Three years ago, this was our healthy giveaway: old crayons re-melted into the shape of candy corns. Our son has always been a big consumer of Crayola products, and its a relief that at least some of them can be recycled. (What to do with the 10,000 dead plastic markers? that is a story for another day.)
We had this nice ice mold from Ikea, put the crayons in, put in the oven on VERY low heat (barely on) until melted, and then let the crayons re-solidify in their new configuration. Some turned out looking more candy-corn-ish than others. Never really heard whether anyone liked this giveaway… for older kids, I bet crayons are probably a disappointment.