Systems and methods for packaging food products in containers and containers packaged by such systems and methods

A method for packaging a food product in a container, said method comprising:

• moving a tray in a machine direction, the tray including at least one wall defining a cavity and a flange extending from an edge of the wall;
• depositing the food product into the cavity;
• positioning a cover relative to the tray, wherein the cover is positioned to overlap the flange of the tray, the cover and the tray forming the container;
• positioning a first bonding module including a disc-like rotary horn in close proximity to a second bonding module including a disc-like rotary anvil, wherein the disc-like rotary anvil has an annular face that is continuous about a circumference of the disc-like rotary anvil, and wherein at least one of the first bonding module and the second bonding module vibrates at an ultrasonic frequency;
• positioning the flange and the cover between a fixed nip defined by the first bonding module and the second bonding module;
• and
• delivering ultrasonic energy to at least one of the cover and the flange at the fixed nip to form an ultrasonic bond on the container, the ultrasonic bond extending continuously in the machine direction along the entirety of the cover and the flange.

A container for a food product, the container comprising:

• a tray comprising:
• a bottom having a perimeter;
• a sidewall extending along the perimeter of the bottom to form a cavity sized to receive the food product, the sidewall defining an opening for the food product to be placed into the cavity, the sidewall comprising;
• a pair of first portions defining longitudinal sides of the container;
• a pair of second portions defining transverse sides of the container;
• and
• an edge extending along the first portions and the second portions;
• a flange extending from the edge of the sidewall and around the opening, the flange having a first area with a first thickness and a second area with a second thickness, the second thickness being about twice that of the first thickness;
• and
• a cover attached to the flange of the tray by ultrasonic bonds, the ultrasonic bonds extending along the entire longitudinal and transverse sides of the container.