during the spraying operation . Mixing shall continue for at least
5 minutes after spraying has terminated . The sides of the mixer shall be
scraped free of any coating matrix and the coating matrix shall be incorporated
into the rest of the matrix in the mixer by blending for at least an additional
5 minutes . The remaining ingredients shall be preblended uniformly . The
matrix will then be added to the other preblended ingredients in a mixing
device , and blended in such a manner as to result in a uniform mixture without
appreciably reducing the size of the freeze dried noodles or freeze dried
mushrooms .

4.2 Twenty one grams of the product shall be compressed in a 3 " x 1 " mold with
minimal pressure ( equivalent to 100 to 150 lbs . as indicated by gauge on
Carver Press ) and a 15 second dwell time . The bars shall then be packaged .
The bars shall be sufficiently strong to be handled during processing and
packaging without breaking apart .

5. Finished Product .

5.1 Physical Requirements . The finished product shall comply with the
following physical requirements :

C- 3
 (a) There shall be no foreign material such as , but not limited to ,
dirt , glass or paint .

(b) There shall be no evidence of incomplete dehydration such as

damp or soggy areas .

(c ) There shall be no evidence of thawing in the dehydrator .

(a) When 21 grams of product is rehydrated with 120 grams of either

cool water (80°F . ) or hot water ( 180°F . ) for 10 minutes and stirred with a
spoon , the product shall be rehydrated completely .

(e ) When rehydrated as in ( d ) above , or consumed dry , the product

shall have a pleasing flavor . There shall be no off flavor or odors .

(f ) When rehydrated as in ( d ) above , the product shall show

distinct noodles , mushrooms , and beef particles .

5.2 Moisture Requirement . The product shall contain not more than 3.3 per-
cent moisture when tested as follows : Weigh 10 grams of the ground material
into a dry aluminum weighing dish ( approximately 3 3/4 inches in diameter
and 3/4 inch in depth ) . Place the dish in a rapid moisture tester for 20
minutes at 130°c . After 20 minutes read percent moisture directly from
rapid moisture tester .

C -4
 APPENDIX D

Production Guide
Compressed Food Bar Prototype
US Army Natick Laboratories
June 1971

CORN FLAKE BAR

1. This product is a compressed cereal bar containing corn flakes , powdered

milk , powdered sugar and low D.E. hydrolyzed cereal solids . Brand names of
ingredients or equipment were those used in development work and no indorsement
of these items over other similar items is stated or implied .

2. Material . All material shall be in excellent condition , clean , sound ,

wholesome and free from evidence of insect infestation , foreign and undesirable
odors , flavors , colors and extraneous materials .

2.1 Corn Flakes . A variety of plain corn flakes shall be used which when
hydrated to a moisture of 12.5% will be pliable and withstand compression
without shattering .

2.2 Non -Fat Dry Milk . Non -fat dry milk shall be instantized .

2.3 Powdered Sugar . Powdered sugar shall be confectioners powdered sugar .

2.4 Maltrin 20. A variety of low D.E. hydrolyzed cereal solids shall be
used which has a high solubility , forms clear , bland glazes and coatings which
maintain their clarity on storage . It should also be slightly sweet . Maltrin -20
was used in development work .

3. Formula .

Percent by weight

Corn Flakes 33.3

Powdered Sugar 25.0
Maltrin 20 8.3
Powdered Milk 33.3

4. Preparation .

4.1 Mixing . All of the ingredients shall be mixed gently so that the corn
flakes are not shattered . A moisture determination of this mixture shall
then be made . It shall then be determined how much water must be added to bring
the mixture to a 12.5% moisture level . This mixture shall then be placed on a
flat surface which is supported by a weighing scale . A fine spray of water
shall then be applied to achieve the proper increase in weight as determined
by the required amount of added moisture . The spraying procedure shall include
several periods of gentle mixing of the mixture . The mixture shall then be
placed in a sealed container and the mixture allowed to equilibrate until
D-1
the product is pliable .

4.2 Bar Formation . Thirty grams of the cornflake mixture shall be used to
make the bars . The mixture will be placed in a 3" x 1 " mold and compressed at
200+ 25 psi . The bars shall be dried at 100° F . in a vacuum oven and packaged .
The bars shall be sufficiently strong to be handled during processing and
packaging without breaking apart .

5. Finished Product .

5.1 Physical Requirements . The finished product shall comply with the
following physical requirements :

(a ) There shall be no foreign material .

(b) When 30 grams of product is rehydrated with 30 cc of cool

water ( 70°F . ) for 10 minutes , the product shall be rehydrated completely .

(c) When rehydrated as in B above , the product shall have a

pleasing flavor and odor . There shall be no off flavors or odors .

5.2 Analytical .

5.2.1 Moisture Requirement . The finished product shall contain not more
than 2.5% moisture when tested as follows :

Weigh 10 grams of the ground material into a dry aluminum

weighing dish (approximately 3 3/4 inches in diameter and 3/4 inch in depth ) .
Place the dish in a rapid moisture tester for 20 minutes at 130°C . After
20 minutes read percent moisture directly from rapid moisture tester .

D-2
 APPENDIX E

Packaging Production Guide

Compressed Food Bar Prototype
US Army Natick Laboratories
June 1971

1. Packaging . Components packaging shall be performed in accordance with 1.1 .

Materials used shall be those listed in 1.2 .

1.1 . The following sequence shall be followed in the packaging operation .

1.1.1 Labeling of the inner bag . The specific pressure sensitive directions
label ( 1.2.c. ) for the food bars being packaged shall be applied to the poly-
ethylene bag 1
(.2.a ) by placing the bottom edge of the label 1-3/4 inches + 1/8
inch parallel to the bottom of the bag .

1.1.2 . The food bar ( as applicable ) shall be packaged into the

Filling .
labeled polyethylene bag with the long dimension of the bar parallel to the
opening of the bag . The bag shall be closed by folding the excess bag material
neatly around the bar . The bag shall not be sealed . One paper clip ( 1.2.e. )
shall be placed under the final fold of the polyethylene bag . The package
shall then be placed into a plastic - foil laminated bag ( 1.2.b. ) with the long
dimension of the bar parallel to the long dimension of the bag .

1.1.2 . Sealing . The filled laminated bag shall be closed by evacuating the
air from within the packages to a vacuum level of not less than 28 inches
( i.e. 2 inches of mercury pressure ) as registered on a vacuum gauge on the
closing machine . The evacuated air shall be replaced by flushing back pure
nitrogen into the package to a level of 10 to 15 inches of mercury . The bag
shall then be closed by heat sealing with a seal of not less than 1/4 inches
(+16) wide . Prior to performing the closing operation the accuracy of the
vacuum gauge on the closing machine shall be verified by means of a manometer
or other suitable device . The verification check shall be performed each day
prior to the start of the packaging operation and a record of this verification
shall be maintained by the supplier . The sealed package shall be capable of
passing the leakage test specified in paragraph 4 .

1.2 Materials . The following materials used in the packaging and labeling
operations shall be furnished by the US Army Natick Laboratories :

a. Polyethylene bag ( inner ) , size 4 by 7 inches .

b. Plastic -foil laminated bag , size 2 by 5 inches ( ID ) .
C. Pressure - sensitive instructions label .
d. Pressure - sensitive component label .
e. Paper clips .

Shipping containers shall be furnished by the contractor and shall be in

accordance with the provisions of paragraph 2 .

E -1
2. Packing. Two hundred and fifty bars (all of one component ) shall be packed
in layers in a fiberboard shipping container which is acceptable to the common
carrier for safe transportation to the US Army Natick Laboratories at the lowest
rate for such supplies .

3. Labeling and Marking .

3.1 Component Bag . Each component bag shall be labeled with the applicable
pressure sensitive component label ( 5.1.2.d. ) .

3.2 Shipping Container . Each shipping container shall convey the identification
of the specific food bar contained . These shall be as follows :

Kidney Bean Salad Bar

Corn Flake Bar
Cherry Dessert Bar
Beef Noodle Soup Bar

4. Leakage Examination on Component Package . The filled and sealed food bar
component package shall be examined for leakage by submerging in water contained
in a desiccator or other suitable container , and maintaining a vacuum of 10
inches of mercury (atmospheric pressure 29.9 inches ) for at least 30 seconds .
A steady progression of bubbles from any point of the package will indicate
a leak . Isolated or static bubbles caused by entrapped air in seams or surfaces
of the packages will not be considered as signs of leaks .

E-2
 FOOD ENGINEERING LABORATORY DISTRIBUTION LIST

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P.O. Box 464 Deputy for Science & Technology
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Department of the Army
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U.S. Army Medical Research & Dev
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Washington , D.C. 20314 Military Assistant for Medical & Life
Sciences
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Fort Lee , VA 23801 National Marine Fisheries Service
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Acting Assistant Administrator Gloucester , MA 01930
ARS - U.S. Dept. of Agriculture
Washington, D.C. 20250 1 Ch , Food Service Division
1
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University of Rhode Island 1- Director
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543 SPACE SCI CTR Technical Center
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1 - Commandant of the Marine Corps

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2800 South 20th Street APO NY NY 09825
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·
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-
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ization Management Section

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UNIVERSITY OF MINNESOTA

3 1951 TOO 114 786 E