This is the packaging used by my mail-order pharmacy to ship my insulin to me every 90 days. It has plenty of room to hold 10 vials of insulin. It’s a cardboard box with outside dimensions measuring 11.5" wide by 9.5" deep by 11.5" tall. The box holds a styrofoam container with a lid and a heavy foil bag on the inside that contains two gel freezer packs. The insulin is placed in a zip-lock bag(s) in between the frozen gel packs.
It is shipped by UPS next day air. When it arrives, the gel packs are still partially frozen. It seems like a bit of overkill to me but I’ve never received any damaged insulin (thermally or otherwise) with this method.
Do you have someone on the receiving end that can unpackage and place the insulin in a refrigerator upon arrival? If so, make sure they don’t place the insulin in the freezer! The freezer-gel packs may give them the wrong idea.
Here are some photos:
If you know anyone in your local area that receives their insulin via mail-order you may be able to reuse their packaging materials.