The centrifuged material, which is light and fluffy, is sent in trash bags to Lucent Polymers in Evansville, Ind. All of it--even the bags--goes into a vat for densification. It is melted down, chopped up, and emerges looking like popcorn.
NEXT: Poured into the mold
Last updated April 12 2011: 6:21 AM ET