This may not seem like much of a problem to the unenlightened observer, but at twenty three bucks a box these granules are competitively priced with most illegal substances. Unnecessary waste of this precious commodity causes unneeded expense as well as wasting perfectly good granules.
The photos below will give you some idea of the scale of the problem - please keep in mind that this illustration represents an accumulation of about three days' running - or to put it another way, twelve cycles. Replenishing at this rate would be very cost prohibitive.
Anyway - I've solved the problem. One could, of course, call CatGenie and just get a new bowl sent out - but there's no guarantee the new bowl will be better - or one could implement my solution. Its cheap, easy and it works.
Step 1: Disclaimer, Safety and Required Equipment
While I do not believe anything in this Instructable is warranty-voiding (no hole drilling, for example) you follow these instructions at your own risk. I am not liable for your death, loss of injury or income, spousal abuse or vague feelings of unrest you may feel because you did or did not follow the steps herein. Caveat Emptor, buyer beware, don't feed the tribbles and above all, be good humans.
This Instructable requires the use of a cutting implement and chemical adhesives. Perform only in a well ventilated area, wear gloves and be careful. Use common sense and be careful. Seek medical attention if you are injured. Don't drink and drive.
Everything you will need is shown in the photo below: a silicone baking sheet, your CatGenie upper housing ("brim"), some 3M Contact Adhesive, a boxcutter (or other cutting tool), a Sharpie (or other marking implement), a ruler and a foam brush or other similar applicator.
Feel free to make substitutions, although as to the adhesive I can state for the record that hot melt glue and carpet tape are poor choices - they don't stick to silicone well.
Step 2: Mark Your Mat
For your purposes, I highly recommend using the clear opaque mat. If you're careful with the adhesive the modification is nearly invisible.
From the approximate center of the long edge of the mat, measure toward the middle five-eighths of an inch or so and make a mark. Measure an additional inch and make another mark.
Step 3: Arc Your Mat
You'll notice that I had to make a correction or two to get it to look right. Feel free to follow my stellar example.
Step 4: Cut Your Mat
Cut along your marks, being careful not to cut through into a good kitchen table or any other furniture that will earn you a whack to the back of the head and an angry look.
Step 5: Mark the Length on the Housing
With one hand, hold one end of the arced piece of mat against the lip of the housing, with the inner arc upward. With the other hand follow it down to the other end of the mat, and (releasing the start end) mark it there.
This gives us the area of the housing to apply the adhesive to.
Step 6: Sticky Business - Applying the Adhesive
Take your little arc and put it on the big piece of waste mat that we're not using. It'll make a great work surface for applying the adhesive. Now, on the large, outer half of the arc apply the adhesive. Leave the small, inner half clean. Set aside to dry.
Step 7: Break Time!
Since we're almost done, now would be a good time to do a little cleanup: put the tools and adhesive away, throw away any trash and take a little break.
Ready? Let's move on...
Step 8: Stick It On
Do not accidentally touch the two surfaces. They will bond instantly and will remove the adhesive when you try to pull them apart, after which you'll have to reapply.
Taking special care to keep the two surfaces from accidentally touching and screwing up all your hard work (can you tell this has happened to me?), start at one end and stick them together. You want to try to keep any of the adhesive from showing, so go slowly, working your way to the other end.
Once you have it stuck on, stand back and admire your handiwork.
Step 9: Reinstall and Reap the Savings
Now, however, this improvisational flange will stay pressed against the side of the bowl, keeping out all the little escape artists and preventing their escape. They'll have to get out the normal way - on the bottom of cat feet.
A Word Of Caution:
You may be tempted, since you have all this extra silicone mat, to continue this modification all the way around the circumference of the brim, sealing the little buggers in for all time. I strongly advise against this. I tried it this way, and the increased friction from the flange kept the bowl from rotating CCW. The friction was so great that I could not turn the bowl. It may not seem like much, but it adds up.
I hope this Instructable helps - Enjoy.