How to keep insulin cold while traveling for more than 28 days and more than 24 hours

Last Updated on March 15, 2023 by PowersToTravel

The Challenge

Only a few weeks before our planned departure on our 65-day Southeast Asia Odyssey I learned that I needed to keep my insulin cold while traveling, that is, REFRIGERATED, for the entire first month of the trip.

I had planned to travel with my insulin in a couple of usual over-the-counter insulin refrigeration containers.  However, in talking with the pharmacist, she pointed out that we would be gone for two months, that insulin only has a lifetime of 28 days once it has been taken out of the refrigerator, and that we had a 36 hour transit time to Bangkok without access to refrigerators.

On a normal 2 week trip, I have had no issues keeping insulin COOL while traveling, that is protected, in that I place my insulin in my insulated container in my carry-on for the plane trip, and my husband places the container in his Diet Dr. Pepper Koolatron travel refrigerator (which plugs into the car and into the hotel room) for the rest of the vacation.   Here’s a link to Greg’s Diet Dr. Pepper travel refrigerator.  We highly recommend it.  (I’m not compensated for this link.)

In preparing initially for the 65-day trip I had felt confident about my ability to keep my insulin cool while traveling.  However, with the information from the pharmacist I now had to address two problems:

• How to travel with my insulin completely refrigerated (not just room-temperature) for almost two straight days, as we went to the airport, flew in a plane to Doha, Qatar, onward to Bangkok and transferred to our Bangkok hotel for a morning arrival, with check-in later in the day.  No normal refrigeration container could keep the insulin cool for that length of time, and my husband’s cooler could not be plugged in while in transit.
• How to keep my insulin completely refrigerated for the first month of the trip while traveling around from country to country in various transports. Once we get into the 2^nd month, the 28-day clock will start and I can keep the insulin using my usual technique, described above, thanks to Diet Dr. Pepper and his travel refrigerator.  But until then?

The solution for how to keep insulin cold while traveling was right in front of me

My mail order pharmacy had already solved the problem for me!  The solution was to utilize the packaging in which my 90-day mail order pharmacy ships my insulin.  The cardboard box (measuring 7 ¼ by 7 ¼ by 8 ½ inches) has specially fitted insulation blocks, specially-sized freezer gel packs, and is sized for a 90-day supply!  It is also certified to keep insulin to a refrigerated level for forty-eight hours, which is more time than I need.

I will prepare and freeze the box and gel packs ahead of time; then I will take the box from the freezer, wrap my refrigerated insulin in bubble-wrap, and pack it in the box.  I will place the box in my carry-on luggage.  It just fits.  I have already checked with TSA regulations and frozen medical transport is approved as long as the freezer gel has not melted, and I have a letter from my doctor regarding the need for the medical supplies.  I’m all set.

Now for the remainder of the trip and its complexities.

How to keep insulin cold while traveling around the countries

I can’t trust that there will be refrigerators in all of the hotel rooms, or that the refrigerators won’t be full of wine and beer, or will keep the right temperature.  I don’t want to be under constant stress during our trip protecting my insulin.

I found a small lunch soft-sided cooler which is almost the same size as the cardboard box.  The freezer gel packs will fit in well, and leave space for the 90-day insulin supply, surrounded by bubble wrap.  So, I will bring this kit, unfrozen, in my checked luggage.  As I reach a hotel, each night, or every two nights, I will have them freeze one set of gel packs, while keeping my insulin safe in the other set in our room.  By placing this prepared kit in my suitcase I will have additional insulation.    Then, after a month, I will be able to throw away the cardboard box kit, and rely only on my lunch-cooler set to provide adequate protection.  Since the insulin will last 28 days at room temperature, my concern then will be to make sure it doesn’t over-heat in the tropics / car, which is my normal practice with the off-the-shelf refrigerant container and my husband’s Diet Dr. Pepper cooler.

Other packing challenges and solutions

Click here for my full packing list and challenges.

I feel confident and unstressed.

Update following the trip – did the insulin stay cold?

It all worked as planned!  TSA did question my box in Boston, but when they peeked at the still-frozen gel packs, they gave me the go-ahead.  Airport security at most subsequent airports didn’t even blink at my carry-on.

There was an incident in Myanmar – they didn’t react to my insulin or my spare syringes – they reacted to my stash of prescription drugs – malaria pills for my husband and I, antibiotics for both of us, and my prescription diarrhea, vomiting and blood pressure medications.  The stash does look imposing.  The guard spoke no English and grabbed my medications and started aggressively asking questions in Burmese.  I said “Medical!!”  “Doctor letter!” and quickly pulled out my doctor’s note.  He couldn’t read it, but apparently decided I was legitimate and let me go forward.

I’d never in my life needed that doctor’s note before, and have at times felt foolish with it, but wow, was I happy about it that day!

More Diabetic Travel Tips

Click here for more Diabetic Travel Tips by a travel-pro (that’s me!)