Basically PFOA is used in the making of fluorocarbons as stated by Dr D and in the links. Also, as stated in the Washington Post fry pan story : " ...the PFOA is virtually all gone before the final material comes off the production line. Intermediate chemicals of one kind or another are part of virtually all chemical manufacturing processes and are not allowed to contaminate the final product.
Teflon is microscopically smooth and nonporous (one of the reasons nothing sticks to it). Even if it does harbor trace amounts of PFOA, which is all anyone has suggested, the PFOA is unlikely to seep into food or escape into the air in kitchens -- unless, of course, an empty nonstick pan were abandoned on a hot burner, because above 600 degrees or so (a temperature rarely reached in cooking), the Teflon would begin to decompose into toxic fumes.
Before we even see a nonstick pan in the store, its coating already has been heated to high temperatures during manufacturing, partly to get rid of any residual PFOA. In my opinion, PFOA in the environment probably came from factory emissions, perhaps during the high-temperature phases of manufacturing."
Basically it seems that DuPont is in trouble for releasing factory emissions, created during the fluorocarbon manufacturing process, containing PFOA into the environment. The EPA is concerned mainly with the manufacturing process and not finished products.
As for other fluoro wax manufacturers ... i doubt that any of them work with PFOA directly. The manufacturer that i work with that does the actual bonding of molybdenum to the fluorocarbons doesn't work with PFOA. They purchase the PTFE from DuPont or ????? I've been told that we can use pretty much whatever available PTFE fluorocarbons we want except for aqueous dispersions in the molybdenum bonding process. Which brings me to my last note on working with fluoro powders.
As stated above by Dr. D ... the main health concern of working with fluoro powders is breathing in small dust particles. The smaller the particle size the more likely it is to become airborne. This makes the finer sized material more difficult to work with and i suppose potentially more hazardous as well. At least, as far as a dust hazard is concerned. I have talked to my manufacturer about going with smaller particles but they tell me that the sub-micron particles are almost impossible to work with because as soon as you open the container the static in the air causes many of the particles to become airborne.
As for the guy and the toast ... you may actually be better off eating it than breathing it in. Seems like it may make your digestive track fairly slick for a little while but you'd probably eventually get rid of it. However, I DO NOT REOMMEND EATING, BREATHING, INJECTING OR TRYING TO GET FLUOROPOWDERS INSIDE THE BODY BY ANY MEANS. Perhaps try a natural organic fiber supplement if you want to stay regular.